GE AKR-60-75 Maintenance Manual Download

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Summary of Contents for AKR-60-75

Page 1: ... GEK 64460A Maintenance Manual Low Voltage Power Circuit Breakers Types AKR 75 100 and AKS 50 AKR 60 75 AKR 90 100 AKS 5A 50 Courtesy of NationalSwitchgear com ...

Page 2: ...ionary Intermediate and Main Contacts 24 5 11 Assembly and Adjustment of Crossbar 25 1993 GENERAL ELECTRIC COMPANY 2 Description Page SECTION 6 Breaker Maintenance 26 6 1 Safety Precautions 26 6 2 Lubrication 26 6 3 Breaker Mechanism Adjustments 26 6 3 1 Trip Latch 26 6 3 2 Latch Buffer 26 6 3 3 Reset Latch Bearing and Prop 26 6 4 Electrical Mechanism 28 6 4 1 Control Components 28 6 4 2 Charging ...

Page 3: ...ached mechanically operated switches F and G reverse their shown position the G switch deenergizing the motor and the F switch establishing a circuit to the One Shot electronic With the closing spring propped fully charged the breaker is ready for closing This may be accomplished electrically by depressing the closing switch PB on the breaker if so equipped or by a remote closing switch Operation ...

Page 4: ...FIG 13 MANUAL OPERATION OF CLOSING SOLENOID Courtesy of NationalSwitchgear com ...

Page 5: ... Removal and Replacement 83 12 8 Trip Unit Functions 83 12 9 Trouble Shooting Guide 84 Description Page SECTION 13 Type EC Overcurrent 13 1 13 1 1 13 1 2 13 1 3 13 1 4 13 2 13 3 13 4 13 4 1 13 4 2 13 4 3 13 5 13 5 1 13 5 2 13 5 3 13 5 4 13 6 13 7 13 7 1 13 7 2 13 8 13 9 Trip Device 85 Direct Acting Tripping Device EC 1 B 87 Long Time Delay Tripping 87 Short Time Delay Tripping 87 Instantaneous Tri...

Page 6: ...arrangements be made to open and close it several times in succession Dirt grease or other foreign material on any parts of the breaker should be removed by a thorough and careful cleaning Insulating surfaces should be checked for conditions that could degrade insulating properties During an inspection the breaker s contacts should be slow closed manually with closing springs restrained by the saf...

Page 7: ...rs AKA NF 75F x x Fingers AKA NS 75F x Bar AKA N 100F x Tube AKA N 8 100F x x Fingers 6000 AKA ND 100F x x Fingers AKA NF 1 OOF x x Fingers AKA NS 100F x Bar AKA NW 1 OOF x Bar Example AKR 58 75 identifies a drawout substructure mounted breaker equipped with the SST trip device The EC trip devices are electro mechanical refer to GEi 86157 for detailed information Breaker Models This digit identifi...

Page 8: ...t sets pivots for the movable contacts and provision for mounting the current transformers The interrupter components are in addition to the arcing contacts the arc runners mounted on the back base and the removable arc quencher assemblies In addition to these basic components a breaker may be equipped with any combination of many accessories and interlocking devices Individual breakers may differ...

Page 9: ...Only D AKD 8 F Substructure s AKR 75 100 25 wide w AKR 100 33 wide 2 4 Trip Device There are six types of solid state direct acting self powered trip device systems associated with AKR breakers These systems are for AC applications only For DC applications an electromechanical system is available The trip device system is identified by the first middle digit in the breaker s nameplate designation ...

Page 10: ...amp trip coils Consult factory for application data 8 Rated Maximum Voltage 60 Hz AC 635 508 254 635 508 254 600 635 508 254 635 508 254 635 508 254 600 635 508 254 600 300V DC 300V DC 300i DC 30 Interruption Rating KA RMS Symmetrical Instantaneous Trip Short With Without Time 42 42 42 50 50 50 65 50 42 65 65 65 200 200 42 42 42 65 65 65 65 65 85 65 85 85 85 130 85 200 200 85 85 85 130 85 200 200 ...

Page 11: ... practices to assure conformance 3 Excellent maintenance is essential for reliability and safety of any electrical equipment Industry publications of recom mended maintenance practices such as ANSl NFPA 70B Elec trical Equipment Maintenance should be carefully studied and applied in each user s formation of planned maintenance 3 3 Both long and short term maintenance of all electrical equip ment i...

Page 12: ... energize the motor through the G switch contacts see figs 3A 38 The mo tor through the gear reduction output crank compresses the closing springs until they are fully charged As this fully charged position is reached mechanically operated switch G reverses its shown position deenergizing the motor In the fig 3A diagram switch F reverses its position and es tablishes a circuit for the X relay At t...

Page 13: ...g solenoid This removes the prop releasing the closing springs to close the breaker If the closing switch is maintained closed the anti pump re lay will remain picked up to prevent a second motor charge and closing operation on the breaker in the event it is tripped open automatically The closing impulse must be released and reapplied after the closing springs are fully charged be fore a second cl...

Page 14: ...ich includes a ground fault element for use on 4 wire circuits an additional terminal board is provided on the breaker for connecting to the equipment mounted neutral sensor physically located in the neutral conductor 4 3 2 Drawout Breaker On drawout breakers the control circuits terminate in the breaker compartment on the stationary portion of separable secondary disconnects see fig 5 000000 12 T...

Page 15: ... the breaker can be closed 4 5 Charging and Closing Using the Maintenance Handle In the absence of control power an electric breaker can be closed manually by using the maintenance handle to charge the closing springs Referring to Fig 6 a With the breaker open and springs discharged release holding pawl slide per instruction label 2 b Install maintenance crank 1 568B386G1 to the motor gear reducer...

Page 16: ...ism The breaker is arranged for slow closing by manually charging the springs and then securing them in this compressed state by inserting a restraining safety pin see Fig 7 Following the inspection period a Recharge the closing springs b Remove the safety pins from the guide rods return them to their storage clips 14 5 1 1 Electrical Breaker Referring to Fig 7 a Attach maintenance handle 1 and ch...

Page 17: ...roded to 125 of an inch from original conture or item 2 is cracked Fig 8 the arc quencher should be replaced 5 2 1 Removal and Replacement Referring to Fig 8 a Be sure breaker is open b Loosen nuts 4 and remove the two slotted head jack screws c Remove two hex head bolts 5 that mount channel shaped retaining bar to side support 6 d Remove channel shaped retaining bar Continued next page 15 Courtes...

Page 18: ...two hex head bolts that secure the channel shaped retaining bar to side sheet DO NOT OVERTIGHTEN THESE TWO BOLTS 16 5 3 Separation of Front and Back Frames In order to perform some repair and replacement operation the front frame must be separated from the back frame Proceed as follows referring to Fig 9 a Open the breaker manually compress the closing springs and insert the safety pin as describe...

Page 19: ...bolts 7 i Remove position interlock on AKO AKO 5 AKO 6 type 8 j Remove arc quencher retainer and bolts 9 k Remove the six nuts from the back frame using a socket wrench with an extension These include the two nuts at the top of the frame I Check along the trip shaft for a mechanical interference or connection between the overcurrent trip device and the trip paddles Remove mechanical connection if ...

Page 20: ...rs 1 O and 8 These moveable contact fingers pivot on a stationary pin 11 which fasten them to the lower contact block The insulated link 13 which is attached to the breaker crossbar 1 and moveable contact assembly gives the open and close motion to the contact arm The stationary arcing contact assembly 3 is a separate set of contact fingers pins springs and pivot block The moveable arcing contact ...

Page 21: ... With the breaker open measure the horizontal distance from the edge of the stationary arcing contact to the retainer A dim for main and intermediate contacts measure the horizontal distance from the top of the cont act to the contact arm retainer B dim c Close the breaker and repeat step b The difference between the readings determines the contact wipe See Table 6 for correct readings CAUTION FOR...

Page 22: ...in Qty Force in Breaker Per in Inches Per in Inches Type Pole Lbs B Pole Lbs B AKS 50 AC 3 1 AKS iO IOt 35 55 1 35 55 AKR 75 AC 5 1 16 to 1 AKR 75 DC 5 25 55 64 1 25 55 AKR 100 AC DC 6 2 7 Qty Per Pole 2 3 3 5 5 The intermediate contact wipe should be at least 1 in greater than main contact wipe 20 Lower Stud Arcing Contacts 8 9 Wipe Force In in Inches Lbs A 5 32 to 31 43 9 32 Clevis centerpole Co...

Page 23: ...re the contact open gap between the movable and stationary contacts as shown in Fig 13 This distance should be between 2 1 2 to 2 3 4 This gap may be adjusted by repositioning shims on crossbar assembly The locking nuts on the buffer bolts should be locked in such a position that the buffer bolt may be rotated freely 1 Buffer stop 2 Buffer washers 3 Buffer shims 4 Lock nuts Fig 12 Buffer assembly ...

Page 24: ...feet long over the contact and form the contact either forward or backward by bending it If the proper dimensions are still not obtained the moveable arc ing contacts should be replaced If it has been necessary to make any adjustments while obtaining proper contact sequence the contact wipe must be checked and adjusted if necessary see Section 5 6 Fig 14 Measuring main contact gap 5 10 Replacement...

Page 25: ...side of contact arm 9 Note left and right hand orientation of contact arms and position of intermediate contact c Remove retaining rings 7 from pins 8 Slide pins 8 until contact arms can be withdrawn e Before tightening crossbar see assembly and adjustment of crossbar Section 5 11 iE 7 Retaining rings 8 Pins 9 Spring washers 10 Crossbar bolts 11 Intermediate contact Fig 16 Replacement of main and ...

Page 26: ...rmediate contact arm 3 Arcing contact block 4 Arcing contact 5 Allen screws 6 Contact stop bracket 7 Retaining ring 8 Pivot pin Fig 17 Intermediate and main contacts assembly details f Remove contact noting two spring washers on each contact pivot Upon re assembly position two spring washers into counter bore on one side of contact arm Fig 19 NOTE Left and righthand orientation of contact arms and...

Page 27: ...ontacts Fig 20 Re assembly of arcing contacts screws with locking plates on crossbar finger tight and set crossbar to dimension shown making sure that all three poles of moveable arcing contacts are touching stationary arcing contacts within 032 Tighten screws as shown first A second B and finally C to 400 inch pounds Bend tabs on locking plates to secure screws Refer to Fig 21 After assembling cr...

Page 28: ...28 26 Fig 22A Mechanism in motion before resetting as shown in Fig 22C 6 3 Breaker Mechanism Adjustments Electric and Manual breakers have the same basic mechanism shown in Fig 22 All the adjustments detailed below must be made with the breaker in the upright position and the mechanism in the reset position as shown in Fig 22B Reset the mechanism by manual operation using the slow close method giv...

Page 29: ...ig 22C Mechanism in closed position closing spring discharged il 1 Feeler gage 2 Trip latch 3 Roller Fig 23 Adjusting trip latch and roller 10 Trip latch 11 Trip shaft 12 Clevis pin 13 Clevis 14 Reset latch 15 Roller 16 Prop 17 Bearing 18 Buffer 19 Nut Fig 220 Latch bearing and prop il f 1 Feeler gage 2 Prop 3 Bearing Fig 24 Adjusting bearing and prop 27 Courtesy of NationalSwitchgear com ...

Page 30: ...g screw through the keyhole mounting The entire relay should be replaced rather than changing coils and contacts The antipump relay W is located on the left side of the front channel The connections to this relay are soldered Relay replacement requires unsoldering of these connections and removing the mounting hardware When replacing relay take care in soldering connections Do not use excess amoun...

Page 31: ...in Fig 27 A driving pawl is mounted eccentrically on the motor shaft see Fig 28 As the motor turns the driving pawl rotates the ratchet which charges the closing springs The ratchet is kept from reversing its direction by the holding pawl To remove the motor a On AKS 50 you must remove the side sheet b Disconnect and identify the motor leads at the closing solenoid and cutoff switch c Remove three...

Page 32: ...ee Section 5 1 b Remove the motor see Section 6 4 2 The motor wiring doesn t have to be disconnected c Disconnect the wiring to the closing solenoid and solenoid switch d Remove retaining ring from closing solenoid drive link e Remove three mounting bolts one from the side two from the bottom of the charging mechanism Note the positions of the standoffs on the two bottom mounting bolts and replace...

Page 33: ...k Operate the breaker using the maintenance handle and spring discharge mechanism a few times Verify that the breaker is operating properly I Before applying control voltage to your breaker verify that the motor cut off switches are properly adjusted Charge the closing spring as described in step j roller resting on prop Adjust the motor cut off switches shown in Fig 35 so that they are depressed ...

Page 34: ...andle shaft and pawl assembly and the escutcheon mounted closing handle The closing springs 5 are charged by operating the manual closing handle 22 on the front of the breaker instead of the closing motor as is the case with the electrical breaker Closing this breaker is accomplished by pumping the operating handle four complete cycles first counterclockwise through 120 degrees from its normal ver...

Page 35: ... the upper and lower spring pins 1 31 c Remove the right hand bearing side plate 20 and the side plate shims 18 by removing four mounting bolts 19 thus allowing the main closing crank 25 to be removed d Remove the closing handle 22 by removing two set screws threaded in same hole e Remove the front escutcheon by removing four screws holding it to the front frame center support f Remove handle shaf...

Page 36: ...prings 16 Ratchet Wheel Shaft and Asm 28 Buffer Stop Support 6 Guide Rod 17 Ratchet Wheel 29 Handle Return Spring 7 Pawl Springs 18 Side Plate Shims 30 Mechanism Roller 8 Front Escutcheon 19 Side Plate Mounting Bolts 31 Lower Spring Pin 9 Front Bearing Plate 20 Bearing Side Plate 32 Output Crank 10 Bearing Plate Mounting Bolts 21 Ratchet Pawls 33 Ant Rebound Spring 11 Output Crank Roller 22 Manual...

Page 37: ...given in Section 6 5 3 36 Retaining ring Fig 39 Anti rebound pawl removal 7 Disconnect 26 Buffer springs stop 35 Retaining ring Fig 40 Ratchet pawl removal 6 5 3 Adjustments Frequent adjustments to the mechanism should not be required If the mechanism has been disassembled it will be necessary to check the following adjustments 1 It may be necessary to add shims 13 to reduce the end play of the ra...

Page 38: ...sembly and replace with new cam d Align center of worm with worm gear on racking cam then position collars firm against supports and tighten set screws in collars To replace guide support 4 a Remove screws 5 and support 6 b Remove guide 4 and replace with new guide c Reassemble Drawout Mechanism Lock Fig 41 Drawout mechanism 6 7 Drawout Mechanism Lock Breakers manufactured after January 1993 have ...

Page 39: ...gement that is crisscrossed through the tubular stud When reassembling mounting hardware apply equal amounts of torque to nuts so distortion to tubular mounting stud does not occur Torque nuts between 250 to 300 in lbs Fig 43 shows the finger type disconnect assembly used on AKD 6 AKD 8 switchgear and substructure type breakers If replacement of primary finger is needed you must replace complete s...

Page 40: ... assembly Fig 46 Partial primary disconnect ASM 38 Fig 47 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 46 The engagement of the fingers with the retainer Also the location of the bowtie spacers in the fingers both upper and lower Fig 45 Partial primary disconnect ASM Fig 47 Partial primary disconne...

Page 41: ... circuits They are mounted on a horizontal cross channel at the top rear of the breaker as shown in Fig 49 These secondary disconnects cillow removal of the breaker without having to detach external connections The moveable part of the secondary disconnects consists of an insulating body which holds a conducting spring loaded plunger to which a flexible lead is attached see Fig 50 As the breaker m...

Page 42: ... link rotates the auxiliary switch operating shaft 1 Crossbar 4 2 Triangular link 5 3 Operating rod 7 3 1 Replacement Referring to Fig 51 GE SB 12 a Disconnect all leads b Remove two mounting bolts c Disengage auxiliary switch shaft 4 from triangular link 2 d Orient the shaft of the new switch so that the arrow stamped on the shaft end points towards the front of the breaker e Push auxiliary switc...

Page 43: ...t coil leads b Remove mounting hardware and the device c Install new device in reverse order ml m AA 1 IE D E L I D 1 6 7 4 2 Adjustments With the shunt trip de energized and the breaker mechanism reset there must be clearance between trip paddle 11 and armature arm 10 0 03 in min A minimum 0 03 in over travel of the armature is required when the breaker is tripped If any adjustment is necessary t...

Page 44: ...ens This causes an extension of the armature to strike the paddle on the trip shaft An extension on the other end of the armature towards the front of the breaker extends through the device frame and limits the movement of the armature When the armature is released this extension stops against a stop which is factory set To check positive trip the armature should be held down the end of a 1 32 inc...

Page 45: ...ay unit The static time delay undervoltage can also be furnished with a thermotector control unit Overheating of motor windings causes the thermotector imbedded in the motor windings to open This de energizes the undervoltage device on the breaker and drops the motor load In the event the device fails to pick up the following checks are recommended to determine whether the magnetic device or i the...

Page 46: ...I I _ _ __ t i I I I 2 Pull knob for manual defeat of lockout device 3 Manual defeat linkage 4 Adjusting nuts Each electric lockout device also includes a By Pass or manual defeat linkage to permit closing the breaker when the lockout is de energized This allows startup of dead systems A pull knob for this purpose is located beneath the breaker frame 7 7 1 Adjustment All lockout devices are factor...

Page 47: ...r is opened This keeps the breaker trip free until the bell alarm is reset Operating the manual trip button must not actuate the bell alarm device With the manual trip button fully depressed the trip rod release collar 7 should be positioned on trip rod 8 so that latch 9 and catch 10 disengage before the breaker opens When the manual trip button is not depressed there should be approximately a 3 1...

Page 48: ...ng the device to the side plate and front frame Lower the lockout device guiding _ J 0 0 rod 3 through rod guide 2 Continue lowering the device until movement is restricted by the device wiring harness 2 Disconnect coil leads 3 Remove two screws holding the trip device to the device mounting plate 4 Bend lower end of brass coil clamp straight 5 Remove coil Install new coil and replace parts in rev...

Page 49: ...s with a bracket mounted to the breaker s center channel The SST programmer units can be optionally equipped with trip indicators targets These are pop out mechanically 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 overload the second for short circuit actuated by the short time and in...

Page 50: ...companion primary winding on a ground differential transformer mounted in the programmer unit Its secondary output is zero so long as there is not ground current 48 Fig 60 AKS 5A 50 Application of the Ground Fault element on 4 wire systems with neutral grounded at the transformer requires the additional separately mounted neutral sensor Fig 62 inserted in the neutral conductor its secondary is con...

Page 51: ...AKA 75 100 AKS 50 Fig 61 SST phase sensors with tap board AKA 75 100 Tap terminal board Fig 62 SST neutral sensors AKS 50 49 Courtesy of NationalSwitchgear com ...

Page 52: ...ng harness from the sensor tap board b Remove the tap board retaining hardware c Remove the lower connection strap d Sensors are secured with ATV Loosen ATV and remove sensors e If the front and back frame have not been separated replacement of the center pole sensor requires removal of the mechanism prop Refer also to Fig 24 1 Remove retaining rings 2 Disconnect spring 3 Remove bearings 4 Remove ...

Page 53: ... the breaker opens the actuator arm is returned to its normal Reset position via linkage driven by a crank on the breaker s main shaft The permanent magnet again holds the armature captive in readiness for the next trip signal The trip device requires only one adjustment the trip rod length As shown in Fig 68 the clearance between the trip rod end and the trip shaft paddle is gaged by a 0 109 inch...

Page 54: ...r stop 3 Crossbar Fig 66 Flux shift trip device linkage attachment 1 Actuator 2 Actuator arm 3 Trip rod 4 Trip rod adjuster end 5 Reset linkage 6 Actuator bracket 7 Mounting base Fig 67 Flux shift trip device with operating linkages 52 Courtesy of NationalSwitchgear com ...

Page 55: ...OD i 09 IN RESET 0 1 DIA ROD POSITION ADJUSTER END CROSSBAR BKR OPEN Fig 68 Flux shift trip device adjustments Fig 69 SST ECS test set cat no TAK TS1 BUFFER STUD POSITION 53 Courtesy of NationalSwitchgear com ...

Page 56: ...cteristics 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 addition includes means for continuity checking the phase sensors 54 8 4 1 SST Test Set The TAK TS1 Test Set Is a portable instrument designed to field check time current characteristics and pickup claibration of the SST s trip elements It can veri...

Page 57: ... tap setting the differential transformer can produce output sufficient to trip the breaker Similarly discontinuity between any sensor and the programmer unit can cause a false trip signal If nuisance tripping is encountered on any breaker whose SST components have previously demonstrated satisfactory perfor mance via the TAK TS1 Test Set the sensors and their connec tions should be closely scruti...

Page 58: ...P 201297 1 Fig 70 Cabling diagram SST without ground fault A B c AAA BREAKER BACK FRAME f 1 b b I I LEFT POLE I I CURRENT SENSOR FLUX SHIFT TRIP DEVICE PROGRAMMER UNIT 1 48V de c H o TO SCA ANODE WHITE BLACK WHITE BLACK WHITE I I BLACK I __ K _ J rrr LOAD I l_____J HARNESS CONNECTOR PROGRAMMER AMP 201298 1 CONNECTOR AMP 201297 1 Fig 71 Cabling diagram SST with ground fault on 3 wire load Courtesy ...

Page 59: ... WIRE LOAD HARNESS CONNECTOR PROGRAMMER A CONNECTOR MP 201298 1 AMP 201297 1 Fig 72 Cabling diagram SST with ground fault on 4 wire load MALE END FEMALE END ANY SST PROGRAMMER UNIT WITH GROUND FAULT ELEMENT Fig 73 Cabling diagram with ground fault defeat cable inserted between breaker harness and SST programmer unit for use during single phase high current low voltage testing 57 Courtesy of Nation...

Page 60: ...ch of the tabulated ampere ratings which span the same range as SST see Fig 76 4 Neutral sensors are not required because there is no Ground Fault function In all other respects the ECS trip device system operates and can be treated identically to SST This includes circuitry size construction component location programmer unit set points performance characteristics operating range quality reliabil...

Page 61: ...X Minimum 3 4 5 Minimum 4 6 8 10 l 0 095 3 3 Time delay at lower limit of band 6L Time delay at lower limit of band Table 12 lnstan taneous Pickup Multiple of L 4 5 6 8 10 12 l 9 1 ECS Cabling Diagram Sensor Resistance Values Breaker Ampere Resistance In Ohms A 4 B 4 C PROGRAMMER Type Rating Between Terminals AAA FLUX SHIFT TRIP DEVICE UNIT BREAKER T1 t 1 BACK FRAME r 100 3 0 3 4 48V de 150 4 4 5 ...

Page 62: ...RGET INSTANTANEOUS PICKUP GROUND I TARGET SUMMING CIRCUITRY 1 11 2 REGULATED 1s voe 3 POWER SUPPLY Fig 78 MicroVersaTrip block diagram 60 10 1 1 Fault Trip Indicators The optional fault trip Indicators are similar to the SST in dicators They are mechanical pop out type for Identifying overload or short circuit over currents faults when breakers are ordered without Integral ground fault protection ...

Page 63: ... Multiple Delay Maximum Sensors Sensors Current of Current D Frame Rating Rating Rating Seconds Size Amps Sensor Current Rating Amps X C 100 150 100 150 225 300 5 6 7 8 9 2 5 5 AKR 30 800 225 300 or 8 85 9 1 0 1 1 10 21 400 600 300 400 95 1 0 C 800 600 800 X 300 400 300 400 600 800 AKR 50 1600 600 800 or AKS 50 1200 1600 600 BOO 1200 1600 AKST 50 800 1200 800 1200 AKRT 50 2000 1600 2000 1600 2000 ...

Page 64: ...ig 81 Remote fault indicator disconnect t 10 2 MicroVersaTrip Installation 8 Fig 82 Programmer secondary connector 62 The programmer is located on the left side of the breaker s center channel as shown in Fig 81 It mounts to the bracket assembly shown in Figs 83 or 84 Referring to either Fig 83 or 84 the guide pins mate with the holes on either side of the programmer_ connector They provide the ne...

Page 65: ...ifference in the designs is in the operation of the locking lever see Fig 84 ORIGINAL DESIGN LATER DESIGN Fig 84 AKR 75 100 program mer mounting Installation using each design is as follows a Insert the guide pins into the holes and push on the programmer engaging the connectors b Original design push in the locking lever securing the programmer Later design the locking lever is released securing ...

Page 66: ...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 instantaneous MicroVersaTrip option H option is required Fig 86 shows an H option phase sensor When the H option phase sensor is installed there are four leads connected to it There is no polarity associated wit...

Page 67: ...rip devices is the solenoid winding Refer to Section 8 3 for details When replacing a MicroVersaTrip flux shifter AMP extraction tool Cat No 455822 2 is required to remove the socket leads from the AMP connector 10 5 Troubleshooting When malfunctioning is suspected the first step in troubleshooting is to examine the circuit breaker and its power system for abnormal conditions such as a Breaker tri...

Page 68: ...el connection so that its output is always zero 2 Test the components of the MicroVersaTrip system using portable Test Set Type TVS1 Fig 89 The applicable test procedures are detailed in instruction Book GEK 64464 Fig 89 Test set cat no TVTS1 10 5 1 Resistance Values For use in troubleshooting the MicroVersaTrip current sensors the resistance of the tapped and fixed windings is given in Tables 15 ...

Page 69: ...am d On Ground Fault breakers serving 4 wire loads check that the neutral sensor is properly connected see cabling diagram Fig 92 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 secondar...

Page 70: ...SS CONNECTOR PROGRAMMER AMP 1 350356 9 CONNECTOR Fig 92 Cabling diagram MicroVersaTrip with ground fault on 4 wire load 4 WIRE LOAD PROGRAMMER UNIT 111 BREAKER r 4 I FLUX SHIFT TRIP DEVICE EQUIPMENT MOUNTED I NEUTRAL SENSOR r I I 1 N L BACK FRAME A b A I LEFT POLE I CURRENT SENSOR t I 1 I A I NEUTRAL I SENSOR I DISCONNECT I 1 LOAD LOAD HARNESS CONNECTOR PROGRAMMER AMP 1 350356 9 CONNECTOR Fig 93 C...

Page 71: ... I I 0 4 v I I o t 0 I I o I I I L J L I I L _j Fig 94 Cabling diagram with ground fault defeat module inserted between breaker harness and MicroVersaTrip programmer unit for use during single phase high current low voltage testing A B C AAA s E rt 1 t _ 1 Partial r LEFT POLE I I CURRENT YELLOW SENSOR I I I_ rrr LOAD _J YELLOW YELLOW YELLOW HARNESS CONNECTOR PROGRAMMER UNIT I______ PROGRAMMER CONN...

Page 72: ...AMMER I I I I I I I I I I ______ _J 70 AMP 1 350239 9 AMP 1 350246 9 AMP 1 350242 9 AMP 1 350235 9 Fig 96 Cabling diagram remote fault indication PROGRAMMER SECONDARY DISCONNECT EQUIPMENT BREAKER SHORT TIME INPUT _ SHORT TIME OUTPUT _ l GROUND FAULT INPUT _ 4 J PROGRAMMER HARNESS CONNECTOR GROUND FAULT OUTPUT t r f AMP 1 350239 9 AMP 1 350246 9 MICROVERSATRIP PROGRAMMER __ _J Fig 97 Cabling diagra...

Page 73: ...entifying overload or short circuit over current faults when breakers are ordered without integral ground fault protection 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...

Page 74: ...with a push on terminal will be connected to this COMMON terminal All phase sen sors must be correctly wired for the programmer summing circuit to function properly The phase sensors are available with an additional winding This winding is brought out to separate flag terminals These phase sensors are used when the hi level instantaneous RMS 9 option H option is required Fig 102 shows an H option ...

Page 75: ...ck up Pick up Pick Up Pick Up eous Selective of Mult Mult w o ST with ST Mult of Trip Sensor Rating of of Mult of Mult of Frame Fixed High x x x x x Ground Fault Pickup Mult of Sensor Max Rating Plug Current Current Rating Rating Short time Range Amp Delay DelaY Frame Amp Amps Amps Size Rating S X 5 6 AKR 75 3200 3200 7 8 9 95 1 0 1 1 5 6 AKR 100 4000 4000 7 8 9 95 1 0 1 1 1 Time delay shown at 60...

Page 76: ...is inserted into the neutral conductor and therefore is sepa rately mounted in the cable or bus compartment The outputs of the phase sensors and neutral sensors are connected to a programmer circuit which sums these values The total value will remain zero as long as there is no ground current flowing See cable diagram in Fig 108 The neutral sensor is an electrical duplicate of the phase sensor The...

Page 77: ...n established 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 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 connections must be employed for RMS 9 breakers equipped with Gro...

Page 78: ...hat the neutral sensor is properly connected see cabling diagram Fig 108 In particular 1 Verify that the neutral sensor has the same rating 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 break...

Page 79: ...NSOR 4 WIRE LOAD Fig 108 Cabling diagram RMS 9 Epic MicroVersaTrip with ground fault on 4 wire load EQUIPMENT MOUNTED I NEUTRAL SENSOR 4 WIRE LOAD 111 s E rf t 1 LEFT POLE I CURRENT SENSOR FLUX SHIFT TRIP DEVICE t 1 4 o I A I NEUTRAL I SENSOR I DISCONNECT I 1 LOADI 18 PROGRAMMER UNIT I o o HH lN _J L HARNESS CONNECTOR PROGRAMMER AMP 1 350356 9 CONNECTOR LOAD Fig 109 Cabling diagram RMS 9 Epic Micr...

Page 80: ... Socket Class No 5 6 7 8 11 12 9 10 1 4 2 3 Gnd Fault Inputs Gnd Fault Outputs Commnet Spare vc V3 VA 24 Ret 24 voe Note Location of Pin 1 Fig 110 Programmer secondary connector pin locations for zone selective interlock and Epic MicroVersaTrip Trip Device Courtesy of NationalSwitchgear com ...

Page 81: ...func tions include the flexibility of coordination with or without an 12 t ramp and are also available with high range instanta neous MicroVersaTrip PM Trip Unit MicroVersaTrip PM trip unit adds power management sys tem capability advanced metering and protective relays to the basic functions of the MicroVersaTrip Plus MicroVersaTrip PM trip units communicate directly on the GE POWER LEADER commun...

Page 82: ...ug that connects either trip unit to the circuit breaker and equipment circuitry This plug is called the trip unit disconnect Fig 112 Front view of MicroVersaTrip PM Trip Unit 80 CAUTION Removal of a trip unit from its breaker must be performed with the breaker in the OPEN or TRIPPED posi tion Draw out breakers should be racked out first CAUTION Do not attempt to operate the breaker without its as...

Page 83: ...a trip unit is re placed the locking arm snaps back into place to indicate proper engagement WARNING Always de energize Type AKR circuit breakers before attempting to remove or replace the trip unit Be cause of the exposed location of the trip unit failure to ob serve this warning may result in equipment damage or per sonal injury including death Socket Class Fig 114 Programmer secondary connector...

Page 84: ... this common terminal All phase sensors must be correctly wired for the programmer sum ming circuitry to function properly The fixed phase sensors are available with an additional winding This winding is brought out to separate flag termi nals These phase sensors are used when the hi level in stantaneous H option is required Fig 118 shows an H option phase sensor When the H option phase sensor is ...

Page 85: ...ropriate rating plugs for each sensor rating and breaker frame If a replacement rating plug has a different rating than the plug that was removed follow the appropriate setup proce dure in GEH 5891A to enter the new rating Do not attempt to use a rating plug from a Spectra RMS breaker or a MicroVersaTrip RMS 9 MVT 4 function trip in a MicroVersaTrip Plus or MicroVersaTrip PM trip unit TABLE 20 Rat...

Page 86: ...ectly Potential transformer PD primary voltage was defined incorrectly PT connection was defined incorrectly Total power metering Test Kit initiated trip indication Corrective Action 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 Check that the control power supply is prese...

Page 87: ...KA breakers with EC trips are for use on DC system voltages One EC trip device is mounted per breaker pole This device contains its functional adjustments Fig 120 EC 2A trip device The standard EC trip device for the AKS breaker frames is the type EC 2A see Fig 120 An optional trip device for these frames is the type EC 1 see Fig 121 The EC trip device for the 4000 and 6000 amp AKA 75 100 frames i...

Page 88: ...23 sec or 2 5X or High Set 80 160 x 1B INTER 15 sec 3 7X or 2B INTER 15 sec up to 15X EC 1 10 or 4 10X or Non Adjustable lC MIN 5 sec 2C MIN 07 sec 2AA MAX 20 sec 80 160 x 1BB MAX 4 5 sec 2 5X or 4 9X EC 1 B 15 or 3 7X or 2BB INTER 13 sec 6 12X 1 CC MIN 2 sec 4 lOX or 9 15X or 2CC MIN 07 sec 80 250 x X Trip device ampere rating If trip devices are set above 100 3 At lower limit of band at 21 times...

Page 89: ... is governed by the mechanical escapement mechanism consisting of parts 2 3 4 and 5 13 1 3 lnstantaneous Tripping High Set Referring to Fig 123 adjustable instantaneous tripping is accomplished by varying the amount of tensile force on the high set instantaneous spring 21 When a magnetic force greater than the restraining spring force is produced by an over current condition the armature 22 is pul...

Page 90: ... and the insulated coupling which ties onto the trip paddle 14 The approximate distance between the pivot centers on the ends of the connecting rod assembly is six inches The correct exact distance is that which will just cause tripping of the breaker when the armature is closed to a point 1 32 in short of contact with the magnet A step by step procedure for making this adjustment follows 1 Before...

Page 91: ... 3 mark Standard characteristic curves are plotted at these 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 123 is greatest The time adjustment screw 4 may be turned by inserting a Phillips head screwdriver through the hole in the front of the case If it i...

Page 92: ...ing link 2 Calibration plate 10 Series coil 3 Adjustment knob 11 Movable nut 4 Time adjustment screw 12 Instantaneous pickup adj 5 Instantaneous spring 13 Dashpot 6 Trip screw 14 Operating arm 7 Armature 15 Calibration marks 8 Dashpot arm Fig 124 Overcurrent tripping device EC 2A 90 Courtesy of NationalSwitchgear com ...

Page 93: ...etic force produced by an overcurrent condition overcomes this restraining force the armature movement is further retarded by the flow of silicone oil in a dash pot which produces an inverse time delay characteristic The mechanism is shown on Fig 126 al tD 6 llD ill IE IE m Ill m m Left Side View Showing Short Time Delay Mechanism Right Side View Showing Long Time Delay Mechanism 1 Series coil 2 M...

Page 94: ... Positive Trip Adjustment 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 ngagement See Section 6 3 1 In addition to the pick up settings and tim...

Page 95: ...r ltion 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 If the current through the series coil 2 is reversed the armature 10 tends to move in the clockwise direction against the restraint of the calibration spring 6 When the current reversal exceeds the calib...

Page 96: ...witchette 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 overload it will trip on instantaneous only 94 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 indicati...

Page 97: ... 3 B6 76 60 OB 250V 60 064 036 50 07 1 3 17 250V 50 20B 254 12 3 190 064 036 190 50 OB 196 1 1 15 250V 25 035 023 3 42 64 54 OB CD Values are typical and are given only as application information and not intended to be maximum or minimum values Table 24 Bell Alarm Contact Rating Bell Alarm Contacf Control Rating amperes Voltage Inrush Conlin uous De 125 2 5 2 5 250 0 9 0 9 60 Hz 120 30 10 Ac 240 1...

Page 98: ...IA Q 0 CD 240 25 190 254 2 1 1 9 I 16 06 o 380 50 315 410 2 9 2 6 o 22 08 480 60 380 508 3 4 3 1 co 23 08 C1l 480 50 380 508 7 5 7 3 ro 17 06 J o o 480 25 380 508 3 5 3 3 J 0 11 05 ti 0 575 60 475 625 2 8 2 5 16 06 0 0 575 50 475 625 5 1 4 7 14 06 575 25 475 625 3 1 3 0 See Table 30 10 05 TABLE 29 Coil Resistance DC Ohms 25 Nominal Control Anti Pump Control Shunt Voltage Frequency Hz Relay W Relay...

Page 99: ...0 voe 102 36 72 200 voe 177 62 125 240 voe 204 72 144 380 voe 323 114 228 480 voe 408 144 288 575 voe 489 173 345 TABLE 31 Time Delay Undervoltage Device Settings DELAY PICK UP RANGE UVA INSTALLED DROP OUT UNIT UVA ONLY MECHANISM RESET RANGE VOLTAGE VDC NO PICK UP PICK UP 125 voe 77 85 50 90 95 250 VDC MINIMUM 208 240 VAC 125 140 90 160 165 POSSIBLE 97 Courtesy of NationalSwitchgear com ...

Page 100: ...Courtesy of NationalSwitchgear com ...

Page 101: ...Courtesy of NationalSwitchgear com ...

Page 102: ...tion or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter should be referred to the GE Company GE Electrical Distribution Control General Electric Company 41 Woodford Ave Plainville CT 06062 GEK 64460A 1993 General Electric Company Courtesy of NationalSwitchgear com ...

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GE AKR-60-75, Maintenance Manual

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