Courtesy of NationalSwitchgear.com
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: ...onary 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 Lubr...
Page 3: ...ched 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...
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...
Page 6: ...rrangements 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 s...
Page 7: ...s 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 identi...
Page 8: ...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...
Page 9: ...nly 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 s...
Page 10: ...mp 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 Inter...
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 NFP...
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 pos...
Page 13: ...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 charg...
Page 14: ...ch 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 n...
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...
Page 16: ...sm 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 pe...
Page 17: ...oded 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 a...
Page 18: ...wo 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 replaceme...
Page 19: ...olts 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...
Page 20: ...s 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 cont...
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 t...
Page 22: ...n 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...
Page 23: ...e 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 assembl...
Page 24: ...eet 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...
Page 25: ...ide 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...
Page 26: ...mediate 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 n...
Page 27: ...ntacts 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 to...
Page 28: ...8 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 d...
Page 29: ...g 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...
Page 30: ...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...
Page 31: ...n 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 revers...
Page 32: ...e 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 clo...
Page 33: ...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...
Page 34: ...ndle 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 mo...
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...
Page 36: ...rings 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...
Page 37: ...iven 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...
Page 38: ...embly 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 sc...
Page 39: ...ement 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...
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 F...
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 co...
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 D...
Page 43: ...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 rese...
Page 44: ...ns 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 l...
Page 45: ...y 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 en...
Page 46: ...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 clo...
Page 47: ...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 r...
Page 48: ...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...
Page 49: ...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 acro...
Page 50: ...ompanion 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...
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: ...g 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 f...
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...
Page 54: ...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...
Page 55: ...D 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 NationalSwitchg...
Page 56: ...teristics 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 t...
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...
Page 58: ...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...
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 EL...
Page 60: ...h 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 sys...
Page 61: ...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...
Page 62: ...GET 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...
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...
Page 64: ...g 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...
Page 65: ...fference 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 th...
Page 66: ...hase 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 instantaneou...
Page 67: ...ip 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...
Page 68: ...l 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 Bo...
Page 69: ...m 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...
Page 70: ...S 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 MO...
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 hi...
Page 72: ...MMER 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...
Page 73: ...tifying 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 tri...
Page 74: ...ith 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...
Page 75: ...k 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 C...
Page 76: ...s 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 wh...
Page 77: ...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 Condu...
Page 78: ...at 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 s...
Page 79: ...SOR 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 T...
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...
Page 81: ...unc 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...
Page 82: ...g 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 t...
Page 83: ...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...
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...
Page 85: ...opriate 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...
Page 86: ...ctly 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...
Page 87: ...A 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...
Page 88: ...3 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...
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 vary...
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...
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 short...
Page 92: ...ng 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 Armatu...
Page 93: ...tic 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...
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 t...
Page 95: ...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 t...
Page 96: ...itchette 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 tri...
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 n...
Page 98: ...A 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...
Page 99: ...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...
Page 100: ...Courtesy of NationalSwitchgear com...
Page 101: ...Courtesy of NationalSwitchgear com...
Page 102: ...ion 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 Com...
