GE AK-50 User Manual
DEH–40028A Installation Instructions
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INTRODUCTION
GE Conversion Kits are designed for upgrading
existing GE low-voltage power circuit breakers,
rather than replacing the entire breaker. The Conversion Kits include ProTrip™ Trip Units, the latest
technological advance in GE trip systems.
ProTrip Conversion Kits are designed and tested to
conform to ANSI Standard C37.59, allowing the
retrofitter to properly install the kit and acceptance
test the breaker.
This publication covers installation of ProTrip Conversion Kits on GE types AK-50, AKU-50, AKS-50,
AKT-50, AK-75, and AK-100 low-voltage power circuit
breakers. Each Conversion Kit contains all the
components needed to convert from an existing GE
type EC trip system.
ProTrip™ Conversion Kits
For GE Types AK-50, AKU-50, AKS-50,
AKT-50, AK-75, and AK-100 Low-Voltage
Power Circuit Breakers
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TABLE OF CONTENTS
SECTION 1. GENERAL INFORMATION.......................................................................................................4
SECTION 2. BEFORE INSTALLATION..........................................................................................................4
SECTION 3. FRONT FRAME BREAKER CONVERSION
Relocating and Remounting the W and X Relays..........................................................................5
Installing the Flux Shifter Assembly ..............................................................................................6
Breakers with EC or Power Sensor Trip Systems ............................................................. 6
Breakers with a Side Bracket .............................................................................................. 7
AKU-50 Breakers Only........................................................................................................7
Breakers with ECS or SST Trip Systems ...........................................................................8
Installing the Trip Paddle................................................................................................................8
Adjusting the Flux Shifter...............................................................................................................8
Installing the Trip Unit Mounting Bracket......................................................................................9
EC or Power Sensor Trip System.......................................................................................9
ECS or SST Trip System.....................................................................................................9
SECTION 4. BACK FRAME CONVERSION
Crossbar Modification................................................................................................................... 11
Removing the Existing Trip Devices ............................................................................................12
AK-50 & AKS-50 Breakers with EC or Power Sensor Trip Systems................................ 12
AK-50 & AKS-50 Breakers with SST Trip Systems..........................................................12
AK-75 & AK-100 Breakers with EC or Power Sensor Trip Systems................................ 12
AK-75 & AK-100 Breakers with SST Trip Systems .......................................................... 12
Installing the Phase Sensors......................................................................................................... 13
AK-50 & AKS-50 Breakers ................................................................................................. 13
AK-75 & AK-100 Breakers.................................................................................................14
SECTION 5. INSTALLING THE TRIP UNIT
Configuring the Trip Unit.............................................................................................................. 15
SECTION 6 FOUR-WIRE GROUND FAULT OPTION
Installing the Fourth-Wire Disconnect .......................................................................................... 16
AK-50 & AKS-50 Stationary Breakers ............................................................................... 16
AK-50 & AKS-50 Draw-Out Breakers................................................................................17
AK-75 & AK-100 Draw-Out Breakers ................................................................................ 17
Installing the Neutral Sensor........................................................................................................ 19
SECTION 7. EQUIPMENT CONVERSION
Installing Mounting Brackets........................................................................................................ 21
SECTION 8. TESTING AND TROUBLE-SHOOTING
Testing........................................................................................................................................... 23
Trouble-Shooting..........................................................................................................................23
Nuisance Tripping on Ground Fault-Equipped Breakers................................................23
APPENDIX – DRILL TEMPLATES
Appendix 1. Drill Template for Flux Shifter Mounting................................................................ 27
Appendix 2. Drill Template for Trip Unit Mounting.....................................................................29
Appendix 3. Drill Template for Flux Shifter Mounting................................................................ 29
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LIST OF FIGURES
1. Relocation and remounting of the W and X relays................................................................................. 5
2. New X and W relay mounting brackets................................................................................................... 5
3. Flux shifter assembly............................................................................................................................... 6
4. Pattern for flux shifter mounting holes in the side frame...................................................................... 6
5. Flux shifter assembly mounted to the side frame.................................................................................. 6
6. Location of new hole in the flux shifter base..........................................................................................7
7. Locations of new holes for mounting the OFLO terminal block............................................................ 7
8. Existing trip paddles to be removed....................................................................................................... 8
9. Installing the new trip paddle.................................................................................................................. 8
10. Adjusting the flux shifter. ........................................................................................................................ 8
11. Mounting hole drill pattern for the trip unit mounting plate. ................................................................ 9
12. Trip unit mounting plate attached to the breaker front channel............................................................ 9
13. Trip unit mounting bracket attached to the mounting plate................................................................ 10
14. Actuator bracket attached to the left pole link...................................................................................... 11
15. Drill pattern for actuator bracket mounting holes. ............................................................................... 11
16. Existing EC trip devices before removal. .............................................................................................. 12
17. Removal of EC trip devices.................................................................................................................... 12
18. Parts provided for CT installation per pole........................................................................................... 13
19. CT post mounted in the breaker back frame......................................................................................... 13
20. CT installation completed...................................................................................................................... 13
21. Phase sensor installation on AK-75 & AK-100 breakers........................................................................ 14
22. Attaching the trip unit to the mounting plate....................................................................................... 15
23. Trip unit mounted on the breaker. ........................................................................................................ 15
24. Fourth-wire terminal board installation on AK-50 & AKS-50 stationary breakers............................... 16
25. Fourth-wire disconnect installed on AK-50 & AKS-50 draw-out breakers........................................... 17
26. Fourth-wire disconnect assembly for AKD-5 or AKD-6 equipment...................................................... 17
27. Fourth-wire disconnect assembly for AKD equipment......................................................................... 17
28. K-75 & AK-100 back frame conversion.................................................................................................. 18
29. Outline of the neutral sensor for AK-50 breakers.................................................................................. 19
30. Outline of the neutral sensor for AK-75 and AK-100 breakers.............................................................. 20
31. AK-50 & AKS-50 fourth-wire disconnect for AKD. ................................................................................ 21
32. AK-75 & AK-100 fourth-wire disconnect for AKD-5 & AKD-6. .............................................................. 21
33. AK-100 fourth-wire disconnect for AKD. ............................................................................................... 21
34. AK-50 & AKS-50 fourth-wire disconnect for AKD. ................................................................................ 22
35. Fourth-wire disconnect for AKD-5 & AKD-6.......................................................................................... 22
36. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads. ................................ 25
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SECTION 1. GENERAL INFORMATION
SECTION 2. BEFORE INSTALLATION
GE Conversion Kit installation is straightforward, but
does require careful workmanship and attention to
these instructions. Familiarity with the breaker is
highly desirable. The general approach is to first
remove the existing trip devices from the breaker,
then install the ProTrip components. Following this
procedure, the converted breaker is performance
tested before it is returned to service.
The majority of trip unit kit installations do not
require any customized assembly work. However,
some conversions may involve unusual mounting
conditions or accessory combinations that require
minor modifications and/or relocation of components. In most instances, this supplementary work
can be done on site.
In preparation for the conversion, the installer should
verify that the appropriate current sensors and trip
unit have been furnished. Whenever a ProTrip kit is
installed on a breaker with a four-wire system, an
associated neutral sensor (CT) is required for
separate mounting in the equipment. Ensure that
retrofitted breakers are applied within their shortcircuit ratings. For example, if the previous trip unit
provided long-time instantaneous protection, the
short-time rating of the ProTrip Trip Unit will govern
the application.
As a service-related consideration, the installation of
a ProTrip kit provides an excellent opportunity to
perform normal maintenance on the breaker, particularly when the front and back frames are separated. Such procedures are described in the installation and maintenance manuals supplied with the
breaker and equipment.
Before starting any work, turn off and lock out all
power sources leading to the breaker, both primary
and secondary. Remove the breaker to a clean, welllighted work area.
WARNING: Low-voltage power circuit breakers use
high-speed, stored-energy spring operating
mechanisms. The breakers and their enclosures
contain interlocks and safety features intended to
provide safe, proper operating sequences. For
maximum personnel protection during installation,
operation, and maintenance of these breakers, the
following procedures must be followed. Failure to
follow these procedures may result in personal
injury or property damage.
• Only qualified persons, as defined in the
National Electrical Code, who are familiar with
the installation and maintenance of low-voltage
power circuit breakers and switchgear assemblies, should perform any work on these breakers.
• Completely read and understand all instructions
before attempting any breaker installation,
operation, maintenance, or modification.
• Turn off and lock out the power source feeding
the breaker before attempting any installation,
maintenance, or modification. Follow all lockout and tag-out rules of the National Electrical
Code and all other applicable codes.
• Do not work on a closed breaker or a breaker
with the closing springs charged. Trip an OPEN
breaker and be sure the stored-energy springs
are discharged, thus removing the possibility
that the breaker may trip OPEN or the closing
springs discharge and cause injury.
• Trip the breaker OPEN, then remove the breaker
to a well-lighted work area before beginning
work.
• Do not perform any maintenance that includes
breaker charging, closing, tripping, or any other
function that could cause significant movement
of a draw-out breaker while it is on the draw-out
extension rails.
• Do not leave the breaker in an intermediate
position in the switchgear compartment. Always
leave it in the CONNECTED, TEST, or
DISCONNECTED position. Failure to do so could
lead to improper positioning of the breaker and
flashback.
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SECTION 3. FRONT FRAME BREAKER
CONVERSION
Front frame conversion consists of the following
steps:
1. Separation of the front and back breaker frames
for AK-50, AKU-50, AKS-50, and AKT-50 breakers.
(Frame separation is not necessary for AK-75 and
AK-100 breakers.) Refer to the appropriate
installation and maintenance manuals supplied
with the breakers and equipment for instructions
on frame separation. Copies of these publications
may be obtained from your local GE sales office.
2. Relocation and remounting the W and X relays
on AK-50, AK-75, and AK-100 electrically operated
breakers with EC trip devices.
3. Installation of the flux shifter assembly and trip
paddle.
4. Installation of the trip unit mounting bracket.
5. Installation of the trip unit wiring harness.
Relocating and Remounting the W and X
Relays
This step is necessary on electrically operated
breakers with EC trip devices. Figure 1 illustrates this
process. Figure 2 shows the new mounting brackets
supplied with the kit.
1. Remove the W relay and install the mounting
bracket supplied with the conversion kit to the
upper left side of the frame
2. Remove the X relay and its mounting bracket.
Use the new bracket supplied with the conversion kit to remount the X relay in its existing
position.
Figure 1. Relocation and remounting of the W and X relays.
W Relay
Figure 2. New X and W relay mounting brackets.
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Installing the Flux Shifter Assembly
The installation procedure for the flux shifter
assembly, illustrated in Figure 3, varies depending
on the type of breaker and existing trip device. In
some cases, mounting holes must be added, terminal blocks relocated, or breaker side rails removed.
Breakers with EC or Power Sensor Trip Systems
1. Drill the flux shifter mounting holes in the left
side of the breaker frame. The mounting hole
pattern is illustrated in Figure 4. A full-size template is provided in the Appendix.
2. Mount the new flux shifter to the inside of the
side frame with the three screws, lock washers,
flat washers, and nuts supplied, as shown in
Figure 5. Insert the screws from the outside of
the side frame.
Figure 4. Pattern for flux shifter mounting holes in the side frame.
Figure 3. Flux shifter assembly.
Mounting
Screws
Figure 5. Flux shifter assembly mounted to the side frame.
Flux Shifter
Assembly
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Breakers with a Side Bracket
1. Drill a 34” diameter hole into the flux shifter
assembly mounting base to provide the necessary clearance for the bracket. The location of the
new hole is shown in Figure 6.
2. Remove the side bracket from the frame and drill
the holes according to the pattern in Figure 4. A
full-size template is provided in the Appendix.
After the holes are drilled, return the side bracket
to its original location.
3. Mount the new flux shifter to the inside of the
side frame with the three screws, lock washers,
flat washers, and nuts supplied, as shown in
Figure 5. The upper two screws are inserted from
the outside of the frame, while the lower screw
must be inserted from the inside.
AKU-50 Breakers Only
For easier installation of the new flux shifter
assembly on AKU-50 breakers, the open-fuse lockout
(OFLO) may be removed from the breaker.
1. Remove the three bolts attaching the OFLO to the
base of the breaker.
2. The OFLO terminal block must be relocated on
the upper left side of the breaker. Some parts and
tool, not provided with the kit, are necessary for
this task:
• Six strips of 14 AWG wire
• Wire splice
• 12 butt splices
• Wire labels
• Drill and size F bit
•5/16-18 tap
• Flathead screw driver
• Two 5/16-18 bolts and lock washers
3. Drill and tap two holes for the 5/16-18 bolts. Fig-
ure 7 shows the hole locations.
4. Remove the three bolts securing the OFLO to the
breaker and lift off the OFLO device.
5. Remove the wires that connect the OFLO device
to the terminal block.
6. Cut the wires that connect to the coils where they
join and label the wires. Attach butt splices to all
twelve open ends.
7. Connect the strands of wire to the OFLO. Mount
the terminal block in its new location. DO NOT
complete the wire connections until the flux
shifter is installed.
8. Install the new flux shifter assembly as described
above and shown in Figure 5.
9. Connect the cables attached to the terminal block
and tie them together.
Figure 6. Location of new hole in the flux shifter base.
Figure 7. Locations of new holes for mounting the OFLO terminal
block.
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Breakers with ECS or SST Trip Systems
Paddle
1. Remove the ECS or SST trip unit.
2. Remove the existing flux shifter device and the
trip unit control harness.
3. Install the new flux shifter assembly as described
above and shown in Figure 5.
Installing the Trip Paddle
For breakers equipped with an ECS or SST trip system, the existing trip paddle is used with the new
flux shifter.
For all other breakers, the existing trip paddles must
be removed and the new trip paddle installed as
follows:
1. Remove and discard the three trip paddles on the
trip actuator bar, as shown in Figure 8.
2. Assemble the trip paddle and the threaded back
plate by inserting two of the 10-32 x 34" screws
and lock washers provided along the top edge.
3. Slip the trip paddle over the trip actuator bar
approximately one inch from the side frame, as
shown in Figure 9. Insert the remaining 10-32 x
3
4" screw and tighten the other screws to
secure the trip paddle in place.
Trip Paddles
Figure 8. Existing trip paddles to be removed.
1”
Adjusting the Flux Shifter
After the flux shifter and trip paddle are installed and
the breaker frames are reassembled, the following
adjustments must be made.
1. With the breaker OPEN and the mechanism
charged, set the gap between the trip paddle and
the end of the flux shifter rod at 0.10 inch, as
shown in Figure 10. Use a 0.10-inch diameter rod.
Set the adjuster end of the trip rod and lock it in
place with the jam nut. Note that removal of the
buffer stud will make the trip paddle easier to
install and adjust.
2. As the crossbar travels between the breaker
CLOSED and OPEN positions, the tang of the
actuator bracket must clear the buffer stud. If
there is insufficient clearance, loosen the two
mounting screws and rotate the bracket clockwise to take up mounting hole slack. Retighten
the screws.
3. Optional Test – The flux shifter may be tested by
closing the breaker and applying a 9 Vdc power
source to the flux shifter leads (the red wire is
positive). The breaker should trip.
Trip
Figure 9. Installing the new trip paddle.
Figure 10. Adjusting the flux shifter.
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Installing the Trip Unit Mounting Bracket
The new ProTrip trip unit mounts to the left side of
the front channel. A mounting bracket is shock-mounted to a plate that is assembled to the front
channel.
EC or Power Sensor Trip System
1. The holes for the new mounting plate may have
to be added to the front channel. The drill pattern
is shown in Figure 11, with a full-size template in
the Appendix. Tap the holes for 1/4-20 screws.
2. Attach the new mounting plate, as shown in
Figure 12, with two short 1/4-20 screws and lock
washers on the top and the single long 1/4-20
screw and lock washer on the bottom. Be sure to
insert the spacer between the mounting plate and
the breaker channel, as shown.
3. Attach the trip unit mounting bracket to the plate
with two screws, lock washers, and flat washers,
as shown in Figure 13.
ECS or SST Trip System
Remove the existing mounting plate and bracket.
Install the new mounting plate and bracket, using the
holes closest to the front of the breaker, as described
in steps 2 and 3 above.
If the manual indicator assembly busing on AK-50
manual breakers interferes with the mounting
bracket installation, then the bracket must be modified. Cut off a 3/4 x 11/2 inch section from the right
front of the plate to provide clearance.
Figure 11. Mounting hole drill pattern for the trip unit mounting
plate.
Figure 12. Trip unit mounting plate attached to the breaker front
channel.
10
Figure 13. Trip unit mounting bracket attached to the mounting
plate.
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