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DEH–40028A Installation Instructions
ProTrip™ Conversion Kits
For GE Types AK-50, AKU-50, AKS-50,
AKT-50, AK-75, and AK-100 Low-Voltage
Power Circuit Breakers
INTRODUCTION
GE Conversion Kits are designed for upgrading existing GE low-voltage power circuit breakers, rather than replacing the entire breaker. The 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.
TABLE OF CONTENTS |
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SECTION 1. GENERAL INFORMATION ....................................................................................................... |
4 |
SECTION 2. BEFORE INSTALLATION.......................................................................................................... |
4 |
SECTION 3. FRONT FRAME BREAKER CONVERSION |
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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 |
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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 |
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Configuring the Trip Unit.............................................................................................................. |
15 |
SECTION 6 FOUR-WIRE GROUND FAULT OPTION |
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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 |
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Installing Mounting Brackets ........................................................................................................ |
21 |
SECTION 8. TESTING AND TROUBLE-SHOOTING |
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Testing ........................................................................................................................................... |
23 |
Trouble-Shooting .......................................................................................................................... |
23 |
Nuisance Tripping on Ground Fault-Equipped Breakers ................................................ |
23 |
APPENDIX – DRILL TEMPLATES |
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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 |
2
LIST OF FIGURES |
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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 |
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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 |
3
SECTION 1. GENERAL INFORMATION
GE Conversion Kit installation is straightforward, but does require careful workmanship and attention to these instructions. Familiarity with the breaker is highly desirable. The general approach is to first remove the existing trip devices from the breaker, then install the ProTrip components. Following this procedure, the converted breaker is performance tested before it is returned to service.
The majority of trip unit kit installations do not require any customized assembly work. However, some conversions may involve unusual mounting conditions or accessory combinations that require minor modifications and/or relocation of 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.
SECTION 2. BEFORE INSTALLATION
Before starting any work, turn off and lock out all power sources leading to the breaker, both primary and secondary. Remove the breaker to a clean, 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.
4
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
X Relay
Figure 2. New X and W relay mounting brackets.
5
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.
Mounting |
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Screws |
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Flux Shifter |
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Assembly |
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Figure 5. Flux shifter assembly mounted to the side frame.
Figure 3. Flux shifter assembly.
6
Breakers with a Side Bracket
1.Drill a 3 4” 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. Figure 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.
7
Breakers with ECS or SST Trip Systems
1.Remove the ECS or SST trip unit.
2.Remove the existing flux shifter device and the trip unit control harness.
3.Install the new flux shifter assembly as described above and shown in Figure 5.
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 3 4" screws and lock washers provided along the top edge.
3.Slip the trip paddle over the trip actuator bar approximately one inch from the side frame, as shown in Figure 9. Insert the remaining 10-32 x
3 4" screw and tighten the other screws to secure the trip paddle in place.
Adjusting the Flux Shifter
After the flux shifter and trip paddle are installed and the breaker frames are reassembled, the following adjustments must be made.
1.With the breaker OPEN and the mechanism charged, set the gap between the trip paddle and the end of the flux shifter rod at 0.10 inch, as shown in Figure 10. Use a 0.10-inch diameter rod. Set the adjuster end of the trip rod and lock it in place with the jam nut. Note that removal of the buffer stud will make the trip paddle easier to install and adjust.
2.As the crossbar travels between the breaker CLOSED and OPEN positions, the tang of the actuator bracket must clear the buffer stud. If there is insufficient clearance, loosen the two mounting screws and rotate the 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 Paddles
Figure 8. Existing trip paddles to be removed.
1”
Trip
Paddle
Figure 9. Installing the new trip paddle.
Figure 10. Adjusting the flux shifter.
8
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.
9
Figure 13. Trip unit mounting bracket attached to the mounting
plate.
10
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