GE Entelliguard TU Conversion Kit, MicroVersaTrip Plus Conversion Kit, PM Conversion Kit Installation Instructions Manual

INTRODUCTION

GE Conversion Kits are designed for upgrading existing Allis

Chalmers®, Siemens/Allis®, and Siemens® low-voltage

power circuit breakers, rather than replacing the entire breaker.

The Conversion Kits include Entelliguard TU™,

MicroVersaTrip Plus™ or MicroVersaTrip PM™ Trip Units,

the latest technological advance in GE trip systems.
Entelliguard, MicroVersaTrip Plus and MicroVersaTrip P

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 Entelliguard,
MicroVersaTrip Plus and MicroVersaTrip PM Conversion Kits
on Allis Chalmers®, Siemens/Allis®, and Siemens® LA-4000
low-voltage power circuit breakers. Each Conversion Kit
contains all the components needed to convert from the existing
trip system.

DEH40015

Installation Instructions .

R01

Entelliguard TU™, MicroVersaTrip
Plus™ and PM™ Conversion Kits

for Allis Chalmers®, Siemens/Allis® LA-4000-Blue
Low-Voltage Power Circuit Breakers

1

TABLE OF CONTENTS

Section 1. General Information ............................................................................................................ Page 3

Section 2. Before Installation ................................................................................................................ Page 3

Section 3. Breaker Preparation ............................................................................................................ Page 4

Section 4. Installing the Conversion Kit .............................................................................................. Page 5

Installing Flux Shifter Reset Bracket ............................................................................................................ Page 6

Installing ththe Trip Unit Wiring Harness ..................................................................................................... Page 7

Installing the Trip Unit Mounting Bracket .................................................................................................... Page 9

Installing the Current Sensors ..................................................................................................................... Page 10

Installing the Communications Harness ...................................................................................................... Page 11

Section 5. Installing the Trip Unit ...................................................................................................... Page 11

Section 6. Four-Wire Ground Fault Option ...................................................................................... Page 12

Section 7. Testing and Trouble-shooting ........................................................................................... Page 13

Testing ........................................................................................................................................................ Pages 13

Trouble-Shooting ........................................................................................................................................ Page 14

Nuisance Tripping on Ground Fault-Equipped Breakers .............................................................. Page 14

2

LIST OF FIGURES

1. Primary disconnects removed from the bottom studs. ............................................................................................. Page 4

2. Components supplied with the conversion kit. ........................................................................................................ Page 5

3. Old and New Reset Assembly. ................................................................................................................................ Page 6

4. Installed Reset Assembly. ........................................................................................................................................ Page 6

5. Flux shifter mounting location. ................................................................................................................................ Page 6

6. Flux shifter mounting.. ............................................................................................................................................. Page 6

7. Flux shifter mounting. .............................................................................................................................................. Page 6

8. Installing Reset Link. ............................................................................................................................................... Page 6

9. 36-pin trip unit connector ......................................................................................................................................... Page 7

10. 36-pin connector adapter bracket ............................................................................................................................. Page 7

11. Adapter bracket locking tabs.................................................................................................................................... Page 8

12. Installing the push nuts ono the guide pins. ............................................................................................................. Page 8

13. Locking tabs on mounting plate.. ............................................................................................................................. Page 8

14. Trip unit bracket mounting. ..................................................................................................................................... Page 9

15. Securing trip unit bracket. ........................................................................................................................................ Page 9

16. Position of current sensors. .................................................................................................................................... Page 10

17. Installing current sensors ....................................................................................................................................... Page 10

18. Installing wire harness. .......................................................................................................................................... Page 10

19. Caution label to be applied to the breaker and compartment door... ...................................................................... Page 11

20. Trip unit installed on the breaker. .......................................................................................................................... Page 11

21. Neutral sensor outline for 3000A through 4000A breakers ................................................................................... Page 13

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 Entelliguard,
MicroVersaTrip Plus and MicroVersaTrip PM kit 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 ground-fault trip element 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, when the trip elements of the
breaker are to be changed from long-time instantaneous to
long-time short-time, the short-time rating will govern the
application.

As a service-related consideration, the installation of a
Entelliguard, MicroVersaTrip Plus and MicroVersaTrip PM kit
provides an excellent opportunity to perform normal
maintenance on the breaker. 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, well-lighted work area.

WARNING: Low-voltage power circuit breakers use high­speed, 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 lock-out 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 the breaker OPEN and be
sure the stored-energy springs are discharged, thus
eliminating 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.

• Refer to DEH-4567 for supplementary instructions of
settings of the Entelliguard Electronic Trip Unit.

• Refer to DEH-3456 for supplementary instructions for
wiring the RELT circuit.

• Refer to DEH-6273 for supplementary instructions of
settings of the MicroVersaTrip Plus and MicroVersaTrip
PM.

4

SECTION 3. BREAKER PREPARATION

The following steps are performed to prepare the breaker for
installation of the new conversion kit. Unless otherwise
indicated, the procedure is the same for LA-3000 Gold, LA­4000 Gold, RL-3200 and RL-4000 breakers.

WARNING: Before installing the conversion kit, turn the
breaker OFF, disconnect it from all voltage sources, and
discharge the closing springs.

1. Open the breaker and remove it from its enclosure.

Carefully place the breaker on a suitable work surface so
that the rear of the breaker is initially accessible.

2. If the conversion kit is to be installed on a fused breaker

(LAF series), remove the fuse structure from the upper
(line) studs to allow easier access to the load studs.
Additional work may be required to install kit into fused
breaker.

3. Loosen the three Allen-head screws securing each of the

primary disconnects to the line (upper) and load (lower)
studs and remove the primary disconnects.

4. Remove the wires from the original current sensors (CTs),

if present, and slide off the CTs.

5. Remove manual charging handle. Remove the two bolts

holding the escutcheon to the breaker frame and lift off the
escutcheon.

6. Remove old flux shifter and mounting bracket. Also

remove old trip unit and its mounting bracket along with its
wire harness.

Figure 1: Primary disconnects removed from bottom studs