GE Industrial Solutions 8007R, 10007R User Manual

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HIGH SPEED DC CIRCUIT BREAKER

GERAPID 8007R, 10007R WITH ARC CHUTES 1X2, 1X3

USERS GUIDE

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 1

2 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

INDEX

1. WARNINGS........................................................................................................ 4

5. DIMENSIONS & SAFETY DISTANCES .................................................... 26

5.1 Safety distances and outlined dimensions. ..................27

2. GENERAL USAGE CONDITIONS................................................................ 4

2.1 Transportation and storing ..................................................... 4

2.2 Installation....................................................................................... 5

2.2.1 Operational environment................................................. 5

2.2.2 Installation and interfaces............................................... 5

2.3 Usage................................................................................................. 5

2.3.1 Supply and load ...................................................................5

2.3.2 Adjusting the over current release.............................. 5

3. TECHNICAL INFORMATION ........................................................................6

3.1 Introduction.................................................................................... 6

3.2 Components and accessories................................................ 6

3.2.1 Contact system ....................................................................6

3.2.2 Arc chute (Code 2)................................................................ 6

3.2.3 Mechanism .............................................................................6

3.2.4 Polarized over current release (Code 7)................... 7

3.2.5 ED impulse coil release (Code 12).................................7

3.2.6 Auxiliary tripping devices (Code 11)............................7

3.2.7 Forced tripping release (Code 13) ................................ 8

3.2.8 Lever for manual operating (Code 16)......................8

3.2.9 Auxiliary switches (Code 9).............................................. 9

3.2.10 Indicators.............................................................................. 9

3.2.11 Solenoid closing drive (Code 3)................................... 9

3.2.12 Electronic control system.............................................10

3.3 Technical data tables...............................................................11

6. INSPECTIONS AND MAINTENANCE ...................................................... 29

6.1 List of inspections......................................................................29

6.1.1 General visual inspection...............................................30

6.1.2 General functional inspection......................................30

6.1.3 Inspection of the arc chute...........................................30

6.1.4 Inspection of the contact system..............................31

6.1.5 Inspection of contacts’ tilt and gap ..........................32

6.1.6 Inspection of the screw connections.......................32

6.1.7 Inspection of the mechanical components ..........32

6.1.8 Checking the blockade of the POCT...........................32

6.2 List of maintenance works. ...................................................33

6.3 Spare parts lists..........................................................................34

6.3.1 Mechanical spare parts..................................................34

6.3.2 Electrical spare parts.......................................................34

7. CUSTOMER SUPPORT................................................................................. 35

7.1 Options overview. ......................................................................35

7.2 Ordering. ........................................................................................36

7.3 Glossary .........................................................................................37

7.4 Troubleshooting..........................................................................38

7.5 GE service teams........................................................................39

7.6 Notes................................................................................................40

4. ELECTRICAL CIRCUITS................................................................................13

4.1 Controls and plugs layout......................................................13

4.2 Connectors for external wiring............................................14

4.3 Electrical diagrams....................................................................15

4.3.1 Wiring code...........................................................................15

4.3.2 Controls supply circuit.....................................................16

4.3.3 ED coil with external capacity bank .........................17

4.3.4 NEKO control circuits .......................................................18

4.3.5 SU control circuit................................................................20

4.3.6 Shunt trip control circuit.................................................22

4.3.7 Zero voltage releases control circuit........................23

4.3.8 Indicators...............................................................................24

4.3.9 Auxiliary switch...................................................................25

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 3

1. Warnings

Warnings:

During operation, electrical equipment carries dangerous voltages. In addition, circuit breaker emits hot, ionized gases when switching currents, especially short circuit currents.

Installing, commissioning, maintaining, changing or refitting of this equipment must be carried out only by qualified and suitably trained personnel and under strict observation of national and international applicable safety regulations.

During their operation, circuit breakers must be equipped with appropriately fitted covers, e.g. in suitable enclosures or panel boards. Safety distances must be preserved. Suitably trained service personnel shall only carry out certain works.

Non-compliance with these warnings may result in death, and/or severe physical damage and extensive damage to equipment.

Prior to carrying out maintenance, inspection or checks, the circuit breaker must be open, the both terminals must be grounded, the circuit breaker must be switched off and the control plugs removed.

Manual activation of the breaker while energized is forbidden. Manual activation must only be used for maintenance and inspection purposes, when breaker power is off and grounded.

The circuit breaker consists of high energy moving components. Do not touch the circuit breaker while it is being switched ON (closing) or OFF (opening). There is a high risk of major injury.

The control circuits may include capacitor banks, which can be charged with dangerous voltages. Work on this section must be carried out carefully.

2. General usage conditions

2.1 Transportation and storing

• The breaker is transported on wooden palette. It is fixed by shrunken plastic film. A cardboard box covers the breaker on the palette. Truck, railway, airplane and ship transport is possible. In case of sea transport, special protection against salty and humid environment is provided.

• The circuit breaker must always be transported to the installation site vertically and fully packed. The packaging protects the device against damage and dust; it should only be removed prior to installation.

• If the packaging is damaged, the breaker and the arc chute must be inspected for damage. Ensure that all packaging materials have been carefully removed prior to breaker installation.

• For handling the unpacked breaker use the lifting rings

provided [Fig.0]. The rings are located on both sides of the breaker. For lifting, it is recommended to use 4-leg wire rope slings of 1 m length (max. 8mm diameter) or 4-leg chain slings of 1.5 m length (max. 20 mm chain diameter).

Lifting rings

Fig. 0 Lifting rings for handling the breaker

• WARNING: Breaker and arc chute must be transported separately. Never handle the breaker with arc chute installed!

• Take care that the bottom isolation plate of the unpacked breaker is not damaged during handling. Do not push the breaker back and forth on any rough surface.

• The breaker’s weight, including arc chute is listed in Table

1. Arc chute’s weight is approximately 30 kG (66 lb) for “1x_” type.

WARNING:

• Store in original packaging!

• Do not store outdoors!

• Use protection against crush and impact!

• Do not store the breaker in a damp area!

• Storing temperature-range –25 °C…+60 °C!

Adaptor

4 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

2.2 Installation

2.2.1 Operational environment

• The breaker, as delivered, is IP00 (NEMA 1) protected. It is intended to work in indoor applications, without pollutions, with non-conductive dust, protected against high humidity and condensation. Low conductivity dust deposit due to frequent condensation of humidity is acceptable. General environmental conditions refer to EN 50123-1 - annex B, and IEC 60947, class PD3.

• The breaker can operate at rated current within ambient temperature range of –5 °C to +40 °C (23 to 104 °F). Maximum operating ambient temperature is +55 °C (130 °F) with continuous current derated by 10 %.

• The breaker can operate at altitude up to 2000 m (~6500 ft) without derating.

• The breaker shall not be subjected to strong vibrations. Maximum vibrations of 0.5 g per 30 sec are allowed. Resonance frequency is in range of 31 to 33 Hz.

• Air shall be clean and its relative humidity shall be not

more than 50 % r.h. at the maximum temperature of +40 °C (104 °F). Relative humidity may be higher if the temperatures are lower, for example, 90 %r.h. at +20 °C (68 °F). Slight condensation might occur during variations of temperature

2.2.2 Installation and interfaces

• The lower and upper main terminals (Code 4) must be connected directly to the main cables or bus bars.

• WARNING: The breaker must only be used in an upright operation position with the arc chute in place and fully secured.

• After arc chute installation check for tightness both connections to the arc probes.

• The safety distances as listed in Table 4 shall be maintained to grounded or insulated parts. Suitable measures must be taken to protect personnel from arcs.

• Strong, external magnetic fields, caused by improperly located supply conductors or stray fields from other devices, can lead to a shift of the trip setting thresholds. This may result in premature tripping, or no tripping at all. This has to be accounted for when installing and operating the device with shielding added if appropriate.

• The control wires must be connected to the control terminals (Code 19), as shown in the schematic circuit diagrams in section 4. The protective grounding wire must be connected at the terminal –X2:3. This point is a common grounding for the drive and control box.

2.3 Usage

2.3.1 Supply and load

• The breaker has polarized main connections. The marks are stamped at the ends of the main connections [Fig. 1]. The normal current flow, forward direction, is from plus to minus terminals and does not cause breaker to trip. The reverse current flow, from minus to plus, does cause the breaker to trip.

• In accordance with its type, the breaker has been designed for the current and voltage listed in Table 1.

• During continuous operation, breaker must only be loaded up to its maximum rated current. Load currents in excess of breaker nameplate rating are allowable for brief periods. Refer to the short time currents listed in Table 1.

• Do not exceed the rated operating voltage shown on the breaker’s nameplate.

• Supply voltage for the drive and the auxiliary-tripping devices (Code 8) shall be within the specified control voltage range. Maximum current values for the auxiliarytripping devices are listed in Table 2a.

• WARNING: Plugging in or unplugging of the auxiliary connectors (-X2 :1/:2) (-X3 :4/:5) is only allowed with disconnected primary (mains) and secondary voltages.

2.3.2 Adjusting the over current release

• POCT is a polarized over-current tripping release (Code 7), which trips and releases the breaker in case of over currents for one direction only.. This is an instantaneous and direct acting device.

• If equipped with an adjustable POCT, the response threshold can be easily adjusted [Fig.2], by turning the adjustment nut 1 with a SW6 hexagon wrench 2.

• The adjustment must only be carried out after the breaker has been disconnected from the main circuit. For fixed installations breaker’s main terminals shall be grounded.

• Turning the adjustment screw clockwise increases the trip threshold, turning the screw counter-clockwise decreases the tripping threshold.

• Align the arrow and the desired marking 3, to perform adjustment.

SW 6

Fig. 2 Setting of the POCT release

Fig. 1 Polarization markings on the lower main terminals.

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3. Technical information

3.1 Introduction

• Gerapid R-type (rectifier type) is a single pole, high-speed DC circuit breaker, designed for use in railway propulsion power distribution systems with operating currents up to 8000 A (Code 1) and operating voltages up to 1200 V (Code 2).

• Gerapid breaker has a very high interruption capacity combined with a current limiting characteristic. The arc chute works on the basis of an asbestos-free arc splitting principle.

• A wide variety of accessories and spares are available for maintenance, repair, or as a possible enhancement.

• Use the catalogue coding system described in section 7.1 to configure the breaker. Each rating, option or accessory has own code.

• Closing of the circuit breaker is performed through a highpower solenoid drive (Code 3).

• During inspections, opening and closing may be carried out by means of a hand lever (Code 16), which is mounted onto the armature of the closing drive.

• Tripping and release is obtained directly by means of the POCT release (Code 7), or optionally by ED impulse release (Code 12). Indirect remote tripping can be achieved by means of a shunt trip, or optionally by a zero voltage release (Code 11).

• Gerapid breakers have a compact and enclosed construction. Gerapid is IP 00 protected. All parts are mounted on thick-walled, non-breakable and fireproof insulation panels.

3.2 Components and accessories

3.2.1 Contact system

• Gerapid breakers are equipped with a two-stage contact system [Fig. 3], consisting of a main contact and an arcing contact. With this proven design, the main contact is not subjected to any appreciable wear or tear. Each breaker has two such contacts, working as a single pole.

• The main contact is made of a silver composite material. The arcing contact and link braid are made of copper and can be easily replaced.

• The flexible bend is linked to the arcing contact by means of very tight braid.

3.2.2 Arc chute (Code 2)

• Compact and modular design of the arc system requires no additional magnetic blow out support and allows small safety distances with high breaking capacity.

• An adaptor [Fig. 1] is used to mount the arc chute on the breaker.

• The arc chutes consist of a highly durable, arc-proof material, in which the arc plates have been integrated.

• The arc plates split the arc into partial arcs and increase the arcing voltage by multiplying the anode and cathode voltage drop. Because of their high heat capacity, the plates and arc chute walls absorb a large amount of the arc’s energy.

3.2.3 Mechanism

• Gerapid is equipped with a modular designed mechanism, which is wear-resistant and nearly maintenance-free. This mechanism ensures an extended electrical and mechanical endurance of the breaker as well as a high level of safety under all operation conditions.

• The breaker is rated for 10 000 operations when opened by the shunt trip or zero voltage release, and 500 operations by means of ED impulse coil or POCT releases, before maintenance should be required.

• The mechanism is mechanically latched in the CLOSED position. The principle of a mechanically latched mechanism offers an advantage compared to often used electro magnet holding system. No auxiliary control power source is required to keep breaker closed.

• The mechanism is provided with two tripping latches [Fig. 4]. First latch, called “slow latch”, is used for opening under normal conditions, like actuation of shunt trip or zero-voltage release. The second one, “quick latch”, declutches the main contact arm from the mechanism and opens the contacts with an extremely short delay. This is used when interrupting short-circuit or overloads. All safety releases operate onto “quick latch” latch.

• The mechanisms in rectifier breakers are the same type, but different from standard, feeder breakers mechanisms. Therefore mechanisms cannot be exchanged between rectifier and feeder breakers.

Fig. 3 Two-stage contact system

Fig. 4 Latching and tripping system

6 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

3.2.4 Polarized over current release (Code 7)

• The POCT release is a magnet with two magnetic circuits. The first one (tripping yoke) provides bi-directional tripping function. The second one (blocking yoke) provides unidirectional blocking function.

• This technology ensures fast tripping in reverse current direction and no tripping in case of forward current. This system does not require an auxiliary control voltage or protection relay to operate. It is a direct acting and instantaneous tripping device.

• The tripping yoke [Fig. 7] consists of the holding circuit [6], the movable armature [3] and the tripping circuit [7]. The holding and the tripping magnetic circuits are both excited by load current [1]. Until the static overload release’s response threshold has been reached, the armature [3] is held in position by the holding flux (ΦH) [2] and the counter spring’s force [4]. Once the load current exceeds the set static response threshold, the attraction flux (ΦA) [2] takes over and rapidly pulls down the flexible armature [3]. During this operation, the armature hits the seesaw, which releases the quick latch in the mechanism. The latch and contacts are opened immediately.

• The response threshold can be easily adjusted by turning the adjustment nut with a SW6 hexagon wrench. The available ranges are described below. Other ranges might be possible on request.

• The blocking system of POCT consists of main magnet circuit, permanent magnet oscillator and blockades. If the main current in forward direction exceeds 250A, the locking system starts to operate and counteracts tripping. This makes the breaker a unidirectional device.

• Following tripping ranges are available: 0.4-1.2 kA; 0.8-

2.5 kA; 2.0-6.0 kA; 4.0-8.0 kA.

3.2.5 ED impulse coil release (Code 12)

• To detect high short circuit currents early and to record leakage currents in long peripheral sections (for railway equipment), whose final values are lower than the highest operating currents, protective relays for monitoring a current increase should be utilized. If a fault occurs, a release signal can be passed on to the ED impulse coil and capacitor release (NEKO), which causes the breaker to open rapidly (opening delay <3ms).

• This tripping device can be ordered as an accessory for the breaker, either alternatively, or additionally to a shunt trip or a zero voltage release.

• ED impulse release requires an external protective relay for monitoring a current increase. This relay must be provided and installed by the customer.

• Customer supplied capacitor trip unit may be used. Rated voltage of 300 V and capacity of 2 000 µF per coil is required. Rectifier breakers utilize two ED coils.

• WARNING: ED Firing signal voltage level is between 6 V and 24 V. There should be no spikes on the signal of duration less 3 ms. This can lead to failure of the NEKO board!

• WARNING: Maximum duration of the firing signal must not exceed ~1 sec. Longer signal can lead to NEKO overheating! It is recommended to use an auxiliary contact in serial connection with firing circuits. It will automatically cut off the firing circuits after opening.

3.2.6 Auxiliary tripping devices (Code 11)

• The breaker can be equipped with either a shunt trip (ST, a-release) or a zero voltage release (UVR, r-release).

• Both trips work at a voltage level of 24VDC. A voltage transformer, which is integrated into the breaker, adapts to other voltage levels and provides the energy required by the breaker mechanism (except for the drive).

• Optionally, it’s possible to supply both devices directly to external 24 V DC ( ± 5%). In this case the release signal for ST shall not be longer 100 ms.

• The shunt trip is used for remote actuation. It is designed for intermittent operation (ED=9%) and is always connected through an auxiliary contact to ensure that is only energized during the time until the breaker is opened.

• The UVR’s winding is designed for continuous operation. In case of a control voltage drop, the release mechanism opens the breaker. It is therefore possible to use the release in combination with the electronic trip unit for voltage monitoring, i.e. for motor starters, where an unintended re-start of a motor after a temporary voltage breakdown is to be prevented. Due to their operational mode, UVRs are self-monitoring devices, i.e. the breaker is tripped upon a break of the pilot wire (EMERGENCY-OFF principle).

• WARNING: Manual closing of the breaker with shunt trips installed, while signal OPEN is active and control power is applied, may lead to shunt coil overheating and damage.

Fig. 5 Tripping yoke of the POCT release.

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3.2.7 Forced tripping release (Code 13)

• Optionally, the forced tripping release (FT) can be installed in the breaker [Fig. 6]. This mechanical trip releases the breaker, by pressing the pin located in the bottom plate. Force required to trip the breaker is about 110 N (~25 ftlb). The tripping pin position is shown on Fig. 6.

• WARNING: This device, when active, does not prevent breaker from closing. Closing the breaker against activated FT may lead to damage of this release.

• With a correctly designed interlock in an enclosure, FT provides safety-tripping function. During withdrawal operation of the trolley, the breaker is tripped BEFORE its main terminals disconnect from the bus.

Bottom view

Fig. 6 Forced tripping release

3.2.8 Lever for manual operating (Code 16)

• Optionally, a hand lever for manual closing and opening operation during maintenance is available. This tool must not be use while breaker is energized!

• To close the contacts, install hand lever (1) on the drive’s rod, and pull it out smoothly until latches snap [Fig. 7]. Safe manual closing is shown on the Fig. 26, chapter 6.1.2.

• To open the contacts, insert lever’s pin (3) into the ring (2) and push it hard until breaker opens [Fig. 8] and [Fig 27].

• WARNING: Manual closing and opening – only during maintenance!

• Alternative manual closing and opening operation is possible by rotating the main shaft of the breaker mechanism, which is accessible from both side. Use 10 mm hexagon-box wrenches to OPEN/CLOSE [Fig. 9]. To close the breaker, shafts from both sides have to be rotated simultaneously.

• WARNING: Pay attention to control rotation speed of the

shaft during manual opening and closing. Impede the wrench to avoid hitting it to the ground, which may lead to a hand injury.

Fig. 7 Closing operation by using a hand lever

Fig. 8 Opening operation by using hand lever

OPEN

Fig. 9 ON/OFF operation by means of a 10 mm wrench

8 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

3.2.9 Auxiliary switches (Code 9)

• The breaker can be equipped with up to nine isolated form C auxiliary contacts (1 NO/NC each) [Fig. 10]. The contacts are activated by breaker’s main mechanism.

• The contacts are wired to 15-pin control plugs: -X4 and X5, with 5 switches to each plug.

• Conventional thermal current Ith=10 A. Maximum electrical interrupting ratings for switches are 1 A/230 V for AC15. For DC13 are 0.5 A/110 V and 0.3 A/220 V.

Fig. 10 Auxiliary switches block in the control box.

3.2.10 Indicators

Optionally, the circuit breaker can be equipped with following indicators:

• POSITION INDICATOR (Code 14) - mounted at the front of the closing drive [Fig. 12]. Moving drive’s rod is mechanically switching the indicator.

“OPEN” or “O” – means open main contacts “CLOSED” or “I” – means closed main contacts

• OC TRIP TARGET (Code 10) – a potential free, NO contact mounted at the top of the OCT [Fig. 14]. Provides a signal when OCT trips.

• ARC CHUTE INDICATOR (Code 17) – a potential free, NO contact mounted on the sidewall, item (1) on Fig. 11. Locks electrically the closing drive when arc chute is not installed on. The signal is available at terminal –X3 :12:13.

3.2.11 Solenoid closing drive (Code 3)

• The closing drive is mounted at the front of the breaker and is encased in a grounded casing [Fig. 12].

• The closing drive includes a self-interrupt control circuit (SU PCB). This circuit enables a short activation with minimum command duration of approximately 100ms, causing the voltage applied to the solenoid to be switched off after approximately 400ms and prevents, during continuous operation, repeated reclosing (anti-pumping) due to an existing short circuit.

• Closing drive is supplied independently from other controls (-X2 :1/:2), directly from external power source. Voltage level must be defined at order placement. Rated power, depends on breaker type, is 3 kW or 4.5 kW.

• After closing attempt, the switch-in mechanism is electrically blocked for approximately 8 sec. Lock time increases to 14 sec, if internal C-bank (NEKO) is present. This prevents premature closing following a short circuit.

Fig. 12 Closing drive with position indicator.

Fig. 11 Closing drive with position indicator.

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3.2.12 Electronic control system

All the control PCBs are installed in control box [Fig. 13]. Starting from the left, these are:

Fig. 13 Control box with control PCBs.

• (1) NEKO control unit [Fig. 13-1] (Code 12) – internal control unit with capacitor bank. Releases firing signal for ED coil and provides indication of the capacitors charging. NEKO control unit also blocks the firing signal until C-bank is fully charged (~15 sec).

• WARNING: NEKO unit requires a high quality signal. Be sure, that voltage level is between 6 V…24 V DC and there are no short spikes on signal (<3 ms). This may lead to major defect of the NEKO control unit!

• (3) SU control unit.

Fig. 13-3 SU control unit.

• (4) ST (a- trip) and UVR (r- release) control unit..

Fig. 13-4 UVR control unit

Fig. 13-1 NEKO control unit

• (2) Internal voltage converter (Code 8) - converts

external supply voltage (-X3 :4/:5) to the internal 24 V DC. Required by controls (except for the drive supply).

Fig. 13-2 Voltage converter 110 V/24 V DC.

Fig. 13-5 ST control unit

10 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

3.3 Technical data tables

Table 1. Technical data, type Gerapid 8007R & Gerapid 10007R

Parameter Reference Gerapid 8007 R Gerapid 10007 R

Arc chute type N/A 1x2 1x3 1x2 1x3 Rated continuous current [A] ANSI C37.14 p.5.3 6.000 6.000 8.000 8.000 2 hours current [A] N/A 7.200 7.200 9.600 9.600 2 minutes current [A] N/A 12.000 12.000 16.000 16.000 20 seconds current [A] N/A 18.000 18.000 24.000 24.000 Rated short-time current (250ms) [kA] ANSI C37.14 p.5.5 90 (149 peak) 60 (100 peak) 90 (149 peak) 60 (100 peak) Rated maximum voltage [V] ANSI C37.14 p.5.2 800 1200 800 1.200 Rated insulation voltage - UNm [V] EN 50124-1 p.1.3.2.4 2.000 2.000 2.000 2.000 Rated impulse voltage - UNi [kV] EN 50124-1 p.1.3.2.7 18 [1,2/50 µs] 18 [1,2/50 µs] 18 [1,2/50 µs] 18 [1,2/50 µs] Power frequency voltage – Ua [kV] EN 50124-1 a.B 2.2 10 [1 minute 50 Hz] 10 [1 minute 50 Hz] 10 [1 minute 50 Hz] 10 [1 minute 50 Hz] Mechanical endurance [cycles]

Rated short circuit peak / sustained current [kA] Short-circuit characteristic Tests a, b, c, d ANSI C37.14 annex A High-speed High-speed High-speed High-speed Maximum arc voltage [V] N/A 2.500 2.500 2.500 2.500

Mass ca. N/A 220 kG 220 kG 220 kG 220 kG

N/A 10.000 10.000 10.000 10.000

ANSI C37.14 p.5.4 200 / 120 132 / 80 200 / 120 132 / 80

10.000 cycles without parts replacement. Inspection after 5.000 cycles. Max. 5.000 cycles by means of ED impulse coil or POCT release.

Trip by means of POCT (direct-acting, instantaneous, electromechanical and polarized OC release) or by means of ED impulse coil with no intentional delay.

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Control box terminals (1) 12-pole AC 400 V, 20 A

(4) 15-pole AC 250 V, 8 A

Closing solenoid drive

Internal voltage converter

External power supply with plug and socket unit requires filtered DC 24 V (±5%) Aux. contact HS 1…HS 10, Rated operational voltage Ue/AC 230 V OC trip target (code 10) Rated operational current Ie/AC-15 1 A Arc chutes indicator (code 17) Conventional thermal current Ie/AC-12 (Ith) 10 A

Rated voltage AC 110 V - 240 V and DC 60 V - 250 V Operating range 80 % - 115 % of rated voltage Power consumption 60 Vdc drive 3000 W Power consumption all other voltages 4500 W Minimum command signal time 100 ms Minimum interval between two closing operations ~8 s w/o NEKO installed; ~14 s with NEKO Input: Voltage range DC 33 - 85 V Output: Voltage range DC 24 V (±5%) Current 6 A continuous Model description PCMD 150 48 S24W-GE

Input: Voltage range DC 88 - 145 V Output: Voltage range DC 24 V (±5%) Current 6 A continuous Model description PCMD 150 110 S24W-GE

Input: Voltage range AC 115 - 240 V, DC 125 - 353 V Output: Voltage range DC 24 V (±5%) Current 3 A continuous, 5 A for 100 ms Model description PCMA 70 S24W-GE or PCMAS 75 S24-GE

Rated operational voltage Ue/DC 110 V / 220 V Rated operational current Ie/DC-13 0.5 A / 0.3 A Minimum current/voltage ratings 0,1 mA / 6 V DC Contact duty (min. value) DC 10 V / 2 mA

Shunt trip (a-release) Rated voltage/power Uc/Pc 24 V / 100 W

Operating range: OFF 21.6 V - 26.4 V UVR (r-release) Rated voltage Uc 24 V Zero voltage release Operating range: OFF < 4 V

Operating range: ON 24 V (±10%)

Power consumption ~ 10 W ED impulse release Energie source: Capacity 2000 µF

Charging voltage 300 V

Switching interval max. 1/min with 10 consecutive operations

Endurance 1 000 operations with 1 operation per 180 s

Firing signal level / duration

6 - 24 V / 100 - 1000 ms

Charging signalization relay AC duty : AC 250 V/ 0.5 A - AC 120 V /1 A

DC duty : DC 220V/0.1A - DC 125V/0.3A - DC 10V/3A

Standard ambient conditions acc. to EN 50123-1 Attachement B. For meeting outside of this standard range, please contact GE.

Table 2a: Technical data of auxiliary circuits

Components Technical datas of control circuits

Us / In

Closing push-button -S1 (-X2 :4 / :5) DC 24 V / approx. 10 mA ST releasing push-button-S2 (-X2 :6 / :7) DC 24 V / approx. 4 A UVR releasing push-button -S2 ( -X2 :6 / :7) DC 24 V / approx. 10 mA

push-button -S2 ( -X2 :8 / :9 ) DC 24 V / approx. 450 mA

Impulse coil tripping w/o NEKO push-button -S3 (R=0.18 Ohm, Tau = 0.5ms) DC 300 V / ~1100 A / 3 ms Impulse coil tripping with NEKO "firing signal" at ( -X2 :10 / :11 ) DC 6 V…24 V / approx.20 mA

Table 2b: Control circuits ( directional values to rate the components )

12 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

4. Electrical circuits

4.1 Controls and plugs layout

Description

X2 Connector: Auxiliary- and control circuits X3 Connector: Auxiliary- and control circuits X4 Connector: Auxiliary contacts HS1...HS5 X5 Connector: Auxiliary contacts HS6...HS9 X10; X110 Control board: Voltage converter X11; X111 Control board: Interface for external DC 24V supply (OPTION) X12 Control board: SU control unit X13, X113 Control board: Shunt trip control unit X14, X114 Control board: Zero voltage release control unit X16; X116 Control board: NEKO control unit for ED impulse coil

Fig. 14 Controls and plugs layout

Designation

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4.2 Connectors for external wiring.

123456789101112131415

-S1 ( signal for CLOSE)

Closing drive supply (~,+) (S3)

Closing drive supply (N,-)

-S2 ( signal for OPEN by 1st shunt trip)

-S3 ed imoulse coil firing signal 6…24

-S2 ( signal for OPEN by 2nd shunt trip)

(+) (-)

123456789101112

Wiring to -X2 connector if shunt trip installed.

-S1 ( signal for CLOSE)

Closing drive supply (~,+) (S3)

Closing drive supply (N,-)

-S2 ( signal for OPEN by 1st UVR)

-S3 ed imoulse coil firing signal 6…24

-S2 ( signal for OPEN by 2nd UVR)

(+) (-)

External Control Voltage Supply (+)

External Control Voltage Supply (-)

1st NEKO charging indicator

(indicates C-bank charging)

POCT trip signal

2nd NEKO charging indicator

(indicates C-bank charging)

Arc chute presence indicator

Wiring to –X3 connector.

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HS 1

HS 2

HS 3

HS 4

HS 5

Wiring to –X4 connector.

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Wiring to -X2 connector if zero release installed.

HS 6

HS 7

HS 8

HS 9

Wiring to –X5 connector .

Fig. 15 Standard connections for external wiring.

14 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

4.3 Electrical diagrams

4.3.1 Wiring code

• The power circuits are not shown in the wiring diagrams for clarity. The control circuit is presented as a typical circuit diagram and is a combination of numbered basic diagrams for closing, tripping and indicators.

• The number of the complete diagram can be derived by using the key numbers of the basic plan.

• WARNING: Non-standard circuits may be issued for special orders. Such circuits do not comply with the diagrams in this instruction. In such a case an appendix is delivered with the breaker.

Coding positions:

Breaker type Aux. voltage supply ED impulse release Closing drive Aux. tripping device Indicators Aux. switches

EXAMPLE:

Key position:

Gerapid rectifier type With voltage converter Without ED and NEKO With closing drive With shunt trip With POCT indicator With 5 aux. switches

Key number:

1 / 2 3 4 5 6 7

37 / 1 0 20 10

Key position

Type

1 36 Gerapid

Auxiliary voltage

2 1 Voltage converter 2 DC 24 V external supply

Tripping coil

3 0 Without ed impulse coil 1 With ed impulse coil 2 With ed impulse coil and

Drive

4 20 Solenoid drive with

Tripping device

5 00 Without trip unit 10 With shunt trip 20 With zero voltage release

Indication device

6 00 Without indicators 01 POCT trip target 02 Arc chute indicator 03 POCT + arc chute indicator

Auxiliary contacts

7 1 3 auxiliary contacts 2 5 auxiliary contacts 3 10 auxiliary contacts

Indication of components

Q1 Closing drive coil Q2, Q3 Impulse ED coil S1 Push button „CLOSE“ S2 Push button „OPEN“ by means of ST or UVR S3 Impulse coil firing signal

SU control PCB:

K1 Closing relay K2 Internal closing stop relay K3 Solid state relay

Shunt trip, zero voltage release PCB:

K1 Internal closing stop relay K2 Tripping relay HS11 Shunt trip self cut-off auxiliary contact

ED-tripping device with internal NEKO PCB:

K1 Voltage monitoring relay

Internal closing stop relay

1) These relays are part of internal closing stop circuit. It is a 24 V DC closed circuit, through all PCBs in the box, except SEL. Serial connection of all relays is realized through connections ( :5/:6) in each PCB. This circuit provides priority of a tripping signal over a closing signal. Additionally it prevents from closing if the internal supply 24 V DC lost at UVR PCB or NEKO PCB.

Key number

Designation

NEKO control unit

SU control unit

Fig. 16 Example code shown on the nameplate.

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 15

4.3.2 Controls supply circuit

Breaker

External

power supply

+ / ~

AC 115-240V ±10% DC 35-350V ±10%

- / N

Breaker

External

power supply

DC 24 V ±5%

37/ X _ _ _ _ _ _

Key position - 2 Key number – 1: Voltage converter DC 35-85 V ; DC 88-145 V ; DC 125-353 V ;AC 115-240 V Ke

-X3

[ 4 ]

[ 5 ]

-X3

[ 4 ]

[ 5 ]

-X10

[ 1 ]

[ 3 ]

-X11

[ 1 ]

[ 3 ]

[ 10 ]

[ 9 ] [ 8 ]

[ 7 ] [ 6 ]

[ 10 ]

[ 9 ] [ 8 ]

[ 7 ] [ 6 ]

DC +24 V ±2% DC +24 V ±2%

GND GND

-X111

DC +24 V ±2% DC +24 V ±2%

GND GND

[ 1 ]

[ 3 ]

number – 2: Interface for direct external voltage DC 24 V +/-

-X110

]

[ 1

[ 10 ]

[ 9 ] [ 8 ]

[

7 ]

[

6 ]

[ 3 ]

[ 10 ]

[ 9 ] [ 8 ]

[ 7 ] [ 6 ]

5% connection.

Fig. 17 Supply with voltage converter or with direct external 24 V DC ±5%.

16 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

4.3.3 ED coil with external capacity bank

• In this option customer provides his own solution for releasing of the ED coils, by means of external capacitor trip device. The NEKO control unit is not furnished. The coils are connected to the front panel of the control box.

External

C-bank

U=300 V C=4000 uF

Breaker

-X2

[ 10 ]

[ 11 ]

-Q2

impulse

coil

-Q3

impulse

coil

37/ _ X _ _ _ _ _

Key position - 3 Key number – 0: Without ED coil.

number – 1: With ED coil and external C-bank.

Fig. 18 ED impulse coil with external capacitor bank.

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 17

4.3.4 NEKO control circuits

Cut-off

contact

i.e. HS 9

Provided

by user!

-X10/11

[ 8 ]

(+)

24 Vdc

[ 6 ]

(-)

-X3

[ 6 ]

C-bank

charging

signalization

[ 7 ]

Closing

STOP relay

-X2

[ 10 ]

Tripping

6V...24V

[ 11 ]

-Q2

ED impulse

coil no.1

signal

-X16: NEKO PCB

[ 1 ]

(+)

(-)

[ 2 ]

[ 9 ]

[ 10 ]

[ 5 ]

[ 6 ]

[ 3 ]

Signals

-K1

-K2

(+)

(-)

[ 4 ]

[ 11]

[ 12 ]

Impulse switching

Input circuit for firing signal

C-bank and output circuit

Isolating Transformer

Charging Control

Charging Voltage

Control

Firing signal

control

37/ _ X _ _ _ _

Key position - 3 Key number - 2: With ED coil and internal NEKO control unit.

• Firing signal at (-X2 :10/:11) is processed by opto-coupler. Pay attention to the polarity!

• Closing STOP signal is provided to lock CLOSE command, until capacitors are fully charged.

• Be sure that voltage level is between DC 6 V - 24 V and there are no transient spikes (<3 ms) on firing signal.

This can lead to major defect of the NEKO control unit!

• Maximum duration of the firing command must not exceed ~1 sec. Longer signal might cause NEKO failure! It is

recommended to use one of HS auxiliary contacts connected in series with firing circuit (-X2 :10). It will automatically cut off the firing circuit after breaker opening.

Fig. 19a 1st impulse release system with ED coil and internal NEKO control unit

18 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

-X110/111

[ 8 ]

24 Vdc

[ 6 ]

-X3

[ 10 ]

C-bank

charging

signalization

[ 11 ]

Cut-off

contact

i.e. HS 9

Provided

by user!

-Q3

ED impulse

coil no.2

(+)

(-)

Closing

STOP relay

-X2

[ 10 ]

Tripping

signal

6V...24V

[ 11 ]

-X116: NEKO PCB

[ 1 ]

(+)

(-)

[ 2 ]

[ 9 ]

[ 10 ]

[ 5 ]

[ 6 ]

[ 3 ]

Signals

-K1

-K2

(+)

(-)

[ 4 ]

[ 11]

[ 12 ]

Isolating Transformer

Impulse switching

Input circuit for firing signal

C-bank and output circuit

Charging Control

Charging Voltage

Control

Firing signal

control

37/ _ X _ _ _ _

Key position - 3 Key number - 2: With ED coil and internal NEKO control unit.

• Firing signal at (-X2 :10/:11) is processed by opto-coupler. Pay attention to the polarity!

• Closing STOP signal is provided to lock CLOSE command, until capacitors are fully charged.

• Be sure that voltage level is between DC 6 V - 24 V and there are no transient spikes (<3 ms) on firing signal.

This can lead to major defect of the NEKO control unit!

• Maximum duration of the firing command must not exceed ~1 sec. Longer signal might cause NEKO failure! It is

recommended to use one of HS auxiliary contacts connected in series with firing circuit (-X2 :10). It will automatically cut off the firing circuit after breaker opening.

Fig. 19b 2 impulse release system with ED coil and internal NEKO control unit

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 19

4.3.5 SU control circuit

Power

supply

+ / ~

AC 110-250V

DC 48-220V

- / N

-S1

-X10/11

[ 9 ]

24 V DC

[ 6 ] (-)

37/ _ _ X _ _ _ _

-Q1 Closing drive

-X12: SU PCB

-X2

[ 1 ]

[ 2 ]

-X2

[ 4 ]

[ 5 ]

(+)

Key position - 4 Key number – 20: Closing solenoid drive with standard SU control unit.

[ 3 ]

[ 4 ]

[ 8 ]

[ 9 ]

[ 10 ]

[ 7 ]

[ 5 ]

[ 6 ]

Transforming of CLOSE signal

-K1

Closing

STOP

-K2

[2]

[1]

Closing control

circuit

-K1

Fig. 20a SU-control circuit for drives supplied with 110 V and over.

20 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

Power

supply

+ / ~

AC 110-250V

DC 48-220V

- / N

-S1

-X2

[ 1 ]

[ 2 ]

-X10

[

+ ]

24 V DC

- ]

[

-X2

[ 4 ]

[ 5 ]

-X10/11

[ 9 ]

(+)

24 V DC

[ 6 ] (-)

37/ _ _ X _ _ _ _

Key position - 4 Key number – 20: Closing solenoid drive with SU control unit for supply voltage 60V d.c..

-X18

[ 1 ] [5]

[ 2 ] [6]

[4] [3]

-X12: SU PCB

[ 3 ]

[ 4 ]

[ 8 ]

[ 9 ]

[ 10 ]

[ 7 ]

[ 5 ]

[ 6 ]

-K1

-K2

Closing

STOP

SSR

[2]

-K3

:1 +

-K3

:A2 -

[1]

:2 -

:A1 +

Transforming of CLOSE signal

-K1

-Q1

Closing drive

Closing control

circuit

Fig. 20b SU-control circuit for closing drives supplied with 60 V d.c.

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 21

4.3.6 Shunt trip control circuit

-X2

[ 6

[ 7 ]

]

-S2

-X2

[ 8 ]

[ 9 ]

-X110/111

](-)

[ 7

24 V DC

[ 9

] (+)

1ST ST coil

Cut-off contact

-HS12

-X113: ST PCB

[ 4 ]

[ 3 ]

[ 5 ]

-K1

[ 8 ] [ 6]

[ 7 ]

[ 10 ]

[ 9 ]

[ 1 ]

[ 2 ]

-K1

Closing

STOP relay

-X10/11

](-)

[ 7

24 V DC

[ 9

] (+)

2ND ST coil

Cut-

off

con

tact

-HS

-X13: ST PCB

[ 4 ]

[ 3 ]

[ 5

-K1

[ 8 ] [ 6 ]

[ 7 ]

[ 10 ]

[ 9 ]

[ 1 ]

[ 2 ]

-K1

Closing

STOP relay

37/ _ _ _ X _ _ _

Key position - 5 Key number - 00: Without shunt trips or zero voltage releases.

number - 10: With shunt trips.

• The closing STOP signal is provided for resetting K2 on the SU-control circuit. It effects with priority in switching OFF (by ST or UVR) before switching ON. Once switching ON and OFF signals are simultaneous, switching OFF command will stay longer, than switching ON. It means, that OFF command is a master command.

• The coils energize for short time only. After main contacts opening, switch HS 11 and HS12 cuts off both trips.

• Manual closing of the breaker, while –S2 contact is closed, leads to overheating of ST coils and its damage.

]

Fig. 21 Shunt trips control circuit

22 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

4.3.7 Zero voltage releases control circuit

-X2

[ 6 ]

[ 7 ]

-S2

-X2

[ 8 ]

[ 9 ]

-X10/11

[ 7 ](-)

DC 24 V

1st UVR coil

X14: UVR PCB [ 5 ]

[ 1 ] [ 6 ]

[ 2 ]

[ 3 ]

[ 4 ]

[ 7 ]

[ 8 ]

[ 9 ]

[ 10 ]

-K2

-K1

-K2

-K1

Closing

STOP relay

-X110/

-X111

[ 7 ](-)

DC 24 V

[ 8 ] (+)

2nd UVR coil

37/ _ _ _ X _ _ _

Key position - 5 Key number - 00: Without shunt trip or zero voltage releases.

number - 20: With zero voltage releases.

• The closing STOP signal is provided for resetting K2 on the SU-control circuit. It effects with priority in switching OFF (by ST or UVR) before switching ON. Once switching ON and OFF signals are simultaneous, switching OFF command will stay longer than switching ON. It means, that OFF command is master command.

-X114: UVR PCB [ 5 ]

[ 1 ] [ 6 ]

[ 2 ]

[ 3 ]

[ 4 ]

[ 7 ]

[ 8 ]

[ 9 ]

[ 10 ]

-K2

-K1

-K2

-K1

Closing

STOP relay

Fig. 22 Zero voltage releases control circuit

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 23

4.3.8 Indicators

-X3

[ 8]

[ 9]

[ 12

[ 13

]

OCT trip target

Arc chute

indicator

37/ _ _ _ _ X _ _

Key position - 6 Key number - 00: Without indicators. Key number - 01: With POCT trip target only. Key number - 02: With arc chute indicator only.

number - 03: With POCT trip target and arc chute indicator.

Fig. 23 POCT trip target and arc chute presence indicator

24 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

4.3.9 Auxiliary switch

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HS 1

HS 2

HS 3

HS 4

HS 5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

HS 6

HS 7

HS 8

HS 9

37/ _ _ _ _ _ X

Key position - 7 Key number - 1: With 3 switches (HS1 thru HS3). Key number - 2: With 5 switches (HS1 thru HS5). Key number - 3: With 9 switches (HS1 thru HS9).

Fig. 24 Auxiliary switches.

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 25

5. Dimensions & safety distances

Warnings

During operation, all metallic parts of the breaker, except housing and

closing solenoid, may carry dangerous voltages.

For installation of the breaker into cubicle, top and side openings shall be provided, in order to reduce internal pressure rise during short circuit clearing.

Cubicle top cover shall have not less than 50% ventilation openings.

26 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

5.1 Safety distances and outlined dimensions.

Units call in mm and inches.

Type Arc chute Main-

Gerapid ConnectionABCDABCD

8007R

10007R

1x2 1x3

1x2

all all

all

Legend for dimensional drawing

K Additional heat sinks for Gerapid 10007R L All openings respectively free areas on the top of the cubical shall be not less than 50% M Solenoid closing drive P Diameter 9 mm [0,35 in], Countersunk screw M8 S Control box Z Main connectors *) Dimensions valid only for Gerapid 8007R version. **) Dimensions valid only for Gerapid 10007R version. ***) Lifting eye fi 25 mm [ ~ 1 in]

Main terminals dimensions:

Type Connection

Gerapid version A B C D

8007R

10007R

R01 R02

74 / 2.91 23 / 0.91 22 / 0.87 22 / 0.87 50 / 1.97 41 / 1.61 27 / 1.06 36 / 1.42

Dimensions on the drawing

mm/in mm/in mm/in mm/in

Cubicle with blank grounded walls Cubicle with insulated walls

mm/in mm/in mm/in mm/in mm/in mm/in mm/in mm/in

600 / 23.6 530 / 20.9 530 / 20.9 190 / 7.5 600 / 23.6 280 / 11.0 280 / 11.0 190 / 7.5 600 / 23.6 530 / 20.9 530 / 20.9 190 / 7.5 600 / 23.6 280 / 11.0 280 / 11.0 190 / 7.5

600 / 23.6 530 / 20.9 530 / 20.9 190 / 7.5 600 / 23.6 280 / 11.0 280 / 11.0 190 / 7.5

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 27

Fig. 25 Gerapid 8007R and 10007R with arc chute 1xtype; dimensions in mm [in].

28 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

6. Inspections and maintenance

6.1 List of inspections

TYPE OF THE INSPECTION A. General visual

inspection

B. General functional inspection

C. Inspection of the arc chute and contact system

D. Inspection of the screw/bolt connections

E. Inspection of the mechanic components

Required tools:

Cleaning tissue; abrasive paper; manual closing lever; metric hex (Allen) wrenches SW5, SW6; Torx® wrenches size T30,T 40, T45; small and medium screwdrivers; ratchet with 10 mm hex socket; pliers; tongs.

Dispose of the breakers if required:

Pay attention to the national and local regulations of disposal!

BY WHOM HOW OFTEN WHAT TO DO/CHECK

-Customer

-Trained technician

-Customer

-Trained technician

-Customer

-Trained technician

-Customer

-Trained technician

-GE

-Service technician

At least once a year.

After:

• high short circuit opening over 25 kA

• 300 openings at load current or frequent overload switching.

At least once a year.

After every inspection:

• of the arc probes

• of the contacts

• of the arc chute

At least once a year.

After 5.000 openings

At least once every 4 years

• Check for damages or cracks of the frame, adapter or arc chute

• Check for missing screws or caps

• Check for damaged labels

• Check for corrosion

• Check for distinct manifestations of flame

or smoke at the frame

• Clean the breaker from dirt and dust

• Clean and degrease the copper terminals

• Manually close and open the breaker to

check the drive and mechanism

• Close the breaker electrically and open by trip unit(s) releasing, to check controls

• Check the blockade of POCT

• Check for wear of the arc probes; shall not

exceed 30 % of its cross section

• Check for wear of the pre-arcing contact. It shall not exceed 2 mm [0.08 in].

• Check for wear of the main contacts at fixed and flexible sides; shall not exceed

1.5 mm [0.06 in] of its depth.

• Check for wear of the arc chute plates; check for deposits inside of arc chute, this area shall be free of deposits.

• Check for wear of protective walls; shall not exceed 1 mm [0.04 in].

• Check for contact tilt and gaps.

Check the position of the countersunk screws in the sidewalls. Check for tightness or use torque tool (torque in SI and Imperial units):

• M8 ~20 Nm [~ 177 in-lbs]

• M6 ~10 Nm [~ 88 in-lbs]

• M5 ~5 Nm [~ 44 in-lbs]

• M4 ~3 Nm [~ 26 in-lbs]

• Carry out inspection “B” above

• Check out settings of the main contacts

and auxiliary switch

• Check out upper dumper of the mechanism; no cracks, deformation or heavy discoloration; hard consistency; without punctures

• Check out main flexband breakage; shall not exceed 30 % of its cross section

• Check out wear of mini flexband; shall not exceed 30 % of its cross section

• Clean and degrease UVR latch and quick latch of the mechanism. Apply dash of Beacon EP2 grease afterwards.

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 29

6.1.1 General visual inspection

• Check for damages or cracks of the frame, the adapter or the arc chute.

• Check the black marks on the countersunk screws. These marks shall be aligned together. If any screw is loosening, shall be replaced with new one, using Loctite

222. Afterwards, mark the screw with black line to sign its position in nest.

• Check for missing screws or caps.

• Check for damaged labels. Clean and repair.

• Check for corrosion. In case of significant corrosion,

please contact GE representative for assistance.

• Check for distinct manifestations of flame or smoke on the frame. Especially in lower area of the breaker. Please document and contact GE representative for assistance.

• Clean the breaker of dirt and dust. Remove all dirt with a dry cloth. No excessive signs of abrasion (rough chips) should be visible anywhere.

• Clean and degrease the copper terminals, if necessary.

6.1.2 General functional inspection

Pay attention to the warnings, Section 1!

• In order to check the latch mechanism, the breaker can be opened and closed with a hand lever.

• Switch the breaker ON and OFF several times. The contacts must close after the ON command, and the contacts must open following the OFF command via the shunt trip or the zero voltage release.

• The breaker mechanism must not appear sluggish nor must ON/OFF be unduly delayed.

Fig. 27 Using of the hand lever for manual opening.

6.1.3 Inspection of the arc chute

Pay attention to the warnings, Section 1!

A) Remove the arc chute

• [Fig. 28]. Take off isolation caps (6). Loosen the clamping screws (3) and (4), using SW5 hexagon wrench and lift off the arc chute (1) from the adapter (2).

B) Check the arc chute

• [Fig. 29]. Check the arc chute’s interior, as far as possible, for presence of many copper pearls on the chute’s plates (1) that could partially link the plates.

• [Fig. 29]. Check the general condition of the insulation plates (4). These shall not be bent or burned. Also other insulation shall not be heavily damaged.

• [Fig. 29]. Check the arc horns (2). The cross section shall not be reduced more than ~30 %.

• [Fig. 29] Check the splitting plates (3). These shall not be burned more than ~20 mm [~0.8 in].

C) Install the arc chute

• [Fig. 28]. Put arc chute (1) into adapter (2).

• [Fig. 28]. Tighten front and backside connections of the

arc probes (3), including lock washer. Use a torque of 10 Nm [88 in-lbs].

• [Fig. 28]. Tighten backside of the arc chute connections (4), use flat washers. Use a torque of 5 Nm [44 in-lbs].

• [Fig. 28]. Put on isolation caps (6).

4 6

Fig. 26 Using of the hand lever for manual closing.

Fig. 28 Arc chute and arc probes fixing.

30 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

Fig. 29 Inspection of the arc chute.

6.1.4 Inspection of the contact system

Pay attention to the warnings, Section 1!

A) Remove the arc chute

• [Fig. 28]. Take off isolation caps (6). Loosen the clamping screws (4) and (3), using SW5 hexagon wrench and take off the arc chute (1) from the adapter (2).

B) Remove the arc chute adapter

• [Fig. 30]. To dismantle the arc chute adapter, loosen and pull out the four upright screws (1) using SW5 tool. Pay attention that no screws or washers fall inside the breaker!

• [Fig. 30]. Draw aside and lift off both halves of the adapter (2). Then pull out two protective walls (3).

Fig. 31 Checking the contact system erosion.

C) Check the protective walls

• [Fig. 31]. The material burn out on the protective walls (5)

must not exceed 1 mm [0.04 in] in any place.

D) Check the pre arcing probes

• [Fig. 31]. The arcing contacts should not be reduced to less than 1/3 of the total cross section in any place. Pay particular attention to the area around probe bend (3) and firing point of pre-arcing contact (2).

E) Check the arcing contact

• [Fig. 31]. Erosion of the pre-arcing contact (1) should amount to no more than 2mm; maximum value is 3mm! If it is greater than 3mm, it must be replaced.

F) Check the main contacts

• [Fig. 44]. The main contacts (4) should not show any obvious signs of material erosion, since, in the case of ordinary short circuits, overload and operating current switching, the arc is ignited between the pre-arcing contacts.

• Arcing can take place on the main contacts only with excessively worn and old pre-arcing contacts, or at very high short circuit currents. The wear should not exceed an area of 1.5 mm [0.06 in].

G) Install the adapter

• [Fig. 30]. Install the two protective walls (3). Use new ones if necessary. Install two halves of the adapter (2) and tighten screws (1) to 10 Nm [88 in-lbs].

H) Install the arc chute

• [Fig. 28]. Put the arc chute (1) into adapter (2). Tighten front and backside of the arc probe screw connections (3) including lock washer, with a torque of 10 Nm (88 inlbs). Tighten front and backside of the arc chute connections (4), including flat washers, with a torque of 5 Nm (44 in-lbs). Put on isolation caps (6).

Fig. 30 Adapter and contacts area.

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 31

6.1.5 Inspection of contacts’ tilt and gap 6.1.6 Inspection of the screw connections

312

Pay attention to the warnings, Section 1!

A) Remove the arc chute and adapter

• See 6.1.4-A/B.

B) Check the tilt of the main contacts

• Use the hand lever for slowly closing the main contacts.

• Once the arcing contact touches arc probe, check the air

gap between main contacts. The gap between main contacts shall have more than 1 mm [0.04 in].

• In case of insufficient tilt (gap), replace the arcing contact with new one. See 6.2.1 and 6.2.2 for details.

• If required gap is not available, even after component replacing, please contact GE Service Team.

C) Check the air gap of arcing contact

• Close the breaker and secure the solenoid drive against unintended opening.

Pay attention to the warnings, Section 1!

• [Fig. 28]. Tighten front and rear arc probes’ screw connections (3). Use torque of 10 Nm [88 in-lbs]. The arc probe’s screw connections (3) must be secured by means of lock washer.

• [Fig. 28]. Tighten arc chute connections (4). Use torque of 5 Nm [44 in-lbs]. The arc chute’s screw connections (4) must be secured by means of flat washer.

• Any other screws shall be tightening with applied torques listed in chapter 6.1, D.

• Ensure that the screws are in good condition, that thread and nest are not damaged. Surface shall be free from rust. Replaced any screw, which does not fulfill above conditions.

• This check must be carried out prior to commissioning or testing, and after maintenance.

6.1.7 Inspection of the mechanical components

Only GE Service Team or its representative shall perform this inspection. These require major disassembly and adjustment of the breaker. Customer, without supervision of trained specialist, shall not execute these.

Fig. 32 Securing closing drive against opening

6.1.8 Checking the blockade of the POCT

Pay attention to the warnings, Section 1!

A) Check the blockade

• During inspection, note the position of the POCT’s blockade (2). Normal position of the blockade, when no current flow, is “unblocked”. [Fig 35]. The spring (1) presses blockade (2) and forces “unblocked” state.

• After long periods of activation, the blockade may become slightly polarized and may stay permanently in the BLOCKED position [Fig 36].

• In this case, use a long thin wire or rod to check if blockade can operate easily. Push blockade into block state and release. Blockade must move back and unlock the POCT.

• Use right access slot (4) to unblock the blockade with rod. Very slowly start to push the blockade. After ~1…2 mm blockade must switch back to unlock state only by spring pressure.

Fig. 33 Inspection of the main contacts gap.

• [Fig. 33]. Check the air gap between the arcing contact and main arm. It shall be minimum 1 mm [0.04 in].

• If required gap is not available, the arcing contact and/or probes have to be replaced.

D) Install back adapter and arc chute

• See 6.1.4-G/H.

Fig. 34 Back view on blockade and access slots

32 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

Push here to unlock

Fig. 35 “Unlock” state of the blockade Fig. 36 “Locked” state of the blockade

6.2 List of maintenance works.

Maintenance works on the rectifier breaker must only be performed by trained personnel !

TYPE OF THE WORK BY WHOM WHEN REQUIRED RECOMMENDATIONS A. Arc chute changing Trained personnel As a result of the inspection C B. Arcing contact and arc

probes changing

C. Protective walls changing Trained personnel As a result of the inspection C D. Adjustment of the

contacts

E. Replacement of the control board F. Adjustment of the mechanism G. Flexband or fixed contact changing

H. Mechanism changing -GE Service Engr As a result of the inspection B,E I. Dumper(s) changing -GE Service Engr As a result of the inspection E Replace upper and lower dumper at

J. Trip unit changing &

adjustment K. Auxiliary contacts adjustment and changing

L. Drive changing -GE Service Engr As a result of the inspection B,E M. Accessories changing -GE Service Engr As a result of the inspection B,E

Required tools:

• Cleaning tissue

• Pocket lamp

• Hand lever

• Hexagon wrench SW 4, SW 5, SW 6

• Screw wrench SW 10, SW 13

• Torx® wrench size T30, T40 and T45

• Small and medium screwdriver

• Pliers

• Wire cutter

• File

• Steel brush

Trained personnel As a result of the inspection C Replace complete arcing set.

-GE Service Engr As a result of the inspection C Only when replacement of the arcing contact results with incorrect gaps. See point 6.1.5.

Trained personnel As a result of the inspection B,E

-GE Service Engr As a result of the inspection B,E

-GE Service Engr As a result of the inspection C,E

the same time.

-GE Service Engr As a result of the inspection B,E

Trained personnel As a result of the inspection B,E In case of improper operation of the

switches, adjustment might be necessary.

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 33

Hints for parts identification:

6.3 Spare parts lists.

6.3.1 Mechanical spare parts.

NOTE: Gray-shaded parts are recommended for a

maintenance stock.

Component Part no. Ver. Package

Arcing contact 128 122 R02 Each Arc probes set - back side 128 541 Complete Arc probe front side 128 547 Complete Protection wall 128 516 R03 Each Fixed main contact 128 110 R05 Each Movable main contact 128 108 R05 Each Ground insulation 128 203 R03 Complete Adapter 128 505 R01 Each

Probe protection cap 128 529 Each Arc chute 1x2 128 550 R01 Complete

Arc chute 1x3 128 550 R02 Complete

6.3.2 Electrical spare parts.

NOTE: Gray-shaded parts are recommended for a

maintenance stock.

Component Place Part no. Ver. Package

SU control PCB X12 128 700 Each

Voltage converters : X10, X110

PCMD150 24 S24W-GE PCMD150 48 S24W-GE PCMD150 110 S24W-GE PCMA150 70 S24W-GE

Standard NEKO PCB X16, x116 128 750 R01 Each

ST control PCB X13, X113 128 710 R01 Each

UVR control PCB X14, X114 128 710 R02 Each

Auxiliary contact HS1 - HS9 174 349 Each

Shunt trip right side/left side 128 300 R06/07 Complete

Zero release right side/left side 128 320 R02/03 Complete

Plug: PC 4/12-STF-7.62 X2 Each

Plug-in: DFK-PC 4/12-GF-7.62 X2 Each

Plug: MSTB2.5/15-STF X3, X4, X5 Each

Plug-in: DFK-MSTB2.5/15-GF X3, X4, X5 Each

128 730 R02 Each 128 730 R03 Each 128 730 R04 Each

128 730 R05 Each

128 541 128 108 R05

128 547 128 516 R03

128 110 R05

128 203 R03

34 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

128 529 128 122 R02

128 505 R01

7. Customer support

7.1 Options overview.

• The coding system, introduced in 2008, is a catalog configuration tool based on Excel®.

• The catalogue code consists of 20 digits. Each digit represents specific rated value or component.

• Table 7 shows all available values, components and accessories for the Gerapid breaker family. Detailed descriptions are available in section 3. Please contact GE Sales representative in case of any questions.

• The coding system is valid for Gerapid feeder type (F), rectifier type (R) and disconnector type (DS). This User Manual relates only to standard, feeder type breakers (F).

• Not all of the options from Table 7 are compatible. To avoid improper configurations use the “Gerapid configuration tool” for ordering.

• This Excel® based tool provides a quick and mistake proof configuration with automatic generating of the proper catalogue code and set of characteristics helpful for order description. Ask your GE Representative for details. The number of this tool is:

APN460437.

Table 7. General options overview for Gerapid breakers.

Breaker type Code number: 123 4 567891011121314151617181920 Relevant standards

1 Gerapid 2607 5 Gerapid 8007R LV DC acc. IEC60947-2 4 Railway DC acc. EN50123-2 1 2 Gerapid 4207 6 Gerapid 10007R On Request R LV DC acc. IEEEC37.14 2 3 Gerapid 6007 7 Gerapid 8007DS China acc. IEC947-2 & GB14048.2 3 4 Gerapid 8007

Arc chute type Code 2 Gearapid SE retrofit 3 Railway & Industry applications 1

1 1X2 (1000 V) 4 2X2 (2000 V) S 2X2 S (1500 V) Heavy Industry type 4 Military type acc. MIL-C-5015G 2

2 1X3 (1500 V) 5 2X3 (3000 V) E EF4-12 (3600 V) R 3 1X4 (2000 V) 6 2X4 (3600 V)

Closing solenoid supply voltage Code 3 Mechanical Counter 1 Without 0

1 48 V DC 5 220 V DC 9 125 V AC 2 60 V DC 6 250 V DC A 230 V AC 3 110 V DC 7 110 V AC B 240 V AC Code 17 Arc chute presence signal 4 125 V DC 8 120 V AC R On Request With 1 Without 0

1 H/H - (H)orizontal 4 V/V B Special type B With 1 Without 0 2 H/V - (V)ertical 5 For SEL 6 kA S Special type S 3V/H 6For SEL 12 kA ROn Request

Main terminals polarization Code 5 Sidewalls protection panels 1 Without 0

1 Top connector '+' 2 Top connector '-' 0 Not apply Rodent proofing 2

SEL operation temperature Code 6 Code 14 Contacts position indicator

1 Ta = 35 °C 0 without SEL With 1 Without 0 2 Ta = 55 °C

Over current release (OCT) Code 7 With 1 Without 0

1 Fixed setting up to 15 kA 5 Polarized adj. 0,4-1,2 kA 0 2 Adjustable up to 15 kA 6 Polarized adjust. 0,8-2,5 kA Code 12 Impulse coil release 3 Fixed setting up to 24 kA 7 Polarized adjust. 2-6 kA Impulse coil with internal C-bank (NEKO) 2 Without 0 4 Adjustable up to 24 kA 8 Polarized adjust. 4-8 kA - 3 Impulse coil w/o internal C-bank 1

Control circuits supply voltage Code 8 Code 11 Auxiliary tripping device

1 external 24 V DC±5% 4 88 .. 145 V DC Shunt Trip - external 125 V DC 4 Without 0 2 24 V/24 V (DC stabilizer) 5 125 .. 353 V DC / 115 .. 240 V AC Shunt Trip - external 220 V DC 5 - 1 3 33 .. 85 V DC R On request Standard Zero Voltage Release 6 Standard Shunt Trip 2

Auxiliary contacts quantity - changeover type Code 9 Code 10 OC trip target

1 3 convertible contacts 3 9 convertible contacts R On Request With 1 Without 0 2 5 convertible contacts 4 10 convertible contacts

Main terminals layout (Top / Bottom) Code 4 Code 16 Lever for manual operating

Code 15 Protection options

Code 13 Forced tripping release

Without

OCT

code 19 Control connectors type

Code 18 Counter

0 R Shunt Trip - external 110 V DC 3

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 35

7.2 Ordering.

Please fill in yellow cells for order description. Options preview in chapter 7.1.

Gerapid with arc chute APN460437 rev03 09/2009 Quantity

Catalogue no:

Check if "On Request" options required.

Diagram no:

Need a special reference no. on the nameplate ? =>

Code Name

Breaker type

1 2 3 4

[BAU]: code 1

5 6

Arc chute type

7 8

[LIC]: code 2

Closing solenoid supply voltage

11 12 13 14

[STE]: code 3

15 16

Main terminals layout Top/Bottom

17 18 19 20

[ANS]: code 4

21 22

Main terminals polarization [POL]: code 5

23 24

SEL operation temperature [TSEL]: code 6

25 26

OC release

27 28

[KSA]: code 7

29 30

Requested marks on the scale

31 32

Control circuits supply voltage

[NET]: code 8

34 35

Auxiliary contacts quantity

[HIS]: code 9

37 38

OC trip target [KSM]: code 10 1

39 40

Auxiliary tripping releases

41 42

[HIL]: code 11

43 44

ED impulse coil release [EDA]: code 12 13

45 46

Forced tripping release [ZWA]: code 13 1

47 48

Contact position indicator [STA]: code 14 1

49 50

Protection options [SCH]: code 15 1

51 52

Lever for manual operating [HAN]: code 16 1

53 54

Arc chute presence [LBM]: code 17 1

55 56

Counter [ZAL]: code 18 1

57 58

Control connectors type

[SST]: code 19 R

60 61

Relevant standard

[CUS]: code 20 3R

63 64

Documentation Language [LNG]:

Opt Code Code

Threshold [kA]

Gerapid 2607 Gerapid 4207 Gerapid 6007 Gerapid 8007

1X2 (1000 V) 1X3 (1500 V) 1X4 (2000 V) 2X2 S (1500 V)

48 V DC 60 V DC 110 V DC 125 V DC 220 V DC 250 V DC

H/H - (H)orizontal H/V - (V)ertical V/H V/V Special type B Special type S

Top connector '+' Top connector '-'

Ta = 35 °C Ta = 55 °C

Fixed setting up to 15 kA Adjustable up to 15 kA Fixed setting up to 24 kA

Adjustable up to 24 kA kA kA kA kA kA kA

external 24 V DC±5%

24 V/24 V (DC stabilizer)

33 .. 85 V DC

3 convertible contacts

5 convertible contacts

9 convertible contacts

Without

With

Without

Standard Shunt Trip

Shunt Trip - external 110 V DC

Without

Impulse coil w/o internal C-bank

Without

With

Without

With

Without

Sidewalls protection panels

Without

With

Without

With

Without

Mechanical Counter

Railway & Industry applications

Military type acc. MIL-C-5015G

Railway DC acc. EN50123-2

LV DC acc. IEEEC37.14

China acc. IEC947-2 & GB14048.2

English

German

Name

Check if special customer's ratings required.

kA kA

Breaker number:

Gerapid 8007R

Gerapid 10007R

Gerapid 8007DS

37 4

2X2 (2000 V)

2X3 (3000 V)

2X4 (3600 V)

EF4-12 (3600 V)

SE 17

110 V AC 120 V AC

125 V AC

230 V AC

240 V AC

On Request

6R 15

For SEL 6 kA For SEL 12 kA

On Request

3R 4 B S 10

Not apply 2 1

without SEL

20 15

Polarized adj. 0,4 kA - 1,2 kA

Polarized adjust. 0,8 kA - 2,5 kA

Polarized adjust. 2 kA - 6 kA

Polarized adjust. 4 kA - 8 kA

kA kA 0 kA kA

88 .. 145 V DC

125 .. 353 V DC / 115 .. 240 V AC

On request

10 convertible contacts

On Request

2R 3 0

Shunt Trip - external 125 V DC

Shunt Trip - external 220 V DC

Standard Zero Voltage Release

26 3 02

Impulse coil with internal C-bank (NEKO)

Rodent proofing

Gearapid SE retrofit

Heavy Industry type

On Request 14

LV DC acc. IEC60947-2 2

On Request

En Ch

Chinese

On Request

De R

Name

Without OCT

36 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

7.3 Glossary

a-release – see Shunt trip device; Activating magnet – see Closing drive; Anti-pumping device – see SU control PCB. Prevents

reclosing after a close-open operation, as long as the device initiating closing is maintained in the position for closing Arc probes – (also: arc runners; arc horns). Provide safe arc leading into the arc chute. There are two arc probes mounted in Gerapid breaker, front and back. Arcing contact – – (also: pre-contact; arcing pre-contact). An arcing contact on which the arc is intended to be established, to avoid wearing and burning of the main contacts. It is mounted at the top of flexible band. It is easy to replace. Spring loaded to maintain proper contact force.

Auxiliary contact – (also: make/break contact; a-/b-contact, changeover contact, convertible contact). A contact included

in an auxiliary circuit and mechanically operated by the breaker.

Auxiliary switch – (also: auxiliary switch; make/break contact; a-/b-contact). A switch block containing up to 10 auxiliary

contacts,. Mechanically operated by the mechanism of the breaker during switching operations. Auxiliary switch block is mounted in lower compartment of the control box. Every contact can be either NO or NC, configured by appropriate wiring.

Closing drive – (also: activating magnet; closing solenoid;

solenoid drive). High power, black solenoid coil, mounted at the front of the breaker, below the control box. Use for electric and remote closing of the main contacts. Power consumption is up to 2.6kW. Closing time is ~150ms. Closing operation – (also: switching ON; CLOSE operation). It is operation, by which the breaker is brought from the OPEN position to the CLOSED position.

Closing solenoid - see Closing drive; Control circuit terminals – (also: control sockets/plugs). Fully

insulated sockets at the front cover of control box. Intended for external connection to the auxiliary and control circuits.

ED coil – (also: electro-dynamic coil). An impulse coil release.

Actuating element of ED impulse release, mounted on the base, under the mechanism.

Electro-Dynamic impulse release – (also: ED tripping; impulse release). Release device, consist of actuator (ED coil)

and control circuit (NEKO PCB with C-bank). This is an auxiliary release, activated by high-energy impulse of current. The impulse is shaped by internal (NEKO) or external C-bank. Opening time is less 3ms. Time to charge capacitors is ~15sec.

Lever for manual operating – (also: hand lever). Hand lever

can be used for both, closing and opening manual operation. It is intend for use only during maintenance.

Main circuit – (also: mains; primary circuit; current path). All

the conductive parts of the breaker included in the circuit, which is intend to close or open. It consists of: main terminals

(upper and lower), fixed contact, flexible band and lower bus bar.

Main terminals – (also: main connections). Two conductive bars provided for electrical connection to external main circuit. Different configurations are available.

NEKO control PCB – (also: ED coil control unit; internal C-bank

control). Control circuit PCB to supervise the operation of the ED coil. It consists of control circuit and bank of capacitors. Required to energize the ED impulse coil.

Opening operation – (also: switching OFF; OPEN operation).

An operation by which the breaker is brought from the CLOSED

POCT – An instantaneous, polarized and direct acting

mechanical release. Tripping the breaker in case of fault backward currents, starting from 400A threshold. It is adjustable within predetermined ranges. Opening time depends on short circuit conditions and shall not exceed 7ms. POCT is activated be means of magnetic energy from main circuit. Requires no external control power. Polarized breaker – is a breaker, which trips only in case of specific direction of a current flow, by means of POCT release. The breaker’s main connections are marked with plus and minus. These marks show normal current flow, at which the breaker does not trip. Position indicator – (also: position indicating device). A mechanical device mounted at the front of closing drive. Indicates whether the breaker is in the open or closed position. CLOSED position is marked as “I”. OPEN position is marked as “O”.

Pre-contact – see Arcing contact;

r-release – see Zero voltage release;

Self cut-off function– A safety feature provided to avoid

overstressing of the closing drive and shunt trip release. Closing drive is automatically cut-off from power source after 500ms. Shunt trip coil is connected in series with auxiliary contact(s), which cause cut-off after breaker’s opening. Shunt trip – (also: ST; shunt release; a-release). Instantaneous release energized by means of voltage signal. Within 50ms trips the breaker’s mechanism. Use for remote OPEN operation. ST can be activated by potential free contact or by directly applied voltage from external source. ST can have a single or double winding.

Solenoid drive - see Closing drive; ST control PCB – control circuit PCB supervising the operation

of shunt trip release. SU control PCB – control circuit PCB supervising the remote closing operation by means of solenoid drive. Presents in every breaker, and placed in control box. Provides also anti- pumping and self cut-off functions.

Switching ON – see Closing operation; Switching OFF – see Opening operation;

Trip-free device – A mechanical switching device, the moving

contacts of which return to and remain in the open position when the opening operation is initiated after the initiation of the closing operation, even if the closing command is maintained. To ensure proper breaking of the current, which may have been established, it may be necessary that the contacts momentarily reach the closed position.

UVR control PCB - control circuit, designed as a single PCB,

for supervising the zero-voltage release device.

Zero-voltage release – (also: under-voltage; UVR; r-release).

An auxiliary tripping device. Trips the breaker open on control voltage loss. Opening time is less than 75ms. It is used for remote OPEN operation or control voltage supervision. Interchangeable option with shunt trip release. Activated by means of auxiliary “potential free”, NO or NC contact.

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 37

7.4 Troubleshooting

Breaker does not CLOSE.

A) Closing drive doesn't operate electrically but it is still possible to close the breaker manually by mean of the hand lever.

1) Check the supply voltage of the drive (-X2 :1/:2). The voltage shall not be less than 80% of drive’s rated voltage.

2) Check the supply voltage of the controls (-X3 :4/:5). The voltage shall not be less than minimum input voltage required for installed voltage converter

3) Calculate the voltage drop at both supply lines and check for adequate wire size.

4) Check the polarity of the supply connections.

5) Check continuity of the control connections.

Open the control box:

WARNING! Following operations are done with control voltage connected. Only trained specialist or GE Service representative shall perform them. Risk of electric shock!

6) Check if the PCBs’ plugs are connected and screwed.

7) Check if there is 24 V DC available at output of both voltage converters.

8) Check the status of the red LED diode on the SU PCB.

- Does not light – power supply failure;

- Weak light – system ready to CLOSE;

- Intensive red light – system not ready to

CLOSE. Closing STOP circuit is active, or NEKO PCB is not charged, or “anti-pumping” is active for 15 sec.

9) Check if the Closing STOP circuit is not open. Measure voltage at SU PCB, (-X12 5:/:6). There shall be ~24 V DC available for actuation of “closing stop relay”.

10) Replace any ST/UVR/NEKO PCB if necessary.

11) Replace the SU control PCB.

12) Switch OFF the power at control box! Check continuity and resistance of solenoid winding. Replace the solenoid in case of winding breakage.

Contact GE Service in case the problem is not solved.

B) Closing drive operates electrically, but it is not possible to keep contacts closed.

1) Check the forced tripping release (if installed). A permanently blocked tripping device, during closing operation, will cause closing failure and force contact opening.

2) Check contact system area. Look for any parts that may be stuck between contacts or into mechanism module.

3) If the zero voltage release is installed, check connection of (–S2) pushbutton..

Open the control box (only when UVR is installed).

4) Check the wiring connections for UVR PCBs.

5) Check 24V DC supply for the UVR PCBs.

Contact GE Service in case the problem is not solved.

Breaker does not OPEN.

WARNING! Below operations are done with control voltage connected. Only trained specialist or GE Service representative shall perform them. Risk of electric shock!

A) Shunt trip does not operate. Breaker is able to CLOSE and OPEN by means of hand lever.

1) Check points A2 to A5.

2) Check the self cut off contacts HS11 and HS12.

3) Check the wiring and 24 V DC supply for ST PCBs.

4) Check the continuity of shunt trip coils.

5) Replace the ST PCB or ST coil if necessary.

Contact GE Service in case of problem is not solved.

B) Zero voltage release does not operate. Breaker is able to CLOSE and OPEN by means of hand lever.

1) Check points A2 to A5.

2) Check point B3 to B5.

3) Check the continuity of UVR’s coils.

4) Replace the UVR PCB or UVR coil if necessary.

Contact GE Service in case the problem is not solved.

C) ED impulse release does not operate. Breaker is able to CLOSE and OPEN by means of hand lever.

1) Check points A2 to A5.

2) Check the wiring and 24 V DC supply for NEKO PCBs.

3) Check the voltage level and timing of firing signal. Voltage signal shall be between 6-24 V DC and duration of minimum 3 ms.

4) Check if the NEKO is signaling C-bank charging correctly. Relay is closed when NEKO is ready to operate.

5) Check the continuity of ED coils.

6) Replace the NEKO PCBs if necessary.

Contact GE Service in case the problem is not solved.

38 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

7.5 GE service teams

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 39

7.6 Notes

40 Design and specifications are subject to change without notice DTR01807 rev.02 2010-02-16

GE Industrial Solutions

2010-02-16 DTR01807 rev.02 Design and specifications are subject to change without notice 41

GE Industrial Solutions 8007R, 10007R User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INDEX

1. Warnings

2. General usage conditions

2.1 Transportation and storing

2.2 Installation

2.2.1 Operational environment

2.2.2 Installation and interfaces

2.3.1 Supply and load

2.3.2 Adjusting the over current release

Fig. 2 Setting of the POCT release

3.1 Introduction

3.2 Components and accessories

3.2.1 Contact system

3.2.2 Arc chute (Code 2)

3.2.3 Mechanism

Fig. 3 Two-stage contact system

Fig. 4 Latching and tripping system

3.2.4 Polarized over current release (Code 7)

3.2.5 ED impulse coil release (Code 12)

3.2.6 Auxiliary tripping devices (Code 11)

Fig. 5 Tripping yoke of the POCT release.

Fig. 6 Forced tripping release

3.2.8 Lever for manual operating (Code 16)

Fig. 7 Closing operation by using a hand lever

Fig. 8 Opening operation by using hand lever

Fig. 9 ON/OFF operation by means of a 10 mm wrench

3.2.9 Auxiliary switches (Code 9)

Fig. 10 Auxiliary switches block in the control box.

3.2.10 Indicators

3.2.11 Solenoid closing drive (Code 3)

Fig. 12 Closing drive with position indicator.

Fig. 11 Closing drive with position indicator.

3.2.12 Electronic control system

Fig. 13 Control box with control PCBs.

Fig. 13-3 SU control unit.

Fig. 13-4 UVR control unit

Fig. 13-1 NEKO control unit

Fig. 13-2 Voltage converter 110 V/24 V DC.

Fig. 13-5 ST control unit

3.3 Technical data tables

4. Electrical circuits

4.1 Controls and plugs layout

Fig. 14 Controls and plugs layout

4.2 Connectors for external wiring.

Fig. 15 Standard connections for external wiring.

4.3 Electrical diagrams

4.3.1 Wiring code

Indication of components

Fig. 16 Example code shown on the nameplate.

4.3.2 Controls supply circuit

Fig. 17 Supply with voltage converter or with direct external 24 V DC ±5%.

4.3.3 ED coil with external capacity bank

Fig. 18 ED impulse coil with external capacitor bank.

4.3.4 NEKO control circuits

Fig. 19a 1st impulse release system with ED coil and internal NEKO control unit

4.3.5 SU control circuit

Fig. 20a SU-control circuit for drives supplied with 110 V and over.

Fig. 20b SU-control circuit for closing drives supplied with 60 V d.c.

4.3.6 Shunt trip control circuit

Fig. 21 Shunt trips control circuit

4.3.7 Zero voltage releases control circuit

Fig. 22 Zero voltage releases control circuit

4.3.8 Indicators

Fig. 23 POCT trip target and arc chute presence indicator

4.3.9 Auxiliary switch

Fig. 24 Auxiliary switches.

5. Dimensions & safety distances

5.1 Safety distances and outlined dimensions.

Fig. 25 Gerapid 8007R and 10007R with arc chute 1xtype; dimensions in mm [in].

6. Inspections and maintenance

6.1 List of inspections

6.1.1 General visual inspection

6.1.2 General functional inspection

Pay attention to the warnings, Section 1!

Fig. 27 Using of the hand lever for manual opening.

6.1.3 Inspection of the arc chute