GE Industrial Solutions 2607, 4207, 6007, 8007 User Manual
GE Consumer & Industrial
Power Protection
High Speed DC Circuit Breaker
Gerapid 2607, 4207, 6007, 8007
with arc chutes 1X2, 1X4, 2X2, 2X3, 2X4
USER MANUAL
2010-06-07 S47183-E rev.03 Design and specifications are subject to change without notice 1
2 Design and specifications are subject to change without notice S47183e rev.03 2010-06-07
INDEX
1. WARNINGS........................................................................................... 4
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 ............................................................................. 7
3.2.4 Over current release (Code 7)....................................... 7
3.2.5 ED impulse coil release (Code 12).................................8
3.2.6 Auxiliary tripping devices (Code 11)............................8
3.2.7 Forced tripping release (Code 13)................................ 8
3.2.8 Lever for manual operating (Code 16)...................... 9
3.2.9 Auxiliary switch (Code 9) ................................................10
3.2.10 Indicators............................................................................10
3.2.11 Solenoid closing drive (Code 3).................................10
3.2.12 Current measurement system (Code 6) ...............11
3.2.13 Electronic control system............................................11
3.3 Technical data tables...............................................................13
4. ELECTRICAL CIRCUITS...................................................................15
4.1 Controls layout............................................................................15
4.2 Terminals wiring system ........................................................16
4.3 Electrical diagrams....................................................................17
4.3.1 Wiring code...........................................................................17
4.3.2 Controls supply circuit.....................................................18
4.3.3 ED coil with external capacity bank .........................19
4.3.4 NEKO control circuit .........................................................20
4.3.5 SU control circuit................................................................21
4.3.6 Shunt trip control circuit.................................................22
4.3.7 Zero voltage release control circuit..........................24
4.3.8 Indicators...............................................................................25
4.3.9 Auxiliary switch...................................................................26
4.3.10 SEL measuring system.................................................27
5. DIMENSIONS & SAFETY DISTANCES........................................28
5.1 Safety distances.........................................................................29
5.2 Outlined dimensions.................................................................30
5.2.1 Gerapid 2607,4207, 6007 with arc chute 1x_......30
5.2.2 Gerapid 2607, 4207, 6007with arc chute 2x_......31
5.2.3 Gerapid 8007 with arc chute 1x_...............................32
5.2.4 Gerapid 8007 with arc chute 2x_...............................33
5.2.5 Gerapid 2607, 4207 with H / H terminals...............34
5.2.6 Gerapid 2607, 4207 with V / V terminals................35
5.2.7 Gerapid 6007 terminals..................................................36
5.2.8 Gerapid 8007 terminals..................................................37
6. INSPECTIONS AND MAINTENANCE.........................................38
6.1 List of inspections......................................................................38
6.1.1 General visual inspection...............................................39
6.1.2 General functional inspection......................................39
6.1.3 Inspection of the arc chute...........................................39
6.1.4 Inspection of the contact system..............................40
6.1.5 Inspection of contacts’ tilt and gap ..........................41
6.1.6 Inspection of the screw connections.......................41
6.1.7 Inspection of the mechanical components ..........41
6.2 List of maintenance works....................................................42
6.2.1 Contact system (after 11/2003)..................................43
6.2.2. Contact system (before 11/2003). .............................44
6.2.3 Layout of control PCB inside control box...............46
6.2.4 Replacement of the control boards..........................46
6.2.5 Adjusting the auxiliary switch......................................48
6.3 Spare parts lists..........................................................................49
6.3.1 Mechanical spare parts..................................................49
6.3.2 Electrical spare parts.......................................................50
6.3.3 Recommend materials for selected works............50
7. CUSTOMER SUPPORT....................................................................51
7.1 Options overview. ......................................................................51
7.2 Ordering. ........................................................................................52
7.2.1 Example of order no. 1....................................................53
7.2.2 Example of order no. 2....................................................54
7.2.3 Example of order no. 3....................................................55
7.3 Glossary .........................................................................................56
7.4 Troubleshooting..........................................................................57
7.5 GE service teams........................................................................58
7.6 Notes................................................................................................59
2010-06-07 S47183e rev.03 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 canvas slings and
position them below the closing drive (a) and below the
lower terminal (b) [Fig. 1].
Fig. 1 Handling the breaker
• WARNING: Breaker and arc chute must be transported
separately. Never handle the breaker with arc chute
installed at!
• 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, page 13. Arc chute’s weight is ca. 30 kG (66 lb) for “1x_”
type, and ca. 60 kG (132 lb) for “2x_” type
WARNING:
• Store in original packaging!
• Do not store outdoors!
• Use protection against crush and blow!
• Do not store the breaker in a damp area!
• Storing temperature-range –25 °C…+55 °C!
4 Design and specifications are subject to change without notice S47183e rev.03 2010-06-07
2.2 Installation
2.3 Usage
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 in vertical and
horizontal directions are allowed.
• 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 runners. See drawing 49, item 3.
• The safety distances as listed in section 5.1 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
during low-level short circuit current events. 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 marked contact [Fig. 2].
2.3.1 Supply and load
• In accordance with its type, the breaker has been
designed for the current and voltage listed in Table 1,
section 3.3.
• 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
• OCT is an over-current tripping release (Code 7), which
trips and releases the breaker in case of overload or short
circuit currents. This is an instantaneous and direct acting
device.
• If equipped with an adjustable OCT, the response
threshold can be easily adjusted [Fig.3], 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. 3 Setting of the OCT unit
Fig. 2 Termination for grounding wire
2010-06-07 S47183e rev.03 Design and specifications are subject to change without notice 5
3. Technical information
3.2 Components and accessories
3.1 Introduction
• Gerapid is a high-speed DC circuit breaker. This is a
single-pole DC breaker, primarily designed for use in
railway power distribution systems with operating
currents up to 8000 A (Code 1) and operating voltages up
to 3600 V (Code 2). Additional applications are special
industrial plants such as electrolysis, mining or steel mills.
• 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.
• Overload tripping and release is obtained directly by
means of the OCT 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 [Fig. 4]. Gerapid is IP 00 protected. All parts
are mounted on thick-walled, non-breakable and
fireproof insulation panels.
3.2.1 Contact system
• All Gerapid breakers are equipped with a two-stage
contact system [Fig. 5], 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.
• 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.
Fig. 5 Two types of the contact system
3.2.2 Arc chute (Code 2)
• Compact and modular design of the arc system requires
no additional magnetic support and allows small safety
distances with high breaking capacity.
• Because of the compact dimensions, these breakers can
be installed in extremely small enclosures (from 500 mm;
Fig. 4 Modular construction overview
6 Design and specifications are subject to change without notice S47183e rev.03 2010-06-07
1.65 ft) and offers a cost-effective solution for
replacements.
• An adaptor [Fig.43] is used to mount the various arc
chutes for different operating voltages on the breakers.
• 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
• The 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.
• Breaker can operate 20 000 cycles when opened by the
shunt trip or zero voltage release, and 1 000 operations
by means of ED impulse coil or OCT releases.
• This mechanism is mechanically latched in the CLOSED
position. The principle of a mechanically latched
mechanism offers a big 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. 6]. 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.
• Different main springs are used in mechanisms for
different breaker frames. Therefore mechanisms cannot
be exchange between breakers of different frame.
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 in the table below. Other
ranges might be possible on request.
• When supplied with the optional transparent side
protection covers (Code 15), a fixed mounted insulated
knob is provided to enable OCT adjustment [Fig. 16].
6
Fig. 6 Latching and tripping system
3.2.4 Over current release (Code 7)
• The OCT release is a magnet with two magnetic circuits,
optimizing the twin magnetic field principle [Fig. 7]. This
technology ensures equally fast tripping in both current
directions. This system does not require an auxiliary
control voltage to operate. It is a direct acting and
instantaneous tripping device.
• The OCT 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,
7
Fig. 7 OCT device.
Default tripping bands for the OCT release 1).
No
OCT band 2607 4207 6007 8007
1 1,5 kA - 2,5 kA
2 1,5 kA – 3 kA
3 1,5 kA – 4 kA
4 1,5 kA – 5 kA
5 2 kA – 6 kA
6 2 kA – 7 kA
7 2 kA – 8 kA
8 2,5 kA - 5,5 kA
9 3 kA – 7 kA
10 3 kA – 8 kA
11 3 kA – 9 kA
12 3 kA – 12 kA
13 5 kA – 10 kA
14 6 kA – 14 kA
15 7 kA – 15 kA
16 8 kA – 18 kA
17 10 kA – 16 kA
18 12 kA – 24 kA
1) Customer specific bands on request.
2010-06-07 S47183e rev.03 Design and specifications are subject to change without notice 7
3.2.5 ED impulse coil release (Code 12)
• ED impulse release requires an external protective relay
for monitoring a current increase. This relay must be
provided and installed by the customer.
• If a fault occurs, an external relay signal wired into the
capacitors’ control unit (internal NEKO or external C-bank),
causes NEKO unit to discharge its energy into ED coil [Fig.
8]. The coil trips the breaker’s quick latch and opens
breaker’s contacts in less 3ms.
• ED impulse release is an optional accessory. Complete set
consists of ED coil and electronic control unit with C-bank
called NEKO. The external release signal shall be 6 V to
24 V DC, and shall be connected at terminals (-X2 :10 /
:11) in standard wiring scheme.
• Customer supplied capacitor trip unit may be used. Rated
voltage of 300 V and capacity of 2 000 µF is required. In
this case only ED coil will be installed in the breaker.
• WARNING: 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 defect of the NEKO board!
• WARNING: Maximum duration of the firing signal must
not exceed ~1 sec. Longer signal can lead to NEKO
overheat! It is recommended to use an auxiliary contact
in serial connection with firing circuit (-X2 :10/:11). It will
automatically cut off the firing circuit after breaker
opening.
• The UVR [Fig. 9] is used for remote actuation and, in
combination with an internal electronic control, for
voltage control.
• The UVR releases at voltage interruption or supply voltage
drop below 20 V. In these cases UVR trips the breaker. It is
therefore possible to use this device in combination with
the electronic trip unit for voltage monitoring, where an
unintended re-start of machines after a temporary
voltage breakdown is to be prevented.
• The UVR is intended for continuous operation. Its rated
power is 10 W.
• Due to its operational mode, the UVR is a self-monitoring
device, i.e. when the breaker is tripped upon a break of
the pilot wire (EMERGENCY-OFF principle).
• NOTE: Manual closing of the breaker with ST installed,
while pushbutton OPEN is pressed and control power
applied, might lead to ST coil’s overheating and damage.
Fig. 8 ED impulse coil with seesaw interface
3.2.6 Auxiliary tripping devices (Code 11)
• The breaker can be equipped with either a shunt trip (ST)
or a zero voltage release (UVR). It is not possible to have
both devices installed in the same breaker. Both devices
are interchangeable.
• In standard configuration, internal voltage converter
(Code 8) transforms external voltage into 24 V DC, which
is required by ST or UVR. Both devices are tripped by a
potential free contact connected as shown in section 4.2.
• Optionally, ST can be connected directly to external
voltage. In this case extinguish capacitors and diode is
used to improve switching of the shunt trip’s coil [Fig 194c]. Double winding shunt trip is available with this option
for 110/125/220 V DC external control supply.
• 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 ST is used for remote actuation. It is designed for
short time operation with max. duty cycle of 9 %. ST’s
supply is connected through auxiliary contacts, which cut
off supply voltage after opening. This protects ST against
overheating.
Fig. 9 Zero voltage release
3.2.7 Forced tripping release (Code 13)
• Optionally, the forced tripping release (FT) can be installed
in the breaker [Fig. 10a]. This unit mechanically trips the
breaker, by pressing the pin against the bottom plate.
Force required to trip the breaker is about 30 N (~7 ft-lb).
The tripping pin position is as on Fig. 10b.
F~30 N
Fig. 10a Forced tripping release
(~0.6 in)
(~0.3 in)
8 Design and specifications are subject to change without notice S47183e rev.03 2010-06-07
• With a correctly designed interlock in an enclosure, FT
g
provides safety-tripping function. During withdrawal
operation of the trolley, the breaker is tripped BEFORE its
main terminals disconnect from the mains.
Bottom view
Fig. 10b Positioning of the forced tripping pin
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 on the drive’s rod,
and pull it out smoothly until latches snap [Fig. 11a].
• To open the contacts, install the tool into the ring and
push it hard against the drive’s rod until breaker opens
[Fig. 11b].
WARNING: Manual closing and opening – only during
maintenance!
Fig. 11b Opening operation by using hand lever
• Alternative manual closing and opening operation is
possible by rotating the main shaft of the breaker
mechanism, which is accessible from the side. Use
10 mm hexagon-socket wrench to OPEN/CLOSE [Fig. 11c].
• WARNING: Pay attention to control rotation speed of the
shaft during manual opening. Impede the wrench to
avoid hitting it to the ground, which may lead to a hand
injury.
CLOSE
(~45 ft-lb)
OPEN
rin
WARNING: Manual closing and opening – only during
maintenance!
WARNING: Manual closing and opening – only during
maintenance!
Fig. 11a Closing operation by using hand lever
2010-06-07 S47183e rev.03 Design and specifications are subject to change without notice 9
Fig. 11c ON/OFF operation by using a 10 mm wrench
3.2.9 Auxiliary switch (Code 9)
• Standard breaker can be equipped with 3, 5 or 10
isolated, form C, invertible auxiliary contacts (1 NO/NC
each). The movable main arm activates the contacts.
• The contacts are wired to 15-pin control terminals: -X4
and -X5, with 5 switches to each terminal [Fig. 21].
• Conventional thermal current Ith=10 A. Maximum
electrical 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. 12 Auxiliary contacts layout in 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. Mechanically switched by means of
drive’s rod. Indicates position of the main contacts.
“O” – means contacts are open
“I” – means contacts are closed
• ARC CHUTE INDICATOR (Code 17) – a potential free, NO
contact mounted on the sidewall. Locks electrically the
closing drive when arc chute is not installed on [Fig. 15].
Fig. 15 Arc chute indicator
3.2.11 Solenoid closing drive (Code 3)
• A high power solenoid is used to perform fast closing
operation. This drive is mounted at the front of the
breaker and is encased in a grounded casing [Fig. 16].
• 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, but is between 1.8 kW
and 2.6 kW.
• CLOSING command is enable by external potential free
contact at (-X2 :4/:5). Signal duration shall be ~300 ms.
• The closing drive system always includes a self-interrupt
control circuit (SU PCB). This circuit enables short
activation with a time of ~150 ms. SU switches power to
the solenoid and automatically disconnects it after
~400 ms.
• The SU unit also prevents repeated drive closing, due to
an existing and continuous short circuit conditions and
provides an “anti-pumping” safety feature.
Fig. 13 Position indicator
• 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.
Fig. 16 Solenoid closing drive and control box
• After closing attempt, the switch-in mechanism is
Fig. 14 OCT trip target
10 Design and specifications are subject to change without notice S47183e rev.03 2010-06-07
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.
3.2.12 Current measurement system (Code 6)
• The SEL current measurement system consists of the
sensing component (1) and signal-processing unit (2)
[Fig.17]. SEL sensor is integrated into a specially shaped
upper terminal of the breaker and is connected by a
shielded cable to the signal-processing unit. SEL control
unit is placed in the control-box [Fig. 18].
Fig. 17 SEL current measurement system
• SEL may be used for recording DC currents in selected
measurement ranges of 6 kA or 12 kA. Measurement of
rated current values and of the current rise may now be
made directly at the breaker.
• The sensor includes Hall-probes and delivers a
proportional signal-output to the SEL control. The signalprocessing unit transforms input signal, into standard
output signals shown in the table below.
• The outputs are insulated from the main voltage. The
insulation withstands voltages up to 4 kV RMS and up to
40 kV in peak.
• Two versions are available. Standard model (T35) for
ambient temperature –5 °C…+35 °C and the model for
higher temperature (T55) –5 °C…+55 °C.
• More details can be found in separate instruction for SEL
usage.
Type SEL 06-1 06-2 06-4 12-1 12-2 12-4
Input - 6 kA…+6 kA -12 kA…+12 kA
U
[V] 1000 2000 4000 1000 2000 4000
Ne
T35 for ambient temperature of the breaker
-5 °C…+35 °C / +23 °F…+95 °F
3.2.13 Electronic control system
All the control PCBs are installed in control box [Fig. 18].
Starting from the left, these are:
Fig. 18 Control box with control units
• (1) NEKO control unit [Fig. 19-1] (Code 12) – internal
control unit with capacitor bank. Releases firing signal for
ED coil (-X2 :10/:11) and provides indication of the
capacitors charging (-X3 :6/:7). NEKO control unit also
blocks the firing signal until C-bank is fully charged
(~15 sec).
• WARNING: NEKO unit requires a high quality firing signal.
Be sure, that voltage level is between 6 V…24 V DC and
there are no short spikes on signal (<3 ms). This might
lead to major defect of the NEKO control unit!
Fig. 19-1 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).
T55 for ambient temperature of the breaker
INe Relating to the rated current of the breaker
Output 4...20 mA
U
[kV] 12 18 40 12 18 40
Ni
-5 °C…+55 °C / +23 °F...+131 °F
-20...20 mA
-10...10 V
Fig. 19-2 Voltage converter 110 V/24 V DC.
2010-06-07 S47183e rev.03 Design and specifications are subject to change without notice 11
• (3) SU control unit – see point 3.2.11
• (5) EMPTY SLOT. – not used.
• (6) SEL control unit – see point 3.2.12
Fig. 19-3 SU control unit.
• (4) ST/UVR control unit – simple relay system. It controls
operation of shunt trip or zero voltage release.
Fig. 19-4a UVR control unit
Fig. 19-6a SEL control unit (T 35)
Fig. 19-6b SEL control unit (T 55)
Fig. 19-4b- ST control unit
Fig. 19-4c Extinguish capacitor for direct ST supply.
12 Design and specifications are subject to change without notice S47183e rev.03 2010-06-07
3.3 Technical data tables
Breaker type
Gerapid 2607
Arc chute type 1X2 1X4 2X2 2X3 2X4 1X2 1X4 2X2 2X3 2X4 1X2 1X4 2X2 2X3 2X4 1X2 2X2
Conventional thermal current I
[A] (IEC/EN)
th
2600 4200 6000
Rated current [A] (ANSI/IEEE C37.14) 2600 4150 -1)
Rated voltage U
Rated insulation voltage U
Short time current 120 min [A]
Short time current 2 min [A]
Short time current 20 sec [A]
e
[V]
1000 2000 2000 3000 3600 1000 2000 2000 3000 3600 1000 2000 2000 3000 3600 1000 2000
[V]
i
2000 2000 2000 3000 4000 2000 2000 2000 3000 4000 1000 2000 2000 3000 4000 1000 2000
3150
5200
7800 12600
Impulse withstand voltage 1,2/50 µs Ui [kV] 18 18 18 30 30 18 18 18 30 30 12 18 18 30 -1) 12 18
according to EN 50124-1:1997
Power frequency withstand voltage 50 Hz Ua [kVeff] 10 10 10 15 15 10 10 10 15 15 7 10 10 15 -1) 7 10
according to EN 50124-1:1997
Rated short circuit making capacity Î
Rated short circuit breaking capacity I
Nss
Nss
[kA]
[kA]
70 50 100 50 42 70 50 100 50 42 70 50 80 50 -1) 70 - 1)
50 35 71 35 30 50 35 71 35 30 50 35 56 35 -1) 50 50
according to EN 50123-2
Rated service short circuit breaking current Ics [kA] 60 40 50 40 40 60 40 50 40 40 60 40 50 40 -1) 60 - 1)
according to IEC 947-2
Short circuit current according to IEEE C37.14 [kA] 120 -1) 120 60 -1) 120 -1)
Peak current according to IEEE C37.14 [kA] 200 -1) 200 100 -1) 200 -1)
Gerapid 4207 Gerapid 6007
5000
8500
7200
12000
18000
Gerapid 8007
8000
6000
9600
16000
24000
Maximum short circuit current [kA] 244 120 100 52 244 120 100 52 200 240
tested at customer request
Maximum arc voltage Uarc [kV] 2445,672445,672445,67 2 4
Weight ca. [kg] 120 120 160 160 160 120 120 160 160 160 150 150 165 165 165 190 210
Weight ca. [lbs] 265 265 352 352 352 265 265 352 352 352 331 331 364 364 364 419 463
1) Rating tests at customer request
Table 1: Technical data of Gerapid 2607, 4207, 6007, 8007.
2010-06-07 S47183e rev.03 Design and specifications are subject to change without notice 13
Control box terminals
Closing solenoid drive
Internal voltage converter
1)
1)
for Gerapid 2607, 4207, 6007, 8007
External power supply
Aux. contact HS 1…HS 10,
OC trip target (code 10)
Arc chutes indicator (code 17)
1x12-pole AC 400 V, 20 A
4x15-pole AC 250 V, 8 A
Rated voltage AC 48 V - 230 V and DC 48 V - 220 V
Operating range 80 % - 115 % of rated voltage
Power consumption Gerapid 2607 / 4207 1750 W / 2000 W
Power consumption Gerapid 6007 / 8007 2600 W / 2600 W
Minimal CLOSING command duration 100 ms
min.interval between two "CLOSE" 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 permanent
Model description PCMD 150 48 S24W-GE
Input: Voltage range DC 88 - 145 V
Output: Voltage range DC 24 V (±5%)
Current 6 A permanent
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 permanent, 5 A/100 ms
Model description PCMA 70 S24W-GE
with plug and socket unit requires extrnal 24 V (±5%) DC
Rated operational voltage Ue/AC 230 V
Rated operational current Ie/AC-15 1 A
Conventional thermal current Ie/AC-12 (Ith) 10 A
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 standard
Rated voltage/power Uc/Pc 24 V / 100 W
Operating range: OFF 21.6 V - 26.4 V
Shunt trip double winded
Rated voltage/power Uc DC 110 V/ DC 125 V/ DC 220 V
Rated power for a single winding Pc 230 W
UVR
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. 2/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
1)
Standard ambient conditions acc. to EN 50123-1 Attachement B. For meeting outside of this standard range, please call back.
Table 2a: Technical data of auxiliary circuits
Components Technical datas of control circuits
Us / In
SU-Control
ST releasing
UVR releasing
CLOSE-push-button -S1 DC 24 V / approx. 10 mA
push-button-S2 DC 24 V / approx. 4 A
push-button -S2 ( -X2 :6 / :7) DC 24 V / approx. 10 mA
push-button -S2 ( -X2 :8 / :9 ) DC 24 V / approx. 450 mA
ED-coil tripping w/o NEKO
ED-coil tripping with NEKO
push-button -S3 DC 300 V / 750 A / 3 ms
Connect "Firing signal" at ( -X2 :10 / :11 ) DC 6 V…24 V / approx.20 mA
Table 2b: Control circuits ( directional values to rate the components )
14 Design and specifications are subject to change without notice S47183e rev.03 2010-06-07
4. Electrical circuits
4.1 Controls layout
Closing solenoid drive
Shunt trip / Zero voltage release
ED coil
OCT device
HS 1...HS 10
OCT trip target
Arc chute-indicator
Description
X2 1.Connector: Auxiliary- and control circuits
X3 2.Connector: Auxiliary- and control circuits
X4 3.Connector: Auxiliary contacts HS1...HS5
X5 4.Connector: Auxiliary contacts HS6...HS10
X6 5.Connector: Current measure system SEL
X10 Control board: Voltage converter
X11 Control board: Interface for external DC 24V supply (OPTION)
X12 Control board: SU control unit
X13 Control board: Shunt trip control unit
X14 Control board: Zero voltage release
X16 Control board: NEKO control unit for ED coil control
X17 Control board: Current measure system SEL
Designation
Fig. 20 Control system’s layout
2010-06-07 S47183e rev.03 Design and specifications are subject to change without notice 15
4.2 Terminals wiring system
X
123456789101112131415
X4
Closing drive supply (~,+) (S3)
Closing drive supply (N,-)
PE
S1 ( CLOSE-Command)
S2 ( OPEN by ST command)
S2 (OPEN by UVR command )
S3 ed-trip firing signal 6…24Vdc
(+) (-)
123456789101112
X2
123456789101112131415
X3
HS 1
HS 2
HS 3
HS 4
HS 5
123456789101112131415
5
HS 6
HS 7
HS 8
HS 9
HS 10
SEL (self check)
External Control Voltage Supply (+)
External Control Voltage Supply (-)
NEKO charging indicator
(indicates C-bank charging)
with OCT indicator
(Indicates tripping by OCT)
Fig. 21 Typical terminals wiring system, external customer connections.
123456789101112131415
Arc chute indicator
(Indicator switch)
X6
+
+
SEL (4…20 mA)
-
-
SEL (4…20 mA)
SEL ( +/- 20 mA)
SEL ( +/- 20 mA)
-
+
SEL ( +/- 10V )
SEL ( +/- 10 V )
16 Design and specifications are subject to change without notice S47183e rev.03 2010-06-07
4.3 Electrical diagrams
4.3.1 Wiring code
• The main circuits are not shown in the wiring diagrams
for transparency. The control circuit is presented as a
typical circuit diagram and is a combination of numbered
basic diagrams for drives, trips and indicators.
• Using the key numbers of the basic plan, you can derive
the number of the complete diagram.
• WARNING: Some non standard electrical circuits do not
comply with the diagrams in this instruction. Such circuits
are coded with unique numbers i.e 36/0033. In such a
case an appendix to this instruction is delivered, which
contains relevant electrical diagrams.
Coding positions:
Breaker type
Aux. voltage supply
ED impulse release
Closing drive
Aux. tripping device
Indicators
Aux. switches
SEL system
EXAMPLE:
Key position:
Gerapid
With voltage converter
Without ED and NEKO
With closing drive
With UVR release
With OCT trip target
With 3 aux. switches
Without SEL system
Key number:
1 / 2 3 4 5 6 7 8
36 / 1 0 20 20 01 1
Key
position
Type
1 36 Gerapid
Auxiliary voltage
2 1 Voltage converter
2 DC 24 V external supply
Tripping coil
3 0 Without ed-trip coil
1 With ed-trip coil
2 With ed-trip coil and NEKO
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 OCT trip target
02 Arc chute indicator
03 OCT + arc chute indicator
Auxiliary contacts
7 1 3 auxiliary contacts
2 5 auxiliary contacts
3 10 auxiliary contacts
Current-measurement system
8 S with SEL
Indication of components
Q1 Impulse ED coil
Q2 Closing drive coil
S1 Push button „CLOSE“
S2 Push button „OPEN“, type NO
S3 Push button “OPEN”, type NC
SU control PCB:
K1 Closing relay
K2 Internal closing stop 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
K2
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 the internal supply
24 V DC lost at UVR PCB or NEKO PCB.
Key
number
Designation
control unit
SU control unit
1)
1)
1)
Fig. 22 Example code shown on the nameplate.
2010-06-07 S47183e rev.03 Design and specifications are subject to change without notice 17
4.3.2 Controls supply circuit
y
External
power supply
+ / ~
AC 115-240V ±10%
DC 35-350V ±10%
- / N
External
power supply
+
DC 24 V ±5%
-
36/ 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
Breaker
-X3
[ 4 ]
[ 5 ]
-X10
[ 1 ]
[ 3 ]
[ 10 ]
[ 9 ]
[ 8 ]
[ 7 ]
[ 6 ]
+DC 24 V ±2%
GND
Breaker
-X3
[ 4 ]
[ 5 ]
number – 2: Interface for direct external voltage DC 24 V +/- 5% connection.
-X11
[ 1 ]
[ 3 ]
[ 10 ]
[ 9 ]
[ 8 ]
[ 7 ]
[ 6 ]
+DC 24 V ±2%
GND
Fig. 23 Supply with voltage converter or with direct external 24 V DC ±5%.
18 Design and specifications are subject to change without notice S47183e rev.03 2010-06-07
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