GE Industrial Solutions AK-1-15, AK-1-25 User Manual
s
DEH–40025 Installation Instructions
g
INTRODUCTION
GE Conversion Kits are designed for upgrading
existing GE low-voltage power circuit breakers, rather
than replacing the entire breaker. The Conversion Kits
include ProTrip™ Trip Units, the latest technological
advance in GE trip systems.
ProTrip Conversion Kits are designed and tested to
conform to ANSI Standard C37.59, allowing the
retrofitter to properly install the kit and acceptance
test the breaker.
This publication covers installation of ProTrip Conversion Kits on GE types AK-1-15 and AK-1-25 lowvoltage power circuit breakers. Each Conversion Kit
contains all the components needed to convert from
an existing GE trip system.
ProTrip™ Conversion Kit
For GE Types AK-1-15 and AK-1-25
Low-Voltage Power Circuit Breakers
TABLE OF CONTENTS
SECTION 1. GENERAL INFORMATION........................................................................................................... 5
SECTION 2. BEFORE INSTALLATION.............................................................................................................. 5
SECTION 3. DISASSEMBLING THE BREAKER
Component Removal............................................................................................................................ 6
SECTION 4. INSTALLING THE CONVERSION KIT
Installing the Current Sensors (CTs) ................................................................................................... 7
Mounting the Trip Paddle .................................................................................................................... 9
Installing the Flux Shifter Assembly ................................................................................................. 10
Installing the Trip Unit........................................................................................................................11
Adjusting the Flux Shifter .................................................................................................................. 12
Connecting the Trip Unit Wiring Harness ........................................................................................ 12
Configuring the Trip Unit ................................................................................................................... 13
SECTION 5. FOUR-WIRE GROUND FAULT OPTION............................................................................... 13
SECTION 6. TESTING AND TROUBLE-SHOOTING
Testing ................................................................................................................................................. 14
Trouble-Shooting................................................................................................................................ 14
Nuisance Tripping on Ground Fault-Equipped Breakers ................................................... 14
3
LIST OF FIGURES
1. Draw-out primary disconnect fingers ...........................................................................................................6
2. EC trip unit removal. .......................................................................................................................................6
3. Removing the trip unit coil connections .......................................................................................................6
4. Disassembled AK-1-25 breaker......................................................................................................................6
5. Bottom bus installation. .................................................................................................................................7
6. CT assembly. ...................................................................................................................................................7
7. Top bus connection ........................................................................................................................................8
8. CT assembly torque........................................................................................................................................8
9. Trip paddle installation...................................................................................................................................9
10. Installing the flux shifter assembly. ............................................................................................................10
11. Trip unit support bracket installed. .............................................................................................................10
12. Trip unit attached to its mounting plate. ....................................................................................................11
13. Harness connector attached to the trip unit. ..............................................................................................11
14. Trip unit mounted on the breaker................................................................................................................11
15. Flux shifter adjustment.................................................................................................................................12
16. Wiring harness installation. .........................................................................................................................12
17. Neutral sensor outline ..................................................................................................................................13
18. Cabling diagram for PtoTrip™ trip units with ground fault on four-wire loads......................................16
4
SECTION 1. GENERAL INFORMATION
SECTION 2. BEFORE INSTALLATION
GE Conversion Kit installation is straightforward, but
does require careful workmanship and attention to
these instructions. Familiarity with the breaker is
highly desirable. Then general approach is to first
remove the existing trip devices from the breaker,
then install the ProTrip components. Following this
procedure, the converted breaker is performance
tested before it is returned to service.
The majority of trip unit kit installations do not
require any customized assembly work. However,
some installations may involve unusual mounting
conditions or accessory combinations that require
minor modifications and/or relocation of components. In most instances, this supplementary work
can be done on site.
NOTE:
patible with the conversion kit.
In preparation for the conversion, the installer should
verify that the appropriate current sensors and trip
unit have been furnished. Whenever a ProTrip kit is
installed on a breaker with a four-wire system, an
associated neutral sensor (CT) is required for
separate mounting in the equipment. Ensure that
retrofitted breakers are applied within their shortcircuit ratings.
Note that all ProTrip trip units supplied with conversion kits are equipped with long-time, short-time,
instantaneous, and defeatable ground fault (LSIGX)
trip functions. The installer should be aware of how
these functions will affect his application before
installing the conversion kit.
As a service-related consideration, the installation of
a ProTrip kit provides an excellent opportunity to
perform normal maintenance on the breaker, particularly when the front and back frames are separated. Such procedures are described in the installation and maintenance manuals supplied with the
breaker and equipment.
The bell alarm accessory may not be com-
Before starting any work, turn off and lock out all
power sources leading to the breaker, both primary
and secondary. Remove the breaker to a clean, welllighted work area.
WARNING:
high-speed, stored-energy spring operating
mechanisms. The breakers and their enclosures
contain interlocks and safety features intended to
provide safe, proper operating sequences. For
maximum personnel protection during installation,
operation, and maintenance of these breakers, the
following procedures must be followed. Failure to
follow these procedures may result in personal
injury or property damage.
• Only qualified persons, as defined in the
National Electrical Code, who are familiar with
the installation and maintenance of low-voltage
power circuit breakers and switchgear assemblies, should perform any work on these breakers.
• Completely read and understand all instructions
before attempting any breaker installation,
operation, maintenance, or modification.
• Turn off and lock out the power source feeding
the breaker before attempting any installation,
maintenance, or modification. Follow all lock-out
and tag-out rules of the National Electrical Code
and all other applicable codes.
• Do not work on a closed breaker or a breaker
with the closing springs charged. Trip an
breaker and be sure the stored-energy springs
are discharged, thus removing the possibility
that the breaker may trip
springs discharge and cause injury.
• Trip the breaker
to a well-lighted work area before beginning
work.
• Do not perform any maintenance that includes
breaker charging, closing, tripping, or any other
function that could cause significant movement
of a draw-out breaker while it is on the draw-out
extension rails.
• Do not leave the breaker in an intermediate
position in the switchgear compartment. Always
leave it in the
DISCONNECTED position. Failure to do so could
lead to improper positioning of the breaker and
flashback.
Low-voltage power circuit breakers use
OPEN
OPEN or the closing
OPEN, then remove the breaker
CONNECTED, TEST, or
5
SECTION 3. DISASSEMBLING THE
BREAKER
GE Type AK-1 breakers need not have their front and
back frames separated for installation of the
conversion kit. The procedure is to remove the old
electromechanical trip units, then install the kit.
First, remove the breaker from its compartment and
place it on a clean, well-lighted workbench in an
upright position, so that both the front and back are
easily accessible.
Component Removal
1. Remove and save the load terminal primary disconnect fingers on all draw-out breakers. They
are held in place with a
Figure 1.
2. Remove and discard the two screws on each side
of the EC trip units, shown in Figure 2, that hold
the covers in place.
3. Remove and discard the Philips-head screw
above each EC trip unit. It may be necessary to
remove the left and right trip paddles. The trip
paddles may be discarded.
4. Remove and discard the two
bolts holding the trip unit coils to the breaker
frame.
5. Remove and discard the three electromechanical
trip units. The disassembled breaker is shown in
Figure 4.
1
/4-20 bolt, as shown in
5
/16-inch Allen-head
Figure 2. EC trip unit removal.
Figure 3. Removing the trip unit coil connections.
Figure 1. Draw-out primary disconnect fingers.
Figure 4. Disassembled AK-1-25 breaker.
6
Loading...