DEH–40027 Installation Instructions
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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-1-50 low-voltage power circuit
breakers. Each Conversion Kit contains all the
components needed to convert from an existing GE type
EC trip system.
ProTrip™ Conversion Kits
For GE Types AK-1-50 Low-Voltage
Power Circuit Breakers
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TABLE OF CONTENTS
SECTION 1. GENERAL INFORMATION ...........................................................................................................4
SECTION 2. BEFORE INSTALLATION.............................................................................................................4
SECTION 3. FRONT AND BACK FRAME DISASSEMBLY........................................................................5
SECTION 4. BACK FRAME BREAKER CONVERSION
Removing the Electromechanical Trip Devices......................................................................................6
Installing the Phase Sensors..................................................................................................................7
SECTION 5. FRONT FRAME BREAKER CONVERSION
Installing the Trip Paddle........................................................................................................................8
Installing the Flux Shifter Assembly .......................................................................................................9
SECTION 6. BREAKER REASSEMBLY
Frame Assembly...................................................................................................................................10
Wiring Harness Installation...................................................................................................................10
Adjusting the Flux Shifter......................................................................................................................11
Installing the Trip Unit...........................................................................................................................12
Configuring the Trip Unit.......................................................................................................................12
SECTION 7. FOUR-WIRE GROUND FAULT OPTION................................................................................13
SECTION 8. TESTING AND TROUBLESHOOTING
Testing..................................................................................................................................................14
Trouble-Shooting..................................................................................................................................14
Nuisance Tripping on Ground Fault-Equipped Breakers........................................................14
LIST OF FIGURES
1. Opening springs and old trip devices on an AK-1-50 circuit breaker (view from bottom of
breaker)............................................................................................................................................................5
2. Crossbar mechanism pin and retaining clip.....................................................................................................5
3. EC trip devices before removal........................................................................................................................ 6
4. Removal of EC trip devises..............................................................................................................................6
5. Parts provided for CT installation per pole.......................................................................................................7
6. CT post mounted in the breaker back frame. .................................................................................................. 7
7. CT installation completed.................................................................................................................................7
8. Front frame assembly, showing the old trip paddles. ......................................................................................8
9. Installing the new trip paddle............................................................................................................................8
10. Flux shifter assembly and mounting bracket ................................................................................................... 9
11. Flux shifter bracket installed on the front frame (view from underneath with breaker
reassembled). ..................................................................................................................................................9
12. Flux shifter assembly attached to the mounting bracket.................................................................................. 9
13. Installing the insulating barrier .......................................................................................................................10
14. Wiring harness connection to the CTs........................................................................................................... 10
15. Adjusting the flux shifter.................................................................................................................................11
16. Attaching the trip unit to the mounting plate................................................................................................... 12
17. Trip unit mounted onto the breaker................................................................................................................12
18. Neutral sensor outline for AK-1-50.................................................................................................................13
19. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads...............................................16
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SECTION 1. GENERAL INFORMATION
GE Conversion Kit installation is straightforward, but
does require careful workmanship and attention to these
instructions. Familiarity with the breaker is highly
desirable. The general approach is to first remove the
existing trip devices from the breaker, then install the
ProTrip components. Following this procedure, the
converted breaker is performance tested before it is
returned to service.
The majority of trip unit kit installations do not require any
customized assembly work. However, some conversions
may involve unusual mounting conditions or accessory
combinations that require minor modifications and/or
relocation of components. In most instances, this
supplementary work can be done on site.
In preparation for the conversion, the installer should
verify that the appropriate current sensors and trip unit
have been furnished. Whenever a ProTrip kit is installed
on a breaker with a four-wire system, an associated
neutral sensor (CT) is required for separate mounting in
the equipment. Ensure that retrofitted breakers are
applied within their short-circuit 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.
SECTION 2. BEFORE INSTALLATION
Before starting any work, turn off and lock out all power
sources leading to the breaker, both primary and
secondary. Remove the breaker to a clean, well-lighted
work area.
WARNING: Low-voltage power circuit breakers use
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 OPEN breaker
and be sure the stored-energy springs are
discharged, thus removing the possibility that the
breaker may trip OPEN or the closing springs
discharge and cause injury.
• Trip the breaker OPEN, then remove the breaker to
a well-lighted work area before beginning work.
• Do not perform any maintenance that includes
breaker charging, closing, tripping, or any other
function that could cause significant movement of a
draw-out breaker while it is on the draw-out
extension rails.
• Do not leave the breaker in an intermediate position
in the switchgear compartment. Always leave it in
the CONNECTED, TEST, or DISCONNECTED
position. Failure to do so could lead to improper
positioning of the breaker and flashback.
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SECTION 3. FRONT AND BACK
FRAME DISASSEMBLY
The installation of a ProTrip Conversion Kit in a GE AK-150 breaker requires that the front and back frames be
disassembled. The following steps describe this
procedure.
1. Remove the breaker opening springs, shown in
Figure 1. Save them for reinstallation.
2. Remove the spring clip on the crossbar mechanism
pin, shown in Figure 2, and slide out the pin. Save
the pin and clip for reinstallation.
3. Remove and save the nuts and lock washers holding
the front and back frames together. Four are used on
manually operated breakers and six are used on
electrically operated breakers.
4. Lift the front frame straight up and off from the back
frame.
5. Place the back frame on its back on a suitable work
surface.
Figure 1. Opening springs and old trip devices on an AK-
1-50 circuit breaker (view from bottom of breaker).
Figure 2. Crossbar mechanism pin and retaining clip.
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SECTION 4. BACK FRAME BREAKER
CONVERSION
Removing the Electromechanical Trip
Devices
1. Remove and discard the two screws at the base of
each trip device, as shown in Figure 3. Discard the
metal mounting brackets (some units have a single
C-shaped bracket).
2. Remove and discard the small Philips-head screw at
the top of each trip device.
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3. Remove and discard the four
securing each trip coil. The coil can then be lifted off
and removed. Figure 4 shows one trip completely
removed, one with the cover removed, and one still
in place.
/16" Allen-head bolts
Figure 3. EC trip devices before removal.
Figure 4. Removal of EC trip devises.
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Installing the Phase Sensors
Figure 5 shows the parts provided for assembly of the CT
on each pole.
1. Mount the new copper CT post to the back frame
with the two
lock washers provided, as shown in Figure 6.
2. Fasten the three small insulated wire fasteners to the
back frame with the
as shown in Figure 7. One fastener is mounted under
each CT.
3. Place a CT over each copper post, first applying a
small amount of RTV or similar adhesive to prevent
the CTs from rotating.
4. Mount the top copper bus over each CT and secure
with the
and flat washers provided.
5. Insert two
washers through each top copper bus into the
contact arm assembly.
6. Tighten the
bolts to 300 in-lb.
WARNING: Step 6 ensures critical electrical integrity
connections. The designated bolts must be correctly
tightened for proper operation. Failure to tighten these
bolts properly will cause a breaker failure, resulting in
property damage and/or personal injury.
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/8-16 x 11/2" bolts, flat washers, and
1
/4-20 x 13/4" screws provided,
1
/2-13 x 11/2" Allen-head bolts, lock washers,
3
/8-16 x 11/2" bolts, lock washers, and flat
3
/8-16 bolts to 200 in-lb and the 1/2-13
Figure 5. Parts provided for CT installation for one pole.
Figure 6. CT post mounted in the breaker back frame.
Figure 7. CT installation completed..
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SECTION 5. FRONT FRAME
BREAKER CONVERSION
Place the front frame on a suitable work surface as
shown in Figure 8.
Installing the Trip Paddle
1. Remove and discard the three trip paddles on the trip
actuator bar, as shown in Figure 8.
2. Assemble the trip paddle and the threaded back
plate by inserting two of the 10-32 x
lock washers provided along the top edge.
3. Slip the trip paddle over the trip actuator bar
approximately one inch from the side frame, as
shown in Figure 9. Insert the remaining 10-32 x
screw and tighten the other screws to secure the trip
paddle in place.
3
/4" screws and
3
/4"
Figure 8. Front frame assembly, showing the old trip
paddles.
Figure 9. Installing the new trip paddle.
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Installing the Flux Shifter Assembly
Figure 10 shows the flux shifter mounting bracket, with
the trip unit support bracket and insulating shield
attached.
1. Remove and discard the grounding strap hardware
on the left side of the front frame. Attach the flux
shifter mounting bracket to the left inside of the front
frame with the two
washers provided, as shown in Figure 11 (showing
the plate in position after reassembly of the front and
back frames).
2. Secure the flux shifter assembly, shown in Figure 10,
to the bracket with the two
provided, as shown in Figure 12.
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/8-16 x 1" bolts, nuts, and lock
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/4-20 x 1/2" bolts
Figure 10. Flux shifter assembly and mounting bracket.
Figure 11. Flux shifter bracket installed on the front frame
(view from underneath with breaker reassembled).
Figure 12. Flux shifter assembly attached to the
mounting bracket.
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SECTION 6. BREAKER REASSEMBLY
Frame Assembly
Follow steps 1–4 in Section 3 Front and Back Frame
Disassembly to reassemble the front and back frames.
CAUTION: Be careful when joining the frames so that
the flux shifter reset arm is not damaged. The reset arm
must be assembled so that it rests on the metal contact
crossbar on the underside. The arm will fit between the
left frame side lever and the first insulated contact
actuator lever.
Wiring Harness Installation
1. Connect the four-pin flux shifter connector to the
mating connector on the wiring harness and tie the
leads to the mounting bracket.
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2. Loosen, but do not remove, the two
mechanism bolts above the center-phase CT and
insert the insulating barrier provided, as shown in
Figure 13. Retighten the bolts to fasten the barrier in
place.
3. Bring the CT leads of the wiring harness around to
the back and bottom of the breaker and connect to
the CTs as shown in Figure 14. Connect the white
and black leads as indicated on the CT terminals.
4. Tie the wiring harness to the insulated fasteners
under each CT with the wire ties provided. Be sure
that the wiring harness will not interfere with the
breaker mechanism.
/8-16
Figure 13. Installing the insulating barrier.
Figure 14. Wiring harness connection to the CTs.
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Adjusting the Flux Shifter
With the breaker in the CLOSED position, the gap
between the adjustment screw and the trip paddle should
1
/16 inch, as shown in Figure 15. For safety, OPEN
be
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the breaker to adjust the screw with a
WARNING: Be extremely careful when working on a
closed breaker. Do not reach into the mechanism while
adjusting the flux shifter.
Optional Test – The flux shifter may be tested by closing
the breaker and applying a 9 Vdc power source to the
flux shifter leads (the red wire is positive). The breaker
should trip.
/4-inch wrench.
Figure 15. Adjusting the flux shifter.
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Installing the Trip Unit
1. Remove the large screw from the rear of the trip unit.
Place the trip unit in position on the mounting plate,
with the 50-pin connector aligned with the opening in
the plate. Secure with the large screw, as shown in
Figure 16.
2. Insert the 50-pin female connector on the wiring
harness into the trip unit connector through the rear
of the mounting plate. Secure to the mounting plate
with the two small screws provided, as shown in
Figure 16.
3. Place the trip unit and mounting plate in position on
the support bracket mounted on the breaker. Secure
with the three screws, lock washers, and flat washers
through the holes in the mounting plate into the
tapped holes in the bracket, as shown in Figure 17.
Configuring the Trip Unit
See DEH-40034 for detailed instructions for setting up
ProTrip trip units.
Figure 16. Attaching the trip unit to the mounting plate.
Figure 17. Trip unit mounted onto the breaker.
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SECTION 7. FOUR-WIRE GROUND
FAULT OPTION
The ground fault option for four-wire installations requires
the installation of an additional current sensor on the
neutral bus in the equipment. The sensor is connected to
the trip unit through the connector provided in the wiring
harness.
1. Mount the neutral sensor on the outgoing neutral
lead, normally in the bus or cable compartment in the
equipment. Figure 18 shows the outline of the neutral
sensor.
2. Connect the neutral sensor wire harness to the
correct taps on the sensor. To maintain the same
polarity as the phase sensors, connect the white wire
to the common terminal, black to the tap.
3. Route the wires through the equipment and connect
to the two-pin connector on the trip unit wiring
harness. The wires should be tied to the breaker
frame in an easily accessible location. They may be
located with the communication harness.
Figure 18. Neutral sensor outline for AK-1-50.
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SECTION 8. TESTING AND
TROUBLESHOOTING
WARNING: Do not change taps on the current sensors
or adjust the trip unit settings while the breaker is
carrying current. Failure to adhere to these instructions
will void all warranties.
Testing
Before installing a converted breaker back into service,
perform the following steps:
1. Verify that the trip unit is securely installed by
performing a continuity test on the CT wiring and the
trip unit.
a. Disconnect the black CT wires at each phase
sensor.
b. Check for continuity with a continuity tester or
VOM from the white lead of the phase A CT to the
white lead of the phase B CT.
c. Repeat this continuity test for the white leads of
the phase A and phase C CTs.
d. Measure the resistance across each phase
sensor and compare the values measured to the
values listed in Table 1.
e. Reconnect the black CT leads to all of the phase
sensors. Ensure that this is done before
continuing with performance testing of the
breaker.
CAUTION: In addition to the continuity test described in
Step 1 and before performance testing of the converted
breaker, each phase of the breaker should be primary
injected with a current level of about 10%, but no more
than 20%, of the CT rating.
WARNING: If the converted breaker is energized or
tested by primary injection with a sufficiently high test
current with a loose or open circuit between the CTs
and the trip unit, damage will occur to the trip unit, wire
harness, 50-pin trip unit connector, and CTs. Failure to
adhere to these instructions will void all warranties.
2. Check the insulation on the primary circuit with a
1,000-volt Meggar.
3. Measure the resistance across the line and load
terminals for each phase using a micro-ohmmeter or
millivolt tester. If the resistance differs considerably
from phase to phase, the electrical connections may
not be properly tightened or it could also indicate
improper contact wipe.
4. To verify that the breaker has been properly retrofitted, perform a primary injection test on each phase.
This test will check the CTs, bus, wiring harness, flux
shifter, and trip unit as a complete system.
a. A high-current, low-voltage power supply should
be connected across each line and load terminal
to simulate an overcurrent fault.
b. Set the long-time trip at 0.5 to minimize the
breaker stress.
c. When ground fault is installed, the test can be
performed by wiring two adjacent poles in series
or by using the GE Digital Test Kit, cat. no.
TVRMS2. This will prevent the breaker from
tripping because of an unbalanced current flow.
CAUTION: Do not attempt to use GE Test Kit cat. no.
TVTS1 or TVRMS on this trip unit.
Trouble-Shooting
When malfunctioning is suspected, first examine the
breaker and its power system for abnormal conditions
such as the following:
• The breaker is not tripping in response to overcurrent conditions or incipient ground faults.
• The breaker is remaining in a trip-free state because
of mechanical interference along its trip shaft.
• The shunt trip (if present) is activating improperly.
Nuisance Tripping on Ground Fault-Equipped
Breakers
When nuisance tripping occurs on breakers equipped
with ground fault trip, a probable cause is the existence
of a false ground signal. Each phase sensor is connected
to summing circuitry in the trip unit. Under no-fault
conditions on three-wire load circuits, the currents add to
zero and no ground signal is developed. This current
sum is zero only if all three sensors have the same
electrical characteristics. If one sensor differs from the
others (such as by a different rating or wrong tap setting),
the circuitry can produce an output sufficient to trip the
breaker. Similarly, a discontinuity between any sensor
and the trip unit can cause a false trip signal.
The sensors and their connections should be closely
examined if nuisance tripping is encountered on any
breaker whose ProTrip trip unit has previously
demonstrated satisfactory performance. After disconnecting the breaker from all power sources, perform
the following procedure:
1. Check that all phase sensors are the same type
(current range).
2. Verify that the tap settings on all three phase sensors
are identical.
3. Verify that the wiring harness connections to the
sensors have the proper polarity (white lead to
common, black lead to tap), as shown in the cabling
diagram in Figure 19.
4. On ground fault breakers serving four-wire loads,
check that the neutral sensor is properly connected,
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as indicated in Figure 19. In particular, check the
following:
a. Verify that the neutral sensor has the same rating
and tap setting as the phase sensors.
b. Verify continuity between the neutral sensor and
its equipment-mounted secondary disconnect
block. Also check for continuity from the breakermounted neutral secondary disconnect block
through to the trip unit wiring harness connector.
c. If the breaker’s lower studs connect to the power
source, then the neutral sensor must have its load
end connected to the source.
d. Verify that the neutral conductor is carrying only
the neutral current associated with the breaker’s
load current (the neutral is not shared with other
loads).
5. If the preceding steps fail to identify the problem,
then measure the sensor resistances. The appropriate values are listed in Table 1. Since the phase
and neutral sensors are electrically identical, their
resistances should agree closely.
Breaker CT Rating, A Resistance,
ohms
AK-1-50
800
1600
58–79
130–154
Table 1. CT resistance values.
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Figure 19. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads.
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These instructions do not cover all details or variations in equipment nor do they provide for every possible contingency
that may be met in connection with installation, operation, or maintenance. Should further information be desired or should
particular problems arise that are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the
GE Company.
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GE Industrial Systems
General Electric Company
41 Woodford Ave., Plainville, CT 06062
DEH40027 R03 0899 © 1999 General Electric Company
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