GE Industrial Solutions AK-1-50 User Manual

DEH–40027 Installation Instructions

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

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

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.

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.

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.

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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