GE Industrial Solutions DC OEM Module For use with Gerapid DC Circuit Breaker User Manual
g
GE Energy
Industrial Solutions
DC OEM Module
For use with Gerapid DC Circuit Breaker
Installation and Maintenance Instructions
2011-04-26 S47183Ee rev.01 Design and specifications are subject to change without notice 1
2 Design and specifications are subject to change without notice S47183Ee rev.01 2011-04-26
INDEX
INTRODUCTION ............................ ................................ ................................ .........................5
1-1 General Notes ..................... ................. .................. ................. .................. ................. 5
TESTING AND INSPECTION............................................................................................. 15
6-1 General Notes .................... ........................................ ........................................ ..... 15
Prior to Test .............................. ................................................. ................................. 15
Connecting Control Circuits ............................... .............................. .................. 15
1-2 Instruction Book Arrangement ........................................... .............................. 5
1-3 Related Publications...............................................................................................5
RECEIVING, HANDLING AND STORAGE .......................................................................6
2-1 Receiving ................... ...................... ...................... ....................... ...................... ..........6
Module and Trolley Package ......................................... ............... ............... ..........6
Inspecting for Damage .................................................. ........................... ...............6
Filing a Claim .......... ............................................... ............................................. ..........6
2-2 Handling and unpacking ........................... ........................ ......................... ..........6
Module handling and unpacking .................... ................................... .................6
Trolley handling and unpacking ............................... ..........................................7
2-3 Storage ....................... ................. ................. .................. ................. .................. ............7
Circuit Breakers ................................... ........ ....... ....... ........ ....... ........ ....... ........ ....... .....7
Modules and Trolleys ....... .......... .......... ......... .......... .......... .......... .......... .......... .......... 7
GENERAL DESCRIPTION .....................................................................................................8
3-1 General Notes ..................... ................. .................. ................. .................. ................. 8
3-2 Summary Description ............... ...................... ......................... ....................... .......8
Ratings ................................................... ........................ ......................... ......................... 8
Interlocks ................................. ......................... ......................... ......................... ............8
Accessories .............. .................... .................... .................... .................... .................... ..8
3-3 The Module ............ ............... ............... ............... ................. ............... ............... ..........8
Breaker Compartment ...................................... .................... ....................... ............8
Cable Compartment ............................... ..... ..... ....... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... 9
Control Compartment ..... ............... .............. ............... ............... ............... ............... 9
3-4 The Trolley ............. ........................... ............................ ........................... ....................9
3-5 Gerapid Breakers ............................ ........................... ............................ .............. 10
INSTALLING THE MODULE ............................................................................................. 11
4-1 General Notes ..................... ................. .................. ................. ............... ................. 11
Environmental Requirements ............................ ........................................... .... 11
Foundation Requirements ................................... ........................................... .... 11
4-2 Module Configuration and Assembly ......................................................... 11
Multiple Modules Side by Side Assembly ........................ ............................. 11
Module Preparation ............................................................................................... 11
Module Rejection Interlock ............................. ......................... ......................... .. 12
Main Busbars Connection .... ..................................... ...................................... .... 12
Ground Bus Connection ........................................... .......................................... .. 12
Connecting Secondary Controls ........................................... ........................... 12
Device mounting on control compartment door .................................... 12
6-2 Field Testing Procedure ............. .................................................... .................... 15
Testing the Module with Remote Racking System .................................. 15
Testing the Module w/o Remote Racking System ................................... 15
High Potential Tests .......... ......................................................... ............................ 15
Grounding Circuit Check ............................ ......................... ............................ ..... 15
OPERATING THE MODULE .............................................................................................. 16
7.1 Mechanisms and Interlocks ........... .... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ... 16
Racking Mechanism................................................ ..... ..... ..... ..... ..... ..... ..... ..... ..... ... 16
Access Interlocks ............................... .................................................. .................... 16
Secondary Control Interlock ................................. ............................................. 16
Remote Racking .................................... ............. ............ ............. ............ ............. ..... 17
Trolley Operated Switches ......... ................................... ................................... ... 17
Padlocks................................. ..... ..... .... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ... 17
7.2 Trolley with Manual Racking ...... .......... .......... .......... .......... .......... .......... .......... 18
Operational Positions ............................................... ................................ ............. 18
Racking – In Procedure .................................... ............................................. ........ 18
Rack-Out Procedure .............................. ................................... .............................. 19
7.3 Trolley with Remote Racking .. ............................................. ............................ 19
Operational positions. .............................................. ............ ............. ............ ........ 19
Remote Rack–In Procedure. .................................... ........................................... 20
Manual Rack-Out Procedure.
7.4 Operate the breaker. ........................................................................................... 21
TROUBLESHOOTING AND MAINTENANCE ............................................................... 22
8.1 Troubleshooting ........... ........................................ ........................................ .......... 22
Manually operated trolley ............... .................... .................... .................... ........ 22
Motor driven trolley .............................................. ............... ............... ............... ..... 22
8.2 Maintenance ........... ...................................................... ........................................... 22
CUSTOMER SUPPORT ....................................................................................................... 23
8.1 Warranty ..................... ............. ............ ............ ............. ............ ............. ............ ........ 23
8.2 Field Service Support ........ .................................................. ................................. 23
8.3 Publications and other support .......................................... ............. ............ ... 23
APPENDIX “A” – MODULE & TROLLEY DRAWINGS ................................................ 24
APPENDIX B – PRIMARY TERMINALS DRAWINGS .................................................. 26
APPENDIX C – LAYOUT DRAWINGS ............................................................................ 29
........................... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... 21
INSTALLING THE BREAKER ............................................................................................ 13
5-1 General Notes ..................... ................. .................. ................. ............... ................. 13
5-2 Installing Gerapid Breaker ............... ................................... ............................. 13
Prior to Installation ................................................................................................ 13
Installation Procedure .................................. ................................................. ....... 13
Configuration of the Rejection Interlock .............................................. ....... 14
2011-04-26 S47183Ee rev.01 Design and specifications are subject to change without notice 3
APPENDIX D – TIGHTENING TORQUES TABLES...................................................... 30
APPENDIX E – ELECTRICAL DIAGRAMS...................................................................... 31
APPENDIX F – RATING TABLES ..................................................................................... 39
APPENDIX G – ACCESSORIES & INSTALLATION DRAWINGS ............................. 40
APPENDIX H – FIELD TEST PROCEDURE ................................................................... 43
4 Design and specifications are subject to change without notice S47183Ee rev.01 2011-04-26
DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS
Chapter 1 Introduction
Introduction
1-1 General Notes
This manual contains procedures for receiving, handling,
storage, operation, and maintenance of GE’s DC OEM Module
(called also the Module in this document) with withdrawable DC
OEM Trolley (referred to as Trolley in this document) for use with
Gerapid high speed DC circuit breaker (referred to as Breaker in
this document).
The OEM Module is designed to simplify the construction of a DC
switchgear assembly. Typical applications for such equipment
are Heavy and Light Rail Transit systems, commercial IT
systems (Data Centers), heavy industrial applications in mining
and metals. Other applications include equipment to supply DC
motors, excitation systems or high power DC testing and
research facilities.
DC OEM Module and Trolley described in this document are UL
Recognized components for use with GE’s UL listed Gerapid
high-speed circuit breaker.
NOTE: The personnel responsible for installing, operating,
and servicing this equipment should be thoroughly familiar
with the contents of this manual.
Before any installation work is performed, thoroughly read and
understand the material in this instruction manual. A copy of
the instruction manual is shipped with each module, in the
control compartment. When requesting additional information
from GE Energy, include the complete data appearing on the
equipment nameplate, including requisition number. The
module’s label is located inside the control compartment. The
trolley’s nameplate is located on the right side of the trolley,
next to doors.
When requesting information concerning any specific item
furnished with module and/or trolley, refer to that item by
description, part number, its location within this manual, and
any applicable drawing number. Any materials, which may be
required to meet local codes, such as mats, screens, railings,
etc., are not included, and not furnished by GE Energy.
If there are any questions or requirements not covered in this
manual or in the accompanying drawings, please contact the
local sales office of GE Energy.
Chapter 5 Installing and Removing the Breaker - gives a
step-by-step procedure for lifting the breaker from the
floor, and installing it on the trolley. Information on
configuring the Rejection Interlock on the trolley is
included.
Chapter 6 Testing and Inspection - reviews items which
should be field-tested or inspected prior to energizing and
operating the switchgear.
Chapter 7 Operating the Module - covers how to operate
the trolley, the module and the breaker. This section
contains information concerning drawout provisions, and
functions of various accessories.
Chapter 8 Energizing the Module - outlines the steps to be
taken before and during the electrical energization of the
completed equipment.
Chapter 9 Maintaining the Module - provides instructions
for recommended preventive maintenance, servicing, and
lubrication information for the module.
Appendixes - contains information covering ratings,
dimensional drawings, electric diagrams; screw and bolt
torque values, field testing procedures, and accessories.
1-3 Related Publications
Detailed Users Guides and Instruction Books for the Gerapid
breaker and other devices not fully described in this instruction
book are available at: http://www.geindustrial.com
Go to: Products -> Circuit Breakers -> Gerapid
1-2 Instruction Book Arrangement
Information and procedures in this instruction book are divided
into Chapters as follows:
Chapter 1 Introduction - provides applicable data for the
module and its components.
Chapter 2 Receiving, Handling and Storage - describes
procedures required for receiving, handling and storage
the module and trolley.
Chapter 3 Component Description - describes the module
and its various components. Included are the cable
compartment, breaker compartment, and instrument
compartment. This section also lists the electrical and
mechanical components and explains their assigned
functions.
Chapter 4 Module Installation - provides the information
needed prior to installation, site location and foundation
requirements, and how to anchor the equipment properly
and safely. It also covers information on electrical
connections and mechanical construction.
2011-04-26 S47183Ee rev.01 Design and specifications are subject to change without notice 5
Fig. 11-1 DC OEM Module and Trolley with Gerapid High
Speed Circuit Breaker
DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS
Chapter 2 Receiving, handling and storage
Receiving, handling and storage
2-1 Receiving
Module and Trolley Package
Every package leaving the factory is plainly marked with the
case number, requisition number, and customer's order
number.
The Module and the trolley are shipped in separate wooden
crates. The contents of each shipping package are listed on
the crate.
NOTE: Breakers, Trolleys and Modules are ordered
individually and shipped separately. Module accessories, if
ordered, are shipped separately.
See Fig. 21-1 for crates dimensions. Crates load weights are:
Crate with module, 6.5x2.6x8.0 [ft] / ~850 [lbs],
Crate with trolley, 3.9x2.6x5.8 [ft] / ~ 500 [lbs],
D
W
Remove the carton box and check plastic covers for any
damages. Do not remove the plastic if the breaker will be
stored for long periods. (See. Fig. 21-2 and 21-3)
Fig. 21-2 Gerapid circuit breaker package
H
Fig. 21-1 Typical wooden module crate for shipment
Inspecting for Damage
All equipment leaving the factory is carefully inspected and
packed by personnel experienced in the proper handling and
packing of electrical equipment. Upon receipt of any
equipment, immediately perform a visual inspection to
ascertain if any damage has been sustained in shipping or if
there are any loose parts. Be sure to inspect all devices
mounted inside compartments of each section to see if any
have been dislodged or damaged.
Gerapid circuit breakers are shipped separately in individual
boxes with the breaker in the open position. (See Fig. 21-2)
Circuit breakers should be unpacked and visually inspected for
damage or loose parts as soon as possible after they have
been received.
Fig. 21-3 Breaker plastic shrink-wrap protection
Filing a Claim
If any damage is evident, or indication of rough handling is
visible, file a claim for damage at once with the transportation
company and notify the nearest GE Energy Sales Office
immediately. Information on damaged parts, part number,
case number, requisition number, etc., should accompany the
claim.
2-2 Handling and unpacking
Module handling and unpacking
NOTE: The Module should be transported and installed in
its final location prior to installing the trolley.
The module shipping crate should be transported using forklift
only. During transport, the module should remain in its original
package. To unpack the module, start by removing the top
cover, then remove sidewalls and all inner supports.
CAUTION: Never use a forklift to transport an unpacked
module, as the module is not bolted to the shipping
palette.
6 Design and specifications are subject to change without notice S47183Ee rev.01 2011-04-26
DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS
Chapter 2 Receiving, handling and storage
Removable lifting plates are provided on the top of each
module, as standard equipment. Using a crane or overhead
hoist, carefully lift the module from the palette using the four
lifting plates. (See Fig. 22-1)
Min. 4 ft
NOTE: After transportation, but before installing of the
breaker, loosen six attachment screws and remove lifting
frame from the trolley. Replace and tighten these screws!
Lifting slots.
Fixing screws.
Fig. 22-2 Lifting of the trolley
CAUTION: Never use forklift to transport unpacked trolley,
as it is not bolted or fixed to the shipping palette
NOTE: Do not lift or transport the trolley, using forklift.
Never lift the trolley with a breaker mounted. Never roll the
trolley on the floor with a breaker set in place, unless the
breaker is properly bolted to the trolley and arc chutes
properly secured to the breaker (if installed).
2-3 Storage
Fig. 22-1 Overhead lifting of the module
To preserve the external appearance of the equipment, it is
suggested that the lifting plates be left in place. Utilize four
equal length cables or slings, each with a minimum load rating
of twice the weight of the Module package. See section 2.1.
NOTE: The angle between the cables and the top of the
equipment must be at least 45 degrees. This requires the
use of chains/slings at least 4 ft long. If this is not possible,
spreader bars must be used.
NOTE: Do not move, lift or handle the module with a trolley
installed.
Take up the slack in the lifting device very carefully and
manually stabilize the module to prevent it from rotating.
WARNING: Do not stand under the module while it is being
moved. Serious injury may occur if the cables or lifting
device fail.
CAUTION: Gently lower the module onto the level site
location. If the module is roughly handled or jarred, it is
possible to damage or misalign internal components.
Trolley handling and unpacking
The trolley, in its original package, should be transported using
forklift only. To unpack the trolley, remove the top cover first,
and then remove sidewalls and all inner supports. To lift the
trolley, use special lifting frame available. See Fig. 22-2.
2011-04-26 S47183Ee rev.01 Design and specifications are subject to change without notice 7
Circuit Breakers
Open shipping cartons and thoroughly inspect shipping
materials for damage. If shipping plastic is in satisfactory
condition, leave the breakers in their shipping cartons for
storage. Do not remove the circuit breaker shipping material
(shrink wrap) at this time.
Store the circuit breakers in a clean, dry location in an upright
position. If shipping plastic is damaged, a plastic or canvastype cover should be provided to reduce the possibility of
damage or contamination to the breakers due to dust and
water. For details concerning Gerapid breakers handling
consult the breaker’s User Guide, S47183De.
Modules and Trolleys
Remove protective covering. Check thoroughly for damage.
Store in a clean, dry, rodent-free location with moderate
temperature and provide protective coverings to prevent dirt,
water, or other foreign substances from entering the
equipment.
If dampness or condensation may be encountered in the
storage location, heaters must be placed inside the module
breaker compartment (module must be without trolley) and in
the front of the trolley with trolley door open to prevent
condensation. Approximately 250 watts of heat in each
section is required. Incandescent lamps can be used and
located in the bottom of the breaker compartment and
supported so the bulbs will not touch adjacent materials.
DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS
Chapter 4 Installing the Module
General Description
3-1 General Notes
This section contains a description of the GE DC OEM Module and
Trolley for use with Gerapid high speed DC circuit breaker. It also
describes the functions of the electrical and mechanical systems.
3-2 Summary Description
The DC OEM Module is an individual, freestanding, metal-enclosed
switchgear section, designed to be used in conjunction with the
withdrawable trolley, containing a Gerapid circuit breaker,
auxiliary contacts, primary finger clusters and secondary
disconnect.
Ratings
The module is designed to be used on DC systems operating up to
800VDC and 6000A continuous.
The module is available in two continuous current ratings:
4000A for use with 2500A and 4000A Gerapid breaker,
6000A for use with 5000A and 6000A Gerapid breaker,
NOTE: See Appendix “F” for complete ratings of the Module
and the breaker.
Interlocks
Module and trolley are equipped with variety of safety interlocks
that minimize risk of incorrect operations. The following interlocks
are incorporated into the module and trolley:
Positive Interlock preventing movement of the trolley to or
from CONNECTED position when breaker is closed.
Negative Interlock preventing breaker closing unless the
trolley is in CONNECTED or TEST position.
Access Interlock – ensures breaker opening before any
manual operations.
Secondary Control Interlock preventing movement of the
trolley from TEST position to CONNECTED position unless
secondary disconnect is connected. The same interlock
prevents the trolley from being fully withdrawn from the
module unless the secondary disconnect is unplugged.
Breaker Disconnected Padlock Provisions allows padlocking
the trolley in DISCONNECTED position.
Control Compartment Padlock Provisions allows for
padlocking of the controls compartment door.
Rejection Interlock prevents trolley coded for particular
breaker current rating from being inserted into the module
that is coded to different rating.
Shutter Safety Padlock allows padlocking of the safety
shutters in closed position.
Accessories
Several accessories are available with the module and the trolley
for user convenience:
Side Covers for cable compartment,
Crank Handle for trolley racking operations,
Cable Channel connectors and covers,
Attachment Hardware Kits for different components,
Hinges for user furnished compartment doors,
NOTE: See Appendix “G” for full list of accessories, their codes
and illustrations.
NOTE: Detailed description of all accessories functions is given
in Chapter 7.
3-3 The Module
Breaker Compartment
The module is metal-enclosed construction, and consists of the
front breaker compartment, upper controls compartment and
rear cable compartment. Fig. 33-1 shows the location of the
module compartments.
Dead-front, drawout circuit breaker compartment is a standard
construction feature with all modules. The breaker compartment
door remains closed and latched while the breaker is racked out
from the CONNECTED position through TEST position, to the
DISCONNECTED position. See chapter 7.
Control
Compartment
Cable
Compartment
Breaker
Compartment
Fig. 33-1 Front view of the Module with Trolley inside
Control Compartment
Padlock Provisions
Secondary Disconnect
Secondary Control Interlock
Primary Disconnect Shutters
In front of Primary Stabs
Racking Drive Socket
Grounding Circuit Stab
Rejection Interlocks
Fig. 33-2 Front view of the module
8 Design and specifications are subject to change without notice S47183Ee rev.01 2011-04-26
DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS
g
Rej
Chapter 4 Installing the Module
Grounded steel barriers on the top, sides, bottom, and front
enclose the breaker compartment. In the back, a flame-retardant,
track resistant, glass-filled polyester base minimizes the possibility
of fault communication between compartments or to the bus.
Breaker compartment has primary stabs for connecting the
breaker. Insulated shutters cover primary stabs. See Fig 33-2.
NOTE: See Appendix A for all dimensional drawings of the
breaker Compartment.
Primary disconnect shutters are provided as standard feature to
provide protection against contact with the energized stationary
primary stabs when the trolley is removed from its compartment.
The shutters are constructed from fiberglass reinforced thermoset
polyester. A padlock can lock the shutters in the closed position.
See Fig. 33-3.
4000A
Terminals
6000A
Terminals
Ground
Bus
Connection
Fig. 33-4 Rear views of 4000A and 6000A Modules
Shutters
Padlock
Fig. 33-3 Safety padlock on the shutters
Every module is equipped with rejection Interlock that must be
properly configured by the OEM. This interlock allows
configurations for all current ratings. It is placed on both sides of
the breaker compartment. See Fig. 33-2.
Cable Compartment
The primary stabs extend into the cable compartment and are
suitable for connection with ANSI type busbars. Fig 33-4 shows
primary terminals for 4000A and 6000 A rated modules. Ground
bus connection in the cable compartment is the same on all
module types. Cable compartment is provided without side
covers. See Fig. 33-1. Painted and pre-punched side covers can
be ordered as separate accessories.
NOTE: See Appendix A for all dimensional drawings of the
primary terminals and cable compartment.
Module is also equipped with trolley-operated contacts that are
activated in CONNECTED and TEST position as well as with some
other limit switches that are used for internal interlocks.
3-4 The Trolley
The module is designed to be used with Gerapid high-speed
circuit breaker installed on the withdrawable trolley. The trolley
can be ordered in two different versions, with manual racking or
with motor operated remote racking system.
Remote racking trolley equipped with motor drive can also be
operated manually by the crank handle.
NOTE: The crank handle is an accessory and has to be
ordered separately.
Trolley structure is compatible with all the modules and all
Gerapid circuit breakers listed in Section 3-5. The OEM must
correctly configure the rejection Interlock on the trolley and in the
module for the specific rating of breaker being installed.
All breaker controls, control power supply and auxiliary contacts
are extended to the control compartment via the secondary
disconnect and harness. Negative and positive interlocks are
operated from access console at the front of the trolley. The
access opening for the manual crank handle is there as well.
Secondary Disconnect Plu
Access
Console
Control Compartment
The secondary control plug located in the breaker compartment
is prewired, with a 3ft tagged wire harness brought into the
controls compartment for User’s connections. The matching
secondary disconnect plug is mounted on the trolley.
NOTE: See Appendix A for all dimensional drawings of the
Control Compartment.
2011-04-26 S47183Ee rev.01 Design and specifications are subject to change without notice 9
Fig. 34-1 Trolley features (motorized racking shown)
ection Interlock
Motordrive
DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS
Chapter 4 Installing the Module
3-5 Gerapid Breakers
The GE Gerapid DC Circuit Breaker is a high speed, single pole breaker
used for protection of high power DC supply systems. The main features
of the Gerapid circuit breaker are:
Modular construction, easy to inspect and maintain
Non-flammable and non-toxic insulation materials
High speed, current limiting short circuit characteristics
Up to 24kA tripping threshold for OC release
High speed remote impulse release for distant faults
Shunt or zero voltage releases for opening operation
Powerful closing solenoid enables quick closing operation
Easy and safe remote and local control of the breaker,
Wide variety of accessories, such as counter, indicators,
interlocks, manual handle, etc..
See Fig. 35-1 for overview of the breaker construction.
NOTE: See Appendix F for all ratings and see User Manual
S47183De for breaker details and accessories.
Four current ratings of Gerapid circuit breakers are available for
mounting on the trolley and used in the module. These circuit
breakers are UL Listed and type tested in accordance with
IEEE/ANSI C37.14-2000 Standards. Continuous current ratings
range from 2500 to 6000 ampere frame size. All Gerapid circuit
breakers of the same type and rating may be interchanged,
provided the breaker accessories have the same ratings.
Gerapid 2508 (See Fig. 35-2)
2500A frame size
Standard 200kA peak interrupting current at 800VDC
3700V power frequency withstand level
Current limiting characteristic
Tested for duty type a, b, c and d according to ANSI C37.14
Trip-free capability according to ANSI C37.100
Gerapid 4008 (See Fig. 35-2)
4000A frame size
Standard 200kA peak interrupting current at 800VDC
3700V power frequency withstand level
Current limiting characteristic
Tested for duty type a, b, c and d according to ANSI C37.14
Trip-free capability according to ANSI C37.100
Gerapid 5008 (See Fig. 35-3)
5000A frame size
Standard 200kA peak interrupting current at 800VDC
3700V power frequency withstand level
Current limiting characteristic
Tested for duty type a, b, c and d according to ANSI C37.14
Trip-free capability according to ANSI C37.100
Gerapid 6008 (See Fig. 35-3)
6000A frame size
Standard 200kA peak interrupting current at 800VDC
3700V power frequency withstand level
Current limiting characteristic
Tested for duty type a, b, c and d according to ANSI C37.14
Trip-free capability according to ANSI C37.100
Fig. 35-1 Gerapid circuit breaker construction
Fig. 35-2 Gerapid 2508 and 4008 circuit breakers
Fig. 35-3 Gerapid 5008 and 6008 circuit breakers
10 Design and specifications are subject to change without notice S47183Ee rev.01 2011-04-26
DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS
Chapter 4 Installing the Module
Installing the Module
4-1 General Notes
This chapter contains instructions for installing the GE DC OEM
Module.
CAUTION: Personnel installing this equipment must be
thoroughly familiar with this instruction manual and all articles
of the National Electrical Code applicable to the installation of
this equipment. In addition, all drawings, both mechanical
installation and electrical, must be understood and strictly
followed to prevent damage to the module.
Environmental Requirements
The module as provided is designed for indoor installations only
and should be placed in an indoor area where clean, dry air is free
to circulate around and above it. Since air is taken into the
equipment at the bottom of each section and exhausted at the
top, a location with good airflow must be provided for efficient
operation.
A minimum of 30 inches of clear space above the equipment is
recommended. In order to properly withdraw the trolley there
should be at least 7 foot of space in the front of the module.
NOTE: See Appendix C for sketches concerning layout.
The foundation must be flat and level in all planes with maximum
deviation of 0.8 inch at the length of 3 foot. The module should be
anchored to the floor through holes shown on Fig. 41-1 using
7/16” or metric M12 grade 5 steel bolts.
4-2 Module Configuration and Assembly
Multiple Modules Side by Side Assembly
Modules can be connected together to form switchgear lineups.
To bolt two modules together, edge trim strips must be removed.
Special connection spacers must be used and are inserted into 12
hex shaped cut outs visible in the sidewalls. Fig. 42-1 shows the
location of the front 4 connection spacer openings. Location of all
openings and installation tips are shown in Appendix G.
A Module Coupling Kit can be ordered under Cat. No.: 289169.
Each kit consists of 12 Connection spacers, bolts and washers
necessary to connect two adjacent modules.
NOTE: See Appendix D for connection drawings.
Foundation Requirements
The foundation requirements detailed in this chapter should be
strictly adhered to.
Top View on the floor.
Anchor Points
Use M12 or
7/16” grade 5
bolts.
Locking Plate
Fig.41-1 Module anchor bolt hole locations
The foundation must be strong enough to prevent sagging due to
the weight of the completed switchgear structure and to
withstand the impact loading caused by the opening of the
breakers under fault conditions. The impact loading is
approximately 1-1/2 times the static load.
Connection Spacers
12 per side-by-side.
Fig. 42-1 Location of front module connection spacers
Module Preparation
Every module is suitable for operating either with manually or
motor operated trolley. Depending on the type of trolley being
utilized, a locking plate in the module may need to be removed:
If motor operated trolley is going to be used with the
Module, remove the locking plate.
If manually operated trolley is going to be used with the
module, keep the locking plate in place
See Fig. 41-1 and Fig. 42-2 to locate locking plate.
NOTE: Look for the yellow warning label placed on the
module’s floor to find bottom guide rail and the plate.
2011-04-26 S47183Ee rev.01 Design and specifications are subject to change without notice 11
DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS
Rej
Chapter 4 Installing the Module
Locking Plate
Remove for motor
operated trolley !
Fig. 42-2 Locking Plate
Module Rejection Interlock
OEM must configure the rejection interlock in the module, before
its usage. Four different configurations are possible: 2500A,
4000A, 5000A or 6000A. In the module, rejection markers must be
screwed in place aligned with all current ratings except the one
that module is dedicated to. This should be done on the right and
left side of the module.
Fig. 42-3 illustrates a correctly configured module rejection
Interlock for a 2500A rated Gerapid breaker. Rejection markers
must be fixed on both right and left sides of the breaker
compartment, aligned with ratings: 4000A, 5000A and 6000A.
Installed Breaker
Ground Bus Connection
Ground bus connection terminal is located at the bottom of the
module in the cable compartment. See Fig. 33-4. Circuit
connections to a ground bus are made so that it is not necessary
to open-circuit the ground bus to remove any connection made
to the ground bus. Ground connections are provided for all
removable elements to ensure that the frame and mechanism are
grounded until the primary circuit is disconnected and the
removable element is moved a safe distance.
NOTE: See Appendix B for ground terminal drawings.
Connecting Secondary Controls
Secondary disconnect plug in the module is pre-wired with the
harness going into control compartment. All wires that should be
used by OEM for completing the module and breaker control are
numbered and accessible inside the Control Compartment.
NOTE: See Appendix E for electrical schemes for connections.
NOTE: See Appendix A for control compartment dimensions.
All trolley control commands and supply connections are also
available thru the harness in the Control Compartment.
Top mounted wire way
access covers
Rating
Markers
Fig.42-3 Rejection interlock set up for rating of 2500A
NOTE: Always verify that the rating on rejection interlock is not
higher that the module rated current.
NOTE: Always configure rejection interlock on both sides of the
module breaker compartment.
ection Markers
Main Busbars Connection
Module primary terminals are silver plated copper and are
suitable to connect to copper bus bars as per IEEE Std. C37.14
Table 6. Connected bus bars should not have cross sections less
that recommend in Table 6.
Gerapid circuit breakers are not polarized. Therefore the load and
the supply line can be connected to either top or bottom terminal.
See Fig. 33-4 for primary terminals views.
NOTE: See Appendix B for primary terminals drawings and
recommend bus bar dimension.
Components
Mounting Plate
Grounding Stud
Fig.42-4 Control compartment
Device mounting on control compartment door
Control compartment’s door should be removed before making
any cutouts. To remove the door, open and remove grounding
connection. Lift the door up until the pins are free from hinges.
All auxiliary devices can be attached to the mounting plate
provided at the back of the control compartment. However it is
recommend prefabricating a separate metal sheet and installing
it in the control compartment using frame supports.
There are two cover plates that provide access to the top
mounted wire way (cable channel). Remove the covers to use
them. See Fig. 42-4.
12 Design and specifications are subject to change without notice S47183Ee rev.01 2011-04-26
DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS
Chapter 5 Installing the Breaker
Installing the Breaker
5-1 General Notes
Before installing, operating, or removing a circuit breaker, refer to
the Gerapid breaker instruction manual S47183De for
preparation, inspection, and test. Check thoroughly for damaged
or loose parts and for any dirt or foreign matter, which may be in
the breaker.
To install the breaker, proceed as follows:
1) Before installing a breaker, check the contact areas
on each primary disconnect cluster of fingers for foreign
matter that may have accumulated. Clean these areas if
necessary. Be sure that a thin film of the red lubricating
grease “MOBIL GREASE 28” covers the fingers areas before
putting a breaker in the compartment.
2) Check to see that the breakers match their respective
trolley and compartment. Each breaker is assigned a serial
number and ratings. These are shown on the breaker’s
nameplate. The breaker may also be identified using the 20digit PST catalog number. See Fig 51-1.
5-2 Installing Gerapid Breaker
Prior to Installation
Prior to placing a breaker in its intended location on the trolley,
please check following precautions:
1) Find the foil bag with breaker bolting kit no. 700701
that is attached to the trolley’s platform. Remove it.
2) Ensure that the breaker is OPEN.
3) Ensure that arc chute is NOT on the breaker.
4) Ensure that lifting device can carry ~300 lbs and that
lifting slings are min. 6 ft long.
Installation Procedure
To install the Gerapid circuit breaker, proceed as follows:
1) Ensure that the lifting frame has been removed from
the trolley. See Fig. 22-2.
2) Place the lifting slings in position. See Fig. 52-1.
Carefully lift the breaker and place it on the trolley.
3) Slide in the breaker toward the front of the trolley,
until four attachment bolt holes in platform match the holes in
breaker baseplate. Install bolts provided and tighten with
torque listed in Table D-1. The fixing kit is attached to the
trolley’s platform.
4) Plug in all connectors to correct terminals at the front
of breaker’s control box. Tight the connectors. See Fig. 52-3.
WARNING: Do not stand under the circuit breaker during the
lifting and transport operations.
NOTE: Do not transport the circuit breaker with arc chute
installed.
Fig. 51-1 Nameplate of Gerapid breaker
Breakers of the same rating are interchangeable in their
equipment compartments, as long as they have the same
accessories equipped.
The trolley design is the same and universal, regardless of the
Gerapid breaker type intend to operate with.
WARNING: A breaker with different rating fit into any of the
trolleys. If the trolley’s rejection interlock does not match the
breaker’s rating, but it does match the compartment’s
rejection interlock, it is possible to rack-in an incorrect breaker
into the compartment. This may lead to serious damages and
could result in death or serious injury for operator!
Fig. 52-1 Lifting the breaker
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DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS
Chapter 5 Installing the Breaker
Fig. 52-2 Breaker on the trolley
NOTE: Do not use attachment screws longer than ~1.2 in.
Longer screws may damage trolley’s components.
Configuration of the Rejection Interlock
It is strongly recommended to check and set up correct position
of the rejection interlock immediately after breaker is installed on
the trolley.
All trolleys have their rejection interlock set at 2500A, by default. If
the breaker has a different rating, the rejection interlock has to be
configured accordingly.
1) Remove both rejection markers from default positions.
2) Reattach them in to the positions which correspond to
the breaker’s current rating. In example from 2500A to 5000A,
see Fig. 52-4
CAUTION: Make sure both rejection markers on both sides of
the trolley match the breaker current rating.
Fig. 52-3 Control connectors for Gerapid breaker
Fig. 52-4 Rejection Interlock of the trolley
14 Design and specifications are subject to change without notice S47183Ee rev.01 2011-04-26
DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS
Chapter 5 Installing the Breaker
Testing and Inspection
6-1 General Notes
After the equipment has been installed and all connections made,
equipment must be tested and inspected before it is put in
service. Although each module and each breaker have been
tested at the factory, a final field test must be made to be sure
that the equipment has been properly installed and that all
interlocks operate correctly.
Directions for inspection and testing breakers are given in the
instruction book S47183De, furnished with each breaker. The
extent of the tests on the equipment as a whole is given below.
NOTE: See Appendix H for corresponding Field Test Procedure,
where all steps are listed in Tables H-2, H-3 and H-4.
Prior to Test
Before any operation on the module, it is required to check if
corresponding trolley is remote or manual racking type. Remote
racking trolley includes motor drive installed in a bottom-front
compartment of the trolley. See Fig. 34-1.
NOTE: Make sure that locking plate has been removed, if the
trolley is manual racking type. See section 4.2.
Connecting Control Circuits
Some of the field test procedures require control circuits to be
active and energized. Therefore it is necessary to connect the
wiring harness of the module to a dedicated system, which
enables control of the module. To see recommended connections,
please refer to Appendix H, Fig. H-1.
CAUTION: All wires, which are not connected, must be
insulated while test is running.
The Remote Racking option is available only with ~230 V 60 Hz
control voltage. For other values please contact GE Industrial
Solutions representatives. Supply source should be capable to
carry ~3 A permanent current.
NOTE: See Appendix F for details concerning electric
characteristics of auxiliary loads.
High Potential Tests
High-potential tests, to check the integrity of the insulation, are
not necessary if the installation instructions are carefully followed.
Each module and each trolley undergo High Potential Tests
before shipment. Passing of compete Factory Acceptance Test
sequence is marked by sticker note. See Fig. 61-1.
Fig. 61-1 Quality check markings after FAT tests
If local codes demand this test, or the purchaser wishes to make
high-potential tests, the voltage should not exceed, for the power
circuit, 2.8 kV RMS or 3.9 kV DC and for the control circuit
1.2 kV RMS. Testing procedure is described in Appendix H, Table
H-7.
Grounding Circuit Check
If local codes demand this test, or the purchaser wishes to make
earthing system test, refer to procedure described in Appendix H,
Table H-8.
Minimum current required for checking of grounding connections
is 10 A. Resistance for each measured grounding connection
must be less than 0.1 Ohm.
6-2 Field Testing Procedure
NOTE: Extended descriptions of the module operating modes
with illustrations are given in Chapter 7. Refer to these during
Field Testing execution.
Testing the Module with Remote Racking System
Proceed with steps 1.1 to 1.9 from Appendix H, Table H-4.
Testing the Module w/o Remote Racking System
Proceed with steps 1.1 to 1.9 from Appendix H, Table H-5.
2011-04-26 S47183Ee rev.01 Design and specifications are subject to change without notice 15
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