GE Industrial Solutions K-225, K-600, K-800, K-1600 User Manual

DEH–40029 Installation Instructions

ProTrip™ Conversion Kits

For I-T-E K-1600 Low-Voltage Power Circuit Breakers

INTRODUCTION

GE Conversion Kits are designed for upgrading existing I-T-E 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 I-T-E® Types K-225, K-600, K-800, and K-1600 low-voltage power circuit breakers. Each Conversion Kit contains all the components needed to convert from the existing I-T-E electromechanical trip system.

Types K-225, K-600, K-800,

TABLE OF CONTENTS

SECTION 1. GENERAL INFORMATION............................................................................................................4

SECTION 2. BEFORE INSTALLATION..............................................................................................................4

SECTION 3. DISASSEMBLING THE BREAKER

I-T-E 225–800 Ampere Breakers............................................................................................................5

I-T-E 1600 Ampere Breakers..................................................................................................................6

SECTION 4. INSTALLING THE CONVERSION KIT

Installing Phase Sensors (CTs) ..............................................................................................................9

I-T-E 225–800 Ampere Breakers...............................................................................................9

I-T-E 1600 Ampere Red Frame Breakers Only.......................................................................11

I-T-E 1600 Ampere Black Frame Breakers Only.....................................................................13

Installing the Flux Shifter.......................................................................................................................14

Flux Shifter Adjustment.........................................................................................................................15

Mounting the Trip Unit Bracket .............................................................................................................16

Installing the Trip Unit ...........................................................................................................................17

Connecting the Trip Unit Wiring Harness .............................................................................................18

Configuring the Trip Unit.......................................................................................................................18

SECTION 5. FOUR-WIRE GROUND FAULT OPTION................................................................................19

SECTION 6. TESTING AND TROUBLE-SHOOTING

Testing ..................................................................................................................................................21

Trouble-Shooting...................................................................................................................................21

Nuisance Tripping on Ground Fault-Equipped Breakers.........................................................21

LIST OF FIGURES

1. Removing the insulated housing on a K-225, K-600, or K-800 breaker. .........................................................5

2. Trip unit housing removed, 225–800 A breaker s............................................................................................. 5

3. Drilling out the screws holding the trip units to the housing, 225–800 A breakers..........................................6

4. Bolts to be removed from the load stabs, 225–800 A breakers.......................................................................6

5. Removing the draw-out contact block on a K-1600 breaker............................................................................6

6. Removing the trip unit housings on a K-1600 breaker.....................................................................................7

7. Contact arm connections, 1600 A breaker.......................................................................................................7

8. Electromechanical trip unit disassembly, 1600 A breaker...............................................................................7

9. Trip unit housing, 1600 A breaker....................................................................................................................8

10. Installing shims on red frame 225–800 A breakers. ........................................................................................9

11. Copper load terminal installed, 225–800 A breakers....................................................................................... 9

12. Installing a CT assembly., 225–800 A breakers. .............................................................................................9

13. Converted trip unit housing, 225–800 A breakers............................................................................................9

14. Installed CT assemblies, 225–800 A breakers. ............................................................................................. 10

15. Tightening the CT assembly bolts, 225–800 A breakers...............................................................................10

16. Terminal assembly for K-1600 red frame breaker. ........................................................................................ 11

17. CT assembly for K-1600 red frame breaker...................................................................................................11

18. C-shaped barrier modification, 1600 A breakers. .......................................................................................... 12

19. Reassembled 1600 A breaker........................................................................................................................12

20. Terminal assembly, 1600 A black frame breakers......................................................................................... 13

21. CT assembly, 1600 A black frame breakers..................................................................................................13

22. Flux shifter installation, 225–800 A breakers.................................................................................................14

23. Flux shifter installation, 1600 A breakers. ......................................................................................................14

24. Reset linkage assembly. ................................................................................................................................14

25. Flux shifter adjustment................................................................................................................................... 15

26. Removing the top cover screws.....................................................................................................................16

27. Trip unit bracket and insulating barrier assembly.......................................................................................... 16

28. Trip unit bracket attached to the breaker. ......................................................................................................16

29. Attaching the trip unit to the mounting plate...................................................................................................17

30. Harness connector attached to the trip unit. ..................................................................................................17

31. Trip unit mounted on the breaker...................................................................................................................17

32. Optional trip unit mounting position................................................................................................................17

33. Trip unit wiring harness installation................................................................................................................ 18

34. Neutral sensor outline for K-225 and K-600 breakers...................................................................................19

35. Neutral sensor outline for K-800 and K-1600 breakers.................................................................................20

36. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads...............................................23

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. 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. Note that all ProTrip trip units supplied with conversion kits are equipped with longtime, 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.

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.

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.

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. DISASSEMBLING THE BREAKER

I-T-E K series breaker frames need not be separated front and back for installation of the Conversion Kit. The general procedure is to remove and disassemble the trip unit housing, then install the kit.

First, remove the breaker to a clean, well-lighted work bench and place it in the upright position, so that both the front and back are easily accessible.

I-T-E 225–800 Ampere Breakers

The electromechanical trip units are contained in a common, insulated housing, as shown in Figure 1. Use the following procedure to remove the trip units.

1. Remove the five Philips-head screws holding the trip unit housing in place at the rear of the breaker. Save the hardware for later reinstallation.

NOTE: On some I-T-E breakers, the load-side draw-out fingers must also be removed.

2. Remove and discard the two Philips-head screws mounting the trip unit to the contact arm on each phase, as shown in Figure 1.

3. Remove the trip unit housing assembly from the rear of the breaker, as shown in Figure 2.

Figure 2. Trip unit housing removed, 225–800 A

breakers.

Figure 1. Removing the insulated housing on a K-225, K-

600, or K-800 breaker.

4. Carefully drill out the four #10-32 screws on each phase that hold the trip units to the housing, as shown in Figure 3.

-16 x 2" bolt, nut, and lock

5. Remove and save the

washer holding the trip unit to the bus on each phase, as shown in Figure 4. The trip units can be removed and discarded. The breaker is now ready for conversion.

I-T-E 1600 Ampere Breakers

On I-T-E 1600 ampere breakers, each electromechanical trip unit is contained in its own housing.

1. On draw-out breakers with electrical operators, remove the four screws holding the draw-out contact block assembly to the back frame, as shown in Figure 5. Lift off the contact block assembly. Save the hardware for later reinstallation.

2. Remove the two top and two bottom Philips-head screws at the breaker rear holding each insulated trip unit housing to the breaker frame, as shown in Figure

6. Save the hardware for later reinstallation.

NOTE: On some I-T-E breakers, the load-side draw-out fingers must also be removed.

Figure 4. Bolts to be removed from the load stabs, 225–

800 A breakers.

Figure 3. Drilling out the screws holding the trip units to

the housing, 225–800 A breakers.

Figure 5. Removing the draw-out contact block on a K-

1600 breaker.

Figure 6. Removing the trip unit housings on a K-1600

breaker.

3. Remove and discard the four Philips-head screws

above the load terminals that connect each trip unit to the contact arm, as shown in Figure 7. The trip unit assemblies can be removed by pulling them out of the rear of the breaker frame.

4. Carefully drill out the four #10-32 screws holding

each trip unit in its housing, as shown in Figure 8.

5. Remove and save the two Philips-head screws that

hold the copper terminal extensions beneath the load terminals of each trip unit housing, as shown in Figure 8.

6. Remove and discard the hardware holding each

copper load terminal to the metal mounting brackets. Separate each trip unit from its housing. Discard the trip units and save the insulated housing and mounting brackets, shown in Figure 9.

Figure 7. Contact arm connections, 1600 A breaker.

Figure 8. Electromechanical trip unit disassembly, 1600

A breaker.

Figure 9. Trip unit housing, 1600 A breaker.

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