GE Industrial Solutions LA-600, LA-800, LA-1600 User Manual

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DEH–40004A Installation Instructions

ProTrip™ Conversion Kits

for Allis Chalmers®, Siemens/Allis®, and Siemens® LA-600, LA-800, and LA-1600 Gold Low-Voltage Power Circuit Breakers

INTRODUCTION

GE Conversion Kits are designed for upgrading existing Allis Chalmers®,

Siemens/Allis®, and Siemens® 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 Allis Chalmers®, Siemens/Allis®, and Siemens® LA-600, LA800, and LA-1600 gold low-voltage power circuit breakers. Each Conversion Kit contains all the components needed to convert from the existing trip system.

TABLE OF CONTENTS

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

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

SECTION 3. BREAKER PREPARATION......................................................................................................................................................5

SECTION 4. INSTALLING THE CONVERSION KIT.......................................................................................................................6

Installing and Adjusting the Flux Shifter Assembly....................................................................................................7

Installing the Flux Shifter Assembly .....................................................................................................................7

Flux Shifter Adjustment..................................................................................................................................................7

Trip Screw Adjustment.....................................................................................................................................................8

Breaker Reset Linkage ......................................................................................................................................................8

Flux Shifter Test ....................................................................................................................................................................8

Installing the Current Sensors ..................................................................................................................................................10

LA-600 and LA-800 Current Sensors ...................................................................................................................10

LA-1600 Current Sensors ............................................................................................................................................. 10

SECTION 5. FOUR-WIRE GROUND FAULT OPTION..............................................................................................................11

SECTION 6. TESTING AND TROUBLE-SHOOTING

Testing.........................................................................................................................................................................................................13

Trouble-Shooting................................................................................................................................................................................13

Nuisance Tripping on Ground Fault-Equipped Breakers ................................................................... 13

LIST OF FIGURES

1. Primary disconnects removed from the lower studs, showing the original current

sensors (LA-1600 shown)..............................................................................................................................................................................5

2. Original flux shifter and trip unit (Type LTS1 shown) mounting locations (LA-1600

shown).........................................................................................................................................................................................................................5

3. Components supplied with the conversion kit. ...........................................................................................................................6

4. Flux shifter assembly. ......................................................................................................................................................................................7

5. Flux shifter mounting area (LA-800 shown)..................................................................................................................................7

6. Flux shifterassembly installed, as viewed from the bottom of the breaker..........................................................8

7. Flux shifter assembly installed, as viewed from the right front of the breaker (LA-800

8. Attaching the trip unit to the mounting plate...............................................................................................................................9

9. Trip unit mounted on the breaker (LA-600 shown). .................................................................................................................9

10. Installing the current sensors on an LA-600 or LA-800 breaker....................................................................................10

11. Installing the current sensors on an LA-1600 breaker. ........................................................................................................ 10

12. Neutral sensor outline for LA-600 and LA-800 breakers.....................................................................................................11

13. Neutral sensor outline for LA-1600 breakers...............................................................................................................................12

14. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads............................................... 15

SECTION 1. GENERAL INFORMATION

SECTION 2. BEFORE INSTALLATION

GE Conversion Kit installation is straightforward, but does require careful workmanship and attention to these instructions. Familiarity with the breaker is highly desirable. Then general approach is to first remove the existing trip devices from the breaker, then install the ProTrip components. Following this procedure, the converted breaker is performance tested before it is returned to service.

The majority of trip unit kit installations do not require any customized assembly work. However, some installations may involve unusual mounting conditions or accessory combinations that require minor modifications and/or relocation of components. In most instances, this supplementary work can be done on site.

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, shorttime, 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.

Before starting any work, turn off and lock out all power sources leading to the breaker, both primary and secondary. Remove the breaker to a clean, welllighted work area.

WARNING: 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 lowvoltage 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 lockout 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 a CLOSED breaker and be sure the stored-energy springs are discharged. This removes the possibility that the breaker may trip OPEN or the closing springs discharge, which could 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 drawout 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. BREAKER PREPARATION

The following steps are performed to prepare the breaker for installation of the new conversion kit. Unless otherwise indicated, the procedure is the same for LA-600, LA-800, and LA-1600 breakers.

WARNING: Before installing the conversion kit, turn the breaker OFF, disconnect it from all voltage sources, and discharge the closing springs.

1. Open the breaker and remove it from its enclosure. Carefully place the breaker on a suitable work surface so that the rear of the breaker is initially accessible.

2. If the conversion kit is to be installed on a fused breaker (LAF series), remove the fuse structure from the upper (line) studs to allow easier access to the load studs.

3. Loosen the two Allen-head screws securing each of the primary disconnects to the line (upper) and load (lower) studs and remove the primary disconnects, as illustrated in Figure 1.

4. Remove the wires from the original current sensors (CTs), if present, and slide off the CTs.

5. Unscrew the knob on the end of the manual charging handle and pull the handle down part way. Remove the two bolts holding the escutcheon to the breaker frame and lift off the escutcheon.

6. Carefully position the breaker so that it is resting on its back on the line and load studs.

7. Remove the two bolts securing the old flux shifter mounting bracket (if present) to the breaker frame, shown in Figure 2. One bolt is secured with a nut, the other is attached to a tapped hole in the frame. Disconnect the two connectors on the leads to the trip unit and remove the flux shifter.

8. Remove the three bolts securing the trip unit mounting bracket (if present) to the breaker frame. Remove the trip unit and its wiring harness.

Figure 1. Primary disconnects removed from the lower studs, showing

the original current sensors (LA-1600 shown).

Trip Unit

Flux

Shifter

Figure 2. Original flux shifter and trip unit (Type LTS1 shown) mounting

locations (LA-1600 shown).

SECTION 4. INSTALLING THE CONVERSION KIT

This section describes the installation of the MicroVersaTrip Plus or MicroVersaTrip PM conversion kit. The components provided with the kit are shown in Figure 3.

Wiring

Harness

Trip Unit on

Mounting

Plate

Current

Sensor

Support

Bracket

Figure 3. Components supplied with the conversion kit.

Flux

Shifter

Installing and Adjusting the Flux Shifter Assembly

Use the following procedures to install and adjust the new flux shifter assembly, shown in Figure 4. Numbers in brackets in the text refer to the numbered parts in Figure 4. The breaker should still be resting on its back from the previous procedure (removing the old components).

Installing the Flux Shifter Assembly

Figures 6 and 7 show two views of the completed flux shifter installation.

1. Check that the diameters of the two flux shifter mounting holes, shown in Figure 5, are .30 inch. If they are less than this size, drill them out to .30 inch (use an N bit).

2. Loosen the screw on the flux shifter reset link [2] and move the link to the bottom of its slot.

3. Remove and save the nut, lock washer, and flat washer from the two mounting studs [6] on the mounting surface of the flux shifter assembly. Leave the spacers in place, as they are necessary to ensure proper alignment with the breaker reset link [7].

4. Install the flux shifter assembly on the right side of the breaker frame where the original flux shifter (if present) was removed. The two mounting studs should fit through the existing (or modified) holes in the frame, as shown in Figure 5. Secure the flux shifter assembly to the frame with the flat washer, lock washer, and nut removed in step 3.

Flux Shifter Adjustment

1. With the breaker in the open (reset) position,

depress the flux shifter reset arm [1] so that dimension A is held at about 0.4 inch.

2. Move the flux shifter reset link [2] up to contact the breaker reset link [7] and take up any travel in the breaker link.

3. Tighten the screw on the flux shifter reset link [2] to secure it in position. The flux shifter is now in its reset position.

4. Check that there is clearance between the reset pin [5] and the reset latch [4] with the breaker in the OPEN (reset) position. When the breaker is CLOSED, the flat of the reset pin [5] must rest against the reset latch [4].

Figure 4. Flux shifter assembly.

Breaker

Reset

Link

Trip

Paddle

Mounting

Holes

Figure 5. Flux shifter mounting area (LA-800 shown).

Trip Screw Adjustment

With the breaker CLOSED, the trip screw [3] must have zero clearance with the breaker trip paddle. If adjustment is necessary, OPEN the breaker, make the adjustment, then CLOSE the breaker to check the adjustment. Be sure to retighten the adjusting nut.

WARNING: Be extremely careful when working on a CLOSED breaker. Do not reach your hands into the mechanism while adjusting the flux shifter.

Breaker Reset Linkage.

This following procedure is illustrated in Figures 4, 6, and 7

Place a #10 flat washer over the supplied #10-32 bolt. Insert the bolt through the hole in the breaker reset link [7]. Place a flat washer over the bolt, then slide the bolt through the slot in the flux shifter reset arm [1]. Place a flat washer and the selflocking nut on the bolt. Tighten the nut so that the bolt is still free to rotate.

Flux Shifter Test

The operation of the flux shifter may be tested by closing the breaker, then applying 9 Vdc to the flux shifter leads (red is positive). The breaker should trip and reset. If necessary, repeat the adjustments in the previous procedures.

Flux Shifter

Reset Arm [1]

Mounting

Stud [6]

Breaker

Reset

Link [7]

Flux Shifter

Reset Link

Trip

Screw

Figure 6. Flux shifter assembly installed, as viewed from the bottom of

the breaker.

Breaker

Reset Link [7]

Trip

Paddle

Figure 7. Flux shifter assembly installed, as viewed from the right front

of the breaker (LA-800 shown). .

Installing the Trip Unit

1. On LA-600 and LA-800 installations, remove the

microswitch adjusting bolt on the trip unit mounting plate.

2. Remove and the trip unit mounting 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 previously removed trip unit mounting screw, as shown in Figure 8.

3. 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 #4-40 screws and lock washers provided, as shown in Figure 8.

4. Place the trip unit and mounting plate in position on the support bracket. Secure with three

/4 -20 screws, lock washers, and flat washers into the tapped holes in the support bracket, as shown in Figure 9.

5. Place the two slotted mounting holes in the support bracket behind the two existing holes in the breaker frame, as shown in Figure 9. Secure with the 1/4 -20 screws, flat washers, lock washers, and nuts provided.

6. Pass the current sensor and flux shifter leads from the front to the rear through the hole on the lower left side (viewed from the rear) of the breaker frame.

7. If a neutral sensor is to be used in the equipment, pass the corresponding connector through the rear-frame hole with the CT leads. Otherwise, tie it to some convenient point on the breaker frame with wire ties.

8. On LA-1600 installations, adjust the microswitch adjusting bolt so that the microswitch is off when the breaker is open and on when the breaker is closed.

Trip Unit

Mounting

Screw

50-Pin

Connector

Figure 8. Attaching the trip unit to the mounting plate.

Mounting

Plate

Screws

Support Bracket

Mounting

Screws

Figure 9. Trip unit mounted on the breaker (LA-600 shown).

Installing the Current Sensors

The current sensors must be installed differently in the two breaker frame sizes.

LA-600 and LA-800 Current Sensors

The following procedure is illustrated in Figure 10.

1. Slide two of the current sensors (CTs) over the outer load studs with their terminals pointing upward. Slide the other CT over the center line stud with its terminals pointing downward.

2. Connect the CT leads from the trip unit to each of the CTs. The leads are labeled with the letter of the corresponding pole (A is the right pole from rear of the breaker, B is the center pole, C is the left pole), and are also cut to the appropriate lengths. Attach the white wire to the terminal marked with a white paint dot on the A and C (outer) CTs. Attach the black wire to the terminal marked with a white paint dot on the B (center) CT. This difference is necessary to maintain proper polarity.

3. Reattach the primary disconnect assemblies to all the studs if the breaker is unfused or to only the load (lower) studs if the breaker is fused.

4. If the breaker is fused, reinstall the fuse assemblies on the upper studs.

CT Wire

Exit Hole

Figure 10. Installing the current sensors on an LA-600 or LA-800

breaker..

LA-1600 Current Sensors

The following procedure is illustrated in Figure 11.

1. Slide the three current sensors (CTs) over the lower (load) studs, with the terminals pointing up.

3. Reattach the primary disconnect assemblies to all the studs if the breaker is unfused or to only the load (lower) studs if the breaker is fused.

4. If the breaker is fused, reinstall the fuse asse mblies on the upper studs.

CT Wire

xit Hol

Figure 11. Installing the current sensors on an LA-1600 breaker..

SECTION 5. 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 12 shows the sensor outlines for the 600 A and 800 A frame sizes. Figure 13 shows the sensor for the 1600 A frame size.

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, routed through the rear of the breaker with the CT wires. The wires should be tied to the breaker frame in an easily accessible location.

Figure 12. Neutral sensor outline for LA-600 and LA-800 breakers..

Figure 13. Neutral sensor outline for LA-1600 breakers.

SECTION 6. 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.

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.

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 prim ary circuit with a 1,000-volt Megger.

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 retro fitted, perform a primary injection test on each phase. This test will check the CTs, bus,

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 con nected 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 suffi cient 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 follow ing 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 14.

4. On ground fault breakers serving four-wire loads, check that the neutral sensor is properly connected, as indicated in Figure 14. 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 breaker-mounted 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

LA-600

LA-800

LA-1600

150 225 600

150 400 800

800

1600

10.1–15.2

14.5–22 4–58

10.1–15.2 27–41 51–77

54–81

110–166

Table 1. CT resistance values.

Figure 14. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads.

These instructions do not cover all details or variations in equipment nor do they provide for every possi ble 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.

GE Industrial Systems

General Electric Company 41 Woodford Ave., Plainville, CT 06062

GE Industrial Solutions LA-600, LA-800, LA-1600 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual