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

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).

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