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

2

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

shown).........................................................................................................................................................................................................................8

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

3

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.

4

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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