GE Industrial Solutions Power Break Stationary Conversion Kit User Manual
DEH 41502 PBI - PBII Stationary Conversion Kit Instruction R01
Overview
The Power Break Stationary Conversion Kit provides all
the necessary parts and information to assist in the
replacement of a Power Break I stationary circuit breaker
with an equivalently rated Power Break II stationary
circuit breaker (refer to Table 1). This instruction manual
describes the modifications that need to be performed on
the equipment and breaker for installation. For complete
Power Break II installation and operation instructions,
refer to the GEH6279 instruction manual.
Frame
Rating
800A
1600A
2000A
2500A
Front Connect
2500A
Back Connect
3000A
Back Connect
3000A
Front Connect
4000A
Table 1: List of various breaker frame sizes with their respective
conversion kits.
800A Stationary Breaker
Operation
Type
Manual
Electrical
Manual
Electrical
Manual
Electrical
Manual
Electrical
Manual
Electrical
Manual
Electrical
Manual
Electrical
Manual
Electrical
Conversion
Kit
SSF08TPCCR 1
SSF16TPCCR 1-2
SSF20TPCCR 1-2
SSF40TPCCMR
SSF40TPCCER
SSF40TPCCMR
SSF40TPCCER
SSF40TPCCMR
SSF40TPCCER
SSF40TPCCMR
SSF40TPCCER
SSF40TPCCMR
SSF40TPCCER
Page
3
3
3
3
3
Power Break® Stationary Conversion Kit
Figure 1: 800A Panel Cutout
Breaker Installation
Ensure that all accessory connections are secure. Line up
mounting holes with enclosure. Place the bolts and tighten
to 300 in-lbs.
1600–2000A Stationary Breaker
In order to make the conversion to a 1600A or 2000A
Power Break II breaker, four modifications are required.
Begin process by removing existing breaker from
equipment.
Panel Cutout
Figure 2 shows the 14” x 10” cutout required using the
existing cutout as reference (dashed). Once cutout is
complete, mount the standard trim plate using #8-32
screws and torque to 5 in-lbs.
The 800A Power Break II design is similar in dimension to
the 800A Power Break I breaker. The only modification
required is the panel cutout. Begin process by removing
existing breaker from equipment.
Panel Cutout
A 14” x 10” cutout is required for the Power Break II
breaker to fit. Figure 1 shows the new front panel cutout
using the existing cutout as reference (dashed line in
Figure 1). Once cutout is complete, mount the standard
trim plate using #8-32 screws and torque to 5 in-lbs.
Figure 2: 1600 - 2000A Panel Cutout
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Mounting Hole Relocation
Line Shield
Since the mounting holes for the Power Break II breaker
do not align with the holes in panel, new mounting holes
need to be drilled on the panel breaker mounting space.
Figure 3 shows the new locations for the 1600A-2000A
breakers. A 1:1 scale template is provided with the kit to
guide in the drilling of the holes, which should be made for
a ¼-20 tap. It is important to note that new non
magnetic mounting boards or channels may need to be
installed in the existing housing to accommodate for the
relocation of the mounting holes.
Due to the addition of the strap extensions, a shield is
required in the line side of the breaker. To install, place line
shield so that the top of mounting bracket aligns with
where breaker base and mid cover meet. Mark the area to
drill using a drill or white pencil (Figure 5).
Figure 5: Mark the Area for Drilling Holes
After marking the area, drill the holes to a depth of
approximately 0.75” using a 0.156” bit. Finally install the
line shield using #10-16 thread cutting screws provided
(Figure 6).
Figure 3: 1600-2000A Mounting Hole Relocation
Line /Load Strap Extensions
The Power Break I 1600A and 2000A breakers are longer
than their Power Break II counterparts. To compensate
for the difference in length, 6 line strap extensions are
provided with the conversion kit. Please note that the
length for the straps is different, 1600A is 4” long and
2000A is 5.25”. Bolt the extensions using 1/2” screws to the
line and load straps to a torque of 300 in-lbs. The
extensions should be bolted as shown on Figure 4.
Figure 6: Line Shield Installation
Breaker Installation
Ensure that all accessory connections are secure. Line up
mounting holes with enclosure. Place the bolts and tighten
to 300 in-lbs.
Neutral Sensor
For Power Break I connected in a three-phase four-wire
system please note the following regarding neutral sensor:
- If the Power Break I has an Enhanced MVT Plus/PM
trip unit, the neutral sensor can be reused
- If the Power Break I has an Original MVT, RMS-9, or
EPIC trip unit, the neutral sensor can be reused.
However, a 1:1 isolation CT might be required to
properly isolate from multiple grounds.
- For Power Break I with any other trip unit, the
neutral sensor must be replaced. See Page 31, GET8052C for Neutral Sensor Options.
Figure 4: Installed 1600A (left) and 2000A (right) Strap Extenders
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