DEH–40028A Installation Instructions
ProTrip™ Conversion Kits
g
For GE Types AK-50, AKU-50, AKS-50,
AKT-50, AK-75, and AK-100 Low-Voltage
Power Circuit Breakers
INTRODUCTION
GE Conversion Kits are designed for upgrading
existing GE low-voltage power circuit breakers,
rather than replacing the entire breaker. The Con-
version Kits include ProTrip™ Trip Units, the latest
technological advance in GE trip system s.
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 Con-
version Kits on GE types AK-50, AKU-50, AKS-50,
AKT-50, AK-75, and AK-100 low-voltage power circuit
breakers. Each Conversion Kit contains all the
com ponents needed to convert from an existing GE
type EC trip system .
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LIST OF FIGURES
1. Relocation and rem ounting of the W and X relays................................................................................. 5
2. New X and W relay m ounting brackets................................................................................................... 5
3. Flux shifter assem bly. .............................................................................................................................. 6
4. Pattern for flux shifter m ounting holes in the side fram e ...................................................................... 6
5. Flux shifter assem bly m ounted to the side fram e. ................................................................................. 6
6. Location of new hole in the flux shifter base.......................................................................................... 7
7. Locations of new holes for m ounting the OFLO term inal block. ........................................................... 7
8. Existing trip paddles to be rem oved. ...................................................................................................... 8
9. Installing the new trip paddle. ................................................................................................................. 8
10. Adjusting the flux shifter. ........................................................................................................................ 8
11. Mounting hole drill pattern for the trip unit m ounting plate. ................................................................ 9
12. Trip unit m ounting plate attached to the breaker front channel. ........................................................... 9
13. Trip unit m ounting bracket attached to the m ounting plate. ............................................................... 10
14. Actuator bracket attached to the left pole link. ..................................................................................... 11
15. Drill pattern for actuator bracket m ounting holes. ............................................................................... 11
16. Existing EC trip devices before rem oval. .............................................................................................. 12
17. Rem oval of EC trip devices.................................................................................................................... 12
18. Parts provided for CT installation per pole. .......................................................................................... 13
19. CT post m ounted in the breaker back fram e......................................................................................... 13
20. CT installation com pleted.. .................................................................................................................... 13
21. Phase sensor installation on AK-75 & AK-100 breakers........................................................................ 14
22. Attaching the trip unit to the m ounting plate ....................................................................................... 15
23. Trip unit m ounted on the breaker. ........................................................................................................ 15
24. Fourth-wire term inal board installation on AK-50 & AKS-50 stationary breakers............................... 16
25. Fourth-wire disconnect installed on AK-50 & AKS-50 draw-out breakers. .......................................... 17
26. Fourth-wire disconnect assem bly for AKD-5 or AKD-6 equipm ent...................................................... 17
27. Fourth-wire disconnect assem bly for AKD equipm ent......................................................................... 17
28. K-75 & AK-100 back fram e conversion. ................................................................................................. 18
29. Outline of the neutral sensor for AK-50 breakers.................................................................................. 19
30. Outline of the neutral sensor for AK-75 and AK-100 breakers.............................................................. 20
31. AK-50 & AKS-50 fourth-wire disconnect for AKD. ................................................................................ 21
32. AK-75 & AK-100 fourth-wire disconnect for AKD-5 & AKD-6. .............................................................. 21
33. AK-100 fourth-wire disconnect for AKD. ............................................................................................... 21
34. AK-50 & AKS-50 fourth-wire disconnect for AKD. ................................................................................ 22
35. Fourth-wire disconnect for AKD-5 & AKD-6. ......................................................................................... 22
36. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads. ................................ 25
3
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SECTION 1. GENERAL INFORMATION SECTION 2. BEFORE INSTALLATION
GE Conversion Kit installation is straightforward, but
does require careful workm anship and attention to
these instructions. Fam iliarity with the breaker is
highly desirable. The general approach is to first
rem ove the existing trip devices from the breaker,
then install the ProTrip com ponents. Following this
procedure, the converted breaker is perform ance
tested before it is returned to service.
Before starting any work, turn off and lock out all
power sources leading to the breaker, both prim ary
and secondary. Rem ove the breaker to a clean, well-
lighted work area.
WARNING: Low-voltage power circuit breakers use
high-speed, stored-energy spring operating
m echanism s. The breakers and their enclosures
contain interlocks and safety features intended to
provide safe, proper operating sequences. For
m axim um personnel protection during installation,
operation, and m aintenance of these breakers, the
following procedures m ust be followed. Failure to
follow these procedures m ay result in personal
injury or property dam age.
The m ajority of trip unit kit installations do not
require any custom ized assem bly work. However,
som e conversions m ay involve unusual m ounting
conditions or accessory com binations that require
m inor m odifications and/or relocation of com po-
nents. In m ost instances, this supplem entary work
can be done on site.
•
Only qualified persons, as defined in the
National Electrical Code, who are fam iliar with
the installation and m aintenance of low-voltage
power circuit breakers and switchgear assem -
blies, should perform any work on these break-
ers.
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 m ounting in the equipm ent. Ensure that
retrofitted breakers are applied within their short-
circuit ratings. For exam ple, if the previous trip unit
provided long-tim e instantaneous protection, the
short-tim e rating of the ProTrip Trip Unit will govern
the application.
•
•
Com pletely read and understand all instructions
before attem pting any breaker installation,
operation, m aintenance, or m odification.
Turn off and lock out the power source feeding
the breaker before attem pting any installation,
m aintenance, or m odification. Follow all lock-
out and tag-out rules of the National Electrical
Code and all other applicable codes.
As a service-related consideration, the installation of
a ProTrip kit provides an excellent opportunity to
perform norm al m aintenance on the breaker, par-
ticularly when the front and back fram es are sepa-
rated. Such procedures are described in the instal-
lation and m aintenance m anuals supplied with the
breaker and equipm ent.
•
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 rem oving the possibility
that the breaker m ay trip OPEN or the closing
springs discharge and cause injury.
•
•
Trip the breaker OPEN, then rem ove the breaker
to a well-lighted work area before beginning
work.
Do not perform any m aintenance that includes
breaker charging, closing, tripping, or any other
function that could cause significant m ovem ent
of a draw-out breaker while it is on the draw-out
extension rails.
•
Do not leave the breaker in an interm ediate
position in the switchgear com partm ent. Always
leave it in the CONNECTED, TEST, or
DISCONNECTED position. Failure to do so could
lead to im proper positioning of the breaker and
flashback.
4
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SECTION 3. FRONT FRAME BREAKER
CONVERSION
Front fram e conversion consists of the following
steps:
1. Separation of the front and back breaker fram es
for AK-50, AKU-50, AKS-50, and AKT-50 breakers.
(Fram e separation is not necessary for AK-75 and
AK-100 breakers.) Refer to the appropriate
installation and m aintenance m anuals supplied
with the breakers and equipm ent for instructions
on fram e separation. Copies of these publications
m ay be obtained from your local GE sales office.
2. Relocation and rem ounting the W and X relays
on AK-50, AK-75, and AK-100 electrically operated
breakers with EC trip devices.
3. Installation of the flux shifter assem bly and trip
paddle.
4. Installation of the trip unit m ounting bracket.
5. Installation of the trip unit wiring harness.
Relocating and Rem ounting the W and X
Relays
This step is necessary on electrically operated
breakers with EC trip devices. Figure 1 illustrates this
process. Figure 2 shows the new m ounting brackets
supplied with the kit.
1. Rem ove the W relay and install the m ounting
bracket supplied with the conversion kit to the
upper left side of the fram e
2. Rem ove the X relay and its m ounting bracket.
Use the new bracket supplied with the conver-
sion kit to rem ount the X relay in its existing
position.
Figure 1. Relocation and remounting of the W and X relays.
W Relay
X Relay
Figure 2. New X and W relay mounting brackets.
5
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Installing the Flux Shifter Assem bly
The installation procedure for the flux shifter
assem bly, illustrated in Figure 3, varies depending
on the type of breaker and existing trip device. In
som e cases, m ounting holes m ust be added, term i-
nal blocks relocated, or breaker side rails rem oved.
Breakers w ith EC or Pow er Sensor Trip System s
1. Drill the flux shifter m ounting holes in the left
side of the breaker fram e. The m ounting hole
pattern is illustrated in Figure 4. A full-size tem -
plate is provided in the Appendix.
2. Mount the new flux shifter to the inside of the
side fram e with the three screws, lock washers,
flat washers, and nuts supplied, as shown in
Figure 5. Insert the screws from the outside of
the side fram e.
Figure 4. Pattern for flux shifter mounting holes in the side frame.
Mounting
Screws
Flux Shifter
Assembly
Figure 5. Flux shifter assembly mounted to the side frame.
Figure 3. Flux shifter assembly.
6
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Breakers w ith a Side Bracket
1. Drill a 3 4” diam eter hole into the flux shifter
assem bly m ounting base to provide the neces-
sary clearance for the bracket. The location of the
new hole is shown in Figure 6.
2. Rem ove the side bracket from the fram e and drill
the holes according to the pattern in Figure 4. A
full-size tem plate is provided in the Appendix.
After the holes are drilled, return the side bracket
to its original location.
3. Mount the new flux shifter to the inside of the
side fram e with the three screws, lock washers,
flat washers, and nuts supplied, as shown in
Figure 5. The upper two screws are inserted from
the outside of the fram e, while the lower screw
m ust be inserted from the inside.
Figure 6. Location of new hole in the flux shifter base.
AKU-50 Breakers Only
For easier installation of the new flux shifter
assem bly on AKU-50 breakers, the open-fuse lockout
(OFLO) m ay be rem oved from the breaker.
1. Rem ove the three bolts attaching the OFLO to the
base of the breaker.
2. The OFLO term inal block m ust be relocated on
the upper left side of the breaker. Som e parts and
tool, not provided with the kit, are necessary for
this task:
•
•
•
•
•
•
•
•
Six strips of 14 AWG wire
Wire splice
12 butt splices
Wire labels
Drill and size F bit
5/16-18 tap
Figure 7. Locations of new holes for mounting the OFLO terminal
block.
Flathead screw driver
5
Two /16-18 bolts and lock washers
5
3. Drill and tap two holes for the /16-18 bolts. Fig-
ure 7 shows the hole locations.
4. Rem ove the three bolts securing the OFLO to the
breaker and lift off the OFLO device.
5. Rem ove the wires that connect the OFLO device
to the term inal block.
6. Cut the wires that connect to the coils where they
join and label the wires. Attach butt splices to all
twelve open ends.
7. Connect the strands of wire to the OFLO. Mount
the term inal block in its new location. DO NOT
com plete the wire connections until the flux
shifter is installed.
8. Install the new flux shifter assem bly as described
above and shown in Figure 5.
9. Connect the cables attached to the term inal block
and tie them together.
7
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Breakers w ith ECS or SST Trip System s
1. Rem ove the ECS or SST trip unit.
2. Rem ove the existing flux shifter device and the
trip unit control harness.
3. Install the new flux shifter assem bly as described
above and shown in Figure 5.
Installing the Trip Paddle
For breakers equipped with an ECS or SST trip sys-
tem , the existing trip paddle is used with the new
flux shifter.
Trip Paddles
For all other breakers, the existing trip paddles m ust
be rem oved and the new trip paddle installed as
follows:
1. Rem ove and discard the three trip paddles on the
trip actuator bar, as shown in Figure 8.
Figure 8. Existing trip paddles to be removed.
2. Assem ble the trip paddle and the threaded back
3
plate by inserting two of the 10-32 x
4" screws
1”
and lock washers provided along the top edge.
3. Slip the trip paddle over the trip actuator bar
approxim ately one inch from the side fram e, as
shown in Figure 9. Insert the rem aining 10-32 x
3
4" screw and tighten the other screws to
secure the trip paddle in place.
Adjusting the Flux Shifter
After the flux shifter and trip paddle are installed and
the breaker fram es are reassem bled, the following
adjustm ents m ust be m ade.
Trip
Paddle
1. With the breaker OPEN and the m echanism
charged, set the gap between the trip paddle and
the end of the flux shifter rod at 0.10 inch, as
shown in Figure 10. Use a 0.10-inch diam eter rod.
Set the adjuster end of the trip rod and lock it in
place with the jam nut. Note that rem oval of the
buffer stud will m ake the trip paddle easier to
install and adjust.
Figure 9. Installing the new trip paddle.
2. As the crossbar travels between the breaker
CLOSED and OPEN positions, the tang of the
actuator bracket m ust clear the buffer stud. If
there is insufficient clearance, loosen the two
m ounting screws and rotate the bracket clock-
wise to take up m ounting hole slack. Retighten
the screws.
3. Optional Test – The flux shifter m ay be tested by
closing the breaker and applying a 9 Vdc power
source to the flux shifter leads (the red wire is
positive). The breaker should trip.
Figure 10. Adjusting the flux shifter.
8
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Installing the Trip Unit Mounting Bracket
The new ProTrip trip unit m ounts to the left side of
the front channel. A m ounting bracket is shock--
m ounted to a plate that is assem bled to the front
channel.
EC or Pow er Sensor Trip System
1. The holes for the new m ounting plate m ay have
to be added to the front channel. The drill pattern
is shown in Figure 11, with a full-size tem plate in
1
the Appendix. Tap the holes for /4-20 screws.
2. Attach the new m ounting plate, as shown in
1
Figure 12, with two short /4-20 screws and lock
1
washers on the top and the single long /4-20
screw and lock washer on the bottom . Be sure to
insert the spacer between the m ounting plate and
the breaker channel, as shown.
3. Attach the trip unit m ounting bracket to the plate
with two screws, lock washers, and flat washers,
as shown in Figure 13.
ECS or SST Trip System
Figure 11. Mounting hole drill pattern for the trip unit mounting
plate.
Rem ove the existing m ounting plate and bracket.
Install the new m ounting plate and bracket, using the
holes closest to the front of the breaker, as described
in steps 2 and 3 above.
If the m anual indicator assem bly busing on AK-50
m anual breakers interferes with the m ounting
bracket installation, then the bracket m ust be m odi-
fied. Cut off a 3/4 x 11/2 inch section from the right
front of the plate to provide clearance.
Figure 12. Trip unit mounting plate attached to the breaker front
channel.
9
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Figure 13. Trip unit mounting bracket attached to the mounting
plate.
10
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SECTION 4. BACK FRAME
CONVERSION
Left Pole
Link
The back fram e conversion consists of the following
operations:
1. Modification of the crossbar assem bly for the
flux shifter installation.
2. Rem oval of the existing trip devices.
3. Installation of the phase sensors.
4. Installation of the back fram e harness.
Actuator
Bracket
Crossbar Modification
The flux shifter reset linkage is driven by the actuator
bracket, as shown in Figure 3. The actuator bracket
m ust be assem bled to the left side link of the left
pole, as shown in Figure 14.
Figure 14. Actuator bracket attached to the left pole link.
If the actuator bracket m ounting holes are not in the
left side link, the holes m ust be added. Drill and tap
two /16-18 holes using the pattern in Figure 15. A
5
full-size tem plate is provided in the Appendix.
Figure 15. Drill pattern for actuator bracket mounting holes.
11
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Coil Mounting
Bolts
Rem oving the Existing Trip Devices
AK-50 & AKS-50 Breakers w ith EC or Pow er Sensor
Trip System s
1. Rem ove and discard the two screws at the base
of each trip device, as shown in Figure 16. Dis-
card the m etal m ounting brackets.
2. Rem ove and discard the sm all Philips-head
screw at the top of each trip device.
5
3. Rem ove and discard the four
16" Allen-head
bolts securing each trip coil. The coil can then be
lifted off and rem oved. Figure 17 shows one trip
com pletely rem oved, one with the cover
rem oved, and one still in place.
Cover Screws
and Clamps
Figure 16. Existing EC trip devices before removal.
AK-50 & AKS-50 Breakers w ith SST Trip System s
Rem ove the existing SST phase sensors in prepara-
tion for installing the new sensors.
AK-75 & AK-100 Breakers w ith EC or Pow er Sensor
Trip System s
Rem ove the existing trip devices and harnesses and
discard.
AK-75 & AK-100 Breakers w ith SST Trip System s
The new ProTrip phase sensors are visually identical
to the SST sensors. Rem ove the existing sensors and
discard.
Figure 17. Removal of EC trip devices.
12
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Installing the Phase Sensors
AK-50 & AKS-50 Breakers
Figure 18 shows the parts provided for assem bly of
the CT on each pole.
1. Mount the new copper CT post to the back fram e
3
with the two
8-16 x 11 2" bolts, flat washers,
and lock washers provided, as shown in Figure
19.
2. Fasten the three sm all insulated wire fasteners to
Figure 18. Parts provided for CT installation for one pole.
1
the back fram e with the
4-20 x 13 4" screws
provided, as shown in Figure 20. One fastener is
m ounted under each CT.
3. Place a CT over each copper post, first applying a
sm all am ount of RTV or sim ilar adhesive to
prevent the CTs from rotating.
4. Mount the top copper bus over each CT and
1
secure with the
2-13 x 11 2" Allen-head bolts,
lock washers, and flat washers provided.
3
5. Insert two
8-16 x 11 2" bolts, lock washers, and
flat washers through each top copper bus into
the contact arm assem bly.
3
1
6. Tighten the
8-16 bolts to 200 in-lb and the
2-
13 bolts to 300 in-lb.
WARNING: Step 6 ensures critical electrical integrity
connections. The designated bolts m ust be correctly
tightened for proper operation. Failure to tighten
these bolts properly will cause a breaker failure,
resulting in property dam age and/or personal
injury.
Figure 19. CT post mounted in the breaker back frame.
Top Copper
Bus
1
2-13
Bolt
3
8-16
Bolts
Wire
Fastener
Wire
Harness
Figure 20. CT installation completed..
13
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AK-75 & AK-100 Breakers
1. The ProTrip phase sensors m ount on the upper
breaker studs, as shown in Figure 21. The sen-
sors held on the stud with locking rings. Leave
enough of the stud exposed for the prim ary fin-
gers to engage. Engage the sensor’s antiturn lugs
with the notch in the locking ring. Before
tightening the locking rings, position each sensor
so that its leads exit between the pole bases, as
shown.
2. Mount the three sensor term inal boards to the
rear of the back fram e using the hardware pro-
vided.
3. Form each sensor’s leads downward between the
pole bases.
Figure 21. Phase sensor installation on AK-75 & AK-100 breakers.
14
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SECTION 5. INSTALLING THE TRIP
UNIT
1. Rem ove the large screw from the rear of the trip
unit. Place the trip unit in position on the m ount-
ing plate, with the 50-pin connector aligned with
the opening in the plate. Secure with the large
screw, as shown in Figure 22.
Trip Unit
Mounting
Plate
2. Insert the 50-pin fem ale connector on the wiring
harness into the trip unit connector through the
rear of the m ounting plate. Secure to the m ount-
ing plate with the two sm all screws provided, as
shown in Figure 22.
Trip
Unit
3. Place the trip unit and m ounting plate in position
on the support bracket m ounted on the breaker.
Secure with the three screws, lock washers, and
flat washers through the holes in the m ounting
plate into the tapped holes in the bracket, as
shown in Figure 23.
Trip Unit
Mounting
Screw
Wiring
Harness
Connector
Configuring the Trip Unit
See DEH-40034 for detailed instructions for setting
up ProTrip trip units.
Figure 22. Attaching the trip unit to the mounting plate.
Figure 23. Trip unit mounted on the breaker.
15
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SECTION 6 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 equipm ent. The
sensor is connected to the trip unit through the
connector provided in the wiring harness.
Installing the Fourth-Wire Disconnect
AK-50 & AKS-50 Stationary Breakers
The fourth-wire disconnect for stationary breakers
consists of a term inal board m ounted to the lower
front channel, as shown in Figure 24.
•
If the term inal board is already present on the
breaker, just replace the control harness. Main-
tain the following color code: white wire to
com m on, black wire to the tap.
•
If the term inal board m ust be added, m ount it as
shown in Figure 24. The m ounting holes m ay
have to be added to the front channel.
Figure 24. Fourth-wire terminal board installation on AK-50 &
AKS-50 stationary breakers.
16
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AK-50 & AKS-50 Draw -Out Breakers
The fourth-wire disconnect for AK-50 and AKS-50
draw-out breakers m ounts to the lower back fram e,
as shown in Figure 25.
•
If the term inal board is already present on the
breaker, just replace the control harness. Main-
tain the following color code: white wire to
com m on, black wire to the tap.
•
If the disconnect m ust be added, m ount it as
shown in Figure 25.
AK-75 & AK-100 Draw -Out Breakers
Figure 25. Fourth-wire disconnect installed on AK-50 & AKS-50
draw-out breakers.
There are two fourth-wire disconnect designs used
with these breakers. One design is used on breakers
for GE type AKD switchgear, while the other applies
to breakers for GE types AKD-5 and AKD-6
equipm ent. The only difference is the bracket used
for m ounting the disconnect to the breaker. Figures
26 and 27 show these two designs.
The conversion kit contains an assem bled, ready-to-
install m ounting block and bracket for AKD-5 and
AKD-6 installation, plus an addition bracket only for
type AKD equipm ent installations. For AKD equip-
m ent, rem ove the bracket from the assem bled dis-
connect and replace it with the AKD bracket.
Figure 26. Fourth-wire disconnect assembly for AKD-5 or AKD-6
equipment.
The fourth-wire disconnect for AK-75 and AK-100
draw-out breakers m ounts to the lower back fram e
as shown in Figure 28.
•
If the term inal board is already present on the
breaker, just replace the control harness. Main-
tain the following color code: white wire to
com m on, black wire to the tap.
•
If the disconnect m ust be added, m ount it as
shown in Figure 28.
Figure 27. Fourth-wire disconnect assembly for AKD equipment.
17
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Figure 28. AK-75 & AK-100 back frame conversion.
18
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Installing the Neutral Sensor
The neutral sensor is an electrical duplicate of the
phase sensor, including the taps. Therefore, when
taps (if provided) are changed on the phase sensors,
the taps on the neutral sensor m ust be sim ilarly
changed. For kits with fixed phase sensors, be sure
to use the corresponding tap on the neutral sensor.
Mount the neutral sensor on the outgoing neutral
lead, norm ally in the equipm ent bus or cable com -
partm ent. Figure 29 shows m ounting details for the
neutral sensor for AK-50 breakers, while Figure 30
covers AK-75 and AK-100 breakers.
Figure 29. Outline of the neutral sensor for AK-50 breakers.
19
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Figure 30. Outline of the neutral sensor for AK-75 and AK-100 breakers
20
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SECTION 7. EQUIPMENT
CONVERSION
Installing Mounting Brackets
The equipm ent com partm ent contains the m ating
portions of the fourth-wire disconnect and the neu-
tral sensor. The sam e disconnect assem bly is used
for types AKD, AKD-5, and AKD-6 switchgear.
Mounting brackets for AKD, AKD-5, AKD-6, and
AKD-8 switchgear applications are included in the
conversion kit. Figures 31, 32, 33, 34, and 35 are
m ounting diagram s for the various applications.
Table 1 is a key to the num bers used in these figures
to indicate various hardware item s.
Figure 31. AK-50 & AKS-50 fourth-wire disconnect for AKD.
Legend Description
225 Breaker portion of fourth-wire disconnect
226 Equipm ent portion of fourth-wire disconnect
Mounting bracket for AK-100 for AKD
com partm ents
229
230 10-32 x 1.375 inch m ounting screw
231 Insulation
232 # 10 lock washer
233 # 10 flat washer
235 1/8-20 flat washer
236 1/8-20 lock washer
237 1/4-20 nut
Figure 32. AK-75 & AK-100 fourth-wire disconnect for AKD-5 &
AKD-6.
238 1/4-20 x 1.25 inch m ounting screw
239 Bracket
Table 1. Legend for number symbols appearing in Figures 31–
35.
Figure 33. AK-100 fourth-wire disconnect for AKD.
21
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Figure 34. AK-50 & AKS-50 fourth-wire disconnect for AKD.
Figure 35. Fourth-wire disconnect for AKD-5 & AKD-6.
22
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ter or m illivolt tester. If the resistance differs
considerably from phase to phase, the electrical
connections m ay not be properly tightened or it
could also indicate im proper contact wipe.
SECTION 8. TESTING AND TROUBLE-
SHOOTING
WARNING: Do not change taps on the current sen-
sors or adjust the trip unit settings while the
breaker is carrying current. Failure to adhere to
these instructions will void all warranties.
4. To verify that the breaker has been properly
retrofitted, perform a prim ary injection test on
each phase. This test will check the CTs, bus,
wiring harness, flux shifter, and trip unit as a
com plete system .
Testing
a. A high-current, low-voltage power supply
should be connected across each line and load
term inal to sim ulate an overcurrent fault.
Before installing a converted breaker back into
service, perform the following steps:
b. Set the long-tim e trip at 0.5 to m inim ize the
1. Verify that the trip unit is securely installed by
perform ing a continuity test on the CT wiring and
the trip unit.
breaker stress.
c. When ground fault is installed, the test can be
perform ed 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 cur-
rent flow.
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
CAUTION: Do not attem pt to use GE Test Kit cat. no.
TVTS1 or TVRMS on this trip unit.
of the phase A and phase C CTs.
d. Measure the resistance across each phase
sensor and com pare the values m easured to
the values listed in Table 1.
Trouble-Shooting
e. Reconnect the black CT leads to all of the
phase sensors. Ensure that this is done before
continuing with perform ance testing of the
breaker.
When m alfunctioning is suspected, first exam ine the
breaker and its power system for abnorm al condi-
tions such as the following:
•
The breaker is not tripping in response to over-
current conditions or incipient ground faults.
CAUTION: In addition to the continuity test described
in Step 1 and before perform ance testing of the
converted breaker, each phase of the breaker
should be prim ary injected with a current level of
about 10%, but no m ore than 20%, of the CT rating.
During the application of test current, activate the
trip unit screen by depressing the battery button on
the trip unit face and check that the test current is
displayed on the screen for each phase tested. If the
trip unit fails to display the test current, stop the
test im m ediately and verify the installation of the
trip unit and wire harness before proceeding with
any additional testing.
•
The breaker is rem aining in a trip-free state
because of m echanical interference along its trip
shaft.
•
The shunt trip (if present) is activating im prop-
erly.
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 connected to sum m ing 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 sam e 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 sufficient to trip the breaker.
Sim ilarly, a discontinuity between any sensor and
the trip unit can cause a false trip signal.
WARNING: If the converted breaker is energized or
tested by prim ary injection with a sufficiently high
test current with a loose or open circuit between the
CTs and the trip unit, dam age will occur to the trip
unit, wire harness, 36-pin trip unit connector, and
CTs. Failure to adhere to these instructions will void
all warranties.
The sensors and their connections should be closely
exam ined if nuisance tripping is encountered on any
breaker whose ProTrip trip unit has previously
dem onstrated satisfactory perform ance. After dis-
2. Check the insulation on the prim ary circuit with a
1,000-volt Meggar.
3. Measure the resistance across the line and load
term inals for each phase using a m icro-ohm m e-
23
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connecting the breaker from all power sources, per-
form the following procedure:
Breaker
CT Rating, A
Resistance, ohms
300
400
600
20–24
27–32
42–50
1. Check that all phase sensors are the sam e type
(current range).
AK-50
AKS-50
2. Verify that the tap settings on all three phase sen-
800
58–68
1200
1600
93–109
130–154
sors are identical.
3. Verify that the wiring harness connections to the
sensors have the proper polarity (white lead to
com m on, black lead to tap), as shown in the
cabling diagram in Figure 36.
1200
1600
2000
3000
20–24
28–34
37–44
61–72
AK-75
4. On ground fault breakers serving four-wire loads,
check that the neutral sensor is properly con-
nected, as indicated in Figure 36. In particular,
check the following:
1600
2000
3000
4000
36–43
47–55
75–88
AK-100
108–127
a. Verify that the neutral sensor has the sam e rat-
Table 2. CT resistance values.
ing and tap setting as the phase sensors.
b. Verify continuity between the neutral sensor
and its equipm ent-m ounted secondary discon-
nect block. Also check for continuity from the
breaker-m ounted neutral secondary discon-
nect block through to the trip unit wiring har-
ness connector.
c. If the breaker’s lower studs connect to the
power source, then the neutral sensor m ust
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 m easure the sensor resistances. The appro-
priate values are listed in Table 2. Since the
phase and neutral sensors are electrically
identical, their resistances should agree closely.
24
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Figure 36. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads.
25
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APPENDIX – DRILL TEMPLATES
Appendix 1. Drill Tem plate for Flux Shifter Mounting
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Appendix 2. Drill Tem plate for Trip Unit Mounting
Appendix 3. Drill Tem plate for Flux Shifter Mounting
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These instructions do not cover all details or variations in equipm ent nor do they provide for every possible
contingency that m ay be m et in connection with installation, operation, or m aintenance. Should further
inform ation be desired or should particular problem s arise that are not covered sufficiently for the purchaser’s
purposes, the m atter should be referred to the GE Com pany.
g
GE Industrial System s
General Electric Company
41 Woodford Ave., Plainville, CT 06062
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