Download Power Break® Circuit Breakers 800–2000 A Frames, 240–600 Vac

g
GEH–4693D
Power Break® Circuit Breakers
800–2000 A Frames, 240–600 Vac
User’s Guide
GEH–4693D
WARNINGS, CAUTIONS, AND NOTES
AS USED IN THIS PUBLICATION
WARNINGS
Warning notices are used in this publication to emphasize that hazardous voltages, currents, or
other conditions that could cause personal injury or death are present in this equipment or may be
associated with its use.
Warning notices are also used for situations in which inattention or lack of equipment knowledge
could cause either personal injury or damage to equipment.
CAUTIONS
Caution notices are used for situations in which equipment might be damaged if care is not taken.
NOTES
Notes call attention to information that is especially significant to understanding and operating
the equipment.
This document is based on information available at the time of its publication. While efforts have
been made to ensure accuracy, the information contained herein does not cover all details or variations in hardware and software, nor does it provide for every possible contingency in connection
with installation, operation, and maintenance. Features may be described herein that are not present in all hardware and software systems. GE Industrial Systems assumes no obligation of notice t o
holders of this document with respect to changes subsequently made.
GE Industrial Systems makes no representation or warranty, expressed, implied, or statutory, with
respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness
of the information contained herein. No warrantees of merchantability or fitness for purpose shall
apply.
The following are trademarks of GE Company:
Power Break®, MicroVersaTrip Plus™ , MicroVersaTrip PM™, MagneTrip™, MicroVersaTrip®
© 1998 GE Company
All Rights Reserved
i
Power Break® Circuit Breakers
Table of Contents
Chapter 1. Receiving and Installation
1–1 Overview ................................................................................................................................ 1
1–2 Receiving the Breaker ............................................................................................................. 1
Storage ............................................................................................................................ 1
1–3 Installation............................................................................................................................. 1
Bolted Electrical Connections ............................................................................................ 1
Breaker Mounting............................................................................................................. 1
Chapter 2. Breaker Operation
2–1 Standard Features................................................................................................................... 3
2–2 Operating Instructions ............................................................................................................ 3
Sequence of Operations..................................................................................................... 3
Operating Instructions for Manually Charged Breakers........................................................ 4
Operating Instructions for Electrically Charged Breakers ..................................................... 4
Wiring Notes .................................................................................................................... 5
Application Notes ............................................................................................................. 6
2–3 Trip Unit Setup ...................................................................................................................... 6
MicroVersaTrip® and MicroVersaTrip® RMS-9 Trip Units.................................................. 6
MagneTrip™ Trip Units.................................................................................................... 9
MicroVersaTrip Plus™ and MicroVersaTrip PM™ Trip Units............................................... 9
Chapter 3. Accessories
3–1 Introduction .........................................................................................................................10
3–2 Circuit Breaker Cover.............................................................................................................10
Breaker Cover Removal ....................................................................................................10
Breaker Cover Reassembly ................................................................................................11
3–3 Shunt Trip Device..................................................................................................................12
Mounting Plate Removal ..................................................................................................12
Shunt Trip Installation.....................................................................................................13
Mounting Plate Installation ..............................................................................................13
3–4 Undervoltage Release Device ..................................................................................................14
UVR Installation..............................................................................................................14
3–5 Blown-Fuse Trip Device ..........................................................................................................15
Blown-Fuse Trip Device Installation...................................................................................16
3–6 Auxiliary Switch.....................................................................................................................16
Auxiliary Switch Installation .............................................................................................17
3–7 Remote Close Solenoid and Remote Charge Indication ............................................................18
3–8 Optional Features ..................................................................................................................18
Limited Close Access Button .............................................................................................18
Padlock Function.............................................................................................................19
Chapter 4. Maintenance
4–1 Inspections............................................................................................................................20
4–2 Lubrication ...........................................................................................................................20
ii
Power Break® Circuit Breakers
List of Figures and Tables
Figures
1. Circuit breaker with lifting straps in place. ............................................................................................... 1
2. Location of mounting bolt inserts on 800 A frame breakers ....................................................................... 1
3. Location of mounting bolt inserts on 1600–2000 A frame breakers. ............................................................ 2
4. Manually charged breaker. ..................................................................................................................... 3
5. Motor operator-charged breaker. ............................................................................................................ 3
6. Motor operator charged breaker with the top cover removed. .................................................................... 3
7. Bell alarm wiring to prevent continuous cycling of the automatic charging mechanism. .............................. 5
8. Wiring for optional bell alarm lockout applications................................................................................... 5
9. Tap changer cards. ................................................................................................................................ 6
10. Cover and trip unit removed from the breaker ......................................................................................... 7
11. Neutral CT connection for four-wire ground fault..................................................................................... 7
12. Wiring diagram for MicroVersaTrip and MicroVersaTrip RMS-9 trip units with ground fault on a
top-fed four-wire load. ............................................................................................................................ 8
13. Wiring diagram for MicroVersaTrip and MicroVersaTrip RMS-9 trip units with ground fault on a
bottom-fed four-wire load. ...................................................................................................................... 8
14. Releasing the trip unit interlock to remove or install the trip unit............................................................... 8
15. Aligning the trip unit to the mounting plate. ........................................................................................... 9
16. Adjusting the settings on a MagneTrip trip unit........................................................................................ 9
17. 800 A frame electrically operated breaker................................................................................................10
18. 1600–2000 A frame electrically operated breaker. ....................................................................................11
19. 1600–2000 A frame electrically operated breaker with the outer cover removed. .........................................11
20. Wire ties on the accessory leads and mounring plate insulator. .................................................................11
21. Crossbar hook engaging the drive hook. .................................................................................................11
22. Shunt trip device with cut-off switch........................................................................................................12
23. Shunt trip wiring diagram. ....................................................................................................................12
24. Locations of the mounting plate retaining screws, isolation barrier, and molded drive crank.......................12
25. Shunt trip coil position with no blown-fuse trip device..............................................................................13
26. Shunt trip coil position with blown-fuse trip device. .................................................................................13
27. Attaching the switch bracket to the arm stop. ..........................................................................................13
28. Undervoltage release device...................................................................................................................14
29. Dropping resistor supplied with 240–600 V UVRs.....................................................................................14
30. UVR wiring diagram. ............................................................................................................................14
31. Slide reset lever and spring on the mounting plate...................................................................................15
32. Positioning the UVR assembly on the mounting plate. .............................................................................15
33. Installing the UVR mounting screw. .......................................................................................................15
34. Blown-fuse trip device accessory..............................................................................................................15
35. Blown-fuse trip device wiring diagram.....................................................................................................16
36. Auxiliary switch. ...................................................................................................................................16
37. Auxiliary switch wiring diagram. ............................................................................................................17
iii
Power Break® Circuit Breakers
List of Figures and Tables
38. Trip unit removed from the breaker. ......................................................................................................17
39. Installing the auxiliary switch assembly. ..................................................................................................17
40. Securing the auxiliary switch assembly. ...................................................................................................17
41. Wiring diagram for remote charge indication. ........................................................................................18
42. Wiring diagram for remote charge indication with remote close solenoid..................................................18
43. Limited close access button....................................................................................................................18
44. OFF button padlock with panel door interlock. .......................................................................................19
45. Defeating the OFF button padlock. ........................................................................................................19
Tables
1. Weights of the various breaker frame sizes, with and without a motor operator............................................ 1
2. Bolt sizes and mounting torques for bus connections. ............................................................................... 1
3. Sequence of operations that may be performed with Power Break circuit breakers ....................................... 4
3. Application data for control power. ......................................................................................................... 5
4. Accessory lead color codes .....................................................................................................................10
5. Shunt Trip electrical characteristics........................................................................................................12
6. UVR electrical characteristics.................................................................................................................14
7. Auxiliary switch electrical characteristics.................................................................................................17
8. Catalog numbers and ratings for the remote close solenoid ......................................................................18
iv
Power Break® Circuit Breakers
Chapter 1. Receiving and Installation
1–1 Overview
condensation, preferably by storage in a warm, dry room.
Circuit breakers for outdoor equipment should be stored
in that equipment only when power is available and heaters are in operation, to prevent condensation.
The Power Break® line of insulated-case circuit breakers
is designed to protect low-voltage power circuits and
equipment. Current models are offered with MagneTrip™, MicroVersaTrip Plus™, and MicroVersaTrip PM™
trip units for fault detection.
The breaker should be stored in a clean location, free
from corrosive gases or fumes. In particular, protect the
breaker from moisture and cement dust, as that combination may be corrosive.
1–2 Receiving the Breaker
If the breaker is stored for any length of time, it should be
inspected periodically to ensure good mechanical condition.
Unpack the circuit breaker and inspect it for shipping
damage. Ensure that the breaker has the proper current,
voltage, and interruption ratings for the application.
The weights of the various frame sizes are listed in Table
1, for reference. Figure 1 shows a breaker with straps for
lifting.
1–3 Installation
CAUTION: Do not attempt to lift the circuit breaker by
its operating handle.
Using an industry-accepted solvent, remove any foreign
material from the line and load strap surfaces and the
corresponding surfaces of connecting bus and terminal
studs. Ensure that the mating surfaces are smooth and
free of burrs and nicks.
Frame
Rating, A
800
1600
2000
Type
Manual
Electric
Manual
Electric
Manual
Electric
Bolted Electrical Connections
Weight, lbs
50
64
82
96
88
102
Place the bus connections in position and align the
mounting holes. Insert and fasten the mounting bolts and
washers according to the specifications in Table 2.
Bus Connection
Breaker Frame, A
800
1200–1600
2000
Table 1. Weights of the various breaker frame sizes, with and
without a motor operator.
Bolt Dia.
(1) 1/2 in
(2) 1/2 in
(4) 1/2 in
Torque, in-lbs
300
300
300
Table 2. Bolt sizes and mounting torques for bus connections.
Breaker Mounting
For mounting the circuit breaker, use the four 1/4 -20 x 1 /2 inch-deep inserts in the back of the breaker. The locations
of the inserts are shown in Figures 2 and 3 for the two
frame sizes. Tighten the mounting bolts to 50 in-lb.
Figure 1. Circuit breaker with lifting straps in place.
Storage
Figure 2. Location of mounting bolt inserts on 800 A frame breakers.
The breaker should be placed in service immediately in its
permanent location. However, if it must be stored for an
indefinite period, it should be carefully protected against
1
Power Break® Circuit Breakers
Chapter 1. Receiving and Installation
Figure 3. Location of mounting bolt inserts on 1600–2000 A frame
breakers.
2
Power Break® Circuit Breakers
Chapter 2. Breaker Operation
2–1 Standard Features
Power Break circuit breakers are equipped with the following standard features. The letters are keyed to the breaker
illustrations in Figures 4, 5, and 6.
A Indicator
ON – Red
CHG (manual) – yellow
CHARGED (electrical) – yellow
OFF – Green
B ON button
C OFF button
D Manual charging handle
E Lockable manual charge engagement button (motor
operated only)
F Terminal board (motor operator drive unit)
G Removable protective window
J
CT tap setting indicator (MicroVersaTrip only)
Figure 5. Motor operator-charged breaker.
K Removal protective trip unit cover (Magnetrip™
only)
L Cover mounting screws (four)
M Midcover mounting screws (three – motor operated
only)
N MicroVersaTrip RMS-9 trip unit interchangeable rating plug
O Motor operator control circuit fuses
P MicroVersaTrip RMS-9 test set connection port
Figure 6. Motor operator charged breaker with the top cover
removed.
2–2 Operating Instructions
Sequence of Operations
The sequence of operations that may be performed on the
circuit breaker is listed in Table 3.
Figure 4. Manually charged breaker.
3
Power Break® Circuit Breakers
Chapter 2. Breaker Operation
Indicator
OFF
CHARGED / CHG
ON
Main Breaker
Contacts
Open
Open
Closed
Condition of
Charging Springs
Discharged
Fully Charged
Discharged
Next Permissible Operating Function
Mechanism may be charged
Contacts may be closed
Contacts may be opened
Table 3. Sequence of operations that may be performed with Power Break circuit breakers.
Operating Instructions for Manually
Charged Breakers
Operating Instructions for Electrically
Charged Breakers
Charging the Mechanism Springs
Charging the Mechanism Springs
Rotate the operating handle counter-clockwise until the
handle stops (about 120° ). Rotate the handle clockwise
back to its home position. This operation will NOT close
the contacts and turn the breaker ON. The indicator will
display CHG .
Charge the mechanism springs with either of the following methods:
• Local
– Depress the lockable manual charge engagement
button until it is flush with the handle surface.
Slight rotation of the handle may be necessary to
fully depress the button in order to align the
internal coupling.
– Hold the button down and rotate the operating
handle counter-clockwise until the handle stops
(about 120°). Rotate the handle clockwise back to
its home position. This operation will NOT close
the contacts and turn the breaker ON. The
indicator will display CHARGED.
CAUTION: If the breaker latch is held in the tripped
position by any of the following accessories, the
mechanism springs will discharge at the end of the
charging stroke and the breaker will revert to the OFF
condition.
• The key interlock or padlock is in the locked OFF condition.
• On a draw-out breaker, the draw-out interlock is
engaged with the carriage in any position except TEST
or ENGAGED.
• Remote – Connect terminal 3 to terminal 4 to
energize the motor operator mechanism.
• The bell alarm lockout was not reset after an overcurrent lockout.
Closing the Breaker
• The undervoltage release is not energized.
Close the breaker contacts with either of the following
methods:
These conditions must be corrected before the breaker
can be closed. Failure to do so may result in equipment
damage.
• Depress the ON button on the breaker escutcheon.
• Energize the (optional) remote close accessory by
connecting terminal 5 to terminal 6.
Closing the Breaker
Opening the Breaker
Close the breaker contacts with either of the following
methods:
Open the breaker contacts with either of the following
methods:
• Depress the ON button on the breaker escutcheon.
• Depress the PUSH OFF button on the breaker
escutcheon.
• Energize the (optional) remote close accessory by
connecting terminal 5 to terminal 6.
• Energize the (optional) shunt trip accessory or deenergize the (optional) undervoltage release accessory.
Opening the Breaker
Open the breaker contacts with either of the following
methods:
Automatic Operation
For automatic closing of the breaker when the springs are
charged, permanently connect terminal 5 to terminal 6.
The breaker will close as soon as the charging cycle is
complete.
• Depress the PUSH OFF button on the breaker
escutcheon.
• Energize the (optional) shunt trip accessory or deenergize the (optional) undervoltage release accessory.
For automatic charging of the closing springs, permanently connect terminal 3 to terminal 4. The springs will
4
Power Break® Circuit Breakers
Chapter 2. Breaker Operation
charge as soon as the breaker is opened, whether from a
fault trip or from being intentionally opened.
CAUTION: Do not wire breakers for both automatic
charge and automatic close unless a bell alarm with
overcurrent lockout is incorporated. Otherwise, the
breaker may repeatedly close into an overcurrent fault.
CAUTION: The bell alarm lockout and undervoltage
release both hold the breaker latch open when activated.
To prevent continuous cycling (see Application Notes)
when the breaker is wired for automatic charging, interconnect the bell alarm switch to the motor operator terminal board as shown in Figures 7 and 8.
N O T E : The motor operator contains a feature that shuts
off control power if the OFF button is held depressed.
Thus, electrical operation is prevented if a key interlock
or padlock accessory is applied in the breaker OPEN condition. If the breaker is equipped with a draw-out interlock (TPDO-1), electrical operation is permitted only if
the draw-out carriage is in the ENGAGED or TEST position.
Figure 8. Wiring for optional bell alarm lockout applications.
Wiring Notes
Observe the following notes when wiring the breaker for
operation:
• Customer-supplied contacts (such as CHARGE and
CLOSE ) should be momentary action, rated for 0.25
A at 125 Vdc for dc motor operators or rated for 3 A
at 120 Vac for ac motor operators.
• Do not apply power to any terminal board point
other than points 1 and 2.
• Observe the proper polarity for dc motor operators
(point 1 is positive).
• When performing hi-pot or dielectric tests:
– Remove all power leads, both control and power.
– Short all motor operator terminal board points.
– Open the circuit breaker.
– Test between the motor operator terminal board
points and the load side of the breaker’s center
pole (this pole is connected to the frame).
– Test at 2200 Vac for one minute using a currentlimited, nondestructive ac hi-pot tester with
maximum output of 20 mA.
Figure 7. Bell alarm wiring to prevent continuous cycling of the
automatic charging mechanism.
Rated
Voltage
120 Vac
125 Vdc
72 Vdc
48 Vdc
24 Vdc
Operating
Voltage
Range
102–132
100–140
57–81
38–58
19–29
Motor Current, A
Locked
Full
Rotor
Load
Average
8
2.5
1.5
10
2.5
1.5
13
3.0
2.0
20
5.0
2.5
24
7.0
3.0
Close
Solenoid,
peak A
3.0
3.5
5.0
6.6
13.2
Fuses (Slo
Blo 125 V)
2A
2A
3A
4A
6.25 A
Table 3. Application data for control power.
5
Nominal
Charge
Time , s
5.0
6.0
6.0
6.0
7.5
Maximum
Close
Time, s
0.83
0.83
0.83
0.83
0.83
Maximum
Opening
Time, s
0.05
0.05
0.05
0.05
0.05
Power Break® Circuit Breakers
Chapter 2. Breaker Operation
Application Notes
2. Change the settings by twisting the indicator switches
to the desired values or multipliers. See GEH-4657 for
definitions of MicroVersaTrip functions and GEH5369 for MicroVersaTrip RMS-9 functions.
• Size the control power source according to the
information in Table 3. If a single source is to supply
several motor operators, it must be sized appropriately. Where breakers are wired for automatic
charge, it may be necessary to supply power to several
motor operators simultaneously during start up.
Rating Plugs
• The control power source should be sized so that the
drop in voltage from no load to full load does not
exceed 7%.
MicroVersaTrip RMS-9 trip units require the installation
of a rating plug in accordance with GEH-5369 and GEH5371 to set the maximum continuous current rating.
• Acceptable dc power sources are the following:
– dc generator,
– battery,
– three-phase, full-wave rectified ac, or
– any other dc power source with a peak-to-peak
ripple voltage of not more than 15% of the rated
voltage at motor full-load current.
Tap Changer Card
3. Reinstall the window.
Some MicroVersaTrip models include a tap changer card,
shown in Figure 9. When provided, this function allows
the customer to change the rating of the breaker frame.
• Breakers built after approximately June 1978 are
equipped with an anticycling circuit that will lock out
the breaker if the latch fails to reset (such as due to a
deenergized UVR). Lockout occurs if the charge
time exceeds 20 seconds. Reset a locked-out breaker
locally by pushing the OFF button or remotely by
momentarily removing control power from the
motor operator.
Figure 9. Tap changer cards.
2–3 Trip Unit Setup
N O T E : MicroVersaTrip RMS-9 trip unit rating plugs may
be changed per GEH-5369 and GEH-5371 without voiding the UL listing. MicroVersaTrip trip units and tap
changer cards may be installed or replaced per GEH4657 and this manual without voiding the UL listing.
MicroVersaTrip Plus and MicroVersaTrip PM trip units
and rating plugs may be changed or replaced per GEH6273 without voiding the UL listing.
MicroVersaTrip® and MicroVersaTrip®
RMS-9 Trip Units
Trip settings are installed at the factory with minimum
values on all functions. Customers will generally want to
adjust settings to their own requirements.
Adjusting Trip Settings
Use the following procedure to adjust trip settings on
these trip units:
1. Remove the clear plastic protective window, shown in
Figure 4.
6
Power Break® Circuit Breakers
Chapter 2. Breaker Operation
All breakers provided with tap cards are shipped with both
HIGH (100% of the current rating Sensor Amp on the
breaker name plate) and low (50–75% of the current
rating Sensor Amp on the breaker name plate). The low
card is packed and supported on the breaker handle. The
high card is installed in the breaker frame. To change
settings use the following procedure:
W A R N I N G : The circuit breaker must be removed from
the electrical system before attempting any operations
that involve removing the breaker’s cover.
1. Turn the breaker off .
Figure 11. Neutral CT connection for four-wire ground fault.
2. Remove the four cover mounting screws and remove
the top cover. On motor operator-equipped breakers,
remove only the top cover.
Neutral Current Transformer (Four-Wire Ground
Fault System)
3. Withdraw the card from the tap changer support and
replace with the other card, as shown in Figure 10.
The print on the top of the card should be oriented
the same as the breaker cover name plate.
Ground fault protection is offered as an optional function
of the MicroVersaTrip® trip unit. However, all MicroVersaTrip-generation breaker frames are provided with terminal board points for connection to a neutral CT. Do
not short these terminals if there is no neutral CT
connected.
Always match the rating of the CT to the rating of the circuit breaker; specifically, use the following criteria:
• Fixed-rated breaker frames – match the neutral CT
amp rating to the breaker sensor amp rating.
• Tapped or high/low-rated breaker frames – match
the neutral CT amp rating to the high/low setting of
the breaker sensor amp rating.
Note that MicroVersaTrip RMS-9-equipped breakers are
not available with inverted construction (formerly designated by Cat. No. suffix B). These breakers may be either
top fed, as illustrated in Figure 12, or bottom fed, as illustrated in Figure 13.
Figure 10. Cover and trip unit removed from the breaker.
4. Trip units providing ground fault protection must
also have the tap setting changed on the tapped neutral CT (four-wire systems). Change the black wire
lead from the high or low terminal to match the
desired tap setting of the breaker frame, as shown in
Figure 11.
N O T E : The neutral CT is mounted in reverse in Figure
13 when the breaker is bottom (reverse) fed.
CAUTION: Match the tapped terminal for the black lead
to the tap setting, if provided, on the breaker frame.
5. Replace the breaker cover.
6. Operate the breaker manually through the
charge–close–open cycle to ensure that the breaker is
properly functioning mechanically before energizing
or connecting it to the electrical system.
CAUTION: Observe the polarity markings on the neutral
CT shell and the breaker frame.
CAUTION: When a neutral CT is not used or not
required (three-wire ground fault), do not short the
ground fault terminal points on the breaker frame.
Leave them open as supplied by the factory.
NOTE: A deenergized undervoltage release will not allow
the mechanism to charge and close.
7. Store the extra tap card in a convenient place.
7
Power Break® Circuit Breakers
Chapter 2. Breaker Operation
• High short-time or H-function trip units may not be
used in frames that are not wired for H function
(special CTs).
• Special trip units for AK breakers with the M (no
instantaneous) function may not be used with Power
Break breakers.
Refer to GEH-4657 for installation or replacement of
MicroVersaTrip trip units with remote overload indication
and for recommended wiring for zone-selective interlock.
To change or install trip units without remote indication,
use the following procedure.
W A R N I N G : The circuit breaker must be removed from
the electrical system before attempting any operations
that involve removing the breaker’s cover.
1. Remove the four cover-mounting screws and remove
the top cover. On motor-operated breakers, remove
only the top cover to replace the trip unit.
Figure 12. Wiring diagram for MicroVersaTrip and MicroVersaTrip
RMS-9 trip units with ground fault on a top-fed four-wire load.
2. Remove the trip unit as follows:
a. Push in the trip unit-cover interlock, as illustrated
in Figure 14.
b. Lift the trip unit off the mounting plate and terminal plug.
c. The trip unit-cover interlock will now swing out
and lock over the base to prevent reinstallation of
the breaker cover when no trip unit is installed.
Figure 13. Wiring diagram for MicroVersaTrip and MicroVersaTrip
RMS-9 trip units with ground fault on a bottom-fed four-wire load.
MicroVersaTrip RMS-9 Trip Units
The trip units on MicroVersaTrip RMS-9-equipped breakers are not interchangeable. The breaker rating may be
adjusted by changing the rating plug installed in the face
of the trip unit. See GEH-5369 and GEH-5371 for instructions.
MicroVersaTrip Trip Units
MicroVersaTrip-equipped breakers were ordered complete
or as a frame and trip unit only. Some trip units and
frames have rejection schemes to prevent mismatching of
functions.
Figure 14. Releasing the trip unit cover interlock to remove or install
the trip unit.
The limits of interchangeability are as follows:
8
Power Break® Circuit Breakers
Chapter 2. Breaker Operation
3. Install the replacement trip unit as shown in Figure
15:
a. Align the holes in the bottom of the trip unit with
the guide pins in the mounting plate. Lower the
trip unit until it is fully down on the mounting
plate and the connecting plug is secure.
b. Push in the trip unit-cover interlock until it locks
in place, as shown in Figure 14.
N O T E : The trip unit has a stud on the bottom to defeat
the trip unit-cover interlock locking spring.
Figure 16. Adjusting the settings on a MagneTrip trip unit.
MicroVersaTrip Plus™ and MicroVersaTrip
PM™ Trip Units
See GEH-6273 for detailed instructions for setting up
MicroVersaTrip Plus and MicroVersaTrip PM trip units.
Figure 15. Aligning the trip unit to the mounting plate.
4. Replace the top cover and secure with the four covermounting screws.
5. Operate the breaker manually through the
charge–close–open cycle to ensure that the breaker is
properly functioning mechanically before energizing
or connecting it to the electrical system.
NOTE: A deenergized undervoltage release will not allow
the mechanism to charge and close.
6. For trip units with ground fault, a neutral CT must be
provided if a four-wire system is to be used. See the
section on neutral CTs for instructions and precautions. Do not short the ground fault terminals provided on the breaker frame if a neutral CT is not
used.
MagneTrip™ Trip Units
Use the following procedure to change trip settings on
MagneTrip trip units:
1. Remove the protective trip unit cover.
2. Change the trip setting by rotating the plastic buttons
in the base with a screw driver, as shown in Figure 16.
3. Replace the protective cover.
9
Power Break® Circuit Breakers
Chapter 3. Accessories
3–1 Introduction
These instructions cover the field installation of internally
mounted electrical accessories. They are UL listed for use
in all 800–2000 A frame Power Break® circuit breakers
with MicroVersaTrip® trip units. These accessories may
also be installed in 800–1600 A frame Power Break breakers with MagneTrip™ trip units, but the UL listing is
voided.
The control leads of internally mounted accessories exit in
pigtail form from the side of the breaker. These leads are
terminated at the secondary disconnect points of draw-out
breakers or at optional terminal blocks when specified for
stationary-mounted breakers. All leads are color coded as
listed in Table 4.
Accessory
Shunt Trip
Undervoltage
Release
Lead Color
Black
Blue
N O T E : All breakers are equipped with mechanical interlocks that automatically trip the breaker when the cover
is removed with the breaker closed.
Breaker Cover Removal
Manual Breaker
Use the following procedure to remove the cover of a
manually operated breaker:
1. Press the off button to open the circuit breaker.
2. Remove the four cover-mounting screws.
3. Remove the breaker cover.
Electrically Operated Breaker
Use the following procedure to remove the cover of an
electrically operated breaker. An 800 A frame breaker is
shown in Figure 17 and a 1600–2000 A frame breaker is
shown in Figure 18.
No. of
Leads
2
2
1. Press the off button to open the circuit breaker.
Auxiliary Switch
Bell Alarm
(Overcurrent
Lockout)
Blown-Fuse Trip
(3-Coil Shunt Trip)
Closing Solenoid
(Manual Breakers
only)
White – common
Red – OPEN (NO)
Brown/White – CLOSED (NC)
Yellow – common
Purple – CLOSED (NC)
Brown – OPEN (NO)
Line End
Load End Phase
Red
Brown-White
A
Blue
White
B
Yellow
Black
C
White – common
Black – remote indication
Orange – remote close
3 per
switch
2. Disconnect all external leads from the terminal
board.
3. Remove the four cover mounting screws.
3
4. Remove the outer cover.
5. On 1600-2000 A framer breakers only, remove the two
inner-cover mounting screws, as shown in Figure 18.
6
6. Loosen the captive inner-cover lock screw, as shown
in Figure 19.
3
7. Remove the inner cover.
Table 4. Accessory lead color codes.
3–2 Circuit Breaker Cover
Before any accessories can be installed in a Power Break
circuit breaker, the cover(s) must be removed, as
described in the following sections.
W A R N I N G : Before installing any accessories, completely
de-energize the circuit breaker and disconnect it from
the electrical circuit. This is mandatory, since the
breaker must be ON during certain stages of installation
and testing.
CAUTION: Do not turn the breaker upside down, since
loose parts may become lost.
Figure 17. 800 A frame electrically operated breaker.
10
Power Break® Circuit Breakers
Chapter 3. Accessories
Figure 18. 1600–2000 A frame electrically operated breaker.
Figure 20. Wire ties on the accessory leads and mounting plate
insulator.
Electrically Operated Breakers
1. Verify that all connections are secure and the breaker
is free of debris.
CAUTION: Verify that the accessory mounting plate
insulator is properly located, as shown in Figure 26.
2. Slide the inner cover assembly onto the breaker base.
Ensure that the crossbar hook engages the drive stud,
as shown in Figure 21.
Figure 19. 1600–2000 A frame electrically operated breaker with the
outer cover removed.
Breaker Cover Reassembly
Manually Operated Breakers
1. Verify that all connections are secure and the breaker
is free of debris.
2. Verify that the breaker is off .
C A U T I O N : Verify that the accessory mounting plate
insulator, shown in Figure 20, is properly located so it
will not be damaged when the cover is replaced. The
cover phase barrier must pass to the right side of this
insulator.
Figure 21. Crossbar hook engaging the drive hook.
3. Tighten the inner cover lock screw, shown in Figure
19, to 10 in-lbs.
3. Position the charging handle at the home position (6
o’clock) on the cover. Align the cover mounting
screw holes with the breaker base and install the four
cover screws. Tighten the screws to 50–60 in-lbs.
11
4. On 1600–2000 A frame breakers only, replace the two
inner cover mounting screws and tighten to 50–60 inlbs.
Power Break® Circuit Breakers
Chapter 3. Accessories
5. Position the charging handle at the home position (6
o’clock) on the outer cover. Align the outer covermounting screw holes with those on the inner cover
and install the four cover-mounting screws. Tighten
to 50–60 in-lbs.
N O T E : Ensure that the control terminal board properly
engages the cover retaining slots.
6. Connect the control and power wiring as per the
instructions supplied with the circuit breaker.
Figure 23. Shunt trip wiring diagram.
Mounting Plate Removal
3–3 Shunt Trip Device
The shunt trip, shown in Figure 22, allows the breaker to
be tripped electrically from a remote location. A cut-off
switch is supplied as part of the shunt trip to automatically
remove power from the shunt trip coil when the breaker is
tripped. The electrical characteristics of the shunt trip are
listed in Table 5. Figure 23 is the shunt trip wiring diagram.
The mounting plate is used as the anchor position for the
shunt trip, blown-fuse trip, and undervoltage release
accessories. Breakers are shipped from the factory with
either a mounting plate or an L-shaped bracket to retain
the molded-plastic crank. A new mounting plate is provided in the shunt trip kit, blown-fuse trip kit, undervoltage release kit, and auxiliary switch kit.
• If the breaker was supplied with an L-shaped bracket,
remove the two retaining screws, discard the bracket,
and skip to the appropriate installation instructions.
• If the breaker was supplied with a mounting plate,
remove it with the following procedure:
1. Remove the three mounting plate retaining screws
and the isolation barrier, shown in Figure 24.
2. Lift out the accessory mounting plate and remove the
molded drive crank.
3. If a tap changer was supplied, remove the two screws
from the phenolic block before removing the mounting plate.
Figure 22. Shunt trip device with cut-off switch.
Catalog No.
TPST 12S
TPST13S
TPST7S
TPST8S
TPST9S
TPST10S
TPST11S
Voltage
Rating
120 Vac
240 Vac
480 Vac
600 Vac
12 Vdc
24 Vdc
48 Vdc
125 Vdc
250 Vdc
Max. Inrush
Current, A
2.25
4.50
1.64
2.05
4.00
2.18
1.09
1.00
0.21
Table 5. Shunt Trip electrical characteristics.
Figure 24. Locations of the mounting plate retaining screws, isolation
barrier, and molded drive crank.
12
Power Break® Circuit Breakers
Chapter 3. Accessories
Shunt Trip Installation
N O T E : If the shunt trip is being replaced because of a
defective coil, the cause of the initial failure should first
be determined. If necessary, consult the factory for further guidance.
1. Assemble the coil to the mounting plate as shown in
Figure 25. If a blown-fuse trip device is also to be
installed on the mounting plate, mount the shunt
trip coil as shown in Figure 26.
2. When a blown-fuse trip device is included, place the
shunt trip plunger stop nut in contact with the
plunger of the blown-fuse trip device.
3. Depress the actuator on the cut-off switch. Align the
tapped holes in the switch bracket with the holes in
the arm stop (left pole) and secure with #8-32 × 9/16
screws and lock washers, as shown in Figure 27.
Tighten to 23 in-lbs torque.
Figure 26. Shunt trip coil position with blown-fuse trip device.
4. Remove the knockouts in the side of the base, as
required. Each knockout will accommodate up to
three bundles of wire. Remove all sharp edges with a
file.
5. Clean all debris from the inside of the breaker.
NOTE: Shunt trip coils rated at 12 Vdc or 24 Vdc must be
mounted in the position nearest the latch. These coils
may not develop enough force to drive both the latch
and the blown-fuse trip device.
Figure 27. Attaching the switch bracket to the arm stop.
2. Place the mounting plate in position so that its two
operating studs engage the molded drive crank, as
shown in Figure 24. Ensure that the isolating barrier
is in place.
3. Attach the three retaining screws. Tighten the two
small screws to 20 in-lbs and the large screw with tubing to 75 in-lbs.
4. Attach wire ties to the leads and secure them to the
mounting plate, as shown in Figure 20.
Figure 25. Shunt trip coil position with no blown-fuse trip device.
Mounting Plate Installation
1. Replace the molded drive crank onto the mechanism
drive pin, as shown in Figure 24, engaging the roll
pins into the slot in the drive crank.
13
5. Insert the leads into the knockout in the base side
wall, ensuring that one tie is on the inside of the base
and the other is on the outside.
6. Apply the descriptive label to the front of the breaker
cover.
Power Break® Circuit Breakers
Chapter 3. Accessories
3–4 Undervoltage Release Device
The undervoltage release device (UVR), shown in Figure
28, opens the circuit breaker when the supply voltage
drops to 35–60% of its rated value. Figure 29 shows the
dropping resistor supplied with 240–600 volt UVRs. The
UVR electrical characteristics are listed in Table 6. The
UVR wiring diagram is in Figure 30.
Catalog
Number
TPUV1S
TPUV2S
TPUV2S
TPUV6S
TPUV7S
TPUV8S
TPUV9S
TPUV10S
TPUV11S
Voltage
Rating
120 Vac
240 Vac
480 Vac
600 Vac
12 Vdc
24 Vdc
48 Vdc
125 Vdc
250 Vdc
Continuous
Current, mA
25
25
25
25
211
104
54
24
24
Dropping
Resistor*
none
5000 ?, 25 W
15,000 ?, 50 W
20,000 ?, 50 W
none
none
none
none
5000 ?, 25 W
* Ohmite Type 270
Table 6. UVR electrical characteristics.
UVR Installation
1. Remove the circuit breaker cover(s) as described
above in 3–2 Circuit Breaker Cover.
2. The UVR assembles to a mounting plate. Not all
breakers are shipped from the factory with a mounting plate. Some breakers have only an L-shaped
bracket to retain the molded-plastic crank. A mounting plate is provided in the UVR kit.
• If the breaker is supplied with an L-shaped
bracket, remove the two retaining screws and discard the bracket. Follow the Mounting Plate
Installation instructions and continue on to step
3.
• If the breaker is supplied with a mounting plate,
continue with step 3.
Figure 28. Undervoltage release device.
3. Remove the slide reset lever spring from the mounting plate, as shown in Figure 31. Be careful not to
nick or damage the spring in any way, since it will be
needed for reassembly.
Figure 29. Dropping resistor supplied with 240–600 V UVRs.
4. Push the latch and slide reset lever forward to provide mounting clearance for the UVR assembly.
5. Position the UVR assembly mounting bracket so that
its retaining hole engages the latch pivot post, as
shown in Figure 32.
6. Line up the UVR bracket’s mounting hole with the
tapped hole in the accessory mounting plate. Install
the screw and lock washer, as shown in Figure 33.
Tighten the screw to 9–11 in-lbs.
Figure 30. UVR wiring diagram.
7. Replace the slide reset lever spring, shown in Figure
31.
8. Remove the knockouts in the side of the base, as
required. Each knockout will accommodate up to
three bundles of wire. Remove all sharp edges with a
file.
9. Remove all debris from the inside of the breaker.
14
Power Break® Circuit Breakers
Chapter 3. Accessories
Figure 33. Installing the UVR mounting screw.
13. Perform the following functional check of the UVR:
a. Apply rated voltage to the UVR coil.
b. Turn the breaker on.
c. Reduce the control voltage. The breaker should
trip when the voltage drops to 35–60% of its rated
value.
Figure 31. Slide reset lever and spring on the mounting plate.
14. Apply the UVR descriptive label to the left side of the
breaker near the lead-exit area.
3–5 Blown-Fuse Trip Device
The blown-fuse trip device (three-coil shunt trip), shown
in Figure 34, is intended for applications with breakers
and fuses in series. This accessory prevents single-phasing
conditions by monitoring the fuses and automatically
tripping the circuit breaker when a fuse blows. It does not
protect from single-phasing of the power source.
Figure 32. Positioning the UVR assembly on the mounting plate.
10. Use the wire ties provided to secure the leads to the
mounting plate and to secure the wire bundle to the
inside and outside of the breaker base, as shown in
Figure 20.
11. Reassemble the breaker covers as described in
Breaker Cover Reassembly.
12. Mount the dropping resistor (when supplied) and
MOV, shown in Figure 29. Wire these as shown in
Figure 30.
Figure 34. Blown-fuse trip device accessory.
15
Power Break® Circuit Breakers
Chapter 3. Accessories
Each coil of the blown-fuse trip device is wired across a
fuse so that the voltage across an open fuse is fed back to
the accessory coil. When the coil is energized, the solenoid
core releases the spring-biased latch, allowing the slide to
rotate the breaker latch, tripping the breaker. The fuse
must be replaced and the breaker reset before the breaker
can be reclosed.
If the breaker is closed on an open fuse, the blown-fuse
trip device will automatically open the breaker.
Blown-Fuse Trip Device Installation
Installation of the blown-fuse trip device is similar to that
of the shunt trip, described above.
1. The blown-fuse trip device assembles to a mounting
plate. Not all breakers are shipped from the factory
with a mounting plate. Some breakers have only an
L-shaped bracket to retain the molded-plastic crank.
A mounting plate is provided in the blown-fuse kit.
• If the breaker is supplied with an L-shaped
bracket, remove the two retaining screws and discard the bracket.
• If the breaker is supplied with a mounting plate,
follow the instructions under Mounting Plate
Removal.
2. Assemble the blown-fuse trip device to the accessory
mounting plate as shown in Figure 26. If a shunt trip
had previously been mounted as shown in Figure 25,
it must be relocated as shown in Figure 26, with its
plunger stop nut in contact with the plunger of the
blown-fuse trip device.
Figure 35. Blown-fuse trip device wiring diagram.
3–6 Auxiliary Switch
The auxiliary switch, shown in Figure 36, is used for
remote indication of the breaker’s main contact position— open or closed. No distinction is made between
open or tripped mode. A maximum of 12 switches can be
installed per breaker. Each is single-pole, double-throw
(AB-type) and rated as listed in Table 7. Two switch positions must be devoted to each shunt trip accessory (if
used) per breaker. The auxiliary switch wiring diagram is
shown in Figure 37.
3. Follow the procedure for Mounting Plate Installation.
4. Perform the following installation checks:
a. Replace the breaker cover as described above.
Close the breaker contacts.
b. Apply 120 volts to one coil of the blown-fuse trip
device for not more than one second. The
breaker must trip. Repeat the test for each coil.
5. Attach the six lead wires from the blown-fuse trip
device across the three fuses, as shown in the wiring
diagram in Figure 35.
Figure 36. Auxiliary switch.
6. Apply the descriptive label to the front of the breaker.
7. Reassemble the breaker cover(s) as described in
Breaker Cover Reassembly.
16
Power Break® Circuit Breakers
Chapter 3. Accessories
Figure 38. Trip unit removed from the breaker.
Figure 37. Auxiliary switch wiring diagram.
Catalog
Number
Number of
Switch Elements
TPAS2ABx
1–12
Maximum
Current Rating
6 A at 240 Vac
.25 A at 250 Vdc
.50 A at 125 Vdc
*
Replace x with a number from 1–12 for
the number of switch elements.
Table 7. Auxiliary switch electrical characteristics.
Auxiliary Switch Installation
1. Remove the circuit breaker cover(s) as described in
Breaker Cover Removal .
• If the breaker was supplied with an L-shaped
bracket (see Mounting Plate Removal), remove
the two retaining screws, discard the bracket, and
install the mounting plate provided in the kit (see
Mounting Plate Installation).
Figure 39. Installing the auxiliary switch assembly.
2. Both the left and right breaker poles can accept up to
six auxiliary switches. If the left pole contains a shunt
trip, two of the six auxiliary switch positions must be
used for the cut-out switches; thus, only four auxiliary switches may be used in the left pole.
3. If auxiliary switches are to be installed in the right
pole, remove the trip unit by depressing the lock
release lever while lifting up on the trip unit. Remove
the trip unit mounting plate, shown in Figure 38.
4. Position the auxiliary switch assembly so that the
tapped mounting holes on its bracket line up with
the through holes in the arm stop, as shown in
Figure 39.
Figure 40. Securing the auxiliary switch assembly.
6. Remove knockouts in the side of the base, as
required. Each knockout will accommodate up to
three bundles of wire. Remove all sharp edges with a
file.
7. Use the supplied wire ties to secure the leads as
shown in Figure 20.
8. Replace the trip unit mounting plate and trip unit.
5. Secure the auxiliary switch assembly to the arm stop
with two #8 × 9/16 screws and lock washers, as shown
in Figure 40. Tighten the screws to 23 in-lbs.
9. Replace the breaker cover(s) as described in Circuit
Breaker Cover Reassembly.
10. Perform the following functional checks:
a. With the breaker off , use a continuity tester to
verify continuity between the white and brown17
Power Break® Circuit Breakers
Chapter 3. Accessories
white leads. Verify an open circuit between the
red and white leads.
b. With the circuit breaker on, the auxiliary switch
contacts should change sense.
11. Apply the auxiliary switch descriptive label to the
front of the breaker cover.
3–7 Remote Close Solenoid and
Remote Charge Indication
Figure 41. Wiring diagram for remote charge indication.
The remote close solenoid is included with electrically
operated breakers and may be ordered as a factoryinstalled option in manually operated breakers. Catalog
numbers and specifications are listed in Table 8.
Remote charge indication provides for remote indication
that the breaker closing springs are charged. Catalog
numbers are TPXCAS and TSXCAS for 800–2000 A and
for 3000–4000 A frames, respectively. The switch is rated
at 15 A for 250 Vac and at 0.5 A for 125 Vdc. Figure 41 is
the wiring diagram for remote charge indication. Figure
42 is the wiring diagram for remote charge indication
with a remote close solenoid.
Catalog No.
Rated
Voltage
Figure 42. Wiring diagram for remote charge indication with remote
close solenoid.
Operating Current at Max.
Maximum
Range*, V
Voltage, A
Closing Time, s
Maximum
Operating Time, s
TPXCC12S
120 Vac
102–132
3.3
0.083
0.050
TPXCC14S
240 Vac
204–264
1.7
0.083
0.050
TPXCC08S
24 Vdc
19–29
13
0.083
0.050
*
The power source must stay within the rated operating voltage range of the close solenoid from no load to the full peak
current rating of the device.
Table 8. Catalog numbers and ratings for the remote close solenoid.
3–8 Optional Features
Special features may be ordered as specific accessories or
as an integral part of the breaker catalog number. Refer to
the BuyLog®, GEP-1100, for these features.
Limited Close Access Button
This accessory, shown in Figure 43, provides for limited
manual access to the ON button. The breaker can be
closed in an emergency for maintenance by inserting a
1/8-inch diameter pin or rod into the hole in the center of
the button. Manually operated breakers must be ordered
with an accessory closing solenoid.
Figure 43. Limited close access button.
18
Power Break® Circuit Breakers
Chapter 3. Accessories
Padlock Function
Handle Button Lock
A standard feature on motor-operated breakers that prevents manual charging of the mechanism, as shown in
Figure 5.
OFF Button Padlock with Door Interlock
This accessory prevents opening of the panel door when
the breaker is ON or CHARGED. It operates as follows:
• With the breaker OFF the paddle can be rotated
counterclockwise over the breaker nameplate to clear
the enclosure panel door. Rotate the paddle clockwise to lock the door, as shown in Figure 44.
• To defeat the interlock when the breaker is ON or
CHARGED, depress the spring and rotate the paddle
to clear the door, as shown in Figure 45.
Figure 44. OFF button padlock with panel door interlock.
19
Figure 45. Defeating the OFF button padlock.
Power Break® Circuit Breakers
Chapter 4. Maintenance
W A R N I N G : Before beginning any maintenance work,
disconnect the breaker from all voltage sources, both
power and control, and ensure that the breaker is OFF.
4–1 Inspections
Circuit breakers should be maintained through the
implementation of a systematic maintenance program. A
periodic inspection routine is recommended. The frequency of inspection should depend on the environmental conditions of each breaker. All circuit breakers
should be inspected at least annually. It a breaker is operated frequently or installed in an area of high humidity,
dust, or dirt, the frequency of maintenance inspections
should be increased. Under extremely adverse conditions,
monthly inspections are recommended.
The maintenance inspection should begin with an overall
visual check. If dirt, grease, or any other foreign material
is found on or in the breaker, it should be thoroughly and
carefully removed. Do not use solvents on insulating material.
A rotating program providing for a periodic withdrawal
from service of each breaker in turn for inspection and
maintenance is an excellent means of establishing a high
level of service reliability. In such cases, one or more spare
breakers and all accessories should be available during the
maintenance inspection to replace any breaker that may
be removed for repairs.
N O T E : When ordering spare parts, always enclose complete information from the breaker name plate, including the breaker’s serial number.
4–2 Lubrication
Moderate lubrication is all that is required for most circuit
breakers. Mechanical bearing points and sliding surfaces
should be lubricated at the regular inspection periods
with a thin film of molybdenum disulfide (Molykote G) or
Mobil 28 grease. GE recommends the use of kerosene for
removing hardened grease and dirt from the latch and
bearing surfaces. All excess lubricant should be removed
to avoid any contamination of dirt or dust.
CAUTION: Under no circumstances should lubricant be
applied to contact areas.
20
g
GE Industrial Systems
GEH4693 R05 0998
General Electric Company
41 Woodford Ave., Plainville, CT 06062
© 1998 General Electric Company