GE AK-50 manual

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 systems. ProTrip Conversion Kits are designed and tested to conform to ANSI Standard C37.59, allowing th[...]

2 TABLE OF CONTENTS SECTION 1. GENERAL INFORMATION ....................................................................................................... 4 SECTION 2. BEFORE INSTALLATION .......................................................................................................... 4 SECTION 3. FRONT FRAME BREAKER CONVERSION Relocating [...]

3 LIST OF FIGURES 1. Relocation and remounting of the W and X relays. ................................................................................ 5 2. New X and W relay mounting brackets ................................................................................................... 5 3. Flux shifter assembly. ..............................[...]

4 SECTION 1. GENERAL INFORMATION GE Conversion Kit installation is straightforward, but does require careful workmanship and attention to these instructions. Familiarity with the breaker is highly desirable. The general approach is to first remove the existing trip devices from the breaker, then install the ProTrip components. Following this proced[...]

5 SECTION 3. FRONT FRAME BREAKER CONVERSION Front frame conversion consists of the following steps: 1. Separation of the front and back breaker frames for AK-50, AKU-50, AKS-50, and AKT-50 break ers. (Frame separation is not necessary for AK-75 and AK-100 breakers.) Refer to the appropri ate installation and maintenance manuals sup plied with the b[...]

6 Installing the Flux Shifter Assembly The installation procedure for the flux shifter assembly, illustrated in Figure 3, varies depending on the type of breaker and existing trip device. In some cases, mounting holes must be added, termi- nal blocks relocated, or breaker side rails removed. Breakers with EC or Power Sensor Trip Systems 1. Drill th[...]

7 Breakers with a Side Bracket 1. Drill a 34” diameter hole into the flux shifter assembly mounting base to provide the neces- sary clearance for the bracket. The location of the new hole is shown in Figure 6. 2. Remove the side bracket from the frame and drill the holes according to the pattern in Figure 4. A full-size template is provided in[...]

8 Breakers with ECS or SST Trip Systems 1. Remove the ECS or SST trip unit. 2. Remove the existing flux shifter device and the trip unit control harness. 3. Install the new flux shifter assembly 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 us[...]

9 Installing the Trip Unit Mounting Bracket The new ProTrip trip unit mounts to the left side of the front channel. A mounting bracket is shock-- mounted to a plate that is assembled to the front channel. EC or Power Sensor Trip System 1. The h oles for the new mounting plate may have to be added to the front channel. The drill pat tern is shown in[...]

10 Figure 13. Trip unit mounting bracket attached to the mounting plate.[...]

11 SECTION 4. BACK FRAME CONVERSION The back frame conversion consists of the following operations: 1. Modification of the crossbar assembly for the flux shifter installation. 2. Removal of the existing trip devices. 3. Installation of the phase sensors. 4. Installation of the back frame harness. Crossbar Modification The flux shifter reset linkage[...]

12 Removing the Existing Trip Devices AK-50 & AKS-50 Breakers with EC or Power Sensor Trip Systems 1. Remove and discard the two screws at the base of each trip device, as shown in Figure 16. Dis- card the metal mounting brackets. 2. Remove and discard the small Philips-head screw at the top of each trip device. 3. Remove and discard the four 5[...]

13 Installing the Phase Sensors AK-50 & AKS-50 Breakers Figure 18 shows the parts provided for assembly of the CT on each pole. 1. Mount the new copper CT post to the back frame with the two 3  8 -16 x 1 1  2 " bolts, flat washers, and lock washers provided, as shown in Figure 19. 2. Fasten the three small insulated wire fasteners to[...]

14 AK-75 & AK-100 Breakers 1. The ProTrip phase sensors mount 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 primary fin- gers to engage. Engage the sensor’s antiturn lugs with the notch in the locking ring. Before tightening the locking rings, pos[...]

15 SECTION 5. INSTALLING THE TRIP UNIT 1. Remove the large screw from the rear of the trip unit. Place the trip unit in position on the mount- ing plate, with the 50-pin connector aligned with the opening in the plate. Secure with the large screw, as shown in Figure 22. 2. Insert the 50-pin female connector on the wiring harness into the trip unit [...]

16 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 equipment. 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 Stationa[...]

17 AK-50 & AKS-50 Draw-Out Breakers The fourth-wire disconnect for AK-50 and AKS-50 draw-out breakers mounts to the lower back frame, as shown in Figure 25. • If the terminal board is already present on the breaker, just replace the control harness. Main- tain the following color code: white wire to common, black wire to the tap. • If the d[...]

18 Figure 28. AK-75 & AK-100 back frame conversion.[...]

19 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 must be similarly changed. For kits with fixed phase sensors, be sure to use the corresponding tap on the neutral sensor. Mount th[...]

20 Figure 30. Outline of the neutral sensor for AK-75 and AK-100 breakers[...]

21 SECTION 7. EQUIPMENT CONVERSION Installing Mounting Brackets The equipment compartment contains the mating portions of the fourth-wire disconnect and the neu- tral sensor. The same disconnect assembly 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 th[...]

22 Figure 34. AK-50 & AKS-50 fourth-wire disconnect for AKD. Figure 35. Fourth-wire disconnect for AKD-5 & AKD-6.[...]

23 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. Testing Before installing a converted breaker back into service, perform the following steps: 1. Verify that the t[...]

24 connecting the breaker from all power sources, per- form the follow ing procedure: 1. Check that all phase sensors are the same type (current range). 2. Verify that the tap settings on all three phase sen- sors are identical. 3. Verify that the wiring harness connections to the sensors have the proper polarity (white lead to common, black lead t[...]

25 Figure 36. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads.[...]

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27 APPENDIX – DRILL TEMPLATES Appendix 1. Drill Template for Flux Shifter Mounting[...]

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29 Appendix 2. Drill Template for Trip Unit Mounting Appendix 3. Drill Template for Flux Shifter Mounting[...]

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These instructions do not cover all details or variations in equipment nor do they provide for every possi ble contingency that may be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise that are not covered sufficiently for the purchaser’s purposes, the matter [...]