GE AK-100 Series, Maintenance Instructions Manual

Page 1: ...98A GEH 1799 GEH 1823 GEl 5021OA GEI 50211 GEI 50212A GEI 57077 GEl 74600 Types AK 50 75 100 AKT 50 AKU 50 and AKF 2C 2D 2E NOTE To be used in conjunction with GEl 86135 which covers Types AK 75 100 breakers with ECS and SST trip devices ELECTRIC GENERAL Courtesy of NationalSwitchgear com ...

Page 2: ... LOCKOUT DEVICE DIRECT ACTING TRIPPING DEVICE EC 1B SERIES OVERCURRENT TRIPPING DEVICE EC 1 SERIES OVERCURRENT TRIPPING DEVICE EC 2 EC 2A REVERSE CURRENT TRIPPING DEVICE AK 50 ONLY POWER SENSOR TRIP SELECTIVE TRIPPING 23 25 25 26 29 31 33 33 39 42 BREAKER ACCESSORIES PRIMARY DISCONNECTS SECONDARY DISCONNECTS DRAWOUT MECHANISMS SHUNT TRIPPING DEVICE BELL ALARM AND LOCKOUT DEVICE OPEN FUSE LOCKOUT D...

Page 3: ...zF z i oo o L TRIP COIL X M LEGEND CLOSING MOTOR RELAY COIL RELAY CONTACT FftG MECHANICALLY OPERATED SWITCHES NORMALLY OPEN SWITCH CONTACTS NORMALLY CLOSED SWITCH CONTACTS L AUXILIARY SWITCH CONTACT X The U indicates an internal SIMPLIFIED ELEMENTARY DIAGRAM INTERNAL WIRING AK 50 75 AND 100 AKF 2C AKF 2D AKF 2E switches for use in controlling shunt fields of synchronous motors and generators AK 2 ...

Page 4: ... and the closing operation takes place QUICK CLOSE FOR ELECTRICAL BREAKERS Functionally the quick close mechanism differs from the standard electrical mechanism in thatthe pre charge operation is extended to completely charge the closing springs At the end of the charg ing operation which takes approximately 5seconds a latch plate engages the prop roller to prevent the closing springs from dischar...

Page 5: ...ntinue to operate the maintenance handle clos ing the breaker This is done so that the safety pin takes the spring force To install the safety pin of the manual stored energy mechanism refer to the section entitled STORED ENERGY MANUAL MECHANISM on page 17 of these instructions With the safety pin restraining the closing spring force the contacts will close slowly when the breaker is manually oper...

Page 6: ...ip device False Tripping AK 2 Breakers Overcurrent pick up too low Overcurrent time setting too short Bind in overcurrent trip device Tighten Thumb Screw on Desired Setting Captive Thumb Screw on Power Sensor Loose Fail Safe Circuitry Reverts Characteristic to Minimum Setting and Maximum Time Delay Tap Setting Dial on Power Supply Incorrectly Set External Ground Sensor Coil Improperly Connected Se...

Page 7: ... D50H15 Sliding silver plated con tact surfaces should be lubricated with G E Lub ricant D50H47 Hardened grease and dirt should be removed from latch and bearing surfaces by using kerosene ALL EXCESS LUBRICANTSHOULD BE REMOVED TO AVOID ANY ACCUMULATION OF DIRT OR DUST REPLACEMENT AK BREAKERS Be sure the breaker is open 1 2 Remove the channel shaped retaining bar by removing two screws and two nuts...

Page 8: ... nut and withdraw stud 1 6 Remove cap 2 The side 3 and pocket 4 barriers should be free 7 Reassemble and replace the arc quencher in the reverse order Tighten the fastenings after replacement POLE UNIT ASSEMBLY Fig 6 NOTE The text and part identification numbers contained in this section apply to illustrations covering the AK 50 breaker The same text is applicable to the AK 75 and 100 breakers by ...

Page 9: ...eave the main contacts and pivot with them about pin 19 This relative motion is obtained by linkages from the upper pin 7 to the breaker mechanism The stationary main contact assembly includes main and intermediate contacts The intermediate contact surface extends beyond the main contacts and will therefore make before the main contacts and break after the main contacts The number of contacts for ...

Page 10: ...sted on TABLE I refer to the section of these instructions dealing with ADJUSTING CONTACT WIPE AND PRESSURE ADJUSTING CONTACT WIPE AND PRESSURE Fig 6 1 To obtain proper contact wipe and pressure on the center pole dimension A should be increased to increase wipe and decreased to decrease wipe 2 To change dimension A remove the clevis pin 14 and rotate the clevis as necessary 3 To prevent overstres...

Page 11: ...e maintenance handle with the safety pin restraining the closing springs REPLACEMENT OF CONTACTS Fig 6 Stationary Arcing Contacts 2 Fig 6 0 Fig 7 1 Remove the upper plate by removing two screws 1 On the AK 75 and 100 remove the top contact block 25 Fig 7 and remove insulation 3 Fig 7 2 Loosen screws holding spring 5 3 Remove pin 3 freeing the stationary con tacts and springs 22 4 Install new sprin...

Page 12: ...e arcing contacts 4 should be replaced when the stationary arcing contacts are replaced scribed above 2 Remove screws 27 and remove bracket which holds pin 25 in place 3 Remove main and intermediate contact stop 20A which holds the lower part of stationary contact Removal will be facilitated if the force on the contact springs 21 is neutralized This can be accomplished by operating the breaker wit...

Page 13: ... Fig 10 which rides on the closing cam 2 Fig 11 closing cam roller is shown in Fig 11A 11B and 11C center pole unit through a clevis and through a crossbar it controls the opening and closing of the contacts on all pole units Charging the Closing Springs Fig 10 6o Reassemble contacts in reverse order being careful to replace the intermediate contact in the proper position Movable Intermediate and ...

Page 14: ...g spring and charging mechanism 3 As the crank turns the roller pushes the paddle arm upward thereby charging the closing springs through the spring charging arm 15 of the crank shaft 4 As the charging roller approaches dead center a cut off switch opens de energizing the motor circuit Fig 11 541E305 Operating mechanism Closing the Breaker Electrically Operated Fig 10 1 With the mechanism in the p...

Page 15: ...p latch 10 to release the latch prop 5 This allows the forces of the contact and opening springs to reposition the operating mechanism linkage to the position shown in Fig 11A In this position the operating cycle may be repeated Adjustments Fig 11 All adjustments should be made with the opera ting mechanism in the reset position as shown in 1 The gap between the trip latch 10 and the roller 9 of t...

Page 16: ...differs from the standard breaker in that the precharging operation is extended to and slightly past the top dead center position of the closing spring assembly As the springs start to discharge to close the breaker the discharge operation is arrested by a prop and latch arrangement The subsequent closing operation is accomplished by tripping the latch to release the prop which in turn allows the ...

Page 17: ...between screw and lever with clearance on release arm taken up by pressing lever lightly forward Adjust switchette operation by adding washers F under cotter pin so that contact is made when armature is adjusted as shown above The control relay or X relay is located on the left side of the front frame channel It may be removed by disconnecting the wiring loosening the 3 two mounting screws and lif...

Page 18: ...n 4 Safety Pin Hole 5 Closing Springs 6 Guide Rod 7 Pawl Springs 8 Front Escutcheon 9 Front Bearing Plate 10 Bearing Plate Mounting Bolts 31 Lower Spring Pin 11 Output Crank Roller 12 Thrust Bearing 13 Shims 14 Groove Pin 15 Nylok Screw 16 Ratchet Wheel Shaft and Asm 17 Ratchet Wheel 18 Side Plate Shims 19 Side Plate Mounting Bolts 20 Bearing Side Plate 21 Ratchet Pawls 22 Manual Closing Handle 23...

Page 19: ... 9 Remove the roll the closing handle shaft 23 to be removed 10 Remove the ratchet wheel 17 and its assembly 16 by removing Nylok screw 15 and thrust bearing 12 If shims 13 are present they must also be removed 11 Remove front bearing plate 9 by removing three mounting bolts 10 accessible from thefront of the breaker The mechanism is now completely disassembled of the subassemblies removed during ...

Page 20: ...rements 3 Operate closing mechanism with mainten ance handle until arcing contacts of outer poles just touch 4 Measure distance between forward edge of left stationary contact of center pole and surface of insulation block behind contact For contact measurements and adjustments of the two outside poles of the breaker refer to POLE UNIT ASSEMBLY Contact measurements of the center pole field dischar...

Page 21: ...lt 15 c Remove vertical shims 14 to decrease wipe add to increase d Replace bolt 15 and tighten screw 13 e Reassemble front and back frame Adjusting Center pole Open Contact Gap Fig 17 Improper open contact gap of the center pole may be adjusted by the following procedure 1 Loosen screw 13 and bolt 15 2 If gap is to be increased horizontal shims 14 should be removed If it is to be decreased they s...

Page 22: ...ngs and with a bell set across the a terminals of the auxiliary switch The closing of the a contacts can be ad vanced or retarded by extending or reducing the external length of the operating rod 5 The length of the operating rod 5 should be ad justed so that the switch TTaTT contacts close when the arcing contacts are parted by 1 8 to 1 4 in The operating rod should also be aligned vertically so ...

Page 23: ...ds to auxiliary switch 2 Remove mounting bolts 2 and 7 3 Withdraw auxiliary switch 4 Insert new switch with arrowonshaftpoint ing up and towards the back of the breaker as in Fig 18 5 Replace mounting hardware and wiring Adjustments Fig 20 The auxiliary switch operating rod 5 should be adjusted so that the switch a contacts close when the arcing contacts of the outer poles are parted by 1 8 to 1 4...

Page 24: ...evice coil circuit is con tinuously rated and will remain picked up as long as the voltage remains above the predetermined drop out voltage The time delay is field ad justable between 1 and 5 seconds it is factory set at the minimum setting and once the time delay is established it is consistent No more than one undervoltage device should be connected to a static time delay box The Static Time Del...

Page 25: ...R VOLTAGE TRIPPING DEVICE The instantaneousundervotage device is mounted in the same location and manner as thestatic time delay device and its construction is similar The adjustments and replacement of this device are the same as those described above for the static time delay undervoltage device In the event the device fails to pick up the following checks are recommended to determine whether th...

Page 26: ...G Fig 26 The long time delay armature 22 is restrained by the long time delay calibration spring 15 After the magnetic force produced by the over current condition overcomes this restraint the velocity of the armature movement is governed by the flow of oil through an orifice in the piston of the dashpot 17 The time required to displace the piston is inversely proportional to the force tending to ...

Page 27: ...ent device is cali brated at the factory the air gaps between magnet 11 and armatures 1 and 22 are set These gaps are measured at their widest point between the front edge of the armature and magnet The gap for the short time delay armature is 17 64 in and for the long time delay armature is 17 64 in Both have a plus and minus tolerance of l 64in Low set Adjustable If the characteristic of the dev...

Page 28: ...tment screw 7 is provided so that the short time mechanism will pick up the trip link 8 at the same point at which it is picked up by the long time mechanism This may be checked before the device is mounted by pulling forward on the connecting link 10 and checking visually to see that trip link 8 contactsboth theset pin in the long time linkage and the end of adjustment screw 7 After the device is...

Page 29: ...a bracket to the lower part of the pole unit base NOTE In lieu of locknuts some devices are equipped with self locking nylon insert nuts REPLACEMENT Fig 27 1 Remove front frame see SEPARATION OF FRONT AND REAR FRAMES 2 Remove the bolts holding the coil to the lower stud The device can be provided with the same tripping combinations as the EC 1 direct acting device SHORT TIME DELAY TRIPPING Fig 27 ...

Page 30: ... device when parts are worn or damaged Component parts of any overcurrent 5 Replace new device in reverse order n j 6 GENERAL ELECTRIC iliiiv ovi tjt isi rwnwc MVKI Vm EC 2 0 17513 66 2 SO CYCLES 70 AMP INSTANTANEOUS TRIP 150 AMP BREAKER INTERRUPTING RATING IS IMITEQ TO 2S 00Q AMP INSPECTED 5 TIME CURRENT CHARACTERISTIC JC 2 3 2 4 3 it k i 15 i ii 14 4 12 J Fig 29 8024843 801449 8019485 Overcurren...

Page 31: ...urrent Usually expressed in times the ampere rating of the trip coil The variation in pick up setting is accomplished by varying the tensile force on the instantaneous spring 5 Turning the adjustment screw changes the position of the movable nut 11 on the screw The spring is anchored to this movable nut so that when the position of the nut is changed there is a corres ponding change in the spring ...

Page 32: ...ill be necessary to replace the trip paddles on the trip shaft with ones which are slightly longer When required these will be provided with the replacement trip units The top edge of the movable nut 11 serves as an index pointer and should be lined up with the center of the desired calibration mark 15 to obtain the proper instantaneous trip setting The trip screw 6 on the end of the armature 7 sh...

Page 33: ...ne The new device will be factory adjusted so that the top end of the trip rod 3 will extend 1 2 in above the top of the device case and no addi tional adjustments of the trip rod should be required To obtain the proper 1 32 in over travel close the breaker and proceed as follows 1 Loosen the locking nut 2B 2 Manually lift the trip rod and vary the position of the adjusting nut 2A this establish i...

Page 34: ...t the leads to the tripping solenoid be removed to completely eliminate the possibility of the breaker tripping Do not close breaker with power on the main contacts while the disconnect plug to the magnetic coils is disconnected 1 Check for the existence of overcurrent or ground fault conditions that may be causing the breaker to trip as a proper response to these normal circuit conditions 2 The p...

Page 35: ...r components is faulty and in need of replacement If continuity does not now REPLACEMENT OF POWER SENSOR COMPONENTS Power Sensor Unit Fig 35 Loosen screw connecting the unit to the 1 front frame 2 Slide unit forward 3 Remove control plug by alternately loosen ing the two retaining screws 4 Replace in reverse order Trip Solenoid Fig 36 1 Remove opening springs 2 Raise cross bar to gain additional a...

Page 36: ...i i m JtT 4 S UNO _ 1111 I I Sir U sr Ur 4 101 MlOfHx 1W l v OF JK 5 Fig 34 8039648 Power Supply 1 Indicator Terminal Block Capacitor 4 Female Disconnect Plug 5 Male Disconnect Plug 6 Mounting Brackets Fig 35 8039649 Power Sensor Unit 1 Mounting Screw 2 Captive Thumb Screw Name Plate 2 3 3 4 5 6 7 3 2 8 9 Fig 36 8039903 Magnet Trip Device 4 Adjusting Screw 5 Trip Arm 6 Armature 1 Name Plate 2 Spri...

Page 37: ...g by alternately loosening two retaining screws 5 Remove Power Supply Unit with control wiring 3 i 4 3 WIRE A I 6R0UND 1 SENSOR IB 4 W I R E A 1 OlSBBZ43 c it j t i T t3WEL0 R V 4 It i I I i i I l I SURGE SUPPRESSORS I F I 54 0 i i I hi i i I it 4 i I i D 1 0 I T POWER SENSOR IB I OVERCURRENT jH I 6 Reassemble in reverse order i H 1 t T i I I E SENSOR Coils AK 3 50 Only Fig 32 1 Disconnect plug be...

Page 38: ...0AD A evrau ir I I5 FD f IV 1 a I L 1 2 3 4 S I POWER SENSOR COIL I 0 a i U i 41 K 3 KE5 43 ui I N H 0 bLK Ju2 X r 47 W 0 r i i 7 h f T I I 0 4IZ l 2 I 2 5 SI U i i X 4j J D el 5 5 L4 1 BR A Ee 1 OUTUNE I a L J l J I DI I88U 11 LZ ft TeHAS I I I A 57 GROUNDSENSOR T C fec 7 OM r O V SrA7 VCA Aftf BREAKS v i i WIRE SYSTEM TYPICAL SPOUMD Pfi JLT CONNECTIONS CESREAX6R CAB IMS EOUUD SENSOR DISCONNECT A...

Page 39: ...ed in a minimum amount of time by selec tive tripping Overloads producing current up to five or ten times the breaker rating are removed in a matter of a few cycles while currents in excess of this value are removed instantaneously 7 Replace coil assemblies in reverse order Sensor Coils AK 3 75 100 Only Fig 33 1 Disconnect control plug between Power Supply Unit and Sensor Coils 2 If present discon...

Page 40: ... a M n i issi 2 5X J J J ps 7 r 4 iox 0 4 1OX J L ZL n 4 1OX 1 J T Max X 5i 3 J A s s 7 2 y 7 J Z ZV iCli s v s s w P Int K Maximum Total Claarinf Tima AK 15 AK 50 AIMS AK 75 AK 100 S J S J 2xS s V S 0 1 Min M M M V x 2 7 2 V X7 i m J 7 v Shart timo May Unit 7 7 7 7 7 7 7 7 7 Z Application diUnnlnw an lof cwrva 7 Z 7 A a M 7 z Imtontanoow Unit 7 7 w Ml 7 ZV 7 7 A A a a a a naa I IJ a a a a I 4 I I...

Page 41: ...Q 50 Z 8 4 M X s Ul I M n 10 I 7 4 S 1 1 J J 7 M J 4 J J 2 M 2 o o 1 S 1 w s 09 07 1 00 X 09 05 04 03 03 02 02 11 U J 7 0 1 1 3 4 0 7 no 2 3 4 0 7 0 lo J 0 7 4 TT 2 4 1 0 7 0 0 10 j I 7 I t 1 Li 0 7 0 1 2 3 3 4 I I I 0 0111 2 I CURRENT IN MULTIPLES OF GROUND TRIP SETTING Figure 42B 109HL689 Ground fault short time delay time current curves for solid state trip device 41 Courtesy of NationalSwitchg...

Page 42: ...e assembly and the stud of the enclosure the disconnect fingers exert a set amount of force against the stationary stud through the action of the compression springs Retainers and spacers hold the contact fingers in correct alignment for engagement with the stud The amount of force which the fingers exert against the stud is determined by the degree to which the springs are compressed by the bolt ...

Page 43: ...with the breaker The drawout mechanism is equipped with a drawout trip interlock which prevents a racking operation from being performed when the breaker is closed Inserting the breaker into the housing causes the racking pins on the housing to engage the semi circular slot in the racking cam 4 In this position the breaker is ready to be fully racked in by operating the racking handle 1 The first ...

Page 44: ...el the trip lever is bent in or out accordingly REPLACEMENT OF COIL Fig 45 1 Disconnect leads to coil 7 2 Remove magnet 6 and coil from frame 4 Remove coil and install new coil in re verse order BELL ALARM AND LOCKOUT DEVICE FIG 46 The device operating link 2 is engaged with the breaker crossbar side link pin 1 thereby operating the device whenever the breaker is tripped by the overcurrent trip de...

Page 45: ...s the breaker in the trip free position until it is released by operation of the manual reset button lO The coil 6 is de energized as soon as the breaker is tripped open The 3 The lockout adjusting screw 3 should be adjusted so that it engages the lockout trip paddle 5 and displaces the trip shaft 6 when the breaker is opened This assures that the breaker is locked open until the device is reset a...

Page 46: ...emove coil Install new coil and replace parts in reverse order Re I REPLACEMENT If it becomes necessary to replace coil 6 proceed as follows Remove five bolts connecting the device to the side plate and front frame Lower lockout device guiding rod 3 thru rod 1 15 A 1 TRIP PADDLE 2 ROD GUIDE 3 ROD 4 LOCK NUT 5 TRIP DEVICE 6 COIL 7 LINK ASSEMBLY 8 ARMATURE 9 ARM 10 RESET BUTTON 11 ROD RESET BUTTON 1...

Page 47: ...nameplate data of the breaker should be given Screwdrivers Phillips No 1 Phillips No 2 8 in shank Phillips No 3 Long thin slotted screw Standard slotted screw Short shank slotted screw Offset ratchet screwdriver slotter No 3400 Yankee Offset ratchet screwdriver Phillips No 3412 Yankee Renewal parts which are furnished may not be identical with the original parts since design improvements are made ...

Page 48: ...er information call or write your local General Electric Sales Office or General Electric Company 41 Woodford Avenue Plainville CT 06062 U S A ELECTRIC GENERAL GEK 7303C 1086 PSC Courtesy of NationalSwitchgear com ...