GE AK-15, Installation Instructions Manual

Page 1: ... GE trip systems MicroVersaTrip1 Plus and MicroVersaTrip3 PM Conversion Kits are designed and breaker tested to conform with ANSI standard C37 59 allowing the retrofitter to properly install and acceptance test the breaker This publication covers installation of MicroVersaTrip Plus and MicroVersaTrip35 PM Conversion Kits on GE types AK 15 AK 25 AKU 25 AKR 30S AKRU 30S Low Voltage Power Circuit Bre...

Page 2: ... 6 7 8 9 10 11 12 13 16 13 16 SECTION 4 BACK FRAME BREAKER CONVERSION Installing Phase Sensors 17 20 SECTION 5 FOUR WIRE GROUND FAULT OPTION Drawout Breakers Stationary Breakers Installing Neutral Sensors 17 18 19 20 I 21 23 EQUIPMENT CONVERSION Stud Shield Modification Remounting Primary Disconnect Fingers Installing the Insulator Bracket and Wire Harness SECTION 6 21 22 23 SECTION 7 INSTALLING T...

Page 3: ...ttempting any installation maintenance or modification Follow all lock out and tagging rules of the National Electrical Code and all other applicable codes Do not work on a closed breaker or a breaker with the closing springs charged Trip OPEN the breaker and be sure the stored energy springs are discharged avoiding the possibility that the breakers may trip OPEN or the charg ing springs discharge...

Page 4: ...ening the two V x 20 hex capnuts On electrically operated AK 3 3A 25 breakers the Y re lay is mounted on the left end of the retainer so there is no need to remove it On AK 3 2A 25 breakers it is mounted on the right side and will have to be moved to the left side The steps are shown on page 5 Step 2 Remove the three arc quenchers by lifting upward and outward Step 3 Separate the breaker s front a...

Page 5: ... space for the new flux shift trip device remove the Y relay and remount it on the left end of the arc quencher retainer as shown in Figs 3 2 and 3 3 using hardware and parts included Step 2 Modify the breaker s wiring harness to suit The X relay should be remounted after the programmer mount and bracket are installed See installing the programmer bracket and Fig 3 8 Fig 3 2 Right Side View of Fro...

Page 6: ...A ROUTE WIRE HARNESS X SO THAT IT WILL BE TRAPPED BY THIS WIRE KEEPER vTTfWWu LOCATION OF MAGNETIC TRIP DEVICE ON AK 3 25 3A 25 MODELS 0 0 WIRE HARNESS X CONNECT TO PROGRAMMER HARNESS CONNECTOR ON AKD DRAW OUT BREAKER MFG PRIOR TO 1969 CUT OFF THE RACK IN ARM DOTTED SECTION TO CLEAR PROGRAMMER SOCKET TERMINAL CAUTION ROUTE HARNESS X SO THAT IT WILL NOT BE CUT BY MOVING PARTS OF THE CLOSING SOLENOI...

Page 7: ...ip is installed use the 54 spacer provided Fig 3 7 Step 5 When the flux shifter and its trip paddle are installed and the front and back breaker frames are reassembled the following adjustment must be made Note that the back frame must be converted first With the breaker in the OPEN position and the mechanism fully charged set the gap between the trip paddle and the end of the flux shifter trip ro...

Page 8: ...E FLUX SHIFT TRIP DEVICE ASSHOWN RIGHT SIDE OF MECHANISM FRAME VIEWED FROM REAR OF FRONT FRAME RIGHT OPER LINK W JAM NUT v ADJUSTER P C h TRIP PADDLE ON EC EQUIPPED BREAKERS IT WILL BE NECESSARY TO DRILL AND TAP OR BOLT THIS 10 32 HOLE IN THE FRONT FRAME USE THE FLUX SHIFT TRIP DEVICE BRACKET AS TEMPLATE ON POWER SENSOR BREAKERS EQUIPPED WITH SHUNT TRIP MOUNT FLUX SHIFT TRIP DEVICE ON TOP OF THE S...

Page 9: ...rovided see Fig 3 9 Step 3 Modify the X relay harness by adding 16 gauge ex tension wire splices and ring terminals provided Work one wire at a time Route the wires as shown in Fig 3 10 making certain that they do not inter fere with the solenoid plunger or programmer Fig 3 10 X Relay Wire Routing FRONT FRAME 1 o o I D 1 I I I I LTJ_ ft I 0 L w 51 I I y _ o T J 7 NEW LOCATION TRIP UNIT BRACKET PRO...

Page 10: ... HOLD PLUG BODY TIGHT TO THE ADAPTER BRACKET AND BEND OVER 2 LOCKING TABS CAUTION The adapter bracket must be installed onto harness plug as shown in Fig 3 11 Failure to do so will result in harness plugfailure and pro grammer will not provide any protection STEP 3 PRESS ON PUSH NUTS UNTIL BRACKET IS HELD FIRMLY AGAINST PROGRAMMER BRACKET V 40 0 0 0 0 0 0 0 o o o o o o o o o o o o o o o o o o o o ...

Page 11: ...e compart ment door Fig 3 13 and 3 15 show the mounting and installation sequence for AK 15 and 25 break ers A caution label Fig 3 14 should be mounted on the breaker and the compartment door as a warning to prevent unnecessary damage DISCONNECT SECONDARY BEFORE REMOVING BREAKER Fig 3 14 Caution Label Fig 3 15 AK 25 AKR 30S Communications Harness Installation Fig 3 13 AK 15 25 Harness Installation...

Page 12: ...eries breakers For this type of breaker with a 4th wire disconnect device the communica tion harness must be mounted on the left hand side Hole locations given are for reference only The communications disconnect plug location should be determined by a field engineer during job assessment v Fig 3 15 AKR 30S Harness Installation 12 Courtesy of NationalSwitchgear com ...

Page 13: ... using the 2 8 32 x Vi screws pro vided See Fig 4 3 Mount terminal boards TB1 TB2 and TB3 to the bracket using the 6 6 32 x Vi screws and washers provided Step 5 Reassemble the front and back frames REUSE HARDWARE Ml IJl INSULATOR MODIFIED REUSE HARDWARE I l S W 3 1 i r I i i L J O I LOWER STUE BACK PIATE CURRENT SENSOR Fig 4 1 Phase Sensor Assembly Right Side View Step 6 The wiring harness can be...

Page 14: ...SECTION 4 BACK FRAME BREAKER CONVERSION Installing Phase Sensors CT s Cont d Fig 4 3 Back Frame Assembly 9 Fig 4 2 Right Side Mew of Back Frame 14 Courtesy of NationalSwitchgear com ...

Page 15: ...SECTION 4 BACK FRAME BREAKER CONVERSION Installing Phase Sensors CT s Cont d Fig 4 4 AKU 25 Back Frame with MicroVersaTrip PM Conversion Components Installed 15 Courtesy of NationalSwitchgear com ...

Page 16: ...oVersaTrip CT provided with the kit The terminals should point down Step 4 Reassemble the copper bus removed in steps 1 2 See Fig 4 6 Fig 4 5 Removal of the Phase Sensors on AKR 30S Breakers NOTE Ocassionally during current sensor manufacturing a slight separation occurs of the epoxy from the plastic shell This may amount to as much as 0 030M and has no effect on per formance Additionally slight s...

Page 17: ...t the transformer The phase sensors are mounted on the breaker However the neutral sensor is inserted in the neutral bus which is part of the equipment The neutral sensor is connected to the breaker through the 4th wire neutral disconnect Wire harness installation depends on whether the breaker is a 4 wire draw out or a 4 wire stationary system HARNESS HOLE X FRONT VIEW OF BACK FRAME WHITE COM REA...

Page 18: ...t neutral sensor terminal board TB5 to the back frame Step 2 Feed the end of the wire harness to the terminal board and connect as shown in Fig 5 2 Fig 5 2 Harness Connections for Stationary7 Breakers Equipped with 4 Vire Ground Fault 18 Courtesy of NationalSwitchgear com ...

Page 19: ...ollowing modifications are required only in conjunction with breakers being equipped with 4 wire Ground Fault trip elements Step 1 Mount the neutral sensor CT in the outgoing neutral lead normally in the equipment s bus or cable compartment See Fig 5 3 for the sensor s bar drilling plan Check to insure that the neutral and phase sensors match i e have the same ampere range Step 2 Connect the neutr...

Page 20: ...BLOCK 14 MIN WIRE WIRES MUST BE RUN TOGETHER AND TIED TO PREVENT LOOPS LINE NEUTRAL CT TAP TYPICAL TERMINAL 100 FT MAX LOAD A A TAP COM c TERMINAL STRAPS TAP COM 4TH WIRE NEUTRAL SENSOR STATIONARY DISCONNECT BLOCK SPRING LOADED BUTT CONTACTS Fig 5 4 Connecting the 4th Wire Neutral Sensor 20 Courtesy of NationalSwitchgear com ...

Page 21: ...odification Modify the left and right pole lower stud insulator shields per Fig 6 1 Remount on back plate using original screws and special nut supplied with the kit REF Fig 6 1 Stud Insulator Modification MOVABLE CONTACT PIVOT SUPPORT REUSE HARDWARE S S 1 1s V REUSE JL HARDWARE INSULATOR MODIFIED REUSE HARDWARE ci Nj l i r I I LJ I I LOWER STUD BACK PLATE CURRENT SENSOR Fig 6 2 Phase Sensor Assem...

Page 22: ...tep 2 Place the new retaining ring on the stud Insert the tip of the upper fingers under the retaining ring and place the bowr tie spacers in the fingers Step 3 Place the retainer over the upper fingers and insert the bolt Step 4 Insert the tip of the lowrer fingers under the retain ing ring and place the bow tie shaped spacers in the fingers Locate the lower retainer to hold the bow tie shaped sp...

Page 23: ...TB1 TB2 and TB3 Identify by Table 6 1 Step 2 For all four wire draw out breakers connect the ground fault lead to the 4th wire disconnect block Step 3 For all four wire stationary breakers connect the ground fault lead to the 4lh wire terminal block Fig 6 4 Back Frame Wire Harness Table 6 1 Harness Connections To Harness Connector Pin Number From Terminal Board Wire Color Component TB1 White Black...

Page 24: ...s the programmer to the mounting bracket To Install the Programmer The mounting bracket is shown in Fig 7 1 Installa tion is as follows Step 1 Insert the guide pins into the holes and push on the programmer engaging the connectors Step 2 Release the locking lever securing the programmer Step 3 Verify that the locking lever actually engages the programmer pin To remove the programmer pull the locki...

Page 25: ...onverted but before it is energized it must be tested See below for troubleshooting details TESTING Before installing a converted breaker back into ser vice perform the following steps Step 1 Verify that the programmer is securely installed The phase sensors must not be energized if they are open circuited Step 2 Megger the breaker primary circuit using a 1 000 Volt Megger Step 3 To verify that th...

Page 26: ...etween the neutral sensor and its equipment mounted secondary discon nect block Also check for continuity from the breaker mounted neutral secondary disconnect block through to the female harness connector If the breaker s lower studs connect to the sup ply source then the neutral sensor must have its load end connected to the source See Fig 8 1 Make sure that the neutral conductor is earning only...

Page 27: ...f 170 LI CONNECTIONS FOR GROUND FAULT OPTION ONLY 9 08 R W H E HOMM I D NET T 24Vdc POWER E A B C 3 0 VOLTAGES I I t iP o c r 0 FLUX SHIFT TRIP DEVICE 0 lc CONNECTIONS FOR COMMUNICATIONS OPTION ONLY o B r 0 I 4 WIRI LOAD B TO rp 0 lA 0 I BREAKER BACK FRAME NEUTRAL SENSOR DISCONNECT LEFT POLE CURRENT SENSOR 0 NEUTRAL TAP COM LOAD LINE O EQUIPMENT MOUNTED NEUTRAL SENSOR Fig 8 1 Cabling Diagram Micro...

Page 28: ...on or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter should be referred to the GE Company GE Electrical Distribution Control General Electric Company 41 Woodford Ave Plainville CT 06062 1994 General Electric Company GEH 5967 1094 PSA Courtesy of NationalSwitchgear com ...