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P0\1\/ER  CIRCUIT  BREAKERS 

Types 

AK·2·1S 

and 

AK·2/3·25 

I NTROOUCT ION 

The  instructions  contained  herein  provide in­

formation  for 

maintenance procedures 

and  for  replacing 

breaker  compo­

nents and accessories.  For information regarding 

the  receiving,  handling,  storage  and  installation 

of  these  breakers,  refer  to  GEK-7302  furnished 

with  all  AK  breakers. 

OPERATION 

ELECTRICAL OPERATION 

Figure  1 

The electrically operated breaker closes when­

ever  the  closing  solenoid  coil  is  energized.  This 

causes  an upward  movement  of the  solenoid  arma­

ture,  which  initiates  the  mechanical  closing action. 

The  closing  signal  may  be  given  either  by  a 

remote  switch  or  relay,  or  by  a  closing  button 

in  the  front  escutcheon 

if 

the  breaker  is  so 

equipped.  Either  action  (refer  to  the elementary 

of  the  wiring  diagram)  energizes  the  coil  of  the 

X  relay  through  the  bb  contacts  of  cutoff  switch 

G  and  the normally closed  contacts  of the 

relay. 

When  the  X  relay  or  contactor  is  energized,  it 

closes  its  contacts. 

One  of  these  (X1-2)  seals 

in  the  X  coil.  The  other  three  sets  of  contacts, 

which  are  arranged  in  series,  activate  the closing 

solenoid. 

The  breaker  control  scheme  has  an  anti­

pump  feature  which  allows  only  one  closure  of 

the  breaker  for  a  single  operation  of  the  closing 

switch  no  matter  how  long  the  switch  may  be 

held  closed.  This prevents  the repeated operations 

that  would  ensue 

if 

one  of  the  automatic  trip 

devices  was  activated  at  the  time of closing.  The 

relay,  together  with  the  cut-off  switch,  provides 

the  anti-pump  feature.  The  mechanical  action  of 

closing  operates  the  cut-off  switch,  reversing 

the  position  of  the  contacts  from  that  shown  on 

the  diagram. 

This  energizes  the 

relay, 

if 

contact  is  still  maintained  at  the  closing  switch, 

with  the  result  that  the  X  relay  circuit  is  opened 

by 

contacts 

5-6. 

This  prevents  the  X  relay 

from  again  becoming  energized. 

contact  1-2 

seals  in  the 

coil  as  long  as  contact  is  main­

tained at  the  closing  switch. 

Electrically  operated  breakers  may  also  be 

closed  by  means  of  the  maintenance handle  which 

is  furnished  with  the  breaker.  This  is  a separate 

tool  and  is  simply  a  lever  which  permits  an 

operator  to  push  upwards  on  the closing  solenoid 

armature.  Two  small  hooks  on  one  end  of  main­

tenance  handle  are  engaged  in  slots  (9A)  Figure 5, 

located  in  the  lower  portion  of  the  front escutcheon 

(SA)  Figure 

5. 

Rotation  of  the  long  end of the 

handle  downwards  forces  the  shorter  end  of  the 

handle  upwards  against  the  bottom  of the  solenoid 

armature,  and  closes  the breaker. 

The  breaker  may  be  tripped  open  by any  one 

of  a  number  of  electrical  tripping  devices  which 

will  be  described  in  detail  later  in  these instruc­

tions. 

An  individual  breaker  may  have  none  or 

any  combination  of  these  devices.  They  are  the 

overcurrent  tripping device,  shunt  tripping  device, 

undervoltage  tripping  device,  reverse current trip­

ping  device,  and  open  fuse  lockout  device.  All 

of  them  effect  tripping by displacing the  trip  latch 

of  the  mechanism. 

The  trip  latch  is  rigidly 

attached  to  a  trip  shaft  which  runs  through  the 

breaker  from  left  to  right.  Whenever  the  trip 

shaft  is  rotated  in  a  counterclockwise  direction 

looking  from  the  right,  the  latch  is  displaced. 

The tripping  devices  are  all  equipped with strikers 

or  trip arms  which  act against trip paddles  rigidly 

fastened  to  the  trip  shaft,  causing  it  to  rotate 

on  its  bearings  in  a  direction  to  trip  the  breaker. 

The  reverse  current  device  and  the  shunt 

tripping  device each have a set  of  auxiliary  switch 

"a"  contacts  in  their  circuits.  (An  "a"  contact 

is  open  when  the  breaker  contacts  are  open.) 

This  prevents  their  operation  unless  the  breaker 

is  closed. 

The  undervoltage  device  coil  is  normally 

continually  energized.  When  the control  voltage  is 

low  or  non-existent,  as  when  the breaker has been 

pulled  out  for  inspection  or  maintenance,  the 

breaker  is  rendered  trip-free  by  the undervoltage 

device. 

If 

it  is  desired  to  close  the breaker, 

the  device  armature  must  be  tied  down  or  blocked 

closed  against  the  magnet.  The  open  fuse lockout 

device  is  used  on  all  AKU  breakers  and breaker 

fuse  combinations. 

The  purpose  of  this  device 

is  to  trip  the  breaker  upon  the  blowing  of any 

one of the breaker fuses. 

MANUAL  OPERATION 

The  manually  operated  breaker  is  closed  by 

first  rotating  the  handle  in  a  counterclockwise 

direction  through  90  degrees,  then  rotating  it 

clockwise  back  to  its  normal  vertical  position. 

The  counterclockwise stroke resets the mechanism, 

readying  it  for  the  clockwise  closing  stroke. 

The  breaker  may  be  tripped  manually  by 

pushing  the  manual  trip  button.  This  action pushes 

These  instructions  do  not  purport  to  cover  all  details  or  variat1ons  in  equipment  nor  to  provide  for  every  possible 

contingency  to  be  met  in  connection  with  installation,  operation  or  maintenance.  Should  further  information  be  desired 
or  should  particular problems  arise  which  are  not  covered sufficiently  for  the  purchaser's  purposes,  the  maHer  should 

be  referred  to  the  General  Electric  Company. 

www 

. ElectricalPartManuals 

. com 

Summary of Contents for AK-2-15

Page 1: ...enance Instructions Includes Supplement GEI 86153 GEI 50299E Power Circuit Breakers Types AK 2 2A 15 AK 2 3 2A 3A 25 AKU 2 3 2A 3A 25 GENERAL fj ELECTRIC w w w E l e c t r i c a l P a r t M a n u a l s c o m ...

Page 2: ...y Cut Off t Jwitch Closing Switch Shunt Trip Device PROTECTIVE DEVICES Overcurrent Trip Device EC 2 Overcurrent Trip Device EC 1 Overcurrent Trip Device Reverse Current Trip Devices Power lensor Trip Device Selective Tripping Static Time Delay Undervoltage Tripping Vevice Instantaneous Undervoltage Device Undervoltage Lockout Device Bell Alarm Switch and or Lockout Attachment Open Fuse Lockout Dev...

Page 3: ...s forces the shorter end of the handle upwards against the bottom of the solenoid armature and closes the breaker The breaker may be tripped open by any one of a number of electrical tripping devices which will be described in detail later in these instruc tions An individual breaker may have none or any combination of these devices They are the overcurrent tripping device shunt tripping device un...

Page 4: ...e manual handle cam and mechanism connecting link The Tripping is accomplished by the manual trip button on the escutcheon or by any of the electrical tripping devices available for use on the standard breakers 4 o j TRP JA6 1 2 TC A4 A7 ELEMENTARY DIAGRAM t y y FIG LIST OF ABBREviATIONS A TERMINAL BOARD LOCATED TOP RIGHT FRONT VIEW F ANTI PUMP PERMISSIVE RELAY G oa bb CUT OFF SWITCH K Xl CLOSING ...

Page 5: ...current carrying parts of the breaker and their supporting structure The procedure for this operation is as follows 1 Remove the arc quenchers see section on Arc Quenchers 2 Disconnect the two insulated connecting links 6 between the mechanism and the crossbar 10 by removing the tie bolt 7 and slipping the ends of the links off the ends of the should ered pin 5 Figure 5 in the mechanism 3 If the b...

Page 6: ...elease of tripping latch check mechanism latch adjustment Worn or damaged trip unit parts Replace trip unit Bind in overcurrent trip device Replace overcurrent trip device False Tripping Overcurrent trip device pick up too low Check application of overcurrent trip device AK 2 Breakers Overcurrent trip device time setting too short Check application of overcurrent trip device Bind in overcurrent tr...

Page 7: ...nts and external control circuits They are used only on drawout type breakers A terminal board serves the same purpose on stationary mountedandgeneral purpose enclosure mounted breakers The second ary disconnects allow removal of the breaker with out the necessity of having to detach external con nections The movable part of the secondary disconnect consists of an insulating body which holds a con...

Page 8: ...he rear side of the stationary contacts Each of the stationary contacts pivot in a horizontal plane approximately at their mid points The end of the contact opposite to the contact tip end is formed into the shape of a small hook A tension spring engages this hook and provides the necessary contact pressure at the pivot and also at the point of contact with the movable contact arm When the breaker...

Page 9: ...contact replacement will call for re placement of all the movable and stationary con tacts at the same time This will be the case where long use of the breaker in service has resulted in extensive wear or erosion of the silver alloy contact tips A commonly used rule of thumb is that contact replacement is indicated if less than one half of the original thickness 1 8 of an inch of the contact tip m...

Page 10: ...er Base 8 Spring REPLACEMENT OF MOVAB LE C ONTACTS 18 Figure 3 1 Coat the pivot area only of the new movable contacts with a thin coat of D50H47 grease 2 Assemble the center pole movable contacts align the pivot pin holes with the bullet nosed rod and install the pivot pin and split pin 3 Move the cross bar assembly into position and insert the eccentric contact wipe adjust 20 19 14 13 12 FRONT VI...

Page 11: ...should be adjustable using eccentric numbers 1 2 or 3 These numbers are the ones visible when viewing the breaker from the front not from above The higher numbers should be reserved for tightening at future maintenance readjustments after wear Also if higher numbers are used where adequate wipe is obtainable at settings 1 2 or 3 it is possible that the stationary contacts will bottom producing exc...

Page 12: ... function properly it is best to first perform the available remedial measures listed in the Trouble Shooting chart of these instructions One of the remedies 12 listed is that of proper mechanism latch engage ment the amount of engagement be tween the latch 7 and latch roller 5 Figure 6 This is the only adjustment that is required on the breaker mech anism and proper latch engagement is obtained i...

Page 13: ... position where the contacts move before tripping occurs When this position is established note the position of the slot in the head of the adjusting screw 4 Withdraw the adjusting screw three and one half turns from the position noted in step 3 This sets the proper amount of latch engage ment Figure 5 8024457 Cut Away Model of Electrically Operated AK 2 Breaker 1 2 3 4 5 6 7 Arc Quencher Retainer...

Page 14: ...ee Arc Quencher 3 Disconnect the two insulated connecting links between the mechanism and the contacts as in step 2 of the procedure for Separation of Front and Back Frames 4 Remove the two elastic stop nuts whichfasten the upper extensions of mechanism frame to studs connecting with rear frame 5 Remove four screws which fasten the bottom of the mechanism frame to the horizontal cross member of th...

Page 15: ...mbly In replacing the escutcheon it may be necessary to use pliers to pull the operating shaft fully into the escutcheon in order to have space enough to replace the flat washers and the soft retainer The latter may be closed on its groove in the shaft by ordinary gas pliers After re placement check operation of breaker AUXILIARY SWITCH The auxiliary switch is mounted on the left side of the opera...

Page 16: ...ng axis and withdraw it Replace new contacts by reversing the pro cedure slide downward until clear of armature Coil 6 Reassemble with new coil by reversing order of procedure X C ONTACTOR The X contactor is a heavy duty relaywhich performs the function of closing the circuit of the breaker solenoid during electrical operations Three of the four sets of contact of the device are arranged in series...

Page 17: ...ns so that enough wire will remain for connection to the new relay Sufficient original wire is allowed for this purpose 2 JL_ lJ L c 3 4 5 After the old relay has been removed the wire leads to the relay should be stripped of insulation to about 1 4 of an inch from the ends A good mechanical connection should be made before soldering After all connections are completed the relay may should again b...

Page 18: ...side also holds a wiring cleat and spacer which serves to hold the wires clear of the link connecting the mechanism andthe breaker position indicator 4 Remove the front escutcheonfrom the breaker 5 Slide the cut off switch out from between the steel side plates by pulling straight forward 18 6 Mount the replacement switch by reversing the order of procedure CLOSING SWITCH Figure 8 The closing swit...

Page 19: ... Push Button 1 Nut 2 Frame 3 Spring 4 Rivet 5 Weight 5 Movable Contact 6 Spring 7 Hinge 8 Closing Solenoid _ L _ AUX SW LIC A7 M T C A M2 9 Speed Nut 10 Screw TRIP 3 1 1 Figure 9 695C161 Shunt Trip Device 6 Screws 1 1 Armature Arm 7 Magnet 8 Coil 12 Trip Paddle 13 Mechanism Frame 9 Clamp 14 Trip Shaft Clamp 10 Armature 19 w w w E l e c t r i c a l P a r t M a n u a l s c o m ...

Page 20: ...vice the movement of the armature may be delayed for a time by a timing device If a relatively long time delay seconds or minutes is desired the velocity of armature movement is governed by a piston moving through an oil dashpot If only a short time delay cycles or milli seconds is required movement is controlled by an escape ment gear and pallets arrangement An AK 2 15 25 breaker may be equipped ...

Page 21: ...ashpot Arm 8 Connecting Link 9 Instantaneous Pickup Calibration Marks counter clockwise motion decreases it The dash pot arm 7 Figure 1 1 is indexed at four points maximum 2 3 1 3 minimum from the left as viewed in Figure 1 1 When the index mark on the connecting link 8 Figure 11 lines up with a mark on the dashpot arm the approximate tripping time as shown by the charaCteristic curve is in dicate...

Page 22: ... instantaneous pick up value may have one of the following three ranges 4 to 9 times coil rating 6 to 12 times coil rating or 9 to 15 times coil rating The pick up setting may be varied by turning the instantaneous trip adjusting screw 4 Figure 11 Three standard calibration marks will appear on the operating arm at 9 Figure 11 and the value of these calibration marks will be indicated 22 by stampi...

Page 23: ... overcurrent trip devices have been replaced Positive tripping is achieved when adjustment screw 2 Figure 10 is in such a position that it will always carry the trip paddle on the trip shaft beyond the point of tripping the mechanism when the armature closes against the magnet In order to make the adjustment firstunscrew trip screw 2 Figure 10 until it will not trip the breaker even though the arm...

Page 24: ...s against trip paddle 14 tripping thebreaker open ADJUSTMENTS The only adjustment to be made on the reverse current device is to make sure that the trip rod has a minimum overtravel of 1 32 of an inch beyond the point of tripping the breaker The only occasion this adjustment should have to be made is when an old device is being replaced by a new one The new device will be factory adjusted so that ...

Page 25: ...inciple that the instantaneous value of current flowing in the three conductors or in four conductors on four wire systems must add to zero unless ground current is flowing Therefore if the electrical system is a four wire wye system with the neutral grounded at the transformer the fourth sensing coil Figure 18 must be included on the neutral conductor with its secondary combined with the secondar...

Page 26: ...e Power Sensor Successful operations in the test position should be ob tained before proceedingwith the Power Sensor trouble shooting 3 A PST 1 Power Sensor Test Kit must be available Figure 21 Check the Power Sensor Unit for correct function for each pick up setting and one point on each time delay characteristic Then check for the correct operation of each phase of the Power Supply Unit This pro...

Page 27: ... Coil Remotely Located 1 Terminal 2 External Ground Sensor Coil 3 White Polarity Dot 2 Check to be sure no continuity exists between R and A or between R and C 3 Temporarily connect jumper from shield to either terminal at remote C T and check to assure the shield is continuous from Power Sensor Plug to remote C T by checking for continuity between R and A If continuity does not now exist shield i...

Page 28: ...ingle phase testing unless the signal is shorted at the terminal board Figure 22 Jumper points 1 and 5 during overcurrent test The above considerations shouldindicate which of the four major components is faulty and in need of replacement REPLACEMENT OF POWER SENSOR COMPONENTS POWER SENSOR UNIT Figure 1 6 1 Loosen screw connecting the unit to the front frame 2 Slide unit forward 3 Remove control p...

Page 29: ...EC CONTtt ii IT R TO IEt O 1 tE tJi AL c 5RDUNO SEN SO COi l n n 75 11 Jt 50U R C E T P I C L f 0 JtJD F A JLT Co i E TiON eREAK E i 1 C t l 1 G eOuiJD SENSO OiSCO t4 IE i A NC ttlC T R NAl Gi OUNO 5SNS R COI L P R 01 Pb l l ov ER 5E I JSOR TRiP Figure 22 138B2454 Ground Fault Wiring Diagram II a II II Jl n 75 11 11 29 w w w E l e c t r i c a l P a r t M a n u a l s c o m ...

Page 30: ...ANGE AVA IL ABLE PER D E V ICE R A N G E OF 6 TO 12 T IMES IS F U RNISHED U N L E S S 1 f fi H I I I I I I O T H E RW I S E SPECIFI E D S E T T I NGIS ARE AT 12 T IM E S RATING r TOTA L cURVES ARE P L O T T E D AT 25 C AMBIENT r IQ ill CLt ARING TIME I S DURATION OF FAUL T Dlf C U R R E N T INC LUDI N G ARCING TIM E CLEA R I NG T I M E A K 1 50 Dif 30 Jill Ollr Gif r RESETTABLE I 1 tl I S DURATION...

Page 31: ... TIIP liniNG Figure 25 109HL689 Time Curve 5 Unsolder three leads at ground disconnect and pull wire through hole in back frame On stationary breakers withfourthwire ground disconnect unsolder leads at external ground coil and pull wire through hole in back frame 6 Remove primary disconnects per instructions under disconnects 7 Remove three 3 8 hexagon headed bolt con necting coils to breaker copp...

Page 32: ...to wiring diagram 0102C3698 Figure 26 The voltage 208V AC or 230V AC to be monitored is connected to terminals 1 and 2 of the time delay box The undervoltage device 32 R T t C o N NE c T tr o c T O ME R t I N ST I S N OT RE Q D Ju tv PE P UV To T B S on the breaker is always connected through either its secondary disconnects or terminal board tp terminals 4 and 5 of the time delay box The undervol...

Page 33: ...y unit is the faulty component A B Check input voltages across terminals 1 2 on static box These voltages should be as follows 1 Device 177L3 16 G 12 208 or 230volts A C 2 Device 177L316 G 14 125 volts D C 3 Device 177L316 G 15 250 volts D C Check output voltages on terminals 4 5 with the under voltage device connected The approximate voltages are as follows 1 208 Volt A C 177L31 6 G 12 l lOvolts ...

Page 34: ...ay device and its construction is similar The adjustments and replacement of t is device are the same as those described above for the static time delay undervoltage device UNDERVOLTAGE LOCKOUT DEVICE Figure 29 Figure 29 0101C7842 Undervoltage Lockout Device The undervoltage lockout device holds an open breaker trip free when the coil of the device is deenergized When the breaker is in the closed ...

Page 35: ...reaker opens lever 2 rotates counterclockwise about pin 14 The motion is transmitted through links 1 and 13 to paddle 12 which operates bell alarm switch 11 If the device has the lockout feature the movement of link 13 also causes lockout link 8 to slide in a direction that results in its striking trip paddle 5 which by displacement of the breaker mechanism trip latch makes it im possible to reset...

Page 36: ...own to engage the trip shaft paddle in the tripped position 1 Figure 31 8041865 Open Fuse Lockout Device 1 Mounting Holes 2 Lever 3 Reset Button 4 Collor 5 Armature 6 Coil 36 4 2 Check that each armature holds the breaker trip free when the armature position is limited in reset by the lower latch surface on the indicator 3 With the breaker in the closed position the top collor must clear the trip ...

Page 37: ...sembly of the existing backframe with the new front frame Addition of Shunt Trip Device Auxiliary witch Undervoltage Device Bell Alarm Lockout Device Drawout Mechanism Conversion to Elec Oper Covered By 698C900 698C901 698C902 698C904 698C922 698C904 MAINTENANCE TOOLS The following tools are recommended for proper maintenance of AK 2 15 and AK 2 3 25 breakers NOTE Obtain from local hardware firm d...

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Page 40: ... further information call or write your local General Electric Sales Office or Distribution Equipment Division 41 Woodford Avenue Plainville CT 06062 USA GENERAL fl ELECTRIC w w w E l e c t r i c a l P a r t M a n u a l s c o m ...

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