GE Gerapid 2607, User Manual

Page 1: ...008 Design and specifications are subject to change without notice 1 GE Consumer Industrial Power Protection High Speed DC Circuit Breaker Gerapid 2607 4207 6007 8007 with arc chute 1X2 1X4 2X2 2X3 2X4 USER S GUIDE ...

Page 2: ... control unit 19 4 3 5 SU control unit 20 4 3 6 Shunt trip control unit 21 4 3 7 Zero voltage release control unit 22 4 3 8 Indicators 23 4 3 9 Auxiliary switches 24 4 3 10 SEL Measuring system 25 5 DIMENSIONS SAFETY DISTANCES 26 5 1 Safety distances 27 5 2 Outlined dimensions 28 5 2 1 Gerapid 2607 4207 6007 with arc chute 1x_ 28 5 2 2 Gerapid 2607 4207 6007with arc chute 2x_ 29 5 2 3 Gerapid 8007...

Page 3: ...ably trained service personnel shall only carry out cer tain works Non compliance with these warnings may result in death and or severe physical damage and extensive damage to equipment Prior to carrying out maintenance inspection or checks the circuit breaker must be open the both terminals must be grounded the circuit breaker must be switched off and the control plugs removed During breakers ope...

Page 4: ...eral usage conditions 2 1 Transportation The breaker is transported on wooden palette It is fixed by shrunken plastic film A paper cardboard box covers the breaker on the palette Truck railway airplane and ship transport is possible In case of sea transport spe cial protection against salty and humid environment is used The circuit breaker must always be transported to the installation site vertic...

Page 5: ...other de vices can lead to a shift of the trip setting thresholds This may result in premature tripping or no tripping at al during low level short circuit current events This has to be accounted for when installing and operating the device with shielding added if appropriate The control wires must be connected to the control ter minals code nr 19 as shown in the schematic circuit diagram Page 14 ...

Page 6: ...kers have a compact and enclosed con struction Fig 4 They are IP 00 protected All parts are mounted on thick walled non breakable and fireproof insulation panels Fig 4 Modular construction overview 3 2 Components and accessories 3 2 1 Contact system Gerapid breakers are equipped with a two stage con tact system Fig 5 consists of a main contact and an arcing contact With this proven design of the c...

Page 7: ...e Fig 7 This technology ensures an equally fast tripping in both current directions The magnetic system does not require an auxiliary con trol voltage to operate It uses magnetic energy from the main circuit The system consists of the holding circuit 6 the mov able armature 3 and the tripping circuit 7 The holding and the tripping magnetic circuits are both excited by main current 1 Until the stat...

Page 8: ...e breaker In standard configuration internal voltage converter code nr 8 supply the devices with 24VDC This con verter transforms any externally connected voltage into internal 24VDC required by breaker s controls Optionally it s possible to supply both devices with direct external 24VDC 5 In this case release signal for ST shall not be longer 100ms Both devices are tripped by potential free conta...

Page 9: ...with 3 5 or 10 isolated form C auxiliary switches 1 NO NC each The movable main arm activates the contacts The contacts are wired to 15 pin control terminals X4 and X5 5 switches to each terminal Maximum electrical ratings for switches are 5A 230VAC and 0 3A 220VDC Utilization category AC DC 12 and 13 Fig 12 Auxiliary contacts layout in control box 3 2 10 Indicators Optionally the circuit breaker ...

Page 10: ... it off after 400ms SU unit prevents also repeated drive activation anti pumping during continuous operation due to an exist ing short circuit Fig 16 Solenoid closing drive and control box In addition the switch in mechanism is electrically blocked for approximately 8sec or 14sec after activa tion see Table 2a Activating magnet This prevents premature activation following a short circuit 3 2 12 Cu...

Page 11: ...10V UNi kV 12 18 40 12 18 40 3 2 13 Electronic control system All the control units are installed in control box Fig 18 Starting from the left these are Fig 18 Control box with control units 1 NEKO control unit Fig 19 1 internal control unit with capacitors bank It releases firing signal for ED coil X2 10 11 and enable signalization of the capacitors charging X3 6 7 NEKO control unit also blocks t...

Page 12: ...ccording to EN 50124 1 1997 Rated short circuit making capacity ÎNss kA 70 50 100 50 42 70 50 100 50 42 70 50 80 50 1 70 1 Rated short circuit breaking capacity INss kA 50 35 71 35 30 50 35 71 35 30 50 35 56 35 1 50 50 according to EN 50123 2 Rated service short circuit breaking current Ics kA 60 40 50 40 40 60 40 50 40 40 60 40 50 40 1 60 1 according to IEC 947 2 Short circuit current kA at Une 8...

Page 13: ...ators Rated operational current Ie AC 15 1A Rated operational current Ie AC 12 Ith 10A Rated operational voltage Ue DC 110V Rated operational current Ie DC 13 0 5A Contact duty min value DC 10V 2 mA ST 1 Rated voltage Uc 24V Shunt trip Operating range OFF 21 6V 26 4V Power consumption 150W UVR 1 Rated voltage Uc 24V Zero voltage release Operating range OFF 3V Operating range ON 24V 10 Power consum...

Page 14: ...iliary and control circuits X4 3 Connector Auxiliary contacts HS1 HS5 X5 4 Connector Auxiliary contacts HS6 HS10 X6 5 Connector Current measure system SEL X10 Control board Voltage converter X11 Control board Interface for external DC 24V supply OPTION X12 Control board SU control unit X13 Control board Shunt trip control unit X14 X15 Control board Zero voltage release X15 with modified UVR X16 Co...

Page 15: ... 9 10 11 12 X2 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 X 3 NEKO charging indicator indicates C bank charging with OCT indicator Indicates tripping by OCT Arc chute indicator Indicator switch Fig 21 Terminals wiring system 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X4 HS 1 HS 2 HS 3 HS 4 HS 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X5 HS 6 HS 7 HS 8 HS 9 HS 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X6 SEL 4 20...

Page 16: ...y Tripping coil 3 0 Without ed trip coil 1 With ed trip coil 2 With ed trip coil and NEKO control unit Drive 4 20 Solenoid drive with SU control unit Tripping device 5 00 Without trip unit 10 With shunt trip 20 With zero voltage release Indication device 6 00 Without indicators 01 OCT indicator 02 Arc chute indicator 03 OCT arc chute indicator Auxiliary contacts 7 1 3 auxiliary switches 2 5 auxili...

Page 17: ... 353V DC AC 115 290V AC Output DC 24V 5 Voltage converter 33V 353VDC 115V 290VAC N 4 5 1 3 X10 X3 X3 6 7 8 9 10 24V 24V Key position 2 Key number 1 Voltage converter 33 85V DC 88 145V DC 125 353V DC 115 290V AC Key number 2 Interface for direct external voltage 24VDC 5 connection 36 X _ _ _ _ _ _ External voltage supply 24V DC 5 5 24 V X3 X3 4 1 3 X11 10 9 8 7 6 Emergency STOP circuit Emergency ST...

Page 18: ... releasing of the ED coil by means of external capacity bank In this case NEKO control unit is not installed and coil s connected directly to front panel of control box X2 10 11 Fig 24 ED coil with external C bank 11 10 S3 X2 X2 Q1 ed Capacity bank U 300V F 2000µF Key position 3 Key number 0 Without ED coil Key number 1 With ED coil and external C bank 36 _ X _ _ _ _ _ ...

Page 19: ...c Longer signal will lead to NEKO failure It is highly recommended to use an internal auxiliary contact in serial connection with firing circuit X2 10 11 It will automatically cut off the firing circuit after contacts are opened Fig 25 ED coil with internal NEKO control unit Output signal bank charged X10 11 X10 11 Charging control Voltage control Firing circuit Pulse circuit Insulating Transforme...

Page 20: ...uit Power circuit CLOSE signal circuit Closing control Emergency STOP relay 1 2 3 4 9 8 10 7 5 6 X12 X2 X2 X2 X2 X10 11 X10 11 1 2 5 4 9 6 N S1 S3 CLOSE signal External power sup ply for the drive Emergency STOP signal Q1 Drive Key position 4 Key number 20 Closing solenoid drive with SU control unit 36 _ _ X _ _ _ _ K2 ...

Page 21: ...F signals are simultaneous switching OFF command will stay longer than switching ON It means that OFF command is master command The shunt trip operates for short time period only After contacts opening switch HS 11 cuts ST s supply circuit Fig 27 ST control circuit 3 4 5 6 7 6 2 1 7 8 9 10 X10 11 X10 11 X14 K1 K1 HS11 S2 24 V A1 A2 Emergency STOP signal C1 C2 3 4 7 9 Key position 5 Key number 00 W...

Page 22: ...ger than switching ON It means that OFF command is master command S2 X2 6 7 is NO contact predicted for indirect releasing of the UVR by relay K2 S2 X2 8 9 is NC contact predicted for direct releasing of the UVR If it s not used please short this connection perma nently Fig 28 UVR control circuit U 3 4 5 6 7 6 2 1 7 8 9 10 S2 X2 X2 X13 K2 K1 K1 K2 D1 X2 X2 S2 24 V A1 A2 A1 A2 Key position 5 Key nu...

Page 23: ...rs Fig 29 OCT indicator and arc chute indicator 8 9 X3 X3 12 13 X3 X3 Key position 6 Key number 00 Without indicators Key number 01 With OCT indicator only Key number 02 With arc chute indicator only Key number 03 With OCT and arc chute indicators 36 _ _ _ _ X _ _ OCT indicator Arc chute indicator ...

Page 24: ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X4 HS 1 HS 2 HS 3 HS 4 HS 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X5 HS 6 HS 7 HS 8 HS 9 HS 10 Fig 30 Auxiliary switches Key position 7 Key number 1 With 3 switches HS1 HS3 Key number 2 With 5 switches HS1 HS5 Key number 3 With 10 switches HS1 HS10 36 _ _ _ _ _ X _ ...

Page 25: ...hout notice 25 4 3 10 SEL measuring system 1 max 500 Ω 2 max 500 Ω 3 min 300 kΩ Fig 31 SEL current measurement system DC 24V Self check control DC 24V 1 2 3 Signal Processing Unit Voltage stabilizer Key position 8 Key number S With SEL measurment system 36 _ _ _ _ _ _ X ...

Page 26: ...except control box and closing solenoid drive may carry dangerous voltages Insulation covers are available as an option For installation of the breaker into cubicle top and side openings shall be provided in order to reduce internal pressure rise during clearing short circuit All openings respectively free areas on the top of the cubical shall be not less than 50 ...

Page 27: ...50 5 9 1000 39 4 180 7 1 180 7 1 180 7 1 6007 1x2 V V Heat sink 10 0 4 1000 39 4 300 11 8 300 11 8 180 7 1 1x3 1 1 1 1 1 1 1 1x4 V V Heat sink 150 5 9 1000 39 4 300 11 8 300 11 8 180 7 1 2x2 V V Heat sink 80 3 15 1000 39 4 180 7 1 180 7 1 180 7 1 2x3 V V Heat sink 80 3 15 1000 39 4 180 7 1 180 7 1 180 7 1 2x4 1 1 1 1 1 1 1 8007 1x2 V V Heat sink 10 0 4 1000 39 4 300 11 8 300 11 8 180 7 1 1x3 1 1 1...

Page 28: ... are subject to change without notice 28 5 2 Outlined dimensions 5 2 1 Gerapid 2607 4207 6007 with arc chute 1x_ Pay attention to legend warnings and safety distances pages 26 27 Fig 32 Gerapid 2607 6007 arc chute 1X dimensions in mm and inches ...

Page 29: ...ecifications are subject to change without notice 29 5 2 2 Gerapid 2607 4207 6007with arc chute 2x_ Pay attention to legend warnings and safety distances pages 26 27 Fig 33 Gerapid 2607 6007 arc chute 2x dimensions in mm and inches ...

Page 30: ...cations are subject to change without notice 01 2008 5 2 3 Gerapid 8007 with arc chute 1x_ Pay attention to legend warnings and safety distances pages 26 27 Fig 34 Gerapid 8007 with arc chute 1x dimensions in mm and inches ...

Page 31: ...nd specifications are subject to change without notice 31 5 2 4 Gerapid 8007 with arc chute 2x_ Pay attention to legend warnings and safety distances pages 26 27 Fig 35 Gerapid 8007 with arc chute 2x dimensions in mm and inches ...

Page 32: ... to change without notice 01 2008 5 2 5 Gerapid 2607 4207 with H H terminals It s able to combine connections horizontal and vertical dimensions are corresponding Fig 36 Gerapid 2607 4207 with horizontal terminals dimensions in mm and inches ...

Page 33: ...are subject to change without notice 33 5 2 6 Gerapid 2607 4207 with V V terminals It s able to combine connections horizontal and vertical dimensions are corresponding Fig 37 Gerapid 2607 4207 with vertical terminals dimensions in mm and inches ...

Page 34: ...ign and specifications are subject to change without notice 01 2008 5 2 7 Gerapid 6007 terminals Gerapid 6007 is available only with V V terminals Fig 38 Gerapid 6007 with vertical terminals dimensions in mm ...

Page 35: ... Design and specifications are subject to change without notice 35 5 2 8 Gerapid 8007 terminals Gerapid 8007 is available only with V V terminals Fig 39 Gerapid 8007 with vertical terminals dimensions in mm and inches ...

Page 36: ... pre arcing contact It shall not exceed 2mm 0 08in Check out wear of the main contacts at fix and flexible side shall not ex ceed 1mm 0 04in of its depth Check out wear of the arc chute s plates check out for deposits inside of arc chute this area shall be free of deposits Check out wear of protective walls shall not exceed 1mm 0 04 Check out contacts tilt and gaps D Inspection of the screw connec...

Page 37: ...ig 40 Using of the hand lever Switch remotely the breaker ON and OFF several times using ST or UVR and using closing drive The contacts must close after the CLOSE command and must open following the OPEN command The breaker mechanism must not appear sluggish nor must ON OFF be unduly delayed 6 1 3 Inspection of the arc chute Pay attention to the warnings Section 1 A Remove the arc chute Fig 41 Loo...

Page 38: ... and at contact point with pre arcing contact 2 E Check the pre arcing contact Fig 44 Wear of the pre arcing contact 1 must not exceed 2mm 0 08in of its depth Replace the pre arcing contact in that case If the burn out exceeds 4mm 0 16in it might lead to major contact system s failure F Check the main contacts Fig 44 The main contacts 4 shell not shown any particular signs of material erosion sinc...

Page 39: ... please contact GE Service Team D Install back adapter and arc chute See 6 1 4 G H 6 1 6 Inspection of the screw connections Pay attention to the warnings Section 1 Fig 41 Tighten front and backside of the arc runner screw connections 3 and 5 Use torque of 10Nm 88lbf in Fig 41 Tighten arc chute connections 4 Use torque of 5Nm 44lbf in Fig 41 The arc runner s screw connections 3 must be secured by ...

Page 40: ...ction B E Table 4 Required tools Cleaning tissue Pocket lamp Hand lever Hexagon wrench SW 4 SW 5 SW 6 Screw wrench SW 10 SW 13 Small and medium screwdriver Pliers Wire cutter File Steel brush 6 2 1 Maintenance of contact system after 11 2003 Pay attention to the warnings Section 1 This section is valid for breakers manufactured after 11 2003 This section refers to maintenance works A B C from Tabl...

Page 41: ... in E Install the arc chute Fig 49 Put in arc chute 1 into adapter 2 Fig 49 Tighten front and backside connections of the arc arc runners 3 including lock washer use 10Nm 88lbf in Fig 49 Tighten front and backside of the arc chute connections 4 including flat washers use 5Nm 44lbf in Fig 48 Adapter and protective walls Fig 49 Arc chute and arc runners fixing Fig 50 Changing pre arcing contact 8 3 ...

Page 42: ...screws 6a with tool SW4 and take out front wall 6 Fig 51 2 Loosen screw 5a with tool SW5 Fig 51 1 Take out the front arc runner as it s shown Fig 51 2 Take out the back arc runner 4 by loosen two screws 4a with tool SW5 Don t remove the pro tective cap 4b Fig 51 2 Install new front arc runner 5 and new back arc runner 4 Tighten it using torque of 10Nm 88lbf in Fig 51 2 Install front wall 6 and adj...

Page 43: ...g 52 1 Unscrew cooper braid Fig 52 2 Remove safety ring Fig 52 3 R emove axis Fig 52 4 Replace pre arcing contact with new one Use old contact to lift up two washers and slip the new contact under these Remove old contact and ro tate the new one by 180 to its normal orientation Fig 52 2 3 Install back the axis and safety ring Fig 52 5 Initially screw in braid s screws by hand Fig 52 6 Tighten thes...

Page 44: ...730 R2 R4 equipment to right 3 SU control unit 128 700 equipment to left 4 SU control unit 128 700 equipment to right 5 6 SEL control unit 128 785 R1 R2 equipment to left Table 6 Layout of control PCBs inside the box with SEL Attention The isolation plates between the control boards and at the wall of the box have to be always present In older systems it may be the control boards are in stalled 18...

Page 45: ...nserted Fig 55 6 Plug in all control plugs and tighten it by the bolts Fig 55 7 Pay attention that no cables will be crisped between box and front cover during closing Fig 55 8 Carefully close the control box with the front cover and fix the four screws Put on plugs X2 X6 fix the screws of the plugs and switch on control voltage Checking the breaker Make 3 times ON OFF switching in the Test positi...

Page 46: ...en screws 4 on the side which needs to be re adjusted Turn the proper left or right adjust ing screw 5 clockwise until all missing signals switch over Warning Too much turning in may effect with full pressing of the switches pin and its breakdown Fig 56 1 Check the correct signalization of all switches at the connecting plug terminations X4 X5 If necessary re adjust the switches from other side No...

Page 47: ...13 2X2S 2000V 2x_ 128 550 R15 Arc Chute EF4 12 3900V EF4 12 124 900 R17 SU control PCB ALL N A 128 700 ST control PCB ALL N A 128 710 R01 UVR contro PCB ALL N A 128 710 R02 Interface Plug External supply 24VDC 5 N A 128 730 R01 PCMD 150 24 S24W GE N A 128 730 R02 PCMD 150 48 S24W GE N A 128 730 R03 PCMD 150 110 S24W GE N A 128 730 R04 Voltage Converter PCMA 150 70 S24W GE N A 128 730 R05 Standard ...

Page 48: ...108 pole Harting 4 DAD Connector 2 2 1X3 1500V 5 2X3 3000V E On Request R 3 1X4 2000V 6 2X4 3600V Counter code 18 Drive Supply Voltage Code 3 Without 0 1 48 V DC 5 220 V DC 9 125 V AC With Mechanical Counter 1 2 60 V DC 6 250 V DC A 230 V AC With Electronic Counter Battery 2 3 110 V DC 7 110 V AC B 240 V AC 4 125 V DC 8 120 V AC R On Request Arc Chute Indicator Code17 With 1 Without 0 Connectors C...

Page 49: ...ntal vertical SEL Type 35 C TSEL 55 C without SEL Overcurrent Trip Fixed 1 12 kA Polarized adjustable 0 4 1 2 kA Adjustable 1 12 kA Polarized adjustable 0 8 2 5 kA Fixed 12 24 kA Polarized adjustable 2 0 6 0 kA KSA Adjustable 12 24 kA Polarized adjustable 4 0 8 0 kA Calibrated values Without Trip Unit Minimum 200A range between settings Polarization Top Connector Not apply POL Top Connector Voltag...

Page 50: ...range between 6kA 12kA with 7 marks on the scale every 1kA set at 9kA 7 With TOP terminal polarized as 8 With internal voltage converter at Uin 230VAC there is no 24VDC available at the installation 9 With 10 auxiliary switches 10 With OCT indicator 11 With zero voltage release UVR 12 Without electrodynamic tripping device 13 With forced tripping release for withdrawal opera tions 14 With contacts...

Page 51: ...ent tripping unit OCT set perma nently at 9kA 7 With TOP terminal polarized as 8 Without voltage converter Customer wants to sup ply controls directly from his source of 24VDC 5 9 With 3 auxiliary switches 10 With OCT indicator included 11 With shunt trip supply from external 24VDC 5 12 With electrodynamic coil and internal C bank NEKO control PCB 13 Without forced tripping release for withdrawal ...

Page 52: ...ion This is realized by means of auxil iary tripping devices OCT or hand lever Over Current Tripping unit also OCT It s an instantaneous and direct mechanical release tripping the breaker in case of overloads and short circuits It is adjustable within predeter mined range Opening time depends of short circuit conditions and shall not exceed 5ms It does not need any imported en ergy and is activate...

Page 53: ...is not pos sible to keep contacts closed 1 Check the forced tripping release if installed Per manently blocked tripping device during closing op eration will effect with mechanism failure and con tacts opening 2 Check contact system area Look for any part is stuck between contacts or into mechanism module 3 If the zero voltage release is installed in please check connection of S2 pushbutton If onl...

Page 54: ...54 Design and specifications are subject to change without notice 01 2008 GE Consumer Industrial GmbH Berliner Platz 2 6 D 24534 Neumünster Germany Phone 49 4321 201 0 Fax 49 4321 201 444 ...