GE MicroVersaTrip PM AK-100, Installation Instructions Manual

Page 1: ...ing the latest techno logical advancement in GE trip systems MicroVersaTrip Plus and MicroVersaTrip 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 installa tion of MicroVersaTrip Plus and PM Conversion Kits on GE Types AK 50 AKU 50 AKS 50 AKT 50 AK 75 and AK...

Page 2: ...munications Harness 4 11 4 5 8 9 10 11 SECTION 4 BACK FRAME CONVERSION Modifying the Crossbar Installing Phase Sensors 12 14 12 13 14 SECTION 5 FOUR WIRE GROUND FAULT OPTION Stationary Breaker Conversion Draw Out Breaker Conversion Installing Neutral Sensors 15 18 15 16 17 18 SECTION 6 EQUIPMENT CONVERSION Installing Mounting Brackets 19 20 19 20 SECTION 7 INSTALLING THE PROGRAMMER 21 SECTION 8 TE...

Page 3: ...mpting 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 ca...

Page 4: ...trically operated breakers with EC trip devices 3 Installing the flux shifter and trip paddle 4 Installing the programmer mounting bracket 5 Installing the programmer wire harness 6 Installing the communication wire harness when required X a cz w V1 x i I BEFORE I CD CD Relocating remounting W and X Relays a Remove the W Relay and install the mounting bracket supplied with the conversion kit to th...

Page 5: ...r connector bracket as shown in Fig 3 10 BREAKERS WITH A SIDE BRACKET Drill a hole diameter into the mounting base Fig 3 3 This will provide the necessary clearance for the bracket The hole locations are given in Fig 3 5 Remove the side bracket from the frame and drill holes as shown in Fig 3 4 Return the side bracket to its original location upon completion of this step Install the new flux shift...

Page 6: ... wire Wire splice 12 butt splices Wire labels Drill and size F drill bit is 18 tap Flathead screwdriver Two r i6 18 bolts and lock washers To remount the terminal block Step 1 Drill and tap two 2 holes for the Yi6 18 nuts See Fig 3 6 for hole locations Step 2 Separate the Open Fuse Lock Out OFLO device by removing the three bolts shown in Fig 3 7 Step 3 Remove the wires that connect the OFLO devic...

Page 7: ...ST TRIP SYSTEMS Step 1 Remove the ECS or SST Programmer Step 2 Remove the existing flux shifter device and the pro grammer control harness Step 3 Install the new flux shifter device positioning the insulator and programmer connector bracket as shown in Fig 3 10 EC OR POWER SENSOR TRIP SYSTEMS Step 1 Drill the flux shifter mounting holes at the left side of the front frame The drill pattern for the...

Page 8: ...le and the end of the flux shifter rod at 0 100 inches Use a 0 100 inch diameter rod not supplied as shown in Fig 3 12 Set the adjuster end of the trip rod and lock it in place with the jam nut Note that removal of the buffer stud will make the trip paddle easier to install and adjust 2 As the crossbar travels between the breaker CLOSED and the breaker OPEN positions the tang of the actuator brack...

Page 9: ...Fig 3 14 If the manual indicator assembly busing on AJK 50 manual breakers interferes with the mounting bracket installation Fig 3 14 then the bracket will have to be modified This is accomplished by cut ting off a K x 1V2 section off the right front of the plate as shown in Fig 3 15 EC OR POWER SENSOR TRIP SYSTEMS The holes for the new plate may have to be added to the front channel The drill pat...

Page 10: ...de Route the harness under the flux shifter base At tach the harness to this base using the wire keepers provided Install the programmer harness as shown in Fig 3 10 Include the flux shifter leads with this harness Join the 4 pin connector on the programmer har ness to the 4 pin connector on the flux shifter Assemble the programmer bracket to the mounting bracket as shown in Fig 3 17 NOTE LOCATION...

Page 11: ...ll type breakers Figures 3 20 through 3 21 are representative examples of harness connections and routing directions They are not meant to be all inclusive A caution label Fig 3 22 should be mounted on both the breaker door and the compartment door as a warning to prevent unnecessary7 damage Note Hole locations for bracket mounting as shown for reference only The positioning of the commu nication ...

Page 12: ...ux shifter s reset linkage is driven by the ac tuator bracket See Fig 3 3 The actuator bracket must be assembled to the left side link of the left pole as shown in Fig 4 1 If the actuator bracket mounting holes are not in the left side link the holes must be added Drill and tap two 5 i6 18 holes using the hole pattern give in Fig 4 2 Fig 4 1 Flux Shifter Actuator Bracket Installation Fig 4 2 Actua...

Page 13: ...4 4 Fig 4 3 Lower Adapter Connector AK 50 AKS 50 BREAKERS WITH SST TRIP SYSTEMS Step 1 Replace the existing SST phase sensor with the new MicroVersaTrip phase sensor provided Step 2 Install as shown in Fig 4 4 NOTE Occasionally during current sensor manufacturing a slight separation may occur between the epoxy and plastic shell This may amount to as much as 0 030M and has no effect on performance ...

Page 14: ...e MicroVersaTrip RMS 9 sensors mount on the upper breaker studs The sensors are held on the stud with the locking rings as shown in Fig 4 5 Leave enough of the stud exposed for the primary fingers to engage Engage the sensor s anti turn lugs with the notch in the locking ring Before tighten ing the locking rings position each sensor so that its leads will exit between the pole bases as shown in Fi...

Page 15: ...TERMINAL BOARD i MOUNTING HARDWARE 4 TYPES AK 50 AKS 50 STATIONARY BREAKERS The 4th wire disconnect for stationery breakers con sists of terminal board mounted to the lower front channel as shown in Fig 5 1 Step 1 If the terminal board already exists just replace the control harness Maintain the following color code White Common Black Tap Step 2 If the terminal board assembly is being added mount ...

Page 16: ...to the breaker Figures 5 3 5 4 depict the two designs The Conversion Kit contains an assembled ready to install mounting block and bracket for AKD 5 or AKD 6 installation plus a bracket only for type AKD equipment installations For type AKD equipment remove the bracket from the assembled bracket and mounting block furnished with the conversion kit and replace it with the type AKD bracket The 4th w...

Page 17: ...I WHITE COMMON WHITE WIRE BLACK WIRE GREEN I TIE MOUNTING HOUSING Ol P lO Oi MOUNTING HOUSING I WHEN USED THE 4TH WIRE NEUTRAL SENSOR DISCONNECT BLOCK MOUNTS ON TOP OF TAP TERMINAL BOARD VIA ITS 2 LOWER MOUNTING SCREWS THE AKD 5 TYPE MOUNTING IS ILLUSTRATED THE ARRANGEMENT FOR AKD TYPES IS IDENTICAL EXCEPT FOR USE OF A DIFFERENT MOUNTING BRACKET Fig 5 5 AK 75 AK 100 Back Frame Conversion 17 Courte...

Page 18: ...n the phase sen sors the taps on the neutral sensor must be corre spondingly positioned For kits with fixed phase sen sors be sure to use the corresponding tap on the neutral sensor Mount the neutral sensor in the outgoing neutral lead normally in the equipment s bus or cable com partment see Fig 5 6 and 5 7 Pig 5 6 Outline of the AK 75 AK 100 Neutral Sensor 18 Courtesy of NationalSwitchgear com ...

Page 19: ...DIA HOLES MAX STRAP 1 25 MAX STRAP 3 33 ref 1 25 I i i i V i 1 625 m 625 I I 1 18 ref TERMINAL BLOCK 1 75 1 75 88 4 75 I GI T I GI 3 75 MAX I GI 1 75 3 25 I GI y V p I CGI 11 25 Fig 5 7 Neutral Sensor Outline for AK 50 19 Courtesy of NationalSwitchgear com ...

Page 20: ...ar applica tions are supplied in the conversion kit See Figs 6 1 through 6 5 for mounting diagrams 229 230 231 232 233 i 235 1 236 i 237 238 239 CENTER LEFT PHASE SENSOR TERMINAL BOARD PHASE SENSOR TERMINAL BOARD POLE POLE L CENTER LEFT POLE POLE REAR OF BREAKER I 230 REAR OF 9 75 BRACKETS i COMPARTMENT DRILL 2 0 261DIAMETER HOLESIN COMPARTMENT 225 232 i REAR OF BREAKER 233 AK75 7 00 AK100 9 75 22...

Page 21: ...ETER HOLES IN COMPARTMENT REAR OF BREAKER 230 6 00 232 235 235 225 233 246 238 A 237 226 i m 231 246 i i i f 3 75 0 44 5 12 0 88H 7 COMPARTMENT 8 62 SIDE VIEW OF COMPARTMENT VIEW LOOKING AT REAR OF COMPARTMENT DIMENSIONS IN INCHES Fig 6 4 AK 50 AKS 50 4th Wire Disconnect Type AKD CENTER LEFT POLE REAROF BREAKER POLE 230 232 6 00 225 233 DRILL 2 0 224 DIAMETER HOLES IN COMPARTMENT COFBFACKEL l 226 ...

Page 22: ...rogrammer This will engage the connectors and release the locking lever which will move upwards Step 2 Verify that the locking lever actually engaged the programmer pin To remove the programmer move locking lever to horizontal position thus releasing the programmer pin Then remove the programmer TYPE AK 75 AK 100 BREAKERS The AK 75 AK 100 mounting bracket is shown in Fig 7 2 To install Step 1 Inse...

Page 23: ...test kit Cat No TVTS1 or TVRMS on this programmer False Tripping Breakers Equipped with Ground Fault When nuisance tripping occurs on breakers equipped with the ground fault trip element a probable cause is the existence of a false ground signal Each phase sensor is connected to summing circuitry in the programmer Under no fault condi tions on 3 wire load circuits the currents add to zero and no g...

Page 24: ...ed 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 lowrer 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 carrying only that neutral current associated with the break...

Page 25: ...CONNECTIONS FOR GROUND FAULT OPTION ONLY 9 68 0 02 O4 05 R W H E COMM NET I D T 24Vdc POWER E ABC 30 VOLTAGES J il t w 9 O r 0 x1 C FLUX SHIFT TRIP DEVICE 0 CONNECTIONS FOR COMMUNICATIONS OPTION ONLY IC 1 O B r 0 I 4 WTRr LOAD B A A 0 J 0 0 BREAKER BACK FRAME NEUTRAL SENSOR DISCONNECT LEFT POLE CURRENT SENSOR 0 NEUTRAL TAP COM LOAD LINE o o EQUIPMENT MOUNTED NEUTRAL SENSOR Fig 8 1 Cabling Diagram ...

Page 26: ...ation 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 V GE Electrical Distribution Control General Electric Company 41 Woodford Ave Plainville CT 06062 1994 General Electric Company GEH 5965A 1194 PSA Courtesy of NationalSwitchgear com ...