GE Power Break 1 Manual

							g
Power Break® Circuit Breakers
800–2000 A Frames, 240–600 Vac
                                                            
GEH–4693D
User’s Guide 
						

							i
GEH–4693D
WARNINGS, CAUTIONS, AND NOTES
AS USED IN THIS PUBLICATION
WARNINGS
Warning notices are used in this publication to emphasize that hazardous voltages, currents, or
other conditions that could cause personal injury or death are present in this equipment or may be
associated with its use.
Warning notices are also used for situations in which inattention or lack of equipment knowledge
could cause either personal injury or damage to equipment.
CAUTIONS
Caution notices are used for situations in which equipment might be damaged if care is not taken.
NOTES
Notes call attention to information that is especially significant to understanding and operating
the equipment.
This document is based on information available at the time of its publication. While efforts have
been made to ensure accuracy, the information contained herein does not cover all details or varia-
tions in hardware and software, nor does it provide for every pos sible contingency in connection
with installation, operation, and maintenance. Features may be described herein that are not pres-
ent in all hardware and software systems. GE Industrial Systems assumes no obligation of notice  t o 
holders of this document with respect to changes subsequently made.
GE Industrial Systems makes no representation or warranty, expressed, implied, or statutory, with
respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness
of the information contained herein. No warrantees of merchantability or fitness for purpose shall
apply.
The following are trademarks of GE Company:
Power Break®, MicroVersaTrip Plus™ , MicroVersaTrip PM™, MagneTrip™, MicroVersaTrip®
© 1998 GE Company
All Ri
ghts Reserved 
						

							Power Break® Circuit Breakers
Table of Contents
ii
Chapter 1. Receiving and Installation
1–1 Overview................................................................................................................................1
1–2 Receiving the Breaker............................................................................................................. 1
Storage............................................................................................................................ 1
1–3 Installation............................................................................................................................. 1
Bolted Electrical Connections............................................................................................ 1
Breaker Mounting............................................................................................................. 1
Chapter 2. Breaker Operation
2–1 Standard Features................................................................................................................... 3
2–2 Operating Instructions............................................................................................................ 3
Sequence of Operations..................................................................................................... 3
Operating Instructions for Manually Charged Breakers........................................................ 4
Operating Instructions for Electrically Charged Breakers..................................................... 4
Wiring Notes.................................................................................................................... 5
Application Notes............................................................................................................. 6
2–3 Trip Unit Setup...................................................................................................................... 6
MicroVersaTrip® and MicroVersaTrip® RMS-9 Trip Units.................................................. 6
MagneTrip™ Trip Units.................................................................................................... 9
MicroVersaTrip Plus™ and MicroVersaTrip PM™ Trip Units............................................... 9
Chapter 3. Accessories
3–1 Introduction.........................................................................................................................10
3–2 Circuit Breaker Cover.............................................................................................................10
Breaker Cover Removal....................................................................................................10
Breaker Cover Reassembly................................................................................................11
3–3 Shunt Trip Device..................................................................................................................12
Mounting Plate Removal..................................................................................................12
Shunt Trip Installation.....................................................................................................13
Mounting Plate Installation..............................................................................................13
3–4 Undervoltage Release Device..................................................................................................14
UVR Installation..............................................................................................................14
3–5 Blown-Fuse Trip Device..........................................................................................................15
Blown-Fuse Trip Device Installation...................................................................................16
3–6 Auxiliary Switch.....................................................................................................................16
Auxiliary Switch Installation.............................................................................................17
3–7 Remote Close Solenoid and Remote Charge Indication............................................................18
3–8 Optional Features..................................................................................................................18
Limited Close Access Button.............................................................................................18
Padlock Function.............................................................................................................19
Chapter 4. Maintenance
4–1 Inspections............................................................................................................................20
4–2 Lubrication...........................................................................................................................20 
						

							Power Break® Circuit Breakers
List of Figures and Tables
iii
Figures
1. Circuit breaker with lifting straps in place................................................................................................ 1
2. Location of mounting bolt inserts on 800 A frame breakers....................................................................... 1
3. Location of mounting bolt inserts on 1600–2000 A frame breakers............................................................. 2
4. Manually charged breaker...................................................................................................................... 3
5. Motor operator-charged breaker............................................................................................................. 3
6. Motor operator charged breaker with the top cover removed..................................................................... 3
7. Bell alarm wiring to prevent continuous cycling of the automatic charging mechanism............................... 5
8. Wiring for optional bell alarm lockout applications................................................................................... 5
9. Tap changer cards.................................................................................................................................6
10. Cover and trip unit removed from the breaker......................................................................................... 7
11. Neutral CT connection for four-wire ground fault..................................................................................... 7
12. Wiring diagram for MicroVersaTrip and MicroVersaTrip RMS-9 trip units with ground fault on a
top-fed four-wire load............................................................................................................................. 8
13. Wiring diagram for MicroVersaTrip and MicroVersaTrip RMS-9 trip units with ground fault on a
bottom-fed four-wire load....................................................................................................................... 8
14. Releasing the trip unit interlock to remove or install the trip unit............................................................... 8
15. Aligning the trip unit to the mounting plate............................................................................................ 9
16. Adjusting the settings on a MagneTrip trip unit........................................................................................ 9
17. 800 A frame electrically operated breaker................................................................................................10
18. 1600–2000 A frame electrically operated breaker.....................................................................................11
19. 1600–2000 A frame electrically operated breaker with the outer cover removed..........................................11
20. Wire ties on the accessory leads and mounring plate insulator..................................................................11
21. Crossbar hook engaging the drive hook..................................................................................................11
22. Shunt trip device with cut-off switch........................................................................................................12
23. Shunt trip wiring diagram.....................................................................................................................12
24. Locations of the mounting plate retaining screws, isolation barrier, and molded drive crank.......................12
25. Shunt trip coil position with no blown-fuse trip device..............................................................................13
26. Shunt trip coil position with blown-fuse trip device..................................................................................13
27. Attaching the switch bracket to the arm stop...........................................................................................13
28. Undervoltage release device...................................................................................................................14
29. Dropping resistor supplied with 240–600 V UVRs.....................................................................................14
30. UVR wiring diagram.............................................................................................................................14
31. Slide reset lever and spring on the mounting plate...................................................................................15
32. Positioning the UVR assembly on the mounting plate..............................................................................15
33. Installing the UVR mounting screw........................................................................................................15
34. Blown-fuse trip device accessory..............................................................................................................15
35. Blown-fuse trip device wiring diagram.....................................................................................................16
36. Auxiliary switch....................................................................................................................................16
37. Auxiliary switch wiring diagram.............................................................................................................17 
						

							Power Break® Circuit Breakers
List of Figures and Tables
iv 38. Trip unit removed from the breaker.......................................................................................................17
39. Installing the auxiliary switch assembly...................................................................................................17
40. Securing the auxiliary switch assembly....................................................................................................17
41. Wiring diagram for remote charge indication.........................................................................................18
42. Wiring diagram for remote charge indication with remote close solenoid..................................................18
43. Limited close access button....................................................................................................................18
44. OFF button padlock with panel door interlock........................................................................................19
45. Defeating the OFF button padlock.........................................................................................................19
Tables
1. Weights of the various breaker frame sizes, with and without a motor operator............................................ 1
2. Bolt sizes and mounting torques for bus connections................................................................................ 1
3. Sequence of operations that may be performed with Power Break circuit breakers....................................... 4
3. Application data for control power.......................................................................................................... 5
4. Accessory lead color codes.....................................................................................................................10
5. Shunt Trip electrical characteristics........................................................................................................12
6. UVR electrical characteristics.................................................................................................................14
7. Auxiliary switch electrical characteristics.................................................................................................17
8. Catalog numbers and ratings for the remote close solenoid......................................................................18 
						

							Power Break® Circuit Breakers
Chapter 1. Receiving and Installation
1
1–1 Overview
The Power Break® line of insulated-case circuit breakers
is designed to protect low-voltage power circuits and
equipment. Current models are offered with Magne-
Trip™, MicroVersaTrip Plus™, and MicroVersaTrip PM™
trip units for fault detection.
1–2 Receiving the Breaker
Unpack the circuit breaker and inspect it for shipping
damage. Ensure that the breaker has the proper current,
voltage, and interruption ratings for the application.
The weights of the various frame sizes are listed in Table
1, for reference. Figure 1 shows a breaker with straps for
lifting.
CC C C
AA A A
UU U U
TT T T
II I I
OO O O
NN N N
::: : Do not attempt to lift the circuit breaker by
its operating handle.
Frame
Rating, A Type Weight, lbs
800Manual
Electric50
64
1600Manual
Electric82
96
2000Manual
Electric88
102
Table 1. Weights of the various breaker frame sizes, with and
without a motor operator.
Figure 1. Circuit breaker with lifting straps in place.
Storage
The breaker should be placed in service immediately in its
permanent location. However, if it must be stored for an
indefinite period, it should be carefully protected againstcondensation, preferably by storage in a warm, dry room.
Circuit breakers for outdoor equipment should be stored
in that equipment only when power is available and heat-
ers are in operation, to prevent condensation.
The breaker should be stored in a clean location, free
from corrosive gases or fumes. In particular, protect the
breaker from moisture and cement dust, as that combina-
tion may be corrosive.
If the breaker is stored for any length of time, it should be
inspected periodically to ensure good mechanical condi-
tion.
1–3 Installation
Bolted Electrical Connections
Using an industry-accepted solvent, remove any foreign
material from the line and load strap surfaces and the
corresponding surfaces of connecting bus and terminal
studs. Ensure that the mating surfaces are smooth and
free of burrs and nicks.
Place the bus connections in position and align the
mounting holes. Insert and fasten the mounting bolts and
washers according to the specifications in Table 2.
Bus Connection
Breaker Frame, A Bolt Dia. Torque, in-lbs
800 (1) 1/2 in 300
1200–1600 (2) 1/2 in 300
2000 (4) 1/2 in 300
Table 2. Bolt sizes and mounting torques for bus connections.
Breaker Mounting
For mounting the circuit breaker, use the four 1/4-20 x 1/2-
inch-deep inserts in the back of the breaker. The locations
of the inserts are shown in Figures 2 and 3 for the two
frame sizes. Tighten the mounting bolts to 50 in-lb.
Figure 2. Location of mounting bolt inserts on 800 A frame breakers. 
						

							Power Break® Circuit Breakers
Chapter 1. Receiving and Installation
2
Figure 3. Location of mounting bolt inserts on 1600–2000 A frame
breakers. 
						

							Power Break® Circuit Breakers
Chapter 2. Breaker Operation
3
2–1 Standard Features
Power Break circuit breakers are equipped with the follow-
ing standard features. The letters are keyed to the breaker
illustrations in Figures 4, 5, and 6.
AA A A
Indicator
ON – Red
CHG (manual) – yellow
CHARGED (electrical) – yellow
OFF – Green
BB B B
ON button
CC C C
OFF button
DD D D
Manual charging handle
EE E E
Lockable manual charge engagement button (motor
operated only)
FF F F
Terminal board (motor operator drive unit)
GG G G
Removable protective window
JJ J J
CT tap setting indicator (MicroVersaTrip only)
KK K K
Removal protective trip unit cover (Magnetrip™
only)
LL L L
Cover mounting screws (four)
MM M M
Midcover mounting screws (three – motor operated
only)
NN N N
MicroVersaTrip RMS-9 trip unit interchangeable rat-
ing plug
OO O O
Motor operator control circuit fuses
PP P P
MicroVersaTrip RMS-9 test set connection port
Figure 4. Manually charged breaker.
Figure 5. Motor operator-charged breaker.
Figure 6. Motor operator charged breaker with the top cover
removed.
2–2 Operating Instructions
Sequence of Operations
The sequence of operations that may be performed on the
circuit breaker is listed in Table 3. 
						

							Power Break® Circuit Breakers
Chapter 2. Breaker Operation
4
IndicatorMain Breaker
ContactsCondition of
Charging Springs Next Permissible Operating Function
OFF Open Discharged Mechanism may be charged
CHARGED / CHG Open Fully Charged Contacts may be closed
ON Closed Discharged Contacts may be opened
Table 3. Sequence of operations that may be performed with Power Break circuit breakers.
Operating Instructions for Manually
Charged Breakers
Charging the Mechanism Springs
Rotate the operating handle counter-clockwise until the
handle stops (about 120° ). Rotate the handle clockwise
back to its home position. 
This operation will NOT close
the contacts and turn the breaker 
ON. The indicator will
display 
CHG.
CC C C
AA A A
UU U U
TT T T
II I I
OO O O
NN N N
::: : If the breaker latch is held in the tripped
position by any of the following accessories, the
mechanism springs will discharge at the end of the
charging stroke and the breaker will revert to the OFF
condition.
• The key interlock or padlock is in the locked OFF con-
dition.
• On a draw-out breaker, the draw-out interlock  is
engaged with the carriage in any position except TEST
or ENGAGED.
• The bell alarm lockout was not reset after an overcur-
rent lockout.
• The undervoltage release is not energized.
These conditions must be corrected before the breaker
can be closed. Failure to do so may result in equipment
damage.
Closing the Breaker
Close the breaker contacts with either of the following
methods:
• Depress the 
ON button on the breaker escutcheon.
• Energize the (optional) remote close accessory by
connecting terminal 5 to terminal 6.
Opening the Breaker
Open the breaker contacts with either of the following
methods:
• Depress the 
PUSH  OFF button on the breaker
escutcheon.
• Energize the (optional) shunt trip accessory or deen-
ergize the (optional) undervoltage release accessory.
Operating Instructions for Electrically
Charged Breakers
Charging the Mechanism Springs
Charge the mechanism springs with either of the follow-
ing methods:
•
Local
– Depress the lockable manual charge engagement
button until it is flush with the handle surface.
Slight rotation of the handle may be necessary to
fully depress the button in order to align the
internal coupling.
– Hold the button down and rotate the operating
handle counter-clockwise until the handle stops
(about 120°). Rotate the handle clockwise back to
its home position. 
This operation will NOT close
the contacts and turn the breaker 
ON. The
indicator will display 
CHARGED.
•
Remote – Connect terminal 3 to terminal 4 to
energize the motor operator mechanism.
Closing the Breaker
Close the breaker contacts with either of the following
methods:
• Depress the 
ON button on the breaker escutcheon.
• Energize the (optional) remote close accessory by
connecting terminal 5 to terminal 6.
Opening the Breaker
Open the breaker contacts with either of the following
methods:
• Depress the 
PUSH  OFF button on the breaker
escutcheon.
• Energize the (optional) shunt trip accessory or deen-
ergize the (optional) undervoltage release accessory.
Automatic Operation
For automatic closing of the breaker when the springs are
charged, permanently connect terminal 5 to terminal 6.
The breaker will close as soon as the charging cycle is
complete.
For automatic charging of the closing springs, perma-
nently connect terminal 3 to terminal 4. The springs will