GE Power Break 1 Manual
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Power Break® Circuit Breakers Chapter 2. Breaker Operation 5 charge as soon as the breaker is opened, whether from a fault trip or from being intentionally opened. CC C C AA A A UU U U TT T T II I I OO O O NN N N::: : Do not wire breakers for both automatic charge and automatic close unless a bell alarm with overcurrent lockout is incorporated. Otherwise, the breaker may repeatedly close into an overcurrent fault. CC C C AA A A UU U U TT T T II I I OO O O NN N N ::: : The bell alarm lockout and undervoltage release both hold the breaker latch open when activated. To prevent continuous cycling (see Application Notes) when the breaker is wired for automatic charging, inter- connect the bell alarm switch to the motor operator ter- minal board as shown in Figures 7 and 8. NN N N OO O O TT T T EE E E ::: : The motor operator contains a feature that shuts off control power if the OFF button is held depressed. Thus, electrical operation is prevented if a key interlock or padlock accessory is applied in the breaker OPEN con- dition. If the breaker is equipped with a draw-out inter- lock (TPDO-1), electrical operation is permitted only if the draw-out carriage is in the ENGAGED or TEST posi- tion. Figure 7. Bell alarm wiring to prevent continuous cycling of the automatic charging mechanism. Figure 8. Wiring for optional bell alarm lockout applications. Wiring Notes Observe the following notes when wiring the breaker for operation: • Customer-supplied contacts (such as CHARGE and CLOSE) should be momentary action, rated for 0.25 A at 125 Vdc for dc motor operators or rated for 3 A at 120 Vac for ac motor operators. • Do not apply power to any terminal board point other than points 1 and 2. • Observe the proper polarity for dc motor operators (point 1 is positive). • When performing hi-pot or dielectric tests: – Remove all power leads, both control and power. – Short all motor operator terminal board points. – Open the circuit breaker. – Test between the motor operator terminal board points and the load side of the breaker’s center pole (this pole is connected to the frame). – Test at 2200 Vac for one minute using a current- limited, nondestructive ac hi-pot tester with maximum output of 20 mA. OperatingMotor Current, A Close Nominal Maximum Maximum Rated VoltageVoltage RangeLocked RotorFull Load AverageSolenoid, peak AFuses (Slo Blo 125 V)Charge Time , sClose Time, sOpening Time, s 120 Vac 102–132 8 2.5 1.5 3.0 2 A 5.0 0.83 0.05 125 Vdc 100–140 10 2.5 1.5 3.5 2 A 6.0 0.83 0.05 72 Vdc 57–81 13 3.0 2.0 5.0 3 A 6.0 0.83 0.05 48 Vdc 38–58 20 5.0 2.5 6.6 4 A 6.0 0.83 0.05 24 Vdc 19–29 24 7.0 3.0 13.2 6.25 A 7.5 0.83 0.05 Table 3. Application data for control power.
Power Break® Circuit Breakers Chapter 2. Breaker Operation 6 Application Notes • Size the control power source according to the information in Table 3. If a single source is to supply several motor operators, it must be sized appropri- ately. Where breakers are wired for automatic charge, it may be necessary to supply power to several motor operators simultaneously during start up. • The control power source should be sized so that the drop in voltage from no load to full load does not exceed 7%. • Acceptable dc power sources are the following: – dc generator, – battery, – three-phase, full-wave rectified ac, or – any other dc power source with a peak-to-peak ripple voltage of not more than 15% of the rated voltage at motor full-load current. • Breakers built after approximately June 1978 are equipped with an anticycling circuit that will lock out the breaker if the latch fails to reset (such as due to a deenergized UVR). Lockout occurs if the charge time exceeds 20 seconds. Reset a locked-out breaker locally by pushing the OFF button or remotely by momentarily removing control power from the motor operator. 2–3 Trip Unit Setup NN N N OO O O TT T T EE E E ::: : MicroVersaTrip RMS-9 trip unit rating plugs may be changed per GEH-5369 and GEH-5371 without void- ing the UL listing. MicroVersaTrip trip units and tap changer cards may be installed or replaced per GEH- 4657 and this manual without voiding the UL listing. MicroVersaTrip Plus and MicroVersaTrip PM trip units and rating plugs may be changed or replaced per GEH- 6273 without voiding the UL listing. MicroVersaTrip® and MicroVersaTrip® RMS-9 Trip Units Trip settings are installed at the factory with minimum values on all functions. Customers will generally want to adjust settings to their own requirements. Adjusting Trip Settings Use the following procedure to adjust trip settings on these trip units: 11 1 1 ... . Remove the clear plastic protective window, shown in Figure 4.22 2 2 ... . Change the settings by twisting the indicator switches to the desired values or multipliers. See GEH-4657 for definitions of MicroVersaTrip functions and GEH- 5369 for MicroVersaTrip RMS-9 functions. 33 3 3 ... . Reinstall the window. Rating Plugs MicroVersaTrip RMS-9 trip units require the installation of a rating plug in accordance with GEH-5369 and GEH- 5371 to set the maximum continuous current rating. Tap Changer Card Some MicroVersaTrip models include a tap changer card, shown in Figure 9. When provided, this function allows the customer to change the rating of the breaker frame. Figure 9. Tap changer cards.
Power Break® Circuit Breakers Chapter 2. Breaker Operation 7 All breakers provided with tap cards are shipped with both HIGH (100% of the current rating Sensor Amp on the breaker name plate) and low (50–75% of the current rating Sensor Amp on the breaker name plate). The low card is packed and supported on the breaker handle. The high card is installed in the breaker frame. To change settings use the following procedure: WW W W AA A A RR R R NN N N II I I NN N N GG G G ::: : The circuit breaker must be removed from the electrical system before attempting any operations that involve removing the breaker’s cover. 11 1 1 ... . Turn the breaker off. 22 2 2 ... . Remove the four cover mounting screws and remove the top cover. On motor operator-equipped breakers, remove only the top cover. 33 3 3 ... . Withdraw the card from the tap changer support and replace with the other card, as shown in Figure 10. The print on the top of the card should be oriented the same as the breaker cover name plate. Figure 10. Cover and trip unit removed from the breaker. 44 4 4 ... . Trip units providing ground fault protection must also have the tap setting changed on the tapped neu- tral CT (four-wire systems). Change the black wire lead from the high or low terminal to match the desired tap setting of the breaker frame, as shown in Figure 11. 55 5 5 ... . Replace the breaker cover. 66 6 6 ... . Operate the breaker manually through the charge–close–open cycle to ensure that the breaker is properly functioning mechanically before energizing or connecting it to the electrical system. NN N N OO O O TT T T EE E E ::: : A deenergized undervoltage release will not allow the mechanism to charge and close. 77 7 7 ... . Store the extra tap card in a convenient place. Figure 11. Neutral CT connection for four-wire ground fault. Neutral Current Transformer (Four-Wire Ground Fault System) Ground fault protection is offered as an optional function of the MicroVersaTrip® trip unit. However, all MicroVer- saTrip-generation breaker frames are provided with ter- minal board points for connection to a neutral CT. Do not short these terminals if there is no neutral CT connected. Always match the rating of the CT to the rating of the cir- cuit breaker; specifically, use the following criteria: • Fixed-rated breaker frames – match the neutral CT amp rating to the breaker sensor amp rating. • Tapped or high/low-rated breaker frames – match the neutral CT amp rating to the high/low setting of the breaker sensor amp rating. Note that MicroVersaTrip RMS-9-equipped breakers are not available with inverted construction (formerly desig- nated by Cat. No. suffix B). These breakers may be either top fed, as illustrated in Figure 12, or bottom fed, as illus- trated in Figure 13. NN N N OO O O TT T T EE E E ::: : The neutral CT is mounted in reverse in Figure 13 when the breaker is bottom (reverse) fed. CC C C AA A A UU U U TT T T II I I OO O O NN N N ::: : Match the tapped terminal for the black lead to the tap setting, if provided, on the breaker frame. CC C C AA A A UU U U TT T T II I I OO O O NN N N ::: : Observe the polarity markings on the neutral CT shell and the breaker frame. CC C C AA A A UU U U TT T T II I I OO O O NN N N ::: : When a neutral CT is not used or not required (three-wire ground fault), do not short the ground fault terminal points on the breaker frame. Leave them open as supplied by the factory.
Power Break® Circuit Breakers Chapter 2. Breaker Operation 8 Figure 12. Wiring diagram for MicroVersaTrip and MicroVersaTrip RMS-9 trip units with ground fault on a top-fed four-wire load. Figure 13. Wiring diagram for MicroVersaTrip and MicroVersaTrip RMS-9 trip units with ground fault on a bottom-fed four-wire load. MicroVersaTrip RMS-9 Trip Units The trip units on MicroVersaTrip RMS-9-equipped break- ers are not interchangeable. The breaker rating may be adjusted by changing the rating plug installed in the face of the trip unit. See GEH-5369 and GEH-5371 for instruc- tions. MicroVersaTrip Trip Units MicroVersaTrip-equipped breakers were ordered complete or as a frame and trip unit only. Some trip units and frames have rejection schemes to prevent mismatching of functions. The limits of interchangeability are as follows:• High short-time or H-function trip units may not be used in frames that are not wired for H function (special CTs). • Special trip units for AK breakers with the M (no instantaneous) function may not be used with Power Break breakers. Refer to GEH-4657 for installation or replacement of MicroVersaTrip trip units with remote overload indication and for recommended wiring for zone-selective interlock. To change or install trip units without remote indication, use the following procedure. WW W W AA A A RR R R NN N N II I I NN N N GG G G ::: : The circuit breaker must be removed from the electrical system before attempting any operations that involve removing the breaker’s cover. 11 1 1 ... . Remove the four cover-mounting screws and remove the top cover. On motor-operated breakers, remove only the top cover to replace the trip unit. 22 2 2 ... . Remove the trip unit as follows: aa a a ... . Push in the trip unit-cover interlock, as illustrated in Figure 14. bb b b ... . Lift the trip unit off the mounting plate and ter- minal plug. cc c c ... . The trip unit-cover interlock will now swing out and lock over the base to prevent reinstallation of the breaker cover when no trip unit is installed. Figure 14. Releasing the trip unit cover interlock to remove or install the trip unit.
Power Break® Circuit Breakers Chapter 2. Breaker Operation 9 33 3 3 ... . Install the replacement trip unit as shown in Figure 15: aa a a ... . Align the holes in the bottom of the trip unit with the guide pins in the mounting plate. Lower the trip unit until it is fully down on the mounting plate and the connecting plug is secure. bb b b ... . Push in the trip unit-cover interlock until it locks in place, as shown in Figure 14. NN N N OO O O TT T T EE E E ::: : The trip unit has a stud on the bottom to defeat the trip unit-cover interlock locking spring. Figure 15. Aligning the trip unit to the mounting plate. 44 4 4 ... . Replace the top cover and secure with the four cover- mounting screws. 55 5 5 ... . Operate the breaker manually through the charge–close–open cycle to ensure that the breaker is properly functioning mechanically before energizing or connecting it to the electrical system. NN N N OO O O TT T T EE E E ::: : A deenergized undervoltage release will not allow the mechanism to charge and close. 66 6 6 ... . For trip units with ground fault, a neutral CT must be provided if a four-wire system is to be used. See the section on neutral CTs for instructions and precau- tions. Do not short the ground fault terminals pro- vided on the breaker frame if a neutral CT is not used. MagneTrip™ Trip Units Use the following procedure to change trip settings on MagneTrip trip units: 11 1 1 ... . Remove the protective trip unit cover. 22 2 2 ... . Change the trip setting by rotating the plastic buttons in the base with a screw driver, as shown in Figure 16. 33 3 3 ... . Replace the protective cover. Figure 16. Adjusting the settings on a MagneTrip trip unit. MicroVersaTrip Plus™ and MicroVersaTrip PM™ Trip Units See GEH-6273 for detailed instructions for setting up MicroVersaTrip Plus and MicroVersaTrip PM trip units.
Power Break® Circuit Breakers Chapter 3. Accessories 10 3–1 Introduction These instructions cover the field installation of internally mounted electrical accessories. They are UL listed for use in all 800–2000 A frame Power Break® circuit breakers with MicroVersaTrip® trip units. These accessories may also be installed in 800–1600 A frame Power Break break- ers with MagneTrip™ trip units, but the UL listing is voided. The control leads of internally mounted accessories exit in pigtail form from the side of the breaker. These leads are terminated at the secondary disconnect points of draw-out breakers or at optional terminal blocks when specified for stationary-mounted breakers. All leads are color coded as listed in Table 4. Accessory Lead ColorNo. of Leads Shunt Trip Black 2 Undervoltage ReleaseBlue 2 Auxiliary SwitchWhite – common Red – OPEN (NO) Brown/White – CLOSED (NC)3 per switch Bell Alarm (Overcurrent Lockout)Yellow – common Purple – CLOSED (NC) Brown – OPEN (NO)3 Blown-Fuse Trip (3-Coil Shunt Trip) Line End Load End Phase Red Brown-White A Blue White B Yellow Black C6 Closing Solenoid (Manual Breakers only)White – common Black – remote indication Orange – remote close3 Table 4. Accessory lead color codes. 3–2 Circuit Breaker Cover Before any accessories can be installed in a Power Break circuit breaker, the cover(s) must be removed, as described in the following sections. WW W W AA A A RR R R NN N N II I I NN N N GG G G ::: : Before installing any accessories, completely de-energize the circuit breaker and disconnect it from the electrical circuit. This is mandatory, since the breaker must be ON during certain stages of installation and testing. CC C C AA A A UU U U TT T T II I I OO O O NN N N ::: : Do not turn the breaker upside down, since loose parts may become lost. NN N N OO O O TT T T EE E E ::: : All breakers are equipped with mechanical inter- locks that automatically trip the breaker when the cover is removed with the breaker closed. Breaker Cover Removal Manual Breaker Use the following procedure to remove the cover of a manually operated breaker: 11 1 1 ... . Press the off button to open the circuit breaker. 22 2 2 ... . Remove the four cover-mounting screws. 33 3 3 ... . Remove the breaker cover. Electrically Operated Breaker Use the following procedure to remove the cover of an electrically operated breaker. An 800 A frame breaker is shown in Figure 17 and a 1600–2000 A frame breaker is shown in Figure 18. 11 1 1 ... . Press the off button to open the circuit breaker. 22 2 2 ... . Disconnect all external leads from the terminal board. 33 3 3 ... . Remove the four cover mounting screws. 44 4 4 ... . Remove the outer cover. 55 5 5 ... . On 1600-2000 A framer breakers only, remove the two inner-cover mounting screws, as shown in Figure 18. 66 6 6 ... . Loosen the captive inner-cover lock screw, as shown in Figure 19. 77 7 7 ... . Remove the inner cover. Figure 17. 800 A frame electrically operated breaker.
Power Break® Circuit Breakers Chapter 3. Accessories 11 Figure 18. 1600–2000 A frame electrically operated breaker. Figure 19. 1600–2000 A frame electrically operated breaker with the outer cover removed. Breaker Cover Reassembly Manually Operated Breakers 11 1 1 ... . Verify that all connections are secure and the breaker is free of debris. 22 2 2 ... . Verify that the breaker is off. CC C C AA A A UU U U TT T T II I I OO O O NN N N ::: : Verify that the accessory mounting plate insulator, shown in Figure 20, is properly located so it will not be damaged when the cover is replaced. The cover phase barrier must pass to the right side of this insulator. 33 3 3 ... . Position the charging handle at the home position (6 o’clock) on the cover. Align the cover mounting screw holes with the breaker base and install the four cover screws. Tighten the screws to 50–60 in-lbs. Figure 20. Wire ties on the accessory leads and mounting plate insulator. Electrically Operated Breakers 11 1 1 ... . Verify that all connections are secure and the breaker is free of debris. CC C C AA A A UU U U TT T T II I I OO O O NN N N ::: : Verify that the accessory mounting plate insulator is properly located, as shown in Figure 26. 22 2 2 ... . Slide the inner cover assembly onto the breaker base. Ensure that the crossbar hook engages the drive stud, as shown in Figure 21. Figure 21. Crossbar hook engaging the drive hook. 33 3 3 ... . Tighten the inner cover lock screw, shown in Figure 19, to 10 in-lbs. 44 4 4 ... . On 1600–2000 A frame breakers only, replace the two inner cover mounting screws and tighten to 50–60 in- lbs.
Power Break® Circuit Breakers Chapter 3. Accessories 12 55 5 5 ... . Position the charging handle at the home position (6 o’clock) on the outer cover. Align the outer cover- mounting screw holes with those on the inner cover and install the four cover-mounting screws. Tighten to 50–60 in-lbs. NN N N OO O O TT T T EE E E ::: : Ensure that the control terminal board properly engages the cover retaining slots. 66 6 6 ... . Connect the control and power wiring as per the instructions supplied with the circuit breaker. 3–3 Shunt Trip Device The shunt trip, shown in Figure 22, allows the breaker to be tripped electrically from a remote location. A cut-off switch is supplied as part of the shunt trip to automatically remove power from the shunt trip coil when the breaker is tripped. The electrical characteristics of the shunt trip are listed in Table 5. Figure 23 is the shunt trip wiring dia- gram. Figure 22. Shunt trip device with cut-off switch. Catalog No.Voltage RatingMax. Inrush Current, A TPST 12S120 Vac 240 Vac2.25 4.50 TPST13S480 Vac 600 Vac1.64 2.05 TPST7S 12 Vdc 4.00 TPST8S 24 Vdc 2.18 TPST9S 48 Vdc 1.09 TPST10S 125 Vdc 1.00 TPST11S 250 Vdc 0.21 Table 5. Shunt Trip electrical characteristics. Figure 23. Shunt trip wiring diagram. Mounting Plate Removal The mounting plate is used as the anchor position for the shunt trip, blown-fuse trip, and undervoltage release accessories. Breakers are shipped from the factory with either a mounting plate or an L-shaped bracket to retain the molded-plastic crank. A new mounting plate is pro- vided in the shunt trip kit, blown-fuse trip kit, undervol- tage release kit, and auxiliary switch kit. • If the breaker was supplied with an L-shaped bracket, remove the two retaining screws, discard the bracket, and skip to the appropriate installation instructions. • If the breaker was supplied with a mounting plate, remove it with the following procedure: 11 1 1 ... . Remove the three mounting plate retaining screws and the isolation barrier, shown in Figure 24. 22 2 2 ... . Lift out the accessory mounting plate and remove the molded drive crank. 33 3 3 ... . If a tap changer was supplied, remove the two screws from the phenolic block before removing the mount- ing plate. Figure 24. Locations of the mounting plate retaining screws, isolation barrier, and molded drive crank.
Power Break® Circuit Breakers Chapter 3. Accessories 13 Shunt Trip Installation NN N N OO O O TT T T EE E E ::: : If the shunt trip is being replaced because of a defective coil, the cause of the initial failure should first be determined. If necessary, consult the factory for fur- ther guidance. 11 1 1 ... . Assemble the coil to the mounting plate as shown in Figure 25. If a blown-fuse trip device is also to be installed on the mounting plate, mount the shunt trip coil as shown in Figure 26. 22 2 2 ... . When a blown-fuse trip device is included, place the shunt trip plunger stop nut in contact with the plunger of the blown-fuse trip device. 33 3 3 ... . Depress the actuator on the cut-off switch. Align the tapped holes in the switch bracket with the holes in the arm stop (left pole) and secure with #8-32 × 9/16 screws and lock washers, as shown in Figure 27. Tighten to 23 in-lbs torque. 44 4 4 ... . Remove the knockouts in the side of the base, as required. Each knockout will accommodate up to three bundles of wire. Remove all sharp edges with a file. 55 5 5 ... . Clean all debris from the inside of the breaker. NN N N OO O O TT T T EE E E ::: : Shunt trip coils rated at 12 Vdc or 24 Vdc must be mounted in the position nearest the latch. These coils may not develop enough force to drive both the latch and the blown-fuse trip device. Figure 25. Shunt trip coil position with no blown-fuse trip device. Mounting Plate Installation 11 1 1 ... . Replace the molded drive crank onto the mechanism drive pin, as shown in Figure 24, engaging the roll pins into the slot in the drive crank. Figure 26. Shunt trip coil position with blown-fuse trip device. Figure 27. Attaching the switch bracket to the arm stop. 22 2 2 ... . Place the mounting plate in position so that its two operating studs engage the molded drive crank, as shown in Figure 24. Ensure that the isolating barrier is in place. 33 3 3 ... . Attach the three retaining screws. Tighten the two small screws to 20 in-lbs and the large screw with tub- ing to 75 in-lbs. 44 4 4 ... . Attach wire ties to the leads and secure them to the mounting plate, as shown in Figure 20. 55 5 5 ... . Insert the leads into the knockout in the base side wall, ensuring that one tie is on the inside of the base and the other is on the outside. 66 6 6 ... . Apply the descriptive label to the front of the breaker cover.
Power Break® Circuit Breakers Chapter 3. Accessories 14 3–4 Undervoltage Release Device The undervoltage release device (UVR), shown in Figure 28, opens the circuit breaker when the supply voltage drops to 35–60% of its rated value. Figure 29 shows the dropping resistor supplied with 240–600 volt UVRs. The UVR electrical characteristics are listed in Table 6. The UVR wiring diagram is in Figure 30. Figure 28. Undervoltage release device. Figure 29. Dropping resistor supplied with 240–600 V UVRs. Figure 30. UVR wiring diagram. Catalog NumberVoltage RatingContinuous Current, mADropping Resistor* TPUV1S 120 Vac 25 none TPUV2S 240 Vac 25 5000 ?, 25 W TPUV2S 480 Vac 25 15,000 ?, 50 W TPUV6S 600 Vac 25 20,000 ?, 50 W TPUV7S 12 Vdc 211 none TPUV8S 24 Vdc 104 none TPUV9S 48 Vdc 54 none TPUV10S 125 Vdc 24 none TPUV11S 250 Vdc 24 5000 ?, 25 W * Ohmite Type 270 Table 6. UVR electrical characteristics. UVR Installation 11 1 1 ... . Remove the circuit breaker cover(s) as described above in 3–2 Circuit Breaker Cover. 22 2 2 ... . The UVR assembles to a mounting plate. Not all breakers are shipped from the factory with a mount- ing plate. Some breakers have only an L-shaped bracket to retain the molded-plastic crank. A mount- ing plate is provided in the UVR kit. • If the breaker is supplied with an L-shaped bracket, remove the two retaining screws and dis- card the bracket. Follow the Mounting Plate Installation instructions and continue on to step 3. • If the breaker is supplied with a mounting plate, continue with step 3. 33 3 3 ... . Remove the slide reset lever spring from the mount- ing plate, as shown in Figure 31. Be careful not to nick or damage the spring in any way, since it will be needed for reassembly. 44 4 4 ... . Push the latch and slide reset lever forward to pro- vide mounting clearance for the UVR assembly. 55 5 5 ... . Position the UVR assembly mounting bracket so that its retaining hole engages the latch pivot post, as shown in Figure 32. 66 6 6 ... . Line up the UVR bracket’s mounting hole with the tapped hole in the accessory mounting plate. Install the screw and lock washer, as shown in Figure 33. Tighten the screw to 9–11 in-lbs. 77 7 7 ... . Replace the slide reset lever spring, shown in Figure 31. 88 8 8 ... . Remove the knockouts in the side of the base, as required. Each knockout will accommodate up to three bundles of wire. Remove all sharp edges with a file. 99 9 9 ... . Remove all debris from the inside of the breaker.