GE AK-15 User manual

MicroVersaTrifP

Plus

and

Conversion

Kits

For

Types

AKU

AKR

AKRU

Low

Voltage

Power

Circuit

Breakers

Introduction

Conversion

Kits

are

designed

upgrade

existing

Low

Voltage

Power

Circuit

Breakers

rather

than

replace

the

entire

breaker

The

Conversion

Kits

contain

enhanced

solid

state

Micro

VersaTrip

Plus

Micro

VersaTrip

trip

units

representing

the

latest

technological

advancements

trip

systems

Micro

VersaTrip

Plus

and

Micro

VersaTrip

Conversion

Kits

are

designed

and

breaker

tested

conform

with

ANSI

standard

37.59

allowing

the

retrofitter

properly

install

and

acceptance

test

the

breaker

This

publication

covers

installation

MicroVersaTrip

Plus

and

Micro

VersaTrip

Conversion

Kits

types

AKU

AKR

AKRU

Low

Voltage

Power

Circuit

Breakers

Each

Conversion

Kit

contains

all

propriate

material

convert

from

existing

Power

Sensor

ECS

SST

trip

system

upgrade

Micro

VersaTrip

and

Micro

VersaTrip

RMS

trip

systems

Courtesy of NationalSwitchgear.com

TABLE

CONTENTS

GENERAL

INFORMATION

SECTION

PRIOR

INSTALLATION

SECTION

FRONT

FRAME

BREAKER

CONVERSION

Separating

the

Breaker

Remounting

and

Relays

Installing

the

Flux

Shifter

Installing

the

Programmer

Bracket

Installing

the

Programmer

Harness

Installing

the

Communications

Harness

SECTION

BACK

FRAME

BREAKER

CONVERSION

Installing

Phase

Sensors

SECTION

FOUR

WIRE

GROUND

FAULT

OPTION

Drawout

Breakers

Stationary

Breakers

Installing

Neutral

Sensors

EQUIPMENT

CONVERSION

Stud

Shield

Modification

Remounting

Primary

Disconnect

Fingers

Installing

the

Insulator

Bracket

and

Wire

Harness

SECTION

INSTALLING

THE

PROGRAMMER

TESTING

AND

TROUBLESHOOTING

Cabling

Diagrams

SECTION

Courtesy of NationalSwitchgear.com

SECTION

GENERAL

INFORMATION

programmable

trip

unit

have

been

furnished

Whenever

the

ground

fault

trip

element

fur

nished

for

breakers

applied

wire

systems

note

that

associated

neutral

sensor

(

)

required

for

separate

mounting

the

equipment

Make

sure

that

retrofitted

breakers

are

applied

within

their

short

circuit

rating

For

example

when

the

trip

ele

ments

the

breaker

are

changed

from

long

time

instantaneous

long

time

short

time

the

short

time

rating

would

govern

the

application

service

consideration

the

installation

the

MicroVersaTrip

Plus

kits

provides

excel

lent

opportunity

perform

normal

maintenance

the

breaker

particularly

when

the

front

and

back

frames

are

separated

Such

procedures

are

scribed

the

installation

and

maintenance

manu

als

supplied

with

the

Breakers

and

Equipment

Conversion

Kit

installation

straightforward

but

does

require

careful

workmanship

and

atten

tion

these

instructions

Familiarity

with

the

breaker

itself

highly

desirable

The

general

proach

first

strip

the

breaker

its

existing

trip

devices

then

install

the

MicroVersaTrip

Plus

Kit

components

Following

this

procedure

the

con

verted

breaker

performance

tested

prior

storing

the

breaker

service

The

majority

breaker

kit

installations

not

quire

any

customized

assembly

work

However

some

conversions

may

involve

unusual

mounting

circumstances

accessory

combinations

which

cessitate

minor

modification

and

relocation

component

(

)

most

instances

this

supplemen

tary

work

can

done

site

Preparatory

the

conversion

the

installer

should

verify

that

the

appropriate

current

sensors

and

SECTION

PRIOR

INSTALLATION

Turn

off

and

lock

out

the

powder

source

feeding

the

breaker

prior

attempting

any

installation

maintenance

modification

all

lock

out

and

tagging

rules

the

National

Electrical

Code

and

all

other

applicable

codes

not

work

closed

breaker

with

the

closing

springs

charged

Trip

OPEN

the

breaker

and

sure

the

stored

energy

springs

are

discharged

avoiding

the

possibility

that

the

breakers

may

trip

OPEN

the

charg

ing

springs

discharge

causing

injuries

For

both

stationary

and

draw

out

breakers

trip

OPEN

then

remove

the

breaker

well

lighted

work

area

before

beginning

work

not

perform

any

maintenance

including

breaker

charging

closing

tripping

any

other

function

which

could

cause

significant

move

ment

the

breaker

while

the

draw

out

extension

rails

not

leave

the

breaker

intermediate

sition

the

switchgear

compartment

Always

leave

the

CONNECTED

TEST

DIS

CONNECTED

position

Failure

could

lead

improper

positioning

the

breaker

and

flashback

Before

starting

any

work

turn

off

and

lock

out

all

power

sources

leading

the

breaker

(

primary

and

secondary

)

Remove

the

breaker

clean

well

lighted

work

area

WARNING

Low

Voltage

Power

Circuit

Break

ers

utilize

high

speed

stored

energy

spring

erating

mechanisms

The

breakers

and

their

enclosures

contain

interlocks

and

safety

fea

tures

intended

provide

safe

proper

operat

ing

sequences

For

maximum

personnel

pro

tection

associated

with

installation

operation

and

maintenance

these

breakers

the

ing

procedures

must

followed

Failure

fol

low

these

procedures

may

result

personal

jury

property

damage

•

Only

qualified

persons

defined

the

tional

Electrical

Code

who

are

familiar

with

the

installation

and

maintenance

low

voltage

power

circuit

breakers

and

switchgear

assem

blies

should

perform

any

work

associated

with

these

breakers

•

Completely

read

and

understand

all

instructions

before

attempting

any

breaker

installation

eration

maintenance

modification

Courtesy of NationalSwitchgear.com

SECTION

FRONT

FRAME

BREAKER

CONVERSION

The

front

frame

breaker

conversion

consists

the

following

Separation

the

front

and

back

breaker

frames

(

for

and

only

)

Refer

the

appro

priate

installation

and

maintenance

manuals

supplied

with

the

breakers

and

equipment

for

instruction

accomplishing

the

separation

Copies

these

publications

may

obtained

from

your

local

sales

office

Remove

the

existing

trip

devices

electrically

operated

type

and

breakers

with

trip

devices

relocating

and

remounting

the

and

relays

Installing

the

flux

shifter

and

trip

paddle

Installing

the

programmer

mounting

bracket

Installing

the

programmer

and

communications

wire

harness

Separating

the

Breaker

Frames

Verify

that

the

breaker

OPEN

then

perform

the

following

steps

Step

Remove

the

steel

arc

quencher

retainer

loosening

the

two

}

hex

capnuts

electrically

operated

breakers

the

lay

mounted

the

left

end

the

retainer

there

need

remove

breakers

mounted

the

right

side

and

will

have

moved

the

left

side

The

steps

are

shown

page

Step

Remove

the

three

arc

quenchers

lifting

upward

and

outward

Step

Separate

the

breaker

’

front

and

back

frames

(

refer

the

appropriate

maintenance

manuals

)

Remove

the

Existing

Trip

Devices

Step

Remove

the

overcurrent

trip

devices

Step

draw

out

breakers

remove

the

primary

disconnect

fingers

from

the

bottom

(

load

side

)

copper

studs

Step

Remove

the

three

bottom

(

load

side

)

copper

stud

assemblies

Powder

Sensor

equipped

breakers

this

will

have

been

done

during

Step

equipped

breakers

remove

and

discard

the

four

trip

device

support

brackets

mounted

along

the

low

front

the

back

frame

See

Fig

this

point

the

breaker

back

frame

ready

for

instal

lation

the

Conversion

Kit

components

provided

Courtesy of NationalSwitchgear.com

SECTION

FRONT

FRAME

BREAKER

CONVERSION

Remounting

and

Relays

electrically

operated

breakers

equipped

with

trip

device

the

relay

mounted

the

front

frame

the

right

side

the

operation

mechanism

Step

provide

mounting

space

for

the

new

flux

shift

trip

device

remove

the

relay

and

remount

the

left

end

the

arc

quencher

retainer

shown

Figs

and

(

using

hardware

and

parts

included

)

Step

Modify

the

breaker

wiring

harness

suit

The

relay

should

remounted

after

the

programmer

mount

and

bracket

are

installed

See

installing

the

programmer

bracket

and

Fig

Right

Side

View

Front

Frame

Courtesy of NationalSwitchgear.com

SECTION

FRONT

FRAME

BREAKER

CONVERSION

Remounting

and

Relays

(

Cont

’

)

ELECTRICAL

BREAKERS

REMOVE

AND

RELOCATE

“

”

REIAYTO

ARC

QUENCHER

RETAINER

NEW

LOCATION

“

”

REI

OPEN

—

•

TRIP

—

ROUTE

WIRE

HARNESS

“

”

THAT

WILL

TRAPPED

THIS

WIRE

KEEPER

vTTfWWu

LOCATION

MAGNETIC

TRIP

DEVICE

MODELS

WIRE

HARNESS

“

”

CONNECT

PROGRAMMER

HARNESS

CONNECTOR

AKD

DRAW

OUT

BREAKER

MFG

PRIOR

1969

CUT

OFF

THE

RACK

ARM

DOTTED

SECTION

CLEAR

PROGRAMMER

SOCKET

TERMINAL

CAUTION

ROUTE

HARNESS

“

”

THAT

WILL

NOT

CUT

MOVING

PARTS

THE

CLOSING

SOLENOID

Fig

Front

View

Front

Frame

(

AKD

Type

Draw

Out

Shown

)

Courtesy of NationalSwitchgear.com

SECTION

FRONT

FRAME

BREAKER

CONVERSION

FLUX

SHIFTER

Installing

the

Flux

Shifter

The

Flux

Shifter

trip

device

mounted

the

right

the

operating

mechanism

shown

Fig

Step

Remove

the

existing

flux

shifter

device

Step

Mount

the

flux

shifter

trip

paddle

the

breaker

trip

shaft

per

Figs

and

Pushing

the

draw

out

locking

lever

will

allow

the

trip

bar

rotate

easily

accessible

point

Step

Install

the

flux

shifter

actuating

bushing

the

right

hand

operation

link

enlarging

the

link

hole

nec

essary

See

Fig

Step

Mount

the

flux

shifter

assembly

the

right

side

the

front

frame

shown

Fig

Power

Sensor

breakers

equipped

with

shunt

trip

mount

the

flux

shifter

top

the

shunt

trip

bracket

shunt

trip

installed

use

the

spacer

provided

(

Fig

3.7

)

Step

When

the

flux

shifter

and

its

trip

paddle

are

installed

and

the

front

and

back

breaker

frames

are

reassembled

the

following

adjustment

must

made

Note

that

the

back

frame

must

converted

first

With

the

breaker

the

OPEN

position

and

the

mechanism

fully

charged

set

the

gap

between

the

trip

paddle

and

the

end

the

flux

shifter

trip

rod

093

125

inches

Use

0.100

inch

diameter

rod

(

not

supplied

)

shown

Fig

Set

the

adjuster

end

the

trip

rod

and

lock

place

with

the

jam

nut

OPTIONAL

TEST

The

flux

shifter

assembly

may

tested

closing

the

breaker

and

applying

powder

source

the

flux

shifter

leads

The

red

wire

the

positive

lead

The

breaker

should

trip

TRIP

PADDLE

Fig

Rear

View

Front

Frame

Showing

Location

Trip

Paddle

for

Flux

Shift

Trip

Device

Fig

Side

View

Flux

Shifter

Installed

Trademark

the

Loctite

Corp

Courtesy of NationalSwitchgear.com

SECTION

FRONT

FRAME

BREAKER

CONVERSION

Installing

the

Flux

Shifter

(

Cont

’

)

AFTER

BREAKER

REASSEMBLED

ADJUST

THE

FLUX

SHIFT

TRIP

ROD

FOLLOWS

WITH

BREAKER

OPEN

AND

THE

TRIPSHAFT

RESET

TURN

ADJUSTER

UNTIL

GAP

093

125

THEN

LOCK

WITH

JAM

NUT

INSERTED

ACTUATING

BUSHING

WHEN

REASSEMBLING

THE

FRONT

AND

BACK

FRAMES

ENGAGE

BUSHING

(

OPER

LINK

)

WITH

OPERATING

LEVER

THE

FLUX

SHIFT

TRIP

DEVICE

SHOWN

RIGHT

SIDE

MECHANISM

FRAME

VIEWED

FROM

REAR

FRONT

FRAME

RIGHT

OPER

LINK

JAM

NUT

ADJUSTER

TRIP

PADDLE

EQUIPPED

BREAKERS

WILL

NECESSARY

DRILL

AND

TAP

BOLT

THIS

HOLE

THE

FRONT

FRAME

USE

THE

FLUX

SHIFT

TRIP

DEVICE

BRACKET

TEMPLATE

POWER

SENSOR

BREAKERS

EQUIPPED

WITH

SHUNT

TRIP

MOUNT

FLUX

SHIFT

TRIP

DEVICE

TOP

THE

SHUNT

TFUP

BRACKET

SHUNT

TRIP

USE

SPACER

PROVIDED

Fig

Right

Side

View

Mechanism

Frame

Showing

Mounting

Flux

Shift

Trip

Device

Courtesy of NationalSwitchgear.com

SECTION

FRONT

FRAME

BREAKER

CONVERSION

Installing

the

Programmer

Bracket

The

MicroVersaTrip

Plus

programmer

mounts

the

lower

right

side

the

breaker

Step

Assemble

the

programmer

shock

mount

bracket

the

programmer

support

bracket

per

Fig

Step

Mount

the

relay

the

bracket

using

(

)

screws

and

lock

washers

provided

see

Fig

Step

Modify

the

relay

harness

adding

gauge

tension

wire

splices

and

ring

terminals

provided

Work

one

wire

time

Route

the

wires

shown

Fig

making

certain

that

they

not

inter

fere

with

the

solenoid

plunger

programmer

Fig

Relay

Wire

Routing

—

FRONT

FRAME

LTJ

)

[

NEW

LOCATION

TRIP

UNIT

BRACKET

PROGRAMMER

SUPPORT

BRACKET

“

”

RELAY

Fig

Right

Side

View

Showing

Mounting

Position

Programmer

Unit

Courtesy of NationalSwitchgear.com

SECTION

FRONT

FRAME

BREAKER

CONVERSION

NOTE

LOCATION

BEVELED

EDGES

PLUG

BODY

Installing

the

Programmer

Harness

The

programmer

harness

consists

the

mating

programmer

connector

and

the

associated

wiring

Step

Assemble

the

adapter

bracket

the

pro

grammer

connector

(

with

bevels

right

side

)

pushing

the

bracket

over

the

notches

ends

plug

body

(

Step

)

Steps

through

Fig

complete

assembly

programmer

harness

programmer

bracket

Jooooooooo

—

Voooo

ooooo

loooooooooi

foooo

000

ADAPTER

BRACKET

STEP

PUSH

BRACKET

OVER

NOTCHES

END

PLUG

BODY

STEP

HOLD

PLUG

BODY

TIGHT

THE

ADAPTER

BRACKET

AND

BEND

OVER

(

)

LOCKING

TABS

CAUTION

The

adapter

bracket

must

installed

onto

harness

plug

shown

Fig

Failure

will

result

harness

plug

failure

and

pro

grammer

will

not

provide

any

protection

STEP

PRESS

PUSH

NUTS

UNTIL

BRACKET

HELD

FIRMLY

AGAINST

PROGRAMMER

BRACKET

00000000

oooooooo

Step

Plug

the

wiring

harness

connector

into

the

mating

plug

the

flux

shifter

assembly

NOTE

The

current

sensor

leads

can

connected

after

the

front

and

back

frames

are

joined

STEP

HOLD

PLUG

FIRMLY

BEND

LOCKING

TABS

STEP

PULL

WIRE

HARNESS

BRACKET

ASSEMBLY

OVER

GUIDE

PINS

AND

PUSH

ALL

THE

WAY

DOWN

GUIDE

PINS

Fig

Programmer

Harness

Connector

Fig

Programmer

Plate

Installation

Courtesy of NationalSwitchgear.com

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