Power Break Circuit Breakers 800-2000 A Frames, 240-600 Vac User's Guide

GEH–4693D
g Power Break® Circuit Breakers

800–2000 A Frames, 240–600 Vac
User’s Guide
Downloaded from www.Manualslib.com manuals search engine

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 possible 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 Rights Reserved

Power Break® Circuit Breakers
Table of Contents
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
ii

List of Figures and Tables
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
iii

List of Figures and Tables
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
iv

1–1 Overview condensation, preferably by storage in a warm, dry room.

Circuit breakers for outdoor equipment should be stored
The Power Break® line of insulated-case circuit breakers in that equipment only when power is available and heat-
is designed to protect low-voltage power circuits and ers are in operation, to prevent condensation.
equipment. Current models are offered with Magne-
Trip™, MicroVersaTrip Plus™, and MicroVersaTrip PM™ The breaker should be stored in a clean location, free
trip units for fault detection. from corrosive gases or fumes. In particular, protect the
breaker from moisture and cement dust, as that combina-
tion may be corrosive.
1–2 Receiving the Breaker If the breaker is stored for any length of time, it should be
Unpack the circuit breaker and inspect it for shipping inspected periodically to ensure good mechanical condi-
damage. Ensure that the breaker has the proper current, tion.
voltage, and interruption ratings for the application.
The weights of the various frame sizes are listed in Table 1–3 Installation
1, for reference. Figure 1 shows a breaker with straps for
lifting. Bolted Electrical Connections
Using an industry-accepted solvent, remove any foreign
CAUTION: Do not attempt to lift the circuit breaker by
material from the line and load strap surfaces and the
its operating handle.
corresponding surfaces of connecting bus and terminal
studs. Ensure that the mating surfaces are smooth and
Frame free of burrs and nicks.
Rating, A Type Weight, lbs
Manual 50 Place the bus connections in position and align the
800
Electric 64 mounting holes. Insert and fasten the mounting bolts and
Manual 82 washers according to the specifications in Table 2.
1600
Electric 96
Manual 88 Bus Connection
2000
Electric 102 Breaker Frame, A Bolt Dia. Torque, in-lbs
Table 1. Weights of the various breaker frame sizes, with and 800 (1) 1/2 in 300
without a motor operator. 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 1. Circuit breaker with lifting straps in place.
Storage
The breaker should be placed in service immediately in its Figure 2. Location of mounting bolt inserts on 800 A frame breakers.
permanent location. However, if it must be stored for an
indefinite period, it should be carefully protected against
1

Figure 3. Location of mounting bolt inserts on 1600–2000 A frame

breakers.

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.
A Indicator ON – Red
CHG (manual) – yellow
CHARGED (electrical) – yellow
OFF – Green
B ON button
C OFF button
D Manual charging handle
E Lockable manual charge engagement button (motor
operated only)
F Terminal board (motor operator drive unit)
G Removable protective window
J CT tap setting indicator (MicroVersaTrip only)
Figure 5. Motor operator-charged breaker.
K Removal protective trip unit cover (Magnetrip™
only)
L Cover mounting screws (four)
M Midcover mounting screws (three – motor operated
only)
N MicroVersaTrip RMS-9 trip unit interchangeable rat-
ing plug
O Motor operator control circuit fuses
P MicroVersaTrip RMS-9 test set connection port
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.
Figure 4. Manually charged breaker.

Main Breaker Condition of

Indicator Contacts 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 Operating Instructions for Electrically

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

charge as soon as the breaker is opened, whether from a

fault trip or from being intentionally opened.
CAUTION: 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.
CAUTION: 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.
N O T E : The motor operator contains a feature that shuts

Figure 8. Wiring for optional bell alarm lockout applications.
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- Wiring Notes
dition. If the breaker is equipped with a draw-out inter-
Observe the following notes when wiring the breaker for
lock (TPDO-1), electrical operation is permitted only if
operation:
the draw-out carriage is in the ENGAGED or TEST posi-
tion. • 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
Figure 7. Bell alarm wiring to prevent continuous cycling of the maximum output of 20 mA.
automatic charging mechanism.
Operating Motor Current, A Close Nominal Maximum Maximum
Rated Voltage Locked Full Solenoid, Fuses (Slo Charge Close Opening
Voltage Range Rotor Load Average peak A Blo 125 V) Time , s Time, s Time, s
120 Vac 102–132 8 2.5 1.5 3.0 2A 5.0 0.83 0.05
125 Vdc 100–140 10 2.5 1.5 3.5 2A 6.0 0.83 0.05
72 Vdc 57–81 13 3.0 2.0 5.0 3A 6.0 0.83 0.05
48 Vdc 38–58 20 5.0 2.5 6.6 4A 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.

Application Notes 2. Change the settings by twisting the indicator switches

• Size the control power source according to the to the desired values or multipliers. See GEH-4657 for
information in Table 3. If a single source is to supply definitions of MicroVersaTrip functions and GEH-
several motor operators, it must be sized appropri- 5369 for MicroVersaTrip RMS-9 functions.
ately. Where breakers are wired for automatic 3. Reinstall the window.
charge, it may be necessary to supply power to several
motor operators simultaneously during start up. Rating Plugs
• The control power source should be sized so that the MicroVersaTrip RMS-9 trip units require the installation
drop in voltage from no load to full load does not of a rating plug in accordance with GEH-5369 and GEH-
exceed 7%. 5371 to set the maximum continuous current rating.
• Acceptable dc power sources are the following: Tap Changer Card
– dc generator, Some MicroVersaTrip models include a tap changer card,
– battery, shown in Figure 9. When provided, this function allows
– three-phase, full-wave rectified ac, or the customer to change the rating of the breaker frame.
– 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 Figure 9. Tap changer cards.
motor operator.
2–3 Trip Unit Setup

N O T 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:
1. Remove the clear plastic protective window, shown in
Figure 4.

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:
W A R N I N G : The circuit breaker must be removed from

the electrical system before attempting any operations
that involve removing the breaker’s cover.
1. Turn the breaker off .

Figure 11. Neutral CT connection for four-wire ground fault.
2. Remove the four cover mounting screws and remove
the top cover. On motor operator-equipped breakers,
Neutral Current Transformer (Four-Wire Ground
remove only the top cover.
Fault System)
3. Withdraw the card from the tap changer support and
Ground fault protection is offered as an optional function
replace with the other card, as shown in Figure 10.
of the MicroVersaTrip® trip unit. However, all MicroVer-
The print on the top of the card should be oriented
saTrip-generation breaker frames are provided with ter-
the same as the breaker cover name plate.
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
Figure 10. Cover and trip unit removed from the breaker. top fed, as illustrated in Figure 12, or bottom fed, as illus-
trated in Figure 13.
4. Trip units providing ground fault protection must
also have the tap setting changed on the tapped neu- N O T E : The neutral CT is mounted in reverse in Figure
tral CT (four-wire systems). Change the black wire 13 when the breaker is bottom (reverse) fed.
lead from the high or low terminal to match the
desired tap setting of the breaker frame, as shown in
CAUTION: Match the tapped terminal for the black lead
Figure 11.
to the tap setting, if provided, on the breaker frame.
5. Replace the breaker cover.
6. Operate the breaker manually through the
CAUTION: Observe the polarity markings on the neutral
charge–close–open cycle to ensure that the breaker is
CT shell and the breaker frame.
properly functioning mechanically before energizing
or connecting it to the electrical system.
CAUTION: When a neutral CT is not used or not
NOTE: A deenergized undervoltage release will not allow required (three-wire ground fault), do not short the
the mechanism to charge and close. ground fault terminal points on the breaker frame.
Leave them open as supplied by the factory.
7. Store the extra tap card in a convenient place.

• 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.
W A R N I N G : The circuit breaker must be removed from

the electrical system before attempting any operations
that involve removing the breaker’s cover.
Figure 12. Wiring diagram for MicroVersaTrip and MicroVersaTrip 1. Remove the four cover-mounting screws and remove
RMS-9 trip units with ground fault on a top-fed four-wire load. the top cover. On motor-operated breakers, remove
only the top cover to replace the trip unit.
2. Remove the trip unit as follows:
a. Push in the trip unit-cover interlock, as illustrated
in Figure 14.
b. Lift the trip unit off the mounting plate and ter-
minal plug.
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 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 Figure 14. Releasing the trip unit cover interlock to remove or install
frames have rejection schemes to prevent mismatching of the trip unit.
functions.
The limits of interchangeability are as follows:

3. Install the replacement trip unit as shown in Figure

15:
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.
b. Push in the trip unit-cover interlock until it locks
in place, as shown in Figure 14.
N O T E : The trip unit has a stud on the bottom to defeat

the trip unit-cover interlock locking spring.
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.
Figure 15. Aligning the trip unit to the mounting plate.
4. Replace the top cover and secure with the four cover-
mounting screws.
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.
NOTE: A deenergized undervoltage release will not allow

the mechanism to charge and close.
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:
1. Remove the protective trip unit cover.
2. Change the trip setting by rotating the plastic buttons
in the base with a screw driver, as shown in Figure 16.
3. Replace the protective cover.

3–1 Introduction N O T E : All breakers are equipped with mechanical inter-

locks that automatically trip the breaker when the cover
These instructions cover the field installation of internally
is removed with the breaker closed.
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 Breaker Cover Removal
also be installed in 800–1600 A frame Power Break break-
ers with MagneTrip™ trip units, but the UL listing is Manual Breaker
voided. Use the following procedure to remove the cover of a
The control leads of internally mounted accessories exit in manually operated breaker:
pigtail form from the side of the breaker. These leads are 1. Press the off button to open the circuit breaker.
terminated at the secondary disconnect points of draw-out 2. Remove the four cover-mounting screws.
breakers or at optional terminal blocks when specified for
stationary-mounted breakers. All leads are color coded as 3. Remove the breaker cover.
listed in Table 4. Electrically Operated Breaker
Use the following procedure to remove the cover of an
No. of
Accessory Lead Color Leads electrically operated breaker. An 800 A frame breaker is
Shunt Trip Black 2 shown in Figure 17 and a 1600–2000 A frame breaker is
Undervoltage Blue 2 shown in Figure 18.
Release 1. Press the off button to open the circuit breaker.
White – common 3 per
2. Disconnect all external leads from the terminal
Auxiliary Switch Red – OPEN (NO) switch
Brown/White – CLOSED (NC) board.
Bell Alarm Yellow – common 3. Remove the four cover mounting screws.
(Overcurrent Purple – CLOSED (NC) 3
Lockout) Brown – OPEN (NO) 4. Remove the outer cover.
Line End Load End Phase 5. On 1600-2000 A framer breakers only, remove the two
Blown-Fuse Trip Red Brown-White A 6 inner-cover mounting screws, as shown in Figure 18.
(3-Coil Shunt Trip) Blue White B
Yellow Black C 6. Loosen the captive inner-cover lock screw, as shown
Closing Solenoid White – common in Figure 19.
(Manual Breakers Black – remote indication 3 7. Remove the inner cover.
only) Orange – remote close
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.
W A R N I N 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.
CAUTION: Do not turn the breaker upside down, since

loose parts may become lost.
Figure 17. 800 A frame electrically operated breaker.
10

Figure 18. 1600–2000 A frame electrically operated breaker. Figure 20. Wire ties on the accessory leads and mounting plate
insulator.
Electrically Operated Breakers

1. Verify that all connections are secure and the breaker
is free of debris.
CAUTION: Verify that the accessory mounting plate

insulator is properly located, as shown in Figure 26.
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 19. 1600–2000 A frame electrically operated breaker with the

outer cover removed.
Breaker Cover Reassembly

Manually Operated Breakers
1. Verify that all connections are secure and the breaker
is free of debris.
2. Verify that the breaker is off .
C A U T I O 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 Figure 21. Crossbar hook engaging the drive hook.
cover phase barrier must pass to the right side of this
3. Tighten the inner cover lock screw, shown in Figure
insulator.
19, to 10 in-lbs.
3. Position the charging handle at the home position (6 4. On 1600–2000 A frame breakers only, replace the two
o’clock) on the cover. Align the cover mounting inner cover mounting screws and tighten to 50–60 in-
screw holes with the breaker base and install the four lbs.
cover screws. Tighten the screws to 50–60 in-lbs.
11

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.
N O T E : Ensure that the control terminal board properly

engages the cover retaining slots.
6. Connect the control and power wiring as per the Figure 23. Shunt trip wiring diagram.
instructions supplied with the circuit breaker.
Mounting Plate Removal
3–3 Shunt Trip Device The mounting plate is used as the anchor position for the
shunt trip, blown-fuse trip, and undervoltage release
The shunt trip, shown in Figure 22, allows the breaker to
accessories. Breakers are shipped from the factory with
be tripped electrically from a remote location. A cut-off
either a mounting plate or an L-shaped bracket to retain
switch is supplied as part of the shunt trip to automatically
the molded-plastic crank. A new mounting plate is pro-
remove power from the shunt trip coil when the breaker is
vided in the shunt trip kit, blown-fuse trip kit, undervol-
tripped. The electrical characteristics of the shunt trip are
tage release kit, and auxiliary switch kit.
listed in Table 5. Figure 23 is the shunt trip wiring dia-
gram. • 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:
1. Remove the three mounting plate retaining screws
and the isolation barrier, shown in Figure 24.
2. Lift out the accessory mounting plate and remove the
molded drive crank.
3. If a tap changer was supplied, remove the two screws
from the phenolic block before removing the mount-
ing plate.
Figure 22. Shunt trip device with cut-off switch.
Voltage Max. Inrush

Catalog No. Rating Current, A
120 Vac 2.25
TPST 12S
240 Vac 4.50
480 Vac 1.64
TPST13S
600 Vac 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 24. Locations of the mounting plate retaining screws, isolation

barrier, and molded drive crank.
12

Shunt Trip Installation

N O T 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.
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.
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.
3. Depress the actuator on the cut-off switch. Align the
tapped holes in the switch bracket with the holes in Figure 26. Shunt trip coil position with blown-fuse trip device.
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.
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.
5. Clean all debris from the inside of the breaker.
NOTE: 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 27. Attaching the switch bracket to the arm stop.
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.
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.
4. Attach wire ties to the leads and secure them to the
Figure 25. Shunt trip coil position with no blown-fuse trip device. mounting plate, as shown in Figure 20.
5. Insert the leads into the knockout in the base side
Mounting Plate Installation wall, ensuring that one tie is on the inside of the base
1. Replace the molded drive crank onto the mechanism and the other is on the outside.
drive pin, as shown in Figure 24, engaging the roll 6. Apply the descriptive label to the front of the breaker
pins into the slot in the drive crank. cover.
13

3–4 Undervoltage Release Device Catalog Voltage Continuous Dropping

Number Rating Current, mA Resistor*
The undervoltage release device (UVR), shown in Figure TPUV1S 120 Vac 25 none
28, opens the circuit breaker when the supply voltage TPUV2S 240 Vac 25 5000 ?, 25 W
drops to 35–60% of its rated value. Figure 29 shows the TPUV2S 480 Vac 25 15,000 ?, 50 W
dropping resistor supplied with 240–600 volt UVRs. The
TPUV6S 600 Vac 25 20,000 ?, 50 W
UVR electrical characteristics are listed in Table 6. The
TPUV7S 12 Vdc 211 none
UVR wiring diagram is in Figure 30.
TPUV11S 250 Vdc 24 5000 ?, 25 W
* Ohmite Type 270
Table 6. UVR electrical characteristics.
UVR Installation
1. Remove the circuit breaker cover(s) as described
above in 3–2 Circuit Breaker Cover.
2. The UVR assembles to a mounting plate. Not all
Figure 28. Undervoltage release device.
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.
Figure 29. Dropping resistor supplied with 240–600 V UVRs. 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.
4. Push the latch and slide reset lever forward to pro-
vide mounting clearance for the UVR assembly.
5. Position the UVR assembly mounting bracket so that
its retaining hole engages the latch pivot post, as
shown in Figure 32.
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.
Figure 30. UVR wiring diagram. Tighten the screw to 9–11 in-lbs.
7. Replace the slide reset lever spring, shown in Figure
31.
8. Remove the knockouts in the side of the base, as
required. Each knockout will accommodate up to
file.
9. Remove all debris from the inside of the breaker.
14

Figure 33. Installing the UVR mounting screw.
Figure 31. Slide reset lever and spring on the mounting plate. 13. Perform the following functional check of the UVR:
a. Apply rated voltage to the UVR coil.
b. Turn the breaker on.
c. Reduce the control voltage. The breaker should
trip when the voltage drops to 35–60% of its rated
value.
14. Apply the UVR descriptive label to the left side of the
breaker near the lead-exit area.
3–5 Blown-Fuse Trip Device

The blown-fuse trip device (three-coil shunt trip), shown
in Figure 34, is intended for applications with breakers
and fuses in series. This accessory prevents single-phasing
conditions by monitoring the fuses and automatically
tripping the circuit breaker when a fuse blows. It does not
protect from single-phasing of the power source.
Figure 32. Positioning the UVR assembly on the mounting plate.
10. Use the wire ties provided to secure the leads to the
mounting plate and to secure the wire bundle to the
inside and outside of the breaker base, as shown in
Figure 20.
11. Reassemble the breaker covers as described in
Breaker Cover Reassembly.
12. Mount the dropping resistor (when supplied) and
MOV, shown in Figure 29. Wire these as shown in
Figure 30.
Figure 34. Blown-fuse trip device accessory.
15

Each coil of the blown-fuse trip device is wired across a

fuse so that the voltage across an open fuse is fed back to
the accessory coil. When the coil is energized, the solenoid
core releases the spring-biased latch, allowing the slide to
rotate the breaker latch, tripping the breaker. The fuse
must be replaced and the breaker reset before the breaker
can be reclosed.
If the breaker is closed on an open fuse, the blown-fuse
trip device will automatically open the breaker.
Blown-Fuse Trip Device Installation

Installation of the blown-fuse trip device is similar to that
of the shunt trip, described above.
Figure 35. Blown-fuse trip device wiring diagram.
1. The blown-fuse trip device assembles to a mounting
plate. Not all breakers are shipped from the factory
with a mounting plate. Some breakers have only an 3–6 Auxiliary Switch
L-shaped bracket to retain the molded-plastic crank.
A mounting plate is provided in the blown-fuse kit. The auxiliary switch, shown in Figure 36, is used for
remote indication of the breaker’s main contact posi-
• If the breaker is supplied with an L-shaped
tion— open or closed. No distinction is made between
bracket, remove the two retaining screws and dis-
open or tripped mode. A maximum of 12 switches can be
card the bracket.
installed per breaker. Each is single-pole, double-throw
• If the breaker is supplied with a mounting plate, (AB-type) and rated as listed in Table 7. Two switch posi-
follow the instructions under Mounting Plate tions must be devoted to each shunt trip accessory (if
Removal. used) per breaker. The auxiliary switch wiring diagram is
2. Assemble the blown-fuse trip device to the accessory shown in Figure 37.
mounting plate as shown in Figure 26. If a shunt trip
had previously been mounted as shown in Figure 25,
it must be relocated as shown in Figure 26, with its
plunger stop nut in contact with the plunger of the
blown-fuse trip device.
3. Follow the procedure for Mounting Plate Installation.
4. Perform the following installation checks:
a. Replace the breaker cover as described above.
Close the breaker contacts.
b. Apply 120 volts to one coil of the blown-fuse trip
device for not more than one second. The
breaker must trip. Repeat the test for each coil.
5. Attach the six lead wires from the blown-fuse trip
device across the three fuses, as shown in the wiring
diagram in Figure 35. Figure 36. Auxiliary switch.
6. Apply the descriptive label to the front of the breaker.
7. Reassemble the breaker cover(s) as described in
Breaker Cover Reassembly.
16

Figure 37. Auxiliary switch wiring diagram. Figure 38. Trip unit removed from the breaker.
Catalog Number of Maximum

Number Switch Elements Current Rating
6 A at 240 Vac
TPAS2ABx 1–12 .25 A at 250 Vdc
.50 A at 125 Vdc
* Replace x with a number from 1–12 for
the number of switch elements.
Table 7. Auxiliary switch electrical characteristics.
Auxiliary Switch Installation

1. Remove the circuit breaker cover(s) as described in
Breaker Cover Removal . Figure 39. Installing the auxiliary switch assembly.
• If the breaker was supplied with an L-shaped
bracket (see Mounting Plate Removal), remove
the two retaining screws, discard the bracket, and
install the mounting plate provided in the kit (see
Mounting Plate Installation).
2. Both the left and right breaker poles can accept up to
six auxiliary switches. If the left pole contains a shunt
trip, two of the six auxiliary switch positions must be
used for the cut-out switches; thus, only four auxil-
iary switches may be used in the left pole.
3. If auxiliary switches are to be installed in the right Figure 40. Securing the auxiliary switch assembly.
pole, remove the trip unit by depressing the lock
release lever while lifting up on the trip unit. Remove 6. Remove knockouts in the side of the base, as
the trip unit mounting plate, shown in Figure 38. required. Each knockout will accommodate up to
4. Position the auxiliary switch assembly so that the
file.
tapped mounting holes on its bracket line up with
the through holes in the arm stop, as shown in 7. Use the supplied wire ties to secure the leads as
Figure 39. shown in Figure 20.
5. Secure the auxiliary switch assembly to the arm stop 8. Replace the trip unit mounting plate and trip unit.
with two #8 × 9/16 screws and lock washers, as shown 9. Replace the breaker cover(s) as described in Circuit
in Figure 40. Tighten the screws to 23 in-lbs. Breaker Cover Reassembly.
10. Perform the following functional checks:
a. With the breaker off , use a continuity tester to
verify continuity between the white and brown-
17

white leads. Verify an open circuit between the

red and white leads.
b. With the circuit breaker on, the auxiliary switch
contacts should change sense.
11. Apply the auxiliary switch descriptive label to the
front of the breaker cover.
3–7 Remote Close Solenoid and

Figure 41. Wiring diagram for remote charge indication.
Remote Charge Indication
The remote close solenoid is included with electrically
operated breakers and may be ordered as a factory-
installed option in manually operated breakers. Catalog
numbers and specifications are listed in Table 8.
Remote charge indication provides for remote indication
that the breaker closing springs are charged. Catalog
numbers are TPXCAS and TSXCAS for 800–2000 A and
for 3000–4000 A frames, respectively. The switch is rated
at 15 A for 250 Vac and at 0.5 A for 125 Vdc. Figure 41 is
Figure 42. Wiring diagram for remote charge indication with remote
the wiring diagram for remote charge indication. Figure
close solenoid.
42 is the wiring diagram for remote charge indication
with a remote close solenoid.
Rated Operating Current at Max. Maximum Maximum

Catalog No. Voltage Range*, V Voltage, A Closing Time, s Operating Time, s
TPXCC12S 120 Vac 102–132 3.3 0.083 0.050
TPXCC14S 240 Vac 204–264 1.7 0.083 0.050
TPXCC08S 24 Vdc 19–29 13 0.083 0.050
* The power source must stay within the rated operating voltage range of the close solenoid from no load to the full peak
current rating of the device.
Table 8. Catalog numbers and ratings for the remote close solenoid.
3–8 Optional Features

Special features may be ordered as specific accessories or
as an integral part of the breaker catalog number. Refer to
the BuyLog®, GEP-1100, for these features.
Limited Close Access Button

This accessory, shown in Figure 43, provides for limited
manual access to the ON button. The breaker can be
closed in an emergency for maintenance by inserting a
1/8-inch diameter pin or rod into the hole in the center of
the button. Manually operated breakers must be ordered
with an accessory closing solenoid.
Figure 43. Limited close access button.
18

Padlock Function
Handle Button Lock
A standard feature on motor-operated breakers that pre-
vents manual charging of the mechanism, as shown in
Figure 5.
OFF Button Padlock with Door Interlock

This accessory prevents opening of the panel door when
the breaker is ON or CHARGED. It operates as follows:
• With the breaker OFF the paddle can be rotated
counterclockwise over the breaker nameplate to clear
the enclosure panel door. Rotate the paddle clock-
wise to lock the door, as shown in Figure 44.
• To defeat the interlock when the breaker is ON or
CHARGED, depress the spring and rotate the paddle
to clear the door, as shown in Figure 45. Figure 45. Defeating the OFF button padlock.
Figure 44. OFF button padlock with panel door interlock.
19

Chapter 4. Maintenance
W A R N I N G : Before beginning any maintenance work,

disconnect the breaker from all voltage sources, both
power and control, and ensure that the breaker is OFF.
4–1 Inspections
Circuit breakers should be maintained through the
implementation of a systematic maintenance program. A
periodic inspection routine is recommended. The fre-
quency of inspection should depend on the environ-
mental conditions of each breaker. All circuit breakers
should be inspected at least annually. It a breaker is oper-
ated frequently or installed in an area of high humidity,
dust, or dirt, the frequency of maintenance inspections
should be increased. Under extremely adverse conditions,
monthly inspections are recommended.
The maintenance inspection should begin with an overall
visual check. If dirt, grease, or any other foreign material
is found on or in the breaker, it should be thoroughly and
carefully removed. Do not use solvents on insulating mate-
rial.
A rotating program providing for a periodic withdrawal
from service of each breaker in turn for inspection and
maintenance is an excellent means of establishing a high
level of service reliability. In such cases, one or more spare
breakers and all accessories should be available during the
maintenance inspection to replace any breaker that may
be removed for repairs.
N O T E : When ordering spare parts, always enclose com-

plete information from the breaker name plate, includ-
ing the breaker’s serial number.
4–2 Lubrication
Moderate lubrication is all that is required for most circuit
breakers. Mechanical bearing points and sliding surfaces
should be lubricated at the regular inspection periods
with a thin film of molybdenum disulfide (Molykote G) or
Mobil 28 grease. GE recommends the use of kerosene for
removing hardened grease and dirt from the latch and
bearing surfaces. All excess lubricant should be removed
to avoid any contamination of dirt or dust.
CAUTION: Under no circumstances should lubricant be

applied to contact areas.
20

g GE Industrial Systems
General Electric Company

41 Woodford Ave., Plainville, CT 06062
GEH4693 R05 0998 © 1998 General Electric Company

Power Break Circuit Breakers 800-2000 A Frames, 240-600 Vac User's Guide

Uploaded by

Copyright:

Available Formats

You might also like

Power Break Circuit Breakers 800-2000 A Frames, 240-600 Vac User's Guide

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Power Break Circuit Breakers 800-2000 A Frames, 240-600 Vac User's Guide

Uploaded by

Copyright:

Available Formats

GEH–4693D

g Power Break® Circuit Breakers

Downloaded from www.Manualslib.com manuals search engine

The following are trademarks of GE Company:

Downloaded from www.Manualslib.com manuals search engine

Chapter 1. Receiving and Installation

Chapter 2. Breaker Operation

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

38. Trip unit removed from the breaker. ......................................................................................................17

Downloaded from www.Manualslib.com manuals search engine

1–1 Overview condensation, preferably by storage in a warm, dry room.

Table 2. Bolt sizes and mounting torques for bus connections.

Figure 1. Circuit breaker with lifting straps in place.

Downloaded from www.Manualslib.com manuals search engine

Figure 3. Location of mounting bolt inserts on 1600–2000 A frame

Downloaded from www.Manualslib.com manuals search engine

2–1 Standard Features

Figure 6. Motor operator charged breaker with the top cover

2–2 Operating Instructions

Figure 4. Manually charged breaker.

Downloaded from www.Manualslib.com manuals search engine

Main Breaker Condition of

Operating Instructions for Manually Operating Instructions for Electrically

Downloaded from www.Manualslib.com manuals search engine

charge as soon as the breaker is opened, whether from a

CAUTION: Do not wire breakers for both automatic

CAUTION: The bell alarm lockout and undervoltage

N O T E : The motor operator contains a feature that shuts

Table 3. Application data for control power.

Downloaded from www.Manualslib.com manuals search engine

Application Notes 2. Change the settings by twisting the indicator switches

2–3 Trip Unit Setup

MicroVersaTrip® and MicroVersaTrip®

Adjusting Trip Settings

Downloaded from www.Manualslib.com manuals search engine

W A R N I N G : The circuit breaker must be removed from

1. Turn the breaker off .

Downloaded from www.Manualslib.com manuals search engine

• High short-time or H-function trip units may not be

W A R N I N G : The circuit breaker must be removed from

Figure 13. Wiring diagram for MicroVersaTrip and MicroVersaTrip

MicroVersaTrip RMS-9 Trip Units

MicroVersaTrip Trip Units

Downloaded from www.Manualslib.com manuals search engine

3. Install the replacement trip unit as shown in Figure

N O T E : The trip unit has a stud on the bottom to defeat

MicroVersaTrip Plus™ and MicroVersaTrip

Figure 15. Aligning the trip unit to the mounting plate.

NOTE: A deenergized undervoltage release will not allow

6. For trip units with ground fault, a neutral CT must be

MagneTrip™ Trip Units

Downloaded from www.Manualslib.com manuals search engine

3–1 Introduction N O T E : All breakers are equipped with mechanical inter-

Table 4. Accessory lead color codes.

3–2 Circuit Breaker Cover

W A R N I N G : Before installing any accessories, completely

CAUTION: Do not turn the breaker upside down, since