GEK-64460A Maintenance Manual

• Low Voltage
Power Circuit Breakers

Types AKR-75/100 and AKS-50

AKR-6D-75
AKR-9D-100

AKS-5A-50

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Low-Voltage Power Circuit Breakers

Table of Contents
Description Page Description Page

SECTION 1-lntroduction 4 SECTION 6-Breaker Maintenance 26

1.1 Inspection and Maintenance 4 6.1 Safety Precautions 26
1.2 Renewal Parts ...........•.................... 4 6.2 Lubrication , 26
6.3 Breaker Mechanism Adjustments 26
SECTION 2-General Description 6 6.3.1 Trip Latch 26
2.1 Frame Size 6 6.3.2 Latch Buffer 26
2.2 Operation 6 6.3.3 Reset Latch Bearing and Prop 26
2.3 Mounting 7 6.4 Electrical Mechanism , 28
2.4 Trip Device 7 6.4.1 Control Components 28
6.4.2 Charging Motor 29
2.5 Short Circuit Ratings 7
6.4.3 Motor Operator Unit 30
6.4.4 Spring Discharge Interlock 32
SECTION 3-8torage, Safety and
6.5 Manual Mechanism 32
Maintenance 9
6.5.1 Mechanism Part Replacement 33
3.1 Storage 9 6.5.2 Ratchet Pawl Replacement 35
3.2 Safety 9 6.5.3 Adjustments 35
3.3 Maintenance 9 6.6 Drawout Mechanism 36
6.7 Drawout Mechanism Lock 36
SECTION 4-Breaker Operation 10
4.1 Manual Closing 10 SECTION 7-Accessories 37
4.2 Electrical Closing 10 7.1 Primary Disconnects 37
4.2.1 Alternate Control Circuit 11 7.1.1 AKR 75/100 37
4.3 Connections 12 7.1.2 AKSIAKST 50 38
4.3.1 Stationary Breaker 12 7.2 Secondary Disconnects 39
4.3.2 Drawout Breaker " 12 7.2.1 Replacement 39
4.4 Tripping 13 7.3 Auxiliary Switch 40
4.5 Charging and Closing Using 7.3.1 Replacement 40
the Maintenance Handle 13 7.3.2 Adjustments 40
7.4 Shunt Trip 41
SECTION 5-Contact Maintenance 14 7.4.1 Replacement 41
5.1 Slow Closing the Breaker " 14 7.4.2 Adjustment 41
5.1.1 Electrical Breaker 14 7.5 Undervoltage Device 42
5.1.2 Manual Breaker 14 7.5.1 Replacement 42
5.2 Arc Ouencher Removal and Inspection 15 7.5.2 Adjustment 42
5.2.1 Removal and Replacement 15 7.6 Static Time-Delay Undervoltage 43
7.7 Electric Lockout Device 44
5.3 Separation of Front and Back Frames 16
7.7.1 AdJustment 44
5.4 Back Frame Assembly 18
5.5 Measuring Contact Force 19 7.8 Bell Alarm Device 45
5.5.1 Stationary Arcing Contacts 19 7.8.1 Adjustment 45
5.5.2 Stationary Main and Intermediate Contacts 19 7.9 Open Fuse Lockout Device 46
7.9.1 Coil Replacement 46
5.6 Measuring Contact Wipe 19
7.9.2 Adjustments 46
5.7 Adjusting Contact Wipe 19
5.8 Measuring Contact Open Gap 21 SECTION 8-Type SST Overcurrent
5.9 Checking Contact Sequence 22 T'
5.10 Replacement of Contacts 22
np Devlce
. 47
5.10.1 Stationary Arcing Contacts 22 8.1 Programmer Unit 47
5.10.2 Movable Arcing Contacts 22 8.2 Current Sensors 48
5.10.3 Movable Main and Intermediate Contacts 23 8.2.1 Replacement of Current Sensors
5.10.4 Stationary Intermediate and Main Contacts 24 - AKS 50 50
5.11 Assembly and Adjustment of Crossbar 25 8.2.2 Replacement of Current Sensors
- AKR 75/100 51
© 1993 GEN ERAL ELECTRIC COMPANY 8.3 Flux Shift Trip Device 51
8.4 Troubleshooting 54
2 8.4.1 SST Test Set 54

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Insert to document GEK-64459D and GEK-64460A 2/10/97

Breaker operation E.2 ELECTRICAL CLOSING

On electrically operated breakers the closing

This is an insert to the maintenance manuals for
springs are charged by a gear motor. With the springs
AKR 30/50 (GEK 64459D) and AKR 75/100
discharged, voltage applied to the control circuit will
(GEK64460A). The insert describes the operation of the
energize the motor through the "G" switch contacts - see
breaker with the newly introduced electronic closing
Fig. E1. The motor, through the gear reduction output
system.
crank, compresses the closing spring until they are fully
For the AKR 30/50 insert to section 5 starting on
charged. As this fUlly charged position is reached,
page 11.
mechanically operated switches "F" and "G" reverse their
For the AKR 75/100 insert to section 4 starting on
shown position, the "G" switch deenergizing the motor
page 10
and the "F" switch establishing a circuit to the One-Shot
electronic.

With the closing spring propped fUlly-charged, the

Replacement Parts breaker is ready for closing. This may be accomplished
electrically by depressing the closing switch "PB" on the
breaker (if so equipped) or by a remote closing switch.
Replacement printed circuit board assembly for 48 Operation of the closing switch energizes the One-Shot
VDC applications: #10060126G1 electronic, witch in turn energizes the closing solenoid
"CC". This removes the prop, releasing the closing
Replacement printed circuit board assembly for all springs to close the breaker.
other voltage applications: #10060126G2
As the One-Shot electronic is energized through a
closing contact, the "X" relay is energized as well. The
"X" relay will latch in and therefore prevent a second
closing operation on the breaker in the event it is tripped
open automatically. The closing signal must be released
and reapplied before a second closing operation can
occur.

The closing springs on the electrically operated breakers

can be manually charged.
(X)
(+)

LEGEND

CC CLOSING SOLENOID
F CUTOFF SWITCH, CLOSED WHEN
CLOSING SPRING IS FULLY
CHARGED.
G CUTOFF SWITCH. OPEN WHEN
CLOSING SPRING IS FULLY
CHARGED.
L AUXILIARY SWITCH
M CHARGING MOTOR
PB CLOSE PUSH-BUTTON ON BREAKER
(Y)
ESCUTCHEON, OPTIONAL.
(-) X CONTROL RELAY
FIG.E1 - ELEMENTARY DIAGRAM FOR OS ONE-SHOT ELECTRONIC. PULSES
ELECTRICALLY OPERATED DRAWOUT BREAKER. THE CLOSING SOLENOID FOR
CONTACT POSITIONS ARE SHOWN WITH BREAKER 250 MSEC.
OPEN AND CLOSING SPRINGS DISCHARGED. TYP #
183L712 &# 568B736 "E" SERIES
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 FIG. 13 - MANUAL OPERATION OF CLOSING SOLENOID

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Table of Contents
Description Page Description Page
8.4.2 Resistance Values , 55 SECTION 13-Type EC
8.4.3 False Tripping - Breakers
Equipped with Ground Fault , 55
Overcurrent
8.5 SST Cabling Diagrams 55 Trip Device 85
13.1 Direct Acting Tripping Device EC-1 B 87
SECTION 9-Type ECS 13.1.1 Long Time Delay Tripping 87
Overcurrent 13.1.2 Short Time Delay Tripping 87
Trip Device " " 58 13.1.3 Instantaneous Tripping - High Set 87
9.1 ECS Cabling Diagram 59 13.1.4 Instantaneous Tripping - Low Set , 87
13.2 Replacement ,.......................... 87
SECTION 10- MicroVersaTrip ™ 13.3 Adjustments 88
Overcurrent 13.4 Series Overcurrent Tripping
Trip Device , 60 Device EC·2A , .. , . . . . . . . . . . . . . . . . .. 89
10.1 Programmer Unit , 60 13.4.1 Long Time-Delay and High Set
10.1.1 Fault Trip Indicators 60 Instantaneous Tripping , 89'
10.1.2 Remote Fault Indication , 60 13.4.2 Instantaneous Low Set Tripping , 89
10.2 MicroVersaTrip TM Installation , 62 13.4.3 Instantaneous High Set Tripping 89
10.2.1 AKS 50 Installation , 62 13.5 Series Overcurrent Tripping Device EC-1 91
10.2.2 13.5.1 Short Time-Delay Tripping 91
AKR 50/100 Installation , 63
10.3 13.5.2 Long Time-Delay Tripping 91
Current Sensors 64
10.3.1 Replacement of Currenl Sensors 13.5.3 Instantaneous Tripping 92
- AKS 50 65 13.5.4 EC-1 Adjustment 92
10.3.2 Replacement of Curent Sensors 13.6 Positive Trip Adjustment 92
13.7 Reverse Current Tripping Device 93
- AKR 75/100 65
13.7.1 Adjustments 94
10.4 Flux Shift Trip Device 65
13.7.2 Replacements 94
10.5 Troubleshooting 65
13.8 Switchette Feature , 94
10.5.1 Resistance Values , 66
13.9 Trip Device Replacement ., 94
10.5.2 False Tripping-Breakers
Equipped With Ground Fault 67 SECTION 14 - Electrical Characteristics ... 95
106 MicroVersaTrip TM Cabling Diagrams. . . . . . . . . . .. 67
Table 23
SECTION 11-RMS-9/Epic Charging and Closing Operating Currents 95
MicroVersaTrip® 71 Table 24
Bell Alarm Contact-Rating 95
11.1 Programmer Unit 71
Table 25
11.1.1 Fault Trip Indicators 71
Auxiliary Switch Contact Sequence 95
11.2 RMS-9 & Epic MicroVersaTrip Installation 71
Table 26
11.3 Current Sensors ' 72
Auxiliary Switch Contact Ratings 95
11.3.1 Replacement of Current Sensors 75
Table 27
11.4 Flux Shifter Trip Device 75
Charging Times 95
11.5 Troubleshooting 75
11.5.1 Resistance Values 75 Table 28
11.5.2 False Tripping-Breakers Equipped Shunt Trip and Undervoltage Device 96
With Ground Fault , 76 Table 29
11.6 Cabling Diagrams 76 Coil Resistance 96
Table 30
SECTION 12-MicroVersaTrip Plus and N
Instantaneous Undervoltage Device Settings 97
MicroVersaTrip PM Trip Units . .. 79 Table 31
Time-Delay Undervoltage Device Settings 97
12.1 Trip Unit " 79
12.2 Read This First 80
12.3 Product Structure 80 THESE INSTRUCTIONS ARE INTENDED FOR USE BY QUALIFIED
12.4 Trip Unit Removal and Replacement 81 PERSONNEL FOR INSTRUCTION AND MAINTENANCE PURPOSES.
12.5 Phase Current Sensors 82 REPRODUCTION IN WHOLE OR IN PART IS NOT PERMITTED
WITHOUT THE EXPRESS PERMISSION OF GENERAL ELECTRIC.
12.6 Neutral Current Sensors ' 83
12.7 Rating Plug Removal and Replacement , 83
12.8 Trip Unit Functions 83
3
12.9 Trouble-Shooting Guide 84
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SECTION 1-1 ntroduction

Introduction A basic maintenance inspection should consist of an

overall visual check, plus observation of a few closing and
These instructions provide the maintenance procedures opening operations. If a breaker is seldom operated such
and describe the operation of the 1600 thru 4000 amp AC, that it remains open or closed for a period of six months or
6000 amp DC frame size type AKR, AKS low voltage power more, it is recommended that arrangements be made to
circuit breakers listed in Table 1 and Table 2. open and close it several times in succession.
The proper use, care and maintenance of these breakers is Dirt, grease or other foreign material on any parts of the
a prime safety consideration for the protection of breaker should be removed by a thorough and careful
personnel, as well as a means of minimizing equipment cleaning, Insulating surfaces should be checked for
damage when faults occur, Persons who apply, use, and conditions that could degrade insulating properties.
service these breakers will acquire the knowledge they
need by gaining the information contained in these During an inspection, the breaker's contacts should be
instructions, slow-closed manually (with closing springs restrained by
the safety pin) to observe contact alignment and to insure
1.1-lnspection and Maintenance that all mechanism parts move freely, A complete contact
inspection, including measurement of wipe and force,
Breakers should be cared for under a systematic should also be done.
maintenance program. Taking each breaker out of service
periodically for inspection and maintenance is an excellent To properly inspect contacts, the arc quenchers must be
means of establishing high service reliability. It is good removed. At this time thoroughly inspect the inside
policy to have one or more spare breakers to install in surfaces of the arc quencher side plates and inner
place of breakers requiring maintenance. Keeping a stock components,
of recommended renewal parts will insure that
maintenance work can be done quickly. 1.2-Renewal Parts
How frequently an individual breaker should be inspected The AKR breakers contain a variety of parts and
will depend on the circumstances of its use. It would be assemblies, Many of these parts and assemblies are
well to inspect any breaker at least once a year. If it is available as replacement parts when the need arises, See
frequently operated, or installed in an area of high publication GEF4552, Renewal parts, for a complete listing
humidity or a dusty, dirty atmosphere, inspections should of these parts.
be more often. Inspections might be monthly under
adverse conditions,

Table 1-AKS 50 Designations

FRAME SIZE
DRAWOUT MOUNTING STATIONARY
(Amperes) NOTES
MOUNTING
250V.Dc 600V. Ac POLES AKD AKD-5
AKS-(*)-50 AKS-(*)A-50 AKS-(*)S-50
2000 1600 3 (1 )
AKS-(*)-50H AKS-(*)A-50H AKS-(*)S-SOH
- - 2 AKS-(*)-50V AKS-(*)A-50V AKS-(*)S-50V (2)
- 2000 3 AKST-(*)-50H AKST-(*)A-50H AKST-(*)S-SOH (1 )
- 1600 3 AKSU-(*)-50 AKSU-(*)A-50 - (3)

(1) The "H" suffix denotes extended short circuit ratings.

(2) Integrally fLised models.
(*) This digit identifies the trip device type as follows:
2 = EC-1 or EC-2A (Dc only),
4 = ECS
S = SST (50/60 Hertz only)
6 = MicroVersaTrip
N = Non automatic. In addition, all non-automatic 250 VDc breaker types carry the suffix letter D after their
frame number, e,q" AKS-N-50D.
EC-1 & EC-2A trip devices are the electro-mechanical type. ECS, SST, MicroVersaTrip'", RMS-9 and MVT-Plus or MVT-PM
units are Solid State. For detailed information on these trip devices refer to Sections 8 thru 11.
7 = RMS-9
=
9 MVT-PLUS or MVT-PM

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Table 2-AKR 75/100 Designations

FRAME SIZE MOUNTING TYPE

(Amperes) PRIMARY BREAKER
BREAKER DEEP WIDTH
DRAWOUT STUD
6OOV. Ac DESIGNATION Sub- Stationary ESCUTCHEON (Inches)
2SOV. Dc AKD AKD-S AKD-6 AKD-8 TYPE
50/60 Hz. Structure
X Bar
3000 AKR-(*)-75
X Tube
4000 AKR-( *)A-75 X X Tube 25
AKR-(·) B-75 X X Fingers
AKR-(*)G-75 X Fingers
3200
AKR-(*)D-75 X X Fingers
AKR-(*)F-75 X X Fingers
AKR-( *)S-75 X Bar
AKR-(*)D-75H X Fingers
CD 3200 25
AKR-(*)F-75H X Fingers
AKR-(*)-100 X Tube
33
AKR-( ·)A-1 00 X X Tube
AKR-(·) B-100 X X Fingers
6000 4000 AKR-(·)C-100 X Fingers 25
AKR-(·)D-100 X X Fingers
AKR-(*)F-100 X X Fingers
AKR-(·)S-100 X Bar
AKR-(*)W-100 X Bar 33

SPECIAL DC BREAKERS FOR FIELD SWITCHING

ARK-N-75F X Tube
AKR-NB-75F X X Fingers
4000 AKR-ND-75F X X Fingers 25
AKR-NF-75F X X Fingers
AKR-NS-75F X Bar
AKR-N-100F X Tube 33
AKR-N B-1 OOF X X Fingers
6000 AKR-ND-100F X X Fingers
AKR-NF-100F '\ X X Fingers
AKR-NS-100F X Bar 25
AKR-NW-100F X Bar 33

Example: AKR-5B-75 identifies a drawout, substructure-mounted breaker equipped with the SST trip device.
The EC trip devices are electro-mechanical, refer to GEl 86157 for detailed information.
Breaker Models
(*) This digit identifies N = Non-automatic.
the trip device: In addition, all
2 = EC-1 B. Dc only, non-automatic 250V.
4 = ECS Dc breaker types carry the
5 = SST 50/60 Hertz only. suffix letter D after the
6 = MicroVersaTrip 50/60 Hertz only. frame number,
7 = RMS-9 e.g., AKR-NB-75D.
9 = MVT-PLUS or MVT-PM CD AKR-75H not available for DC applications.
For detailed information on
these trip devices refer to
Sections 8 thru 11.

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SECTION 2-General Description

General Description 2.1-Frame Size

Type AKR low-voltage power circuit breakers are used for con- AKR 75 breakers are available in three frame sizes-3200
trolling and protecting power circuits in the low-voltage range amperes A.C. and 4000 amperes D.C. There is also
(usually up to 600 volts). In serving this function, they are a available, for replacement or hole filler application on AKD
means of safely switching loads and automatically clearing cir- or AKD5 switchgear a 3000 amperes A.C. frame.
cuits when abnormal conditions occur. Among these condi-
AKR 100 breakers are available in two frame sizes-4000
tions, the more common are short circuits and sustained
amperes A.C. and 6000 amperes D.C.
overloads and undervoltages.
AKS 50 (replacement breaker for the AK50) is available in
The type AKR breakers are of the "quick-make, quick-
two frame sizes-1600 amperes A.C. and 2000 amperes
break" description, having the feature of storing energy in
A.C. or D.C. depending on trip device.
a closing spring for quick release in closing. In closing,
some energy is transferred to an opening spring to be used These values represent the maximum continuous current
subsequently for fast tripping. capability of the respective frames. However, each breaker
carries a specific rating which is determined by the current
Knowledge of how the breaker is designed and how it
sensor ampere rating or tap setting of the trip device with
operates will enable the purchaser to make proper use of
which it is equipped.
the breaker and to avoid mistakes in its operation. Specific
directions on adjustments and maintenance procedures Individual breaker rating data is shown in Table 5.
will be treated later.
2.2-0 peration
The three main functional components of a breaker are its
mechanism, an assembly comprising the conductive There are Manual and Electrical models. The Manual
members, and the interrupter. breaker has an operating handle which is used to manually
charge the mechanism closing spring. Figure 1 shows a
The mechanism unit is designed to receive energy, store it, typical Manual breaker.
and later (when called upon to do so) deliver it to close the
breaker contacts. It must be able to reverse its
commitment to close the breaker at any point upon the
activation of an automatic trip device (i.e., be "Trip-Free").
Finally, it also must be able to trip open a closed breaker
q\-licky enough to minimize arc erosion and in such a
manner as to effect proper arc transfer to the arc runner.
The current-carrying members of the breaker are
assembled on the back frame, which provides the
mechanical support required and also the insulating
structure needed. The conductive members are the studs
for external connections, movable and stationary contact
sets, pivots for the movable contacts, and provision for
mounting the current transformers.
The interrupter components are, in addition to the arcing
contacts, the arc runners mounted on the back base and
the removable arc quencher assemblies.
I n addition to these basic components, a breaker may be
equipped with any combination of many accessories and
interlocking devices.
Individual breakers may differ in a variety of areas as
shown in Tables 1 and 2. A brief description of these areas Fig. 1. Manually operated, AKD type
follow.
fhe Electrical breaker contains an electric motor which
An outline drawing Is available for each breaker frame size charges the mechanism closing spring. External control
showing critical dimensions. The drawing number appears power is required to energize this motor and its control
on the breaker nameplate and can be obtained from GE.
circuit. A nameplate indicates what voltage is required by
the motor circuit. Figure 2 shows a typical Electrical
breaker.

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 Table 3-Mounting Type Codes
Breaker Type
Code
Letter Drawout Stationary
None AKD ---
A AKD-5,6 ---
B Substructure ---
C AKD-6 Only ---
D AKD-8 ---
F Substructure ---
S --- AKR-75/100 (25" wide)

W --- AKR-100 (33" wide)

2.4-Trip Device
There are six types of solid-state, direct-acting self-
powered trip device systems associated with AKR
breakers. These systems are for AC applications only. For
DC applications an electromechanical system is available.
Fig. 2. Electrically operated, AKD type The trip device system is identified by the first middle digit
in the breaker's nameplate designation as follows:
AKR-(t) C-75
(t) = trip device code per Table 4

2.3-Mounting Table 4- Trip Device Codes

AKR-75 and -100 breakers are furnished in both drawout and
stationary construction. Drawout breakers are equipped with CODE
features which make them easy to install in or withdraw from NUMBER TRIP DEVICE APPLICATION
their associated switch-gear equipment. Stationary breakers 2 EC' DC
are designed to be mounted in a switchboard or enclosure. 3 Power Sensor 2 AC
Mounting consists of bolting the breaker frame to a support- 4 EC AC
ing structure within the switchboard or enclosure. If control 5 SST AC
power connections are needed, a suitable terminal board is 6 MicroVersaTrip AC
supplied. 7 RMS-9 AC
9 MVT-PLUS or MVT-PM AC
The mounting type is identified by the second middle digit
in the breaker nameplate designation as follows: 'EC devices. See Section 11.

AKR-4(tJ-75, where 2Power Sensor devices are discontinued. See publications

(t) = mounting type code letter per Table 3 GEK-7301 and GEK-7309 for detailed servicing
procedures.

2.5-Short Circuit Ratings

Short circuit ratings vary with the applied system voltage. On
240 VAC systems they are also dependent upon whether the
overcurrent trip device contains an instantaneous trip element.
See Table 5.

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Table 5- Breaker Interruption Ratings
30 Interruption Rating
KA RMS Symmetrical
Frame Instantaneous Trip
Size Breaker Rated Maximum Short
(Amperes) Type Voltage (60 Hz AC) With Without Time
635 42 42 42
AKS-50 508 50 50 50
254 65 50 42
1600 AC 635
AKS-50H 508 65 65 65

254
AKSU-50 600 200 200 -
635 42 42
2000 AC AKST-50H 508 42
65 65
254
635
65 65
AKR-75 508 65
254 85 65
3200 AC 635
85 85
AKR-75H 508 85

254 130 85
AKR-75 (fused) 600 200 200 -
635
85 85
AKR-100 508 85
4000 AC
254 130 85
AKR-100 (fused) 600 200 200 -
AKS50
2000 DC 300V DC 50 CD (2) -
AKS 50V
4000 DC AKR 75 300V DC 50 50 -
6000 DC AKR 100 300iJ DC 50 50 -
Q) With 200-2000 amp trip coils
® Consult factory for application data

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SECTION 3-Storage, Safety & Maintenance
3.1-Storage tions, National Electric Safety Code (ANSI C2), The National
Electrical Code, and NFPA 70B Electrical Equipment Mainte-
It is recommended that the breaker be put into service nance must be closely studied and followed. During actual
immediately in its permanent location. If this is not work, supervision should audit practices to assure conformance.
possible, the following precautions must be taken to insure 3. Excellent maintenance is essential for reliability and safety of
the p roper storage of the breaker: any electrical equipment. Industry publications of recom-
1. The breaker should be carefully protected against mended maintenance practices such as ANSI/NFPA 70B, Elec-
condensation, preferably by storing it in a warm trical Equipment Maintenance, should be carefully studied and
dry room, since water absorption has an adverse applied in each user's formation of planned maintenance.
effect on the insulation parts. Circuit breakers for
outdoor switchgear should be stored in the
3.3
equipment only when power is available and the Both long and short term maintenance of all electrical equip-
heaters are in operation to prevent condensation. ment is essential for reliability and safety. Maintenance pro-
grams must be tuned to the specific application, well planned
2. The breaker should be stored in a clean location and carried out consistent with both industry experience and
free from corrosive gases or fumes. Particular care manufacturer's recommendations. Local environment must
should be taken to protect the equipment from always be considered in such programs, including such vari-
moisture and cement dust, as this combination has ables as ambient temperatures, extreme moisture, number of
a very corrosive effect on many parts. operations, corrosive atmosphere or major insect problems
and any other unusual or abusive condition of the application.
One of the critical service activities, sometimes neglected,
CAUTION: IF THE BREAKER IS STORED FOR involves the calibration of various control devices. These
ANY LENGTH OF TIME, IT SHOULD BE monitor conditions in the primary and secondary circuits,
INSPECTED PERIODICALLY TO SEE THAT sometimes initiating emergency corrective action such as
RUSTING HAS NOT STARTED AND TO opening or closing circuit breakers. In view of the vital role
ASSURE GOOD MECHANICAL CONDITION. of these deVices, it is important that a periodic test program
SHOULD THE BREAKER BE STORED UNDER be followed. As was outlined above, it is recognized that the
UNFAVORABLE ATMOSPHERIC CONDI- interval between periodic checks will vary depending upon
TIONS. IT SHOULD BE CLEANED AND DRIED environment, the type of device and the user's experience. It
OUT BEFORE BEING PLACED IN SERVICE. is the General Electric recommendation that, until the user
has accumulated enough experience to select a test interval
better suited to his indiVidual requirements, all significant
3.2 calibrations be checked at an interval of one to two years.

Each user must maintain a safety program for the protection To accomplish this, some items, such as "EC" direct operating
of personnel, as well as other equipment, from the potential trip systems for low voltage breakers, must be tested with
hazards associated with electrical equipment. primary current injection. Others can be adequately tested
using test sets. Specific calibration instructions on particular
The following requirements are intended to augment the devices typically are provided by supplied instruction books.
user's safety program, but NOT supplant the user's respon-
sibility for devising a complete safety program. The follow- Instruction books supplied by manufacturers address com-
ing basic industry practiced safety requirements are appli- ponents that would normaliy require service or maintenance
cable to all major electrical equipment such as switchgear or during the useful life of the equipment. However, they can
switchboards. General Electric neither condones nor assumes not include every possible part that could require attention,
any responsibility for practices which deviate from the following: particularly over a very long service period or under adverse
environments. Maintenance personnel must be alert to dete-
1. ALL CONDUCTORS MUST BE ASSUMED TO BE ENER- rioration of any part of the supplied switchgear, taking ac-
GIZED UNLESS THEIR POTENTIAL HAS BEEN MEASURED AS tions, as necessary to restore it to serviceable status.
GROUND AND SUITABLE GROUNDING CONDUCTORS HAVE
BEEN APPLIED TO PREVENT ENERGIZING. Many accidents Industry publications of recommended maintenance practices
have been caused by back feeds from a wide variety of such as ANSIINFPA 70B, Electrical EqUipment Maintenance,
sources. should be carefully studied and applied in each user's forma-
tion of planned maintenqnce.
2. Although interlocks to reduce some of the risks are provided,
the individual's actions while performing service or maintenance Some users may require additional assistance from General
are essential to prevent accidents. Each person's knowledge; Electric in the planning and performance of maintenance.
his mental awareness; and his planned and executed actions The General Electric Company can be contracted to either
often determine if an accident will occur. The most important undertake maintenance or to provide technical assistance
method of avoiding accidents is for all associated personnel to such as the latest pUblications.
carefully apply a thorough :.Jnderstanding of the specific equip- The performance and safety of this equipment may be com-
rrent from the viewpoints of it's purpose, it's construction, it's promised by the modification of supplied parts or their re-
opJration and the situations which could be hazardous. placement by non identical substitutes. All such design
All personnel associated with installation, operation and mainte- changes must be qualified to ANSI/IEEE Standard C37.59.
nance of electrical equipment, such as power circuit breakers The user should methodically keep wr(tten maintenance
and other power handling equipment, must be thoroughly in- records as an aid in future service planning and equipment
structed, with periodic retraining, regarding power equipment in reliability improvement. Unusual experiences should be
general as well as the particular model of equipment with which promptly communicated to the General Electric Company.
they are working. Instruction books, actual devices and appro- 9
priate safety and maintenance practices such as OSHA publica-
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SECTION 4-Breaker Operation

Breaker Operation 4.2-Electrical Closing

The AKS-50, AKR-75 and AKR-100 breakers are closed by On electrically operated breakers, the closing springs are
the discharging of the energy stored in the closing springs charged by a gear motor. With the springs discharged, volt-
of the breaker. As the closing springs are discharged, the age applied to the control circuit will energize the motor
energy is directed into the closing cam of the breaker through the "G" switch contacts-see figs. 3A & 3B. The mo-
which causes the moveable breaker contacts to be forced tor, through the gear reduction output crank, compresses the
against the stationary contacts, and, at the same time closing springs until they are fully charged. As this fully
causes the opening springs to be charged so they may charged position is reached, mechanically operated switch
open the breaker during a subsequent opening operation. "G" reverses its shown position, deenergizing the motor. In
the fig. 3A diagram switch "F" reverses its position and es-
4.1-Manual Closing tablishes a circuit for the "X" relay. At the same time, a me-
chanical prop is positioned to prevent the discharge of the
Manually operated breakers are equipped with a handle fully charged closing spring.
which extends from the escutcheon of the breaker.
With the closing spring pr-opped fully-charged, the breaker
Alternately rotating the closing handle counterclockwise
is ready for closing. This may be accomplished electrically
then clockwise through approximately 120 degrees of
by depressing the closing button on the bre'aker (if so
rotation through four complete cycles will cause the
equipped) or by a remote closing switch. Operation of the
breaker to close. During the four counterclockwise
closing switch energizes the "X" relay, which in turn
movements and the first three clockwise movements of the
energizes the closing solenoid. This removes the prop,
handle, the springs are progressively charged. After
releasing the closing springs to close the breaker.
approximately seven degrees travel of the fourth clockwise
handle movement, the spring charge mechanism is driven As the closing relay is energized, it energizes anti-pump
"over center" and the energy stored in the closing springs relay "W". If the closing switch is maintained closed, the
is directed into the closing cam and causes the breaker to anti-pump relay will remain picked-up to prevent a second
close. A charge-indicator, numbered one to four, visible closing operation on the breaker in the event it is tripped
through the breaker escutcheon, indicates the number of open automatically. The closing impulse must be released
complete handle movements that have been performed. and reapplied before a second closing operation can occur.

LEGEND

CC - CLOSING SOLENOID
CONTROL
SOURCE F- CUTOFF SWITCH, CLOSED
WHEN CLOSING SPRING IS
FULLY CHARGED.
G- CUTOFF SWITCH. OPEN WHEN
CLOSING SPRING IS
FULLY CHARGED.
CC
L- AUXILIARY SWITCH
M- CHARGING MOTOR
PB - CLOSE PUSHBUnON ON
BREAKER ESCUTCHEON,
OPTIONAL.
TC TC - SHUNT TRIP DEVICE
W- ANTI-PUMP RELAY
X- CONTROL RELAY

Fig.3A. Elementary diagram for electrically operated drawout breaker.

Contact positions are shown with breaker open and closing springs discharged.
TYP #5688736 "R" series.
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4.2.1-Alternate Control Circuit equipped) or by a remote closing switch. Operation of the
closing switch energizes the W-relay, which in turn
Later production breakers use the electrical control circuit
energizes the closing solenoid. This removes the prop,
shown in Fig. 3B. This circuit is similar to the circuit shown
in Fig. 3A except that the X-relay and 'F' switch are elimi- releasing the closing springs to close the breaker.
nated. If the closing switch is maintained closed, the anti-pump re-
lay will remain picked-up to prevent a second motor charge
The motor is energized through the 'G' switch and the W-
and closing operation on the breaker in the event it is tripped
relay contact. The 'G' switch deenergizes the motor when
open automatically. The closing impulse must be released
the closing springs are charged and the prop is engaged.
and reapplied after the closing springs are fully-charged be-
With the closing spring propped fUlly-charged, the breaker fore a second closing operation can occur. The charging
is ready for closing. This may be accomplished electrically time is typically 1 to 3 seconds depending on voltage and
by depressing the closing switch on the breaker (if so the maximum time permitted is 5 seconds.

REMOTE
CLOSE
0-------0- - -1 ~ -.., LEGEND
)...
CONTROL
SOURCE
t~ PB
CC -
G-
CLOSING SOLENOID
CUTOFF SWITCH. OPEN WHEN
CLOSING SPRING IS
FULLY CHARGED.
W L- AUXILIARY SWITCH
M - CHARGING MOTOR
PB - CLOSE PUSHBUTTON ON
BREAKER ESCUTCHEON,
OPTIONAL.
TC ....... SHUNT TRIP DEVICE
L W- ANTI-PUMP RELAY

CC w TC

Fig. 38. Alternate elementary diagram. Contact positions are shown breaker open and
closing springs discharged. TYP #5688736 "8" series.

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SECTION 4-Breaker Operation

4.3-Connections 4.3.1-Stationary Breaker

In all electrical connections good joint conductivity is a Control connections to stationary breakers are made to a
must. When making power connections to stationary terminal board mounted on the breaker. Figure 4 shows
breakers, the mating joint surfaces must be clean and have typical closing and tripping connections. If equipped with
a smooth finish. They should be parallel and firmly bolted an overcurrent trip device which includes a ground fault
or clamped together. In addition, the bus or cable element for use on 4-wire circuits, an additional terminal
conductors must have ample ampacity to prevent board is provided on the breaker for connecting to the
overheat ing. equipment-mounted neutral sensor (physically located in
the neutral conductor).
The outgoing connections to breaker accessories and
control devices must be in accordance with the specific
wiring diagram applicable to that breaker.
4.3.2-Drawout Breaker
On drawout breakers the control circuits terminate in the
breaker compartment on the stationary portion of
separable secondary disconnects - see fig. 5.

Q d 9 0 o 0 0 0 0 0
TERMINAL BOARD 2 3 4 5 6 7 8 9 10
MOUNTED ON FRONT
OF BREAKER AT TO AUX. SW
UPPER LEFT "a" CONTACT

CUSTOMER
CONNECTIONS "-t---'
UV
TRIP
SOURCE 1-) 1+)

REVERSE
CURRENT
'-.,-' '-.,-' DEVICE
POTENTIAL
CLOSING TRIP SOURCE
SOURCE SOURCE

Fig. 4. Control connections to stationary breakers-front view

IYI
IY)}
TRIP CLOSING
SOURCE FUSE
SOURCE
{
(X)~ IX)

TRIP

/\/\/\/\/\/\/\ /\ /\ /\ /\ /\ /\ /\
765432 765432 765432

STATIONARY SECONDARY DISCONNECT BLOCKS

LOCATED AT TOP OF COMPARTMENT -
POSITIONS BAND C FURNISHED
ONLY WHEN-REQUIRED

1 J
Fig. 5. Control connections to drawout breakers - front view of breaker compartment

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4.4-Tripping 4.5-Charging and Closing Using
In the closed position, the breaker movable contacts are the Maintenance Handle
held in by a toggle linkage, The breaker is tripped open by
In the absence of control power, an electric breaker can be
displacing a mechanism latch which allows this toggle
closed manually by using the maintenance handle to
linkage to collapse, The trip latch is rigidly fastened to a
charge the closing springs. Referring to Fig. 6:
horizontal trip shaft running from left to right through the
breaker, In turn, the trip shaft carries paddles actuated by (a) With the breaker open and springs discharged
the manual trip button and the various other trip devices- release holding pawl slide per instruction label (2).
overcurrent, reverse current, shunt trip, undervoltage, (b) Install maintenance crank (1) (5686386Gl) to the motor
open fuse lockout. Viewing the breaker from the right, gear reducer shaft on the front right side of the breaker. Rat-
rotating the trip shaft counterclockwise trips the breaker; chet the maintenance crank up and down until the springs are
clockwise movement resets the mechanism latch, fully charged as indicated by the distinct click as the prop is
In addition to tripping the breaker, some devices hold the set. This prevents any further charging of the closing springs.
breaker trip free, i.e" prevent the contacts from closing After the prop is set do not apply undue force to the
even though a closing impulse is applied to the maintenance handle.
mechanism. Such devices are the undervoltage, bell alarm (c) Depress the "Spring Discharge" lever (3) located
and lockout, electric lockout, open fuse lockout, and the under the horizontal su pport on the front frame. The
key operated locks. springs should discharge and if the latch is properly reset,
These devices and the drawout mechanism interlocks must the breaker will close. Some style breakers, because of an
be in the reset position before the breaker can be closed. interlock in the SWitchgear, can not be manually closed in
the fully engaged position.
(d) Open the breaker by pushing the trip button (4).

1. Maintenance crank
2. Instruction label
3. Spring discharge lever
4. Trip button

Fig. 6. Maintenance handle charging

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SECTION 5-Contact Maintenance

Contact Maintenance 5.1.1-Electrical Breaker

Breakers subjected to frequent interruption of high Referring to Fig. 7:
currents may eventually require replacement of their
a. Attach maintenance handle (1) and charge the
contacts. The general rule for determining need of
closing springs until the crank roller contacts prop (4).
replacement is the loss of one-half or more of the mass of
the contact tip material. Roughening or light pitting of the b. Insert safety pins (3) into the holes in the guide rods
contact surface does not indicate loss of ability to carry or (2).
interru pt cu rrent.
c. Release the prop by depressing closing lever (5). The
For proper operation of the breaker, the contact structures safety pin now takes the full force of the spring and
must be correctly adjusted. Various interrelated restrains it. Now free from spring influence, the breaker
adjustment parameters are involved. Specific amount of contacts can be inspected and moved at will to the fully
contact pressure and wipe must exist between moveable closed position by means of the maintenance handle.
and stationary contacts, The arcing, intermediate and main
contact assemblies must engage and disengage in a 5.1.2-M anual Breaker
prescribed sequence; and with breaker open, an adequate
a. Operate the breaker closing handle through 3%
gap must exist between the movable and stationary arcing
complete movements to charge the closing springs.
contacts.
b. I nsert the safety pins into the gUide rods.
5.1-Slow Closing the Breaker c. Continue to operate the closing handle (4th
To perform contact maintenance work the breaker downstroke) until the spring crank goes over center,
operating mechanism must be "slow-closed", i.e. manually applying full spring force to the safety pin. Closing motion
driven and controlled at will instead of in the high-speed now can be continued and is completely controlled by the
manner produced by spring discharge. Slow closing is breaker closing handle.
achieved by preventing the closing springs from acting on
the mechanism. The breaker is arranged for slow closing
by manually charging the springs and then securing them
WARNING: DO NOT APPLY CONTROL
in this compressed state by inserting a restraining "safety
VOLTAGE OR RACK THE BREAKER INTO
pin" see Fig. 7.
THE TEST OR CONNECTED POSITIONS
Following the inspection period, WHILE THE SAFETY PINS ARE IN USE.
a. Recharge the closing springs.
b. Remove the safety pins from the guide rods, return
them to thei r storage clips.

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 1. Maintenance
2. Guide rods
3. Safety pins
4. Prop
5. Closing springs

Fig. 7. Installation of safety pin

5.2-Arc Quencher Removal and 5.2.1-Removal and Replacement

Inspection Referring to Fig. 8:
a. Be sure breaker is open.
The arc quenchers should be inspected at the regular in-
spection period. If item 1 is eroded to .125 of an inch from b. Loosen nuts (4) and remove the two slotted head jack
original conture or item 2 is cracked, Fig. 8, the arc quencher screws.
should be replaced. c. Remove two hex head bolts (5) that mount channel-
shaped retaining bar to side support (6).
d. Remove channel-shaped retaining bar.
(Continued next page)

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SECTION 5-Contact Maintenance

1., 2. & 3.Barriers

4.Nuts
5.Hex head bolts
6.Side support
7.Protective, barrier
B. Phase barrier screws
9. Mounting bolts
Original design

Fig. 8. Arc quencher removal

e. Lift arc quenchers clear of the movable arcing contact 5.3-Separation of Front and
arms.
Back Frames
f. Inspect arc quenchers carefully and replace if
In order to perform some repair and replacement
necessary.
operation, the front frame must be separated from the back
g. During replacement, tighten jack screw nuts (4) first, frame. Proceed as follows: referring to Fig. 9.
then the two hex head bolts that secure the channel-
a. Open the breaker, manually compress the closing
shaped retaining bar to side sheet. DO NOT
springs and insert the safety pin as described under
OVERTIGHTEN THESE TWO SOLTS.
SLOW CLOSING, Section 5.1. Restraining the springs
properly positions the main operating cam to facilitate the
separation operation.

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 ~-

E1-
1]-

1. Opening springs 4. Flux shifter actuator bracket 7. Side support bolts

2. Clevis pin 5. Auxiliary switch 8. Position interlock
3. Front/back frame operating rod 9. Arc quencher retainer bolts
connector 6. Phase barriers
Fig. 9. Front and back frame separation details

b. Remove the two opening springs (1) (on lower part of k. Remove the six nuts from the back frame using a
the breaker) from the outside pole units. socket wrench with an extension. These include the two
nuts at the top of the frame.
c. Remove the clevis pin (2) from the center pole unit.
I. Check along the trip shaft for a mechanical
d. Disconnect the programmer CT wire harness at each CT
interference or connection between the overcurrent trip
and remove any tye wraps holding leads to back frame.
device and the trip paddles. Remove mechanical
e. Disconnect the flux shifter actuator bracket from the connection if present, or if interference exists, use extreme
crossbar assembly (4). care when removing or reassembling front and back
frames to avoid mechanical breakage of trip devices.
f. Remove the auxiliary switch operating rod (5).
When reassembling the front and back frames, both should
g. Remove outside phase barriers (6).
be positioned vertically so that the trip shaft is horizontally
h. Remove side support bolts (7). aligned. It is recommended that the breaker back frame
i. Remove position interlock on AKD, AKD 5. AKD be fastened to a suitable mounting surface so that the front
6 type (8). frame can be supported by a sling or hook as the bolts are
being installed.
j. Remove arc quencher retainer and bolts (9).

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SECTION 5-Contact Maintenance
5.4-Back Frame Assembly Mating with the stationary contacts is a moveable contact
assembly consisting of multiple main and intermediate con-
The breaker backframe consists of a frame assembly to
tact fingers (10) and (8). These moveable contact fingers
which the pole units are mounted. Each pole unit is
pivot on a stationary pin (11), which fasten them to the lower
connected to a common crossbar which provides for
contact block. The insulated link (13) which is attached to
simultaneous pole unit operation by the breakers
the breaker crossbar (1) and moveable contact assembly
mechanism. A typical backframe is shown in Fig. 10. gives the open and close motion to the contact arm.
The pole units consist of a molded base which supports
The stationary arcing contact assembly (3) is a separate
the line and load stud assemblies, stationary and moveable
set of contact fingers, pins, springs and pivot block.
contact assemblies and the actuating linkage.
The moveable arcing contact assembly (5) consists of
The stationary main contact assembly (9) comprises of a
multiple contact arms carried on two moveable pins (6)
spring loaded contact fingers. Interlocked with these are
and (12). The arcing contact arms interleave the main
the intermediate contact fingers (7) whose contact surface
contacts and pivot with them about pin (6). This relative
project beyond that of the mai n such that the
motion is obtained by the insulating links (13) from the
intermediates make before, and break after the mains.
contact arms to the breaker crossbar.

BACK FRAME ASSEMBLY

1. Crossbar 7. Stationary intermediate contact
2. Pole unit 8. Moveable intermediate contact
3. Stationary arcing contact 9. Stationary main contact
4. Pin-stationary arcing 10. Moveable main contact
5. Moveable arcing contact 11. Pivot pins
6. Pin-moveable arcing 12. Drive pins
13. Insulated link

Fig. 10. Front view of back frame assembly

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5.5-Measuring Contact Force 5.6-Measuring Contact Wipe
a. Remove the arc quenchers. Referring to Fig.11:

b. Separate front and back frames, refer to a. Remove arc quenchers.

Section 5.3 b. With the breaker open measure the horizontal distance
c. Inspect all contacts for wear and arc erosion and, from the edge of the stationary arcing contact to the retainer
if necessary, replace (see criteria for replacement, Section ("A" dim.); for main and intermediate contacts measure the
5.10) horizontal distance from the top of the cont act to the contact
arm retainer ("8" dim.).
d. Measure contact force only if you replace contact
arms. c. Close the breaker and repeat step b. The difference
between the readings determines the contact wipe.
5.5.1-Stationary Arcing Contacts See Table 6 for correct readings.
Referring to Fig. 11:
Place a push scale on the stationary arcing contact at a CAUTION: FOR SAFETY REASONS BE
poi nt 1-3/16 from the contact pivot and depress that EXTREMELY CAREFUL NOT TO TRIP THE
contact 1/4 of an inch. Load on the scale should read BREAKER WHEN MEASURING CONTACT
within the range listed in Table 6, column 8. WIPE.
If the load is not within the range listed in column 8,
replace the spring under that contact assembly.
5.7-Adjusting Contact Wipe
5.5.2-Stationary Main and Referring to Fig. 11:
Intermediate Contacts a. To obtain proper contact wipe and pressure on the
Place a push scale on the stationary contact at a point 2- center pole, dimension "C" should be increased to
7/8 from the contact pivot and depress that contact to the increase wipe and decreased to decrease wipe.
wipe dimension shown in Table 6, column 3 for the mains b. To change dimension "COO remove the clevis pin and
and column 6 for the intermediates. Load on the scale rotate the clevis as necessary.
should read within the range listed in Table 6, column 2 for
c. To prevent overstressing the clevis threads dimension
the mains and column 5 for the intermediates.
"COO should not exceed 3/16 in. and space "COO should be
If the load is not within the range listed replace the spring filled with shims to 0.005 in. of being solid. "
under that contact assembly.
d. With the proper center pole wipe obtained, moving
the crossbar adjusti ng plate on the center pole to the right
will simultaneously increase the wipe on both outside
poles; moving the adjusting plate to the left will have the
reverse effect.
e. To increase the wipe on either outside pole, individually
move the crossbar adjusting plate of that pole to the left; to
decrease the wipe move the adjusting plate to the right. See
Section 5.11.

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SECTION 5-Contact Maintenance

Open gap
/
2'12 to 2314

Clevis
A_.v--+~ (centerpole)
Stationary
Arcing Contact

Lower
UPPER Stationary main contact Stud
STUD

Fig. 11. Measuring contact force

Table 6
Main Contacts Intermediate Contacts Arcing Contacts

Column 1 2 3 4 5 6 7 8 9
Wipe Wipe Wipe
Oty. Force in Oty. Force in Oty. Force In
Breaker Per in Inches Per in Inches Per in Inches
Type Pole Lbs. (B) Pole Lbs. (B) Pole Lbs. (A)
AKS-50 (AC)
AKS-!iO 10C;\
3
~
35-55 1
1
35-55 ·· 2
3 5/32 to
AKR-75 (AC)
AKR-75 (DC)
5
5
25-55
'/'6 to
'/64
1
1 25-55
·· 3
5
31-43 9/32

AKR-100 (AC/DC) 6 2
· 5

'The intermediate contact wipe should be at least '/16 in. greater than main contact wipe.

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5.B-Measuring Contact Open Gap Measure the contact open gap between the movable and
stationary contacts as shown in Fig. 13. This distance
Prior to measuring the open gap verify that the cross arm
buffer assemblies, refer to Fig. 12, are touching. The stack- should be between 2-1/2" to 2-3/4". This gap may be
up dimension of each buffer should be within .015" of each adjusted by repositioning shims on crossbar assembly.
other. Adjust to this dimension by adding or removing wash- The locking nuts on the buffer bolts should be locked in
ers. such a position that the buffer bolt may be rotated freely.

1-B uffer stop

2-Buffer washers
3-Buffer shims
~­ 4-Lock nuts
iF

Fig. 12. Buffer assembly

Fig. 13. Measuring contact open gap

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SECTION 5-Contact Maintenance
5.9-Checking Contact Sequence 5.10-Replacement of Contacts
On the horizontal plane, the difference in the making of the Criteria for replacement:
arci ng contacts on the same pole must be no greater than
a. Arcing contacts should be replaced when eroded to a
1/16 in.; this difference between arcing contacts on
thickness of 5/64.
separate poles must be 1/16 in. If it is desired to advance
or retard the closing of the main contacts of a pole, loosen b. Intermediate contacts should be replaced when flush
the bolts holding the adjustment plate, refer to Fig. 21, of with main contacts (.062 lead when new).
that pole and slide plate to the left to advance contact c. Main contact very seldom needs replacement.
closing, or to the right to retard contact closing. Make this Replace when arcing contacts have been neglected
adjustment on the outer poles, using the center pole as a causing severe erosion of mains so you can not obtain
reference. Upon retightening adjustment plate bolts, make proper contact depression.
sure the locking tabs are turned up around bolt heads,
locking the bolts securely in place. When replacing the arcing contact assemblies you do not
have to separate the front frame from the back frame.
Contact sequence in the vertical plane should be such that
when the arcing contacts are just touching, the 5.1 O.1-Stationary Arcing Contacts
intermediate contact gap should be at least 3/16 in. and
the main contacts gap at least 1/4 in., see Fig. 14. a. Refer to Fig. 15.
b. Remove insulator block (1).
NOTE: This check can best be made by means c. Slide pin (2) to side. Contact assembly (3) will lift
of the maintenance handle, with the safety pin freely exposing two springs (4) and button (5) ..
restraining the closing springs. See Section 5.1
d. Install new parts inreverse order.
for this procedure.

5.10.2-Movable Arcing Contacts

If the gap is under the required minimum, it is usually pos- These contact arms should be replaced whenever the sta-
sible to form the arcing contacts and obtain the required di- tionary arcing contacts are replaced.
mensions. To form the contacts, place a piece of conduit
approximately two feet long, over the contact and form the a. Refer to Fig. 15.
contact either forward or backward by bending it. If the b. Remove retaining rings (6). Slide pins to side and
proper dimensions are still not obtained, the moveable arc-
withdraw the contact arms.
ing contacts should be replaced.
If it has been necessary to make any adjustments while
obtaining proper contact sequence, the contact wipe must
be checked, and adjusted, if necessary, see Section 5.6.

1. Insulator block 4. Springs

2. Pin 5. Button
3. Contact assembly 6. Retaining rings

Fig. 15. Replacement of stationary and

Fig. 14. Measuring main contact gap movable arcing contacts

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 5.10.3-Moveable Main and d. Remove contact arms, noting two spring washers (9)
on each contact pivot.
Intermediate Contacts
Upon re-assembly, position two spring washers into
a. Refer to Fig. 16.
counter bore on one side of contact arm (9). Note left and
b. Loosen crossbar bolts so link (10) can move freely. right hand orientation of contact arms and position of
intermediate contact.
c. Remove retaining rings (7) from pins (8).
Slide pins (8) until contact arms can be withdrawn. e. Before tightening crossbar see assembly and
adjustment of crossbar, Section 5.11.

iE----

7. Retaining rings
8. Pins
9. Spring washers
10. Crossbar bolts
11. Intermediate contact

Fig. 16. Replacement of main and intermediate contacts

23

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SECTION 5-Contact Maintenance
5.10.4-Stationary Intermediate and f. Remove contact, noting two spring washers on each
contact pivot. Upon re-assembly, position two spring
Main Contacts washers into counter bore on one side of contact arm. Fig.
a. Separate the front frame from the back frame. Refer 19.
to Section 5.3.
b. Remove crossbar. NOTE: Left and righthand orientation of
contact arms and position of intermediate
NOTE:ln the steps below, refer to Fig. 17 to contact. Fig. 19.
identify the numbers in the parenthesis.
g. Depress main and intermediate contacts to relieve
c. Remove arcing contact block (3) by removing allen spring pressure on contact stop bracket before starting
screws (4) and (5). screws. Tighten screws before releasing pressure.
Fig. 18.
d. Depress main and intermediate contacts as shown in
Fig. 18 to relieve spring pressure on contact stop bracket h. Re-install arcing contact block by holding arcing
(6) before removing mounting screws. On AKR100 you contacts depressed (Fig. 20) while tightening screws.
must remove the outside moveable contact arm before i. Assemble crossbar.
trying to remove contact stop bracket mounting screws.
j. Always check contact wipe following contact
e. Remove retaining ring (7) and slide pin (8) to side and replacement. See Secton 5.6.
withdraw the contact arm. Fig. 17.

ill
1. Main contact arm 6. Contact stop bracket
2. I ntermediate contact arm
3. Arcing contact block Fig. 18. Relieving spring pressure
4. Arcing contact
5. Allen screws
6. Contact stop bracket
7. Retaining ring
8. Pivot pin

Fig. 17. Intermediate and main contacts-

assembly details

24

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 Fig. 19. Upper stud details Fig. 20. Re-assembly of arcing contacts

5.11-Assembly and Adjustment of screws with locking plates on crossbar finger tight and set
crossbar to dimension shown making sure that all three
Crossbar poles of moveable arcing contacts are touching stationary
When assembling crossbar to back frame push moveable arcing contacts within .032. Tighten screws as shown first
arcing contacts forward until they touch stationary arcing "A", second "B", and finally "C" to 400 inch pounds. Bend
contacts on upper terminal. Then lay crossbar on top of tabs on locking plates to secure screws. Refer to Fig. 21.
links on pole units. Assemble adjusting plates as shown After assembling crossbar always check contact wipe and
making sure slots in plates are properly oriented. Fasten open gap, see Sections 5.6 thru 5.8.

1. Crossbar 3. Moveable arcing contacts

2. Stationary arcing contacts 4. Adjustment plates

Fig. 21. Crossbar assembly

25

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SECTION 6-Breaker Maintenance

Breaker Maintenance 6.3-Breaker Mechanism

Adjustments
Electric and Manual breakers have the same basic
6.1-Safety Precautions mechanism shown in Fig. 22. All the adjustments detailed
BEFORE INSPECTION OR ANY below must be made with the breaker in the upright
MAINTENANCE WORK IS DONE BE SURE position and the mechanism in the reset position as shown
THAT THE BREAKER IS IN THE OPEN in Fig. 22B. Reset the mechanism by manual operation
POSITION. ALL ELECTRICAL POWER, BOTH using the slow close method given in Section 5.1. The
PRIMARY AND CONTROL SOURCES, roller (15) must be clear of the cam (2), see Fig. 22C.
SHOULD ALSO BE DISCONNECTED.
ENSURE THAT THE CLOSING SPRINGS ARE
6.3.1-Trip Latch
DISCHARGED. Referring to Figs. 22C, 220 & 23, the gap between the trip
latch (10) and the roller (9) should be between .015 and
6.2-Lubrication .032. This adjustment can be obtained by loosening nut
(19) and turning allen screw (6).
In general, the circuit breaker requires moderate lubrication.
Bearing points and sliding surfaces should be lubricated at
the regular inspection periods with a thin film of GE Lubricant
6.3.2-Latch Buffer
050HD38 (D6A15A1 Mobilgrease 28). Before lubricating, re- Referring to Fig. 220, the center line of the trip latch (10)
move any hardened grease and dirt from latch and bearing should pass through the center of the roller (9). The latch
surfaces with kerosene. ALL EXCESS LUBRICANT SHOULD buffer (18) on the mechanism frame can be adjusted by
BE REMOVED WITH A CLEAN CLOTH TO AVOID ACCUMU- loosening the retaining screws to reposition the latch with
LATION OF DIRT OR DUST. respect to the roller.

NOTE: The use of cotton waste to wipe bearing

6.3.3-Reset Latch, Bearing
surfaces should be avoided, as the cotton and Prop
ravelings may become entangled under the Referring to Figs. 22C, 220 & 24, the distance between the
bearing surfaces and destroy the surface of the bearing (17) and the prop (5) should be between .015 and
bearing. .032. To obtain this gap, advance or retard the nuts (4A) on
the bottom of the rod using the reset spring (4).
On drawout breakers the contact surface of the disconnect
studs should be cleaned and greased with GE Lubricant
D50H 038 (D6A15A1 Mobilgrease 28).

Fig. 22A. Mechanism in motion before

resetting as shown in Fig. 22C Fig. 228. Mechanism in reset position

26

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 ill] 7----iE
I
11~----iE

iJ'
[II
~--It-I~
-ml
~ d >'-~J--~

II i- ---1
Q---rlJ
\\~,~:---a
.4t=====,;m
~

~
1. Spring 10. Trip latch
2. Cam 11. Trip shaft
3. Link 12. Clevis pin
4. Reset spring 13. Clevis
4A. Spring adjusting nuts 14. Reset latch
5. Prop 15. Roller
6. Adjusting screw 16. Prop
7. Adjusting screw stop pin 17. Bearing
8. Prop return spring 18. Buffer
9. Roller 19. Nut

Fig. 22C. Mechanism in closed position Fig. 220. Latch, bearing, and prop
(closing spring discharged)

-il
-~ -il
-~

-~
-f]

1. Feeler gage 2. Trip latch 3. Roller 1. Feeler gage 2. Prop 3. Bearing

Fig. 23. Adjusting trip latch and roller Fig. 24. Adjusting bearing and prop

27

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SECTION 6-Breaker Maintenance
6.4-Electrical Mechanism 6.4.1-Control Components
The function of the electrical mechanism is to charge and Referring to Fig. 25:
discharge the closing springs either electrically or
The control relay (X) is located on the left side of the front
manually. The electrical mechanism consists of
frame channel. It may be removed by disconnecting the
a. Control components wiring, loosening the two mounting screws and lifting it
slightly to pass the top mounting screw through the
b. Charging motor
keyhole mounting. The entire relay should be replaced
c. Motor operator unit rather than changing coils and contacts.
d. Spring discharge interlock The antipump relay (W) is located on the left side of the
front channel. The connections to this relay are soldered.
Section 4.2 details the associated control circuitry for the
electrical mechanism. Relay replacement requires unsoldering of these
connections and removing the mounting hardware. When
replacing relay take care in soldering connections. Do not
use excess amount of solder on connectors as to impair
operation of contact arms.
The closing solenoid is located in the lower right hand side
of the motor operator unit. The switchette is separately
mounted in front of the solenoid.

1. Terminal board 4. Motor 7. Closing button

2. Auxiliary switch 5. Anti-pump relay (W) 8. Switchette
3. F&G switches 6. Control relay (X) 9. Closing solenoid

Fig. 25. Control component location

28

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After replacing closing solenoid or switchette check
adjustment of switchette and readjust if necessary. With
breaker in discharge position use a .010 feeler gage and
push closing solenoid to position shown in Fig. 26.
Switchette must be activated at this point. To adjust loosen
MOlor
switchette mounting screws and pivot switch until AHembly
OPERATOR
activated, then tighten screws. Recheck. Mounting
Hrmiwr.tre

~ Closing Solenoid
MOTOR
mounting
Hardware
//~
Maintenance
Handle Shall
,
W
'----='l'+.IIF:1Io-""""~Retaining Ring
Drille Link
.0'_.060,men","
required with
lever in posilion
shown Adjust
II necessary

Opening Spring
Bracket

Opt>fd!,ng leyer

Fig. 27. Electrical mechanism

Connection
"0" Points

Fig. 26. Switchette adjustment

6.4.2-Charging Motor
The charging motor is located on the right side of the
breaker. It is mounted on the motor operator as shown in
Fig. 27. A driving pawl is mounted eccentrically on the -iJ
motor shaft, see Fig. 28. As the motor turns, the driving
pawl rotates the ratchet which charges the closing springs.
The ratchet is kept from reversing its direction by the
holding pawl. To remove the motor:
a. On AKS 50 you must remove the side sheet.
b. Disconnect and identify the motor leads at the closing
solenoid and cutoff switch.
c. Remove three motor mounting screws.
1. Driving pawl
d. Remove motor.
e. When reassembling, assemble with the driving pawl Fig. 28. Motor removal
pointing toward the front of the breaker.
See Fig. 28.

29

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SECTION 6-Breaker Maintenance
6.4.3-Motor Operator Unit The motor drives the crank roller/maintenance handle
shaft until the control circuitry stops the motor and roller is
The motor operator unit is located on the right hand side
against the prop. The crank roller drives the cam shaft,
of the breaker as shown in Fig. 29. Operator details are
charging the spring, through the cam shaft paddle,
shown in Fig. 30.
see Fig. 31.
The motor operator unit is not adjustable. To replace the
unit, refer to Fig. 27:
a. Slow close the breaker, see Section 5.1
b. Remove the motor, see Section 6.4.2. The motor
wiring doesn't have to be disconnected.
c. Disconnect the wiring to the closing solenoid and
solenoid switch.
d. Remove retaining ring from closing solenoid drive
link.
e. Remove three mounting bolts, one from the side, two
from the bottom of the charging mechanism. Note the
positions of the standoffs on the two bottom mounting
bolts and replace in the same position when reassembling.
f. Rotate motor operator shaft so its crank roller faces
the rear of the breaker. Refer to Fig. 32.
g. Slide spring charging mechanism out toward the right
of the breaker.

1. Motor operator unit h. Install new spring charging mechanism making sure
the crank roller engages cam shaft guide. Refer to
Fig. 29. Motor operator unit location Figs. 31 and 33.

1)= ===rl -
II II
- - -
Cam
Shaft Pivot I' "
~'II :I Celm Shaft
____ l'==:=:J,L---- Paddle
Crank
Roller

Maintenance Motor
Handle Shaft Operator
Crank
Roller .
Assembly Guide

r"T-t--_ era n k
Roller

Fig. 31. Engagement of the motor operator

crank roller with the cam shaft
Fig. 30. Motor operator unit paddle

30

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 i. Reassemble all components and connect all wires.
j. Remove safety pin from closing spring by placing
your maintenance handle on the shaft which extends from
the spring charging mechanism and charge the closing
spring until the charging mechanism roller engages with
tile prop. Remove safety pin. This must be done before
power is applied to motor.
k. Operate the breaker using the maintenance handle
and spring discharge mechanism a few times. Verify that
the breaker is operati ng properly.
I. Before applying control voltage to your breaker verify
that the motor cut off switches are properly adjusted.
Charge the closing spring as described in
step j. (roller resting on prop). Adjust the motor cut off
switches, shown in Fig. 35, so that they are depressed to
the point where the main stem of each switch is located
.005" to .031" from the threaded barrel, see Fig. 34.
(Continued next page)

Fig. 32. Motor operator removal

______ .031
-4---

.005

Main Stem
Threaded Barrel

Fig. 34. Motor cutoff switch adjustment

1. Cam shaft paddle

2. Guide

Fig. 33. Cam shaft lever and guide

31

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SECTION 6-Breaker Maintenance
6.4.3-Motor Operator Unit (Cont.)
m. When the control voltage is applied to your breaker,
the motor operator will be energized and charge the
closing spring. The G switch (see Fig. 36) of the motor cut
off switch unit will stop the motor operator just before the
roller engages the prop. The breaker may be closed
manually by depressing the spring discharge lever or
electrically by energizing the closing solenoid.

Right Side "G" Switch

Center Channel
Control Voltage
Nameplate

"F" Switch

Fig. 36. F & G switch location

6.S-Manual Mechanism
The manual AKR breaker is equipped with the spring-
_ .l!
charged, stored-energy mechanism shown in
Figs. 37 & 38.
The stored-energy operating mechanism of a manual
breaker consists basically of a closing spring assembly,
Spacer ratchet wheel and output crank assembly, handle shaft and
pawl assembly, and the escutcheon-mounted closing
handle.
The closing springs (5) are charged by operating the
manual closing handle (22) on the front of the breaker,
Paddle - - - ' f - ; ; I
instead of the closing motor as is the case with the
electrical breaker. Closing this breaker is accomplished by
pumping the operating handle four complete cycles, first
counterclockwise through 120 degrees from its normal
vertical position and then clockwise back through 120
degrees from its normal vertical position and then
clockwise back through 120 degrees. When approximately
70 degrees of the fourth clockwise stroke have been
completed, the closing springs, which have been charged
during the previous strokes to the closing handle, are
driven over-center and the breaker closes.
Fig. 35. Motor cutoff switch unit
The first stroke of the closing handle causes the ratchet
pawls (21) attached to the handle shaft (23), to engage the
6.4.4-Spring Discharge Interlock first tooth of the ratchet wheel (17), thus beginning to
charge the closing springs. The subsequent closing handle
Referring to Figs. 27 & 30, the spring is discharged when
strokes perform the same fu nction as the pawls (21)
the prop is pulled out from the roller. This is done
engage the teeth in the ratchet wheel (17), thus rotating
electrically by the closing solenoid and manually by the
the ratchet wheel and output crank (32) and completely
spring discharge interlock.
charging the closing springs. This rotation of the ratchet
The spring discharge interlock drive link must be adjusted wheel and output crank is in a countercloskwise direction
to the .03 to .06 inch dimension shown in Fig. 27. This gap from the lower position, through slightly more than 180
provides the closing solenoid linkage the initial freedom it degrees, to a position just beyond dead center. In this
requires to develop the force necessary to remove the position the closing springs are free to release their
prop. energy, closing the breaker at a high speed.

32

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 1. Upper spring pin 21. Ratchet pawls
3. Safety pin and chain 25. Main closing crank
5. Closing springs 26. Pawl buffer stop
7. Pawl springs 27. Buffer stop shims
18. side plate shims 31. Lower spring pin
19. Side plate mounting bolts 33. Ant. rebound spring
20. Bearing side plate 34. Ant. rebound pawl

Fig. 37. Manual closing mechanism

6.5.1-Mechanism Part d. Remove the closing handle (22) by removing two set
screws threaded in same hole.
Replacement
e. Remove the front escutcheon by removing four
If it is necessary to replace any of the mechanism parts, screws holding it to the front frame center support.
the following total procedure is recommended. This
procedure may be halted at the step required to replace f. Remove handle shaft extension by removing
any particular part. Referring to Figs. 37 & 38: roll pin.

a. Install the safety pin (3) as described in g. Remove the handle return spring (29) by unhooking
Section 5.1.2. either end of the spring.

b. Remove the closing spring assembly by removing the h. Disconnect the top end of each pawl spring (7).
upper and lower spring pins (1,31). i. Remove the roll pin (24), thus allowing the closing
c. Remove the right hand bearing side plate (20), and handle shaft and pawl assembly (23) to be removed.
the side plate shims (18) by removing four mounting bolts j. Remove the ratchet wheel (17) and its assembly (16)
(19), thus allowing the main closing crank (25) to be by removing self locking screw (15) and thrust bearing
removed. (12). If shims (13) are present they must also
be removed.
(Continued next page)

33

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SECTION 6-Breaker Maintenance
MANUAL MECHANISM

- - - - - - - - - - -I---."...-~-::;;i

~. 3 4------~_+-lD\-____L

~~~~y;--ti--5-------++;~
!
I 1E--+-+-++-t+----6---------+,---';--t--'R\
!Oi£-+----7

I i i\II
! !III
I

!
I
; "

II
§D 31

-r-jH .'

(\(),
' 28
\ '

il I

!i \ !~ I
-,r~·- Ji '..
-~jJ
!
j
Partial Front View
With Handle And Escutcheon Removed

1, Upper Spring Pin 12. Thrust Bearing 24. Roll Pin

2. Safety Pin Holder 13. Shims 25. Main Closing Crank
3. Safety Pin and Chain 14. Groove Pin 26. Pawl Buffer Stop
4. Safety Pin Hole 15. Nylok Screw 27. Buffer Stop Shims
5. Closing Springs 16. Ratchet Wheel Shaft and Asm. 28. Buffer Stop Support
6. Guide Rod 17. Ratchet Wheel 29. Handle Return Spring
7. Pawl Springs 18. Side Plate Shims 30. Mechanism Roller
8. Front Escutcheon 19. Side Plate Mounting Bolts 31. Lower Spring Pin
9. Front Bearing Plate 20. Bearing Side Plate 32. Output Crank
10. Bearing Plate Mounting Bolts . 21. Ratchet Pawls 33. Ant. Rebound Spring
11. Output Crank Roller 22. Manual Closing Handle 34. Ant. Rebound Pawl
23. Closing Handle Shaft and Pawl Asm.

Fig. 38. Manual closing mechanism charged position

34

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 k. Remove front bearing plate (9) by removing mounting
bolts (10) accessible from the front of the breaker. The
mechanism is now completely disassembled. It is not
recommended that any of the subassemblies removed
during the above operation be further disassembled in the
field. Replacement sub-assemblies should be obtained
from the factory.
I. To reassemble the mechanism, reverse the procedure
described above and follow the adjustments given in
Section 6.5.3.

6.5.2-Ratchet Pawl Replacement

The manual mechanism is inoperable with broken ratchet
pawls. Therefore, the safety pin probably can't be inserted
into the gUide rod. If this is the case, the following
procedure is used to replace the ratchet pawls. Refer to
Figs. 37 & 38:
a. Remove upper spring pin (1) by removing retainer . 7. Disconnect 26. Buffer 35. Retaining
ring and pushing pin through front channel and spring springs stop ring
support. Closing spring will discharge. Remove individual
closing springs. Remove lower spring pin (31) and Fig. 40. Ratchet pawl removal
remaining part of spring support. When replacing closing
spring assembly, a new assembly is required or
reassembly of the existing parts using a pressing means.
6.5.3-Adjustments
b. Remove the left or right hand bearing side plate (20)
Frequent adjustments to the mechanism should not be
and the side plate shims (18) by removing four mounting
required. If the mechanism has been disassembled, it will
bolts (19), thus allowing the main closing crank (25) to be
be necessary to check the following adjustments:
removed.
1. It may be necessary to add shims (13) to reduce the
c. Remove anti-rebound pawl (34) by removing retaining
end play of the ratchet wheel shaft (16). An end play of
ring (36) shown in Fig. 39 and spring (33).
0.010 to 0.020 inch is recommended. Shims should be
d. Remove retaining ring (35, Fig. 40). Disconnect obtained from the factory.
springs (7) remove buffer stop (26). Both pawls can now
2. It may be necessary to add buffer stop shims (27) to
be removed. See Fig. 40. When reassembling, verify that
the buffer stop (26) to provide a clearance of 1/64 to 1/32
retaining ring (36) is properly seated.
inch between the pawls (21) and the buffE;H stop, when the
e. After replacing parts and before adding closing pawls are touching the ratchet wheel teeth extend.ing a
spri ng check adjustments given in Section 6.5.3. maximum distance from the center of rotation of the
ratchet wheel (17). This measurement should be made
while operating the closing handle during the four spring
charging operations and before the closing springs are
reassembled.
3. The ratchet pawls (21) should operate freely
throughout the closing strokes. They should engage the
ratchet wheel teeth near the end of each cou nterclockwise
and clockwise stroke of the closing handle with a definite
clicking sound, indicating a free non-binding operation.
After the clicking sound is detected, the closing handle
should have a minimum overt ravel of 1/2 in. or 3V2 degrees,
measured at the end of each handle stroke. At the end of
the four stroke the rebound stop (34) must move into place
to properly position the ratchet wheel.
4. The groove pin (14) in the front of the ratchet wheel
assembly (16) must be assembled in a manner that will
allow screw (15) to be tightened securely. A clearance of
36. Retaining ring 1/64 to 1/32 in. should exist between the front of the
groove pin and the rear surface of the
Fig. 39. Anti rebound pawl removal screw head.

35

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SECTION 6-Breaker Maintenance

6.6-Drawout Mechanism c. Remove racking cam assembly and replace with new
cam.
Drawout breakers are manuafactured in five different
styles depending on the type of equipment that the breaker d. Align center of worm with worm gear on racking cam
will be used in. The mounting code and description of then position collars firm against supports and tighten set
each style is found in GEI-86151 furnished with each screws in collars.
breaker. If replacement of racking cam is needed the
To replace guide support (4):
following procedure should be used. See fig. 41.
a. Remove screws (5) and support (6).
a. Remove nut (1) and screw (2).
b. Remove guide (4) and replace with new guide.
b. Loosen set screws in collar (3).
c. Reassemble.

1. Nut 3. Set screw in collar 5. Screws Drawout Mechanism Lock

2. Screw 4. Guide support 6. Support

Fig. 41. Drawout mechanism

6.7-Drawout Mechanism Lock

Breakers manufactured after January, 1993 have a locking
device installed on the drawout mechanism shaft, Fig. 41.
This device provides a stop to prevent the shaft from rotating
unless the interlock slide is depressed by the drawout
wrench. The racking handle cover plate when depressed, re-
leases a pin on the shaft allowing it to rotate.

36

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SECTION 7........ Accessories

7.1-Primary Disconnects replaced or removed simply disassemble nut and bolt

arrangement that is crisscrossed through the tubular stud.
Primary disconnects are found only on drawout breakers.
When reassembling mounting hardware apply equal amounts of
They provide the flexible connection between the breaker
torque to nuts, so distortion to tubular mounting stud does not
line and load terminals and the equipment line and load
occur. Torque nuts between 250 to 300 in Ibs.
terminals.

7.1.1-AKR 75/100 Fig. 43 shows the finger type disconnect assembly used on
AKD-6, AKD-8 switchgear and substructure type breakers.
There are two types of primary disconnects found on the
If replacement of primary finger is needed, you must
AKR 75/100 breakers.
replace complete sUbassembly set of fingers, which are
Fig. 42 shows the tubular type primary stud used on factory adjusted to proper spring tension. Reassemble as
replacement breakers for the older AKD, AKD5, AKD6 described above. See renewal parts publication GEF-4552
sWitchgear. If for any reason the primary stud must be for proper ordering data.

AKR75· AKR100

Fig. 42. Tubular type disconnects

FINGER-TYPE AKR75 AKR100

PRIMARY
DISCONNECTS

Fig. 43. Finger type disconnects

37

Courtesy of NationalSwitchgear.com
SECTION 7-Accessories
1.1.2-AKS/AKST 50 Fig. 47-The position of the spacer in the breaker stud.
The hole in the spacer must be positioned as shown so it
The AKS 50 and AKST 50 use eight primary fingers per will align with the holes in the clip.
phase as shown in Figs. 44 thru 47. Refer to these
illustrations when replacing the disconnects. Note the Fig. 46-The engagement of the fingers with the retainer.
following details. Also the location of the "bowtie" spacers in the fingers,
both upper and lower.
(Continued next page)

Fig. 44. Primary disconnect assembly Fig. 45. Partial primary disconnect ASM

Fig. 46. Partial primary disconnect ASM Fig. 47. Partial primary disconnect ASM

38

Courtesy of NationalSwitchgear.com
Fig. 44 & 45- The position of the upper and lower retainers
and, again, the 'bowtie' spacers.

The primary disconnect assembly is factory adjusted to apply a

force of 85-105 pounds on a 1/2 thick copper bar inserted
between the upper and lower fingers. After installation of the
disconnect assembly this force range is obtained by tightening
the locknuts to set the dimension shown in Fig. 48. Note that
this dimension is measured between the top of the retainer and
the underside of the washer. Also note that no bar is inserted
between the fingers when setting this dimension.

1. Secondary disconnect

Fig. 49. Secondary disconnects

Fig. 48. Primary finger adjustment

1. Body 3. Tube
2. Tip 4. Tabs
7.2-Secondary Disconnects
Fig. 50. Secondary disconnect details
The secondary disconnects for all drawout breakers serve
as connections between breaker control circuit elements
and external circuits. They are mounted on a horizontal 7.2.1-R eplacement
cross-channel at the top rear of the breaker as shown in
Replacement of the disconnects is given below. Refer to
Fig. 49. These secondary disconnects dllow removal of the
Fig. 50:
breaker without having to detach external connections.
a. Unfasten disconnect body from breaker
The moveable part of the secondary disconnects consists
cross-channel.
of an insulating body which holds a conducting spring-
loaded plunger to which a flexible lead is attached, see Fig. b. Open tabs which hold wires on inner side.
50. As the breaker moves into its enclosure, the plunger is
c. Pull contact tip loose from hollow tube.
depressed by sliding onto the stationary disconnects of the
enclosure. d. Remove contact tip by cutting wire at its base.

(Continued next page)

39

Courtesy of NationalSwitchgear.com
SECTION 7-Accessories
7.2.1-(Cont.)
e. Push wire through hollow tube of new disconnect 7.3.1-Replacement
assembly.
Referring to Fig. 51:
f. Strip insulation off end of wire to about '/, in. from the GE SB-12
end.
a. Disconnect all leads.
g. Place new contact tip on end of wire and crimp. b. Remove two mounting bolts.
h. Pull wire through hollow tube until contact tip fits c. Disengage auxiliary switch shaft (4) from triangular
snugly against end of hollow tube. link (2).
i. Crimp tab on other side of assembly to hold wire in d. Orient the shaft of the new switch so that the arrow
place. stamped on the shaft end points towards the front of the
breaker.
j. Any hollow tubes which are not used should be
pushed into the disconnect body and held in that position e. Push auxiliary switch shaft into square hole in link
by placing fiber spacers over inner ends of tubes and (breaker open).
spreading tabs. f. Replace mounting hardware and wiring.
k. When all wires have been connected, refasten the Electro Switch
body of the moveable disconnect assembly to the breaker Follow the above procedure except in step d. In step d, orient
cross-channel. the shaft of the new switch so that the horizontal line on the
end of the shaft is horizontal when the breaker is open.
7.3-Auxiliary Switch 7.3.2-Adjustment
All electrically operated breakers and manual breakers hav-
ing shunt trips are supplied with auxiliary switches. Depend- The auxiliary switch operating shaft must be positioned
ing upon the requirements of the breaker application, the such that during breaker closing, the "a" contacts make
switch may contain two to six stages. Usually each stage before or not later than the first touch of the breaker's
one "A" contact and one "B" contact. "A" contacts are open arcing contacts. If before, the open gap of the arcing
or closed as the breaker is opened or closed. "B" contacts contacts must not exceed %-inch. This can be checked by
are the reverse of this. connecting a bell set across the "a" terminals and slow-
closing the breaker with the maintenance handle. The "a"
The auxiliary switch is mounted on the upper left side of the
mechanism frame as shown in Fig. 51. As the crossbar (1) contact closing can be advanced or retarded by
moves to the open or closed position, it operates triangular lengthening or shortening operating rod (3), Fig. 51.
link (2) via operating rod (3). The triangular link rotates the The operating rod should also be aligned vertically to be
auxiliary switch operating shaft. parallel with the sides of the frame center channel and
perpendicular to crossbar (1). This is done by shifting the
position of bracket (5).

1. Crossbar 4. Switch Shaft

2. Triangular link 5. Bracket
3. Operating rod

40 Fig. 51. Auxiliary Switch

Courtesy of NationalSwitchgear.com
 7.4-Shunt Trip 7.4.2-Adjustments
The shunt tripping device is mounted on a bracket With the shunt trip de-energized and the breaker
attached to the left side of the operating mechanism mechanism reset, there must be clearance between trip
(looking from the front). paddle (11) and armature arm (10) 0.03 in. min.
A remote switch or relay contacts are used to close the circuit A minimum 0.03 in. over-travel of the armature is required
of the device causing the armature (9) to engage the trip paddle when the breaker is tripped. If any adjustment is necessary
(11), thereby tripping the breaker. The spring (1) is used to to provide this amount of overtravel, the trip lever is bent in
return the armature to the neutral position after the breaker or out accordingly.
trips.
To prevent overheating, the coil (7) is cut off by contacts
of the auxiliary switch which are open when the breaker is
open.

7.4.1-Replacement
Referring to Fig. 52:
a. Disconnect coil leads.
b. Remove mounting hardware and the device.
c. I nstall new device in reverse order.

III
IIl~AA
Trip shaft of breaker shown in tripped position and
shunt trip energized.

D ------Ji:t-, 1. Spring
2. Pin
~---....
I-----IE 3. Frame
~ --=::;::::;::=~~ .::>....----'--, ./"--~
4. Weight
5. Screws
;---[D 6. Magnet
~==t:;:==~~~
7. Coil
B. Clamp
w 9. Armature
10. Armature arm
m---< 11. Trip paddle
12. Clamp
13. Mtg. bracket
14. Mtg. hardware

Fig. 52. Shunt trip device

41

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SECTION 7........Accessories

7.5-Undervoltage Device 7.5.2-Adjustment

The undervoltage device (UV) is mounted on a bracket When this device is installed or replaced, its positive ability
attached to the right side of the breaker operating to trip the breaker must be demonstrated.
mechanism (viewed from front). It trips the breaker when
Undervoltage devices trip the breaker when the armature
its coil is deenergized. The coil leads are connected
opens. This causes an extension of the armature to strike
directly to secondary disconnects or to a terminal board.
the paddle on the trip shaft. An extension on the other end
Under normal conditions, the coil remains energized, permit- of the armature (towards the front of the breaker) extends
ting the breaker to be closed. When the system voltage de- through the device frame and limits the movement of the
creases to a value between 30 and 60 percent of its nominal armature. When the armature is released, this extension
value, the armature "drops out" and trips the breaker. An stops against a stop which is factory set. To check positive
open armature prevents the breaker from being closed. The trip, the armature should be held down, the end of a 1/32-
armature picks up and allows breaker closing, when the sys- inch diameter wire should be inserted against the stop, and
tem voltage is 85 percent or more of its nominal value. the armature released. If this trips the breaker, the setting
is correct. The place to insert the wire is shown in Fig. 54.
When the breaker is disconnected and is to be operated Note that only the tip of the wire is to be against the stop.
manually, the undervoltage device may be tied or wired
down to prevent tripping. If the undervoltage device does not have positive tripping
ability, the adjustment screw of the trip paddle assembly
7.5.1-Replacement on the trip shaft may be turned in increments of half turns
until the check is successful.
Referring to Fig. 53:
When the u ndervoltage device is closed and the breaker
a. Disconnect coil leads. mechanism is reset, there must be clearance between the
b. Remove mounting screws and remove device. trip paddle and the device armature.

c. Install new device in reverse order.

1. Spring
2. Bracket
3. Adjusting plate and screw
4. Shading ring
~,,---m 5. Armature
~p'----m 6. Coil
&J~ 7. Clamp
~IT:~~~h--1E 8. Magnet
~----L
9. Screws
m------.., 10.
11.
Pin
Adjusting screws
12. Locking wire*
13. Adjusting screws
14. Trip paddle and clamp
>---Q'J 15. Mtg. hardware
~-------i
* New models may use a
jam nut in place of the
f.i------l l locking wire

Fig. 53. Undervoltage device - energized (breaker reset)

42

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 If the a-c control voltage is any voltage other than
208/240V ac, a control power transformer (also remotely
mounted with respect to the breaker) must be used. This
must have a minimum rating of 100 volt-amperes.
When installed, the voltage to be monitored is connected
across terminals No.1 and No.2 of the static delay box.
The coil of the tripping unit is connected across terminals
No.4 and No.5 of the static box through the secondary
disconnects of the breaker. The secondary disconnects to
be used will be shown on the breaker wiring diagram.
No more than one undervoltage tripping device should be
used in conjunction with one static time-delay unit.
The static time-delay undervoltage can also be furnished
with a thermotector control unit. Overheating of motor
windings causes the thermotector, imbedded in the motor
windings, to open. This de-energizes the undervoltage
device on the breaker and drops the motor load.
In the event the device fails to pick-up, the following
checks are recommended to determine whether the
magnetic device 01") the breaker of the static ti me delay unit
is the faulty component:
1. Stop
2. Armature 1. Check input voltages across terminals 1 and 2 on the
3. Insert wire gage static box. See Table 7 for these values.
2. Check output voltages on terminals 4 and 5 with the
Fig. 54. Positive trip check
undervoltage device connected. See Table 7 for values.
7.6-Static Time-Delay Undervoltage 3. Check resistance of the disconnected undervoltage
device. See Table 7 for values.
In addition to the instantaneous undervoltage tripping
device mourited on the breaker, the static time-delay See Instruction Sheet GEH-4545 for more detailed
undervoltage includes a separately mounted time-delay information, including schematic diagrams and circuit
unit. Table 7 lists the Cat. Nos. available. description.

Table 7-Time-Delay Units

CONTROL APPROXIMATE STEADY STATE NOMINAL DC COIL
VOLTAGE DC OPERATING VOLTAGE RESISTANCE
TERMINALS TERMINALS (OHMS)
CAT. NO. 1& 2 4&5 @ 25°C
TAKYUVT-1 125 VDC 50 440
TAKYUVT-2 250VDC 100 1600
TAKYUVT-3 208/240 VAC 110/125 1600

43

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SECTION 7-Accessories

7.1-Electric Lockout Device Each electric lockout device also includes a By-Pass or
"manual defeat" linkage to permit closing the breaker
The Electric Lockout Device is used in conjunction with the when the lockout is de-energized. This allows startup of
normally-closed auxiliary contacts of another breaker. This "dead" systems. A pull knob for this purpose is located
device provides a convenient method to electrically interlock beneath the breaker frame.
two or more breakers so that no two may be closed at the same
time. When Its coil Is de-energized, the electric lockout device 7.7.1 ~Adjustment
holds an open breaker trip-free. However, once the breaker is
closed, the breaker mechanism cam operates linkage which All lockout devices are factory adjusted. If adjustments are
mechanically holds the lockout device armature closed to pre- needed, referring to Fig. 55:
vent trippng the breaker in the event the lockout coil is de- a. Adjust "manual defeat" linkage adjusting nuts to
energized. obtain max travel of lockout tripping arm.
b. With breaker in open and reset position and lockout
The lockout device is mounted on the right side of the
coil de-energized, pull knob for "manual defeat". Check
mechanism frame viewed from the front as shown in Fig.
clearances between lockout trip arm and adjusting screw.
55. When the breaker opens, the breaker cam moves down,
Clearance must be .06 to .09. Release knob, lockout trip
allowing the lockout device to assume its normal, de-
arm must move trip paddle .03 to .06 beyond point of
energized position.
tripping breaker. Adjust screw accordingly.

,,

-t-

i" - - -~\

,I
I
:
'

I
I ,
I ,
: L _
_ _ _ _I

1. Front of breaker 5. Lockout coil 9. .06 to .090 clearance

2. Pull knob for manual defeat of lockout device 6. Lockout tripping arm 10. Lockout-lever
3. Manual defeat linkage 7. Adjusting screw 11. Mounting screws
4. Adjusting nuts 8. Trip paddle 12. Breaker cam

Fig. 55. Electric lockout device (breaker closed)

44

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 7.8-Bell Alarm Device 7.8.1-Adjustment
This device provides a means for remote indication that In Fig. 56, the components of a bell alarm with lockout are
the breaker has been tripped due to action of one of its shown in the breaker closed position. The device is
automatic trip devices (overcurrent, UV) or drawout actuated by crossbar side link pin (1) which engages
interlocks. It is not activated by the manual trip button or operating link (2). Lockout screw (3) should be adjusted so
shunt trip device. that it engages trip paddle (4) to displace trip shaft (6)
when the breaker is opened. This keeps the breaker trip
The bell alarm device can be equipped with an optional
free until the bell alarm is reset.
lockout feature which, upon activation of the bell alarm,
prevents reclosure of the breaker until the bell alarm is Operating the manual trip button must not actuate the bell
reset. A bell alarm without the lockout feature can be alarm device. With the manual trip button fully depressed,
turned off (reset) by any of three modes: the trip rod release collar (7) should be positioned on trip
rod (8) so that latch (9) and catch (10) disengage before
a. Reclosing the breaker.
the breaker opens. When the manual trip button is not
b. Depressing the manual trip button. depressed, there should be approximately a 3/16" gap
c. Energizing the shunt trip device. For this mode, a between the trip rod release collar (7) and the latch (9).
normally open contact of the bell alarm switch must be The bell alarm is bypassed also whenever the shunt trip is
connected in parallel with the auxiliary switch "A" contact energized. This is accomplished by latch release strap (1))
in the shunt trip circuit. which is engaged by shunt trip armature lever (12). Strap (11) is
For a bell alarm with lockout, only reset modes (b) and (c) part of device latch (9), and must be formed to hook around ar·
apply. mature lever (12) such that the device latch and catch
disengage before the breaker opens.
With the breaker in reset position there must be at least 1/16
clearance between shunt trip armature (12) and breaker trip
paddle (4).

k-r\---D 1. Crossbar side link pin

2. Operating link·
3. Lockout adjusting screw
4. Lockout trip paddle-
affixed to item 5
5. Trip paddle for shunt trip
6. Trip shaft
mJ 7. Trip rod release collar
)
8. Manual trip rod
9. Device latch
10. Device catch
11. Latch release strap
12. Shunt trip armature lever
13. Shunt trip armature
14. Shunt trip
15. Bell alarm switches
16. Switch operating arm

td'

Fig. 56. Bell alarm device

45

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SECTION 7-Accessories

7.9-0pen Fuse Lockout Device rod (3) through rod guide (2). Continue lowering the
device until movement is restricted by the device wiring
The open fuse lockout device (OFLO) is an anti-single-
harness.
phasing device used on breakers employed in conjunction
with currenHimiting fuses. The device consists of an 2. Disconnect coil leads.
individual trip solenoid for each pole, connected directly
3. Remove two screws holding the trip device to the
across the fuse in that phase. Blowing of any fuse operates
device mounting plate.
its solenoid, tripping the breaker. An indicator for each
phase pinpoints the blown fuse. The breaker remains trilJ- 4. Bend lower end of brass coil clamp straight.
free until the involved phase of the OFLO device is reset. 5. Remove coil. Install new coil and replace parts in
Referring to Fig. 57, when a fuse blows, coil (6) in that reverse order.
phase is energized and closes armature (8), engaging trip
paddle (1) which trips the breaker. In the process, spring 7.9.2-Adjustments
(12) discharges and pivots arm (9) counterclockwise, From 1/32 to 1/16 inch armature overt ravel is required
latching armature (8) closed. This motion also moves reset when the breaker is tripped. A 1/8-inch minimum
button (10) forward, indicating which fuse has blown. The clearance is needed between trip paddle (1) and rod (3)
latch-held armature keeps the breaker trip-free until the with breaker in the reset position. To make these
OFLO is reset. Coil (6) is de-energized as soon as the adjustments loosen locknut (4) and turn rod (3) in or out to
breaker is tripped.
obtain the proper overt ravel and clearance. Retig hten lock
nut (4).
7.9.1-Coil Replacement
A 1/8-inch minimum clearance should be maintained at
To replace coil (6), proceed as follows:
reset button (10). To adjust, loosen lock nut ahead of
1. Remove five bolts mounting the device to the side button and turn button until proper distance is obtained.
plate and front frame. Lower the lockout device, guiding Retighten lock nut.

1. Trip paddle
2. Rod guide
3. Rod
4. Lock nut
5. Trip solenoid
6. Coil
7. Link assembly
8. Armature
9. Arm

o 0
10.
11.
Reset button
Rod, reset button
~======~-mJ 12. Springs, reset rod
13. Spring, link assembly
r-----IE 14. Mounting bracket
------ill 15. Trip shaft

~ -J

fj, -J

[D---------J

Fig. 57. Open fuse lockout device

46

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 SECTION 8-Type SST Overcurrent Trip Device

The SST is a solid-state, direct-acting, self-powered trip Each target pops out when its associated trip element
device system. The SST system consists of the SST operates to trip the breaker. After a trip, the popped target
programmer unit, current sensors, and a flux shifter trip must be reset by hand. However, neglecting to reset does
device. Fig. 58 shows a block diagram of the system. not affect normal operation of any trip element or prevent
the breaker from being reclosed.
8.1-Programmer Unit The programmer unit is mounted to the left side of the breaker
Fig. 59 shows a typical SST programmer unit. The as shown in Fig. 60. The bracket attached to the top of the pro-
program mer u nit provides the comparison basis for grammer, see Fig. 59, engages with a bracket mounted to the
overcurrent detection and delivers the energy necessary to breaker's center channel.
trip the breaker. It contains the electronic circuitry for the
var'ious trip elements. Their associated pickup and time
delay adjustments (set-points) are located on the face
plate. Depending on the application, programmer units
may be equipped with various combinations of Long Time,
Short Time, Instantaneous and Ground Fault trip elements.
See Table 8 for available rc'tings, settings and trip
characteristics. Adjustments are made by removing the
clear cover over the face plate, unscrewing (counter-
clockwise) the set-point knob, moving the set-point along
the slot to the new setting, and screwing the set-point
knob in. Once all adjustments are made, install the clear
cover to the face plate.
The SST programmer units can be optionally equipped
with trip indicators (targets). These are pop-out,
mechanically-resettable plungers located across the top of
the programmer's front. Units with a ground fault element
employ three targets: from left to right, the first is for
overload, the second for short circuit (actuated by the
short time and instantaneous elements) and the third for
ground fault. The latter is omitted on units without ground
fault. Fig. 58. SST block diagram

Table 8-SST Trip Characteristics

SST PROGRAMMER ADJUSTMENT RANGE (Set Point)
Ground Fault Long Time Short Time Instan-
Pickup taneous
Breaker Frame Sensor Taps Pickup Delay (L) Delay Pickup Delay Pickup
Frame Size (X) (Multiple Band (Multiple Band (Multiple Band (Multiple
Type (Amperes) (Amperes) of X) (Seconds) of X) (Seconds) of L) (Seconds) of L)

boo, 400. 600, BOO

or .25, .3, .4,
AKS-5/5A-50 1600
600, BOO, 1200, .5,.6 (X)
1600
BOO, 1200. .2..25, .3, .4,
AKST-5/5A-50 2000
1600,2000 .5,.6 (X)
AK-5/5A-75 1200, 1600, Maximum Maximum 1.75,2, Maximum
3000 0.30 22 2.25,2.5, 0.35
AKR-5/5A-75 2000, 3000
.2, .22, .25 3,4 (L) 4,5,6,8,
.3, .35, .37 (X) Intermed. 6 ..7, .8,.9, Intermed. Intermed. 10, 12 (L)
1200,1600, 1,1.1 (X)
AKR-5B/5C/5S-75 3200 0.165 10 ---<Jr- 0.21
2000, 3200 Minimum Minimum 3,4,5,6 Mlnimum
AK·100 1600,2000, .1B, .2, .22, 0.65 4 8, 10 (L) 0.095
4000
AKR·100 3000 4000 .25, .27, .3 (X)
NOTES
, 2 4 2 3 2 4 2

, X = Sensor ampere rating = trip rating. 3 Time delay at lower limit of band @ 6L.
2 Pickup tolerance = :': 10%. 4 Time delay at lower limit of band.
Applicable lime-current curves: GES-6033B, 6034A, 60358

47

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 SECTION 8-Type SST Overcurrent Trip Device

Fig. 59 SST programmer Fig. 60. AKS-5A-50

8.2-Current Sensors Application of the Ground Fault element on 4-wire systems

with neutral grounded at the transformer requires the
T he SST system uses two types of cu rrent sensors, a
additional, separately mounted neutral sensor (Fig. 62)
phase sensor and a neutral sensor. Fig. 61 shows a phase
inserted in the neutral conductor; its secondary is
sensor. Fig. 62 shows the neutral sensors avai lable. The
connected to a fourth primary winding on the ground
current sensor supplies the power and signal inputs
differential transformer. See Fig. 72. This "fourth-wire"
necessary to operate the trip system. Each sensor has four
neutral sensor is an electrical duplicate of the phase
taps which provide field adjustment of the trip device's
sensor, including taps. Therefore, when taps are changed
continuous ampere rating.
on the phase sensors, those on the neutral sensor must be
The SST Ground Fault trip element operates on the principle correspondingly positioned.
that the instantaneous values of current in the three conduc- When used, the neutral sensor is separately mounted in
tors (four on 4-wire systems) add to zero unless ground current the bus or cable compartment of the switchgear. In
exists. On SST's equipped with Ground Fault, the ground trip
drawout construction, its output is automatically
signal is developed by connecting each phase sensor in series
connected to the breaker via secondary disconnect blocks.
with a companion primary winding on a ground differential
See Fig. 63.
transformer mounted in the programmer unit. Its secondary
output is zero so long as there is not ground current.

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 AKA 75/100 AKS 50

Fig. 61. SST phase sensors with tap board

Tap
terminal
board

AKA 75/100 AKS 50

Fig. 62. SST neutral sensors

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SECTION 8- Type SST Overcurrent Trip Device

1. Neutral sensor 2. Equipment-

secondary disconnect block mounted
breaker mounted

Fig. 63. Neutral sensor secondary disconnect block

8.2.1-Replacement of Current
Sensors - AKS 50
Referring to Fig. 64, AKS50 phase sensors are
removed as follows:
a. Remove the connections to and the wiring harness
from the sensor tap board.
b. Remove the tap board retaining hardware.
c. Remove the lower connection strap.
d. Sensors are secured with RTV. Loosen RTV and
remove sensors.
e. If the front and back frame have not been separated,
replacement of the center pole sensor requires removal of
the mechanism prop. Refer also to Fig. 24:
1. Remove retaining rings.
2. Disconnect spring. 1. Connection strap
2. Bearing
3. Remove bearings
3. Retaining ring
4. Remove prop. 4. Prop

Fig. 64. Sensor replacement

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 the underside of the front frame is coupled to the breaker's
trip shaft via a trip rod driven by the actuator arm. The
actuator is a solenoid whose armature is spring-loaded
and held in its normal (Reset) position by a permanent
magnet. In this state the spring is compressed.
So long as the actuator remains in the Reset position, the
breaker can be closed and opened normally at will.
However, when a closed breaker receives a trip signal from
the programmer unit, the actuator is energized and its
solenoid flux opposes the magnet, allowing the spring to
release the armature; this drives the trip rod against the
trip shaft paddle, tripping the breaker.
As the breaker opens, the actuator arm is returned to its
normal (Reset) position via linkage driven by a crank on
the breaker's main shaft. The permanent magnet again
holds the armature captive in readiness for the next trip
signal.
The trip device requires only one adjustment-the trip rod
length. As shown in Fig. 68, the clearance between the trip
rod end and the trip shaft paddle is gaged by a 0.109 inch
diameter rod. Adjust gap to 0.109 inch ± 0.031 inch. To
adjust, open the breaker and restore the breaker
1. Primary disconnects
mechanism to its Reset position. Loosen the jamb nut,
2. Tap board
rotate the adjuster end until the proper gap is attained,
then retighten the jamb nut.
Fig. 65. AKR 75/100 sensor replacement
While operating the breaker, insure that the actuator
bracket does not interfere with the buffer stud. Adjust by
8.2.2-Replacement of Current loosening actuator bracket mounting screws and rotating
Sensors - AKR 75/100 the bracket clockwise to take up mounting hole slack.
Retighten screws.
Referring to Fig. 65, the AKR 75/100 phase sensors are
removed as follows: The actuator is a sealed, factory-set device and requires no
maintenance or field adjustment. In case of malfunction,
a. Disconnect the wiring harness and connections from
the complete actuator unit should be replaced. When
the senser tap board.
making the electrical connection to the replacement unit, it
b. Remove the tap board hardware. is recommended that the breaker harness be cut at some
c. Remove the primary disconnect assemblies from the convenient point and the new actuator leads solder-spliced
stud. thereto. An alternate method is to untie the breaker
harness and remove the old actuator leads directly from
d. Remove the sensor and tap board. the female AMP connector on the end of the breaker
e. Reassemble in reverse order, align projections on rear harness. However, AMP extraction tool Cat. No. 305183 is
of sensor with notches in the position ring which is req uired for this method.
mounted on the stud. Refer to Section 7.1.1 for torque
requirements for the primary disconnect hardware.
CAUTION: IF THE BREAKER MUST CARRY
CURRENT WITHOUT OVERCURRENT
8.3-Flux Shift Trip Device PROTECTION, THE SST TRIP DEVICE SYSTEM
The Flux Shift Trip device is a low-energy, electromagnetic MUST BE PREVENTED FROM OPERATING.
device which, upon receipt of a trip signal from the THE RECOMMENDED METHOD IS TO SHORTEN
programmer unit, trips the breaker by actuating the trip THE TRIP ROD BY TURNING ITS ADJUSTER
shaft. END FULLY CLOCKWISE. THIS PREVENTS
ACTUATION OF THE TRI~ SHAFT PADDLE.
The mounting arrangement of this component is illustrated
in Figs. 66 and 67. An electromagnetic actuator located on

51

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SECTION 8-Type SST Overcurrent Trip Device

1. Actuator bracket
2. Buffer stop
3. Crossbar

Fig. 66. Flux shift trip device - linkage attachment

1. Actuator
2. Actuator arm
3. Trip rod
4. Trip rod adjuster end
5. Reset linkage
6. Actuator bracket
7. Mounting base

Fig. 67. Flux shift trip device with operating linkages

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 CROSSBAR'
(BKR. OPEN)

ACTUATOR
BRACKET - - -...........-t,..; BUFFER
STUD
POSITION

TRIP ROD
O. 109 DIA. IN "RESET"
ROD POSITION
ADJUSTER
END
Fig. 68. Flux shift trip device adjustments

Fig. 69. SST/ECS test set, cat. no. TAK-TS1

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SECTION 8-Type SST Overcurrent Trip Device

8.4-Troubleshooting 8.4.1-55T Test 5et

When malfunctioning is suspected, the first step in The TAK·TS1 Test Set Is a portable instrument designed to
troubleshooting is to examine the circuit breaker and its field·check time-current characteristics and pickup claibration
power system for abnormal conditions such as: of the SST's trip elements. It can verify the ability of the Flux·
a. Breaker tripping in proper response to overcurrents Shift Trip Device to trip the breaker and includes means for
or incipient ground faults. continuity checking phase sensors.

b. Breaker remaining in a trip-free state due to

mechanical interference along its trip shaft.
WARNING: BEFORE CONNECTING TEST SET TO
c. Inadvertent shut trip activations. BREAKER TRIP DEVICE SYSTEM, ENSURE CIR·
CUlT BREAKER IS COMPLETELY DISCON-
WARNING: DO NOT CHANGE TAPS ON THE NECTED FROM ITS POWER SOURCE. ON
CURRENT SENSORS OR ADJUST THE DRAWOUT EQUIPMENT, RACK BREAKER TO
PROGRAMMER UNIT SET KNOBS WHILE DISCONNECTED POSITION. VERIFY BREAKER
THE BREAKER IS CARRYING CURRENT. IS TRIPPED.

o nee it has been established that the circuit breaker can

Either of two test modes may be employed:
be opened and closed normally from the test position,
attention can be directed to the trip device proper. Testing "A" - Programmer Unit Only. These tests are conducted
is performed by either of two methods: with the programmer unit disconnected from the breaker.
During test, the unit can remain attached to the breaker or
1. Conduct high-current, single-phase tests on the
may be completely removed from it.
breaker using a high current-low voltage test set.

CAUTION: NEVER DISENGAGE THE HARNESS

NOTE: For these single phase tests, special
CONNECTOR FROM THE PROGRAMMER UNIT ON
connections must be employed for SST
A BREAKER ENERGIZED AND CARRYING LOAD
breakers equipped with Ground Fault. Any
CURRENT. THIS WILL OPEN·CIRCUIT THE CUR·
single-phase input to the ground differential
RENT SENSORS, ALLOWING DANGEROUS, DAMAG·
transformer will generate an unwanted "ground
ING VOLTAGES TO DEVELOP.
fault" output signal which will trip the breaker.
This can be nullified either by
a. testing two poles of the breaker in
Test scope:
series, or
1. Verify the time-current characteristics and pickup
b. Using the Ground Fault Defeat Cable as
calibration of the various trip elements.
shown in Fig. 73. This special test cable
energizes all the primary windings of the 2. Verify operation of the SST target indicators on
differential transformer in a self-cancelling, programmer units so equipped.
series-parallel connection so that its secondary
"B" - Complete Trip Device System. For these tests, the
output is always zero.
programmer unit must be mounted on the breaker and
connected to its wiring harness.
Test scope:
2. Test the components of the SST system using
1. All "A" tests previously described, pius provision for
portable Test Set Type TAK-TS1 (Fig. 69). The applicable
test procedures are detailed in Instruction Book GEK- optionally switching the programmer's output to activate
64454 and are summarized in Section 8.4.1. the Flux-Shift Device and verify its operation by physically
tripping the breaker.
The TAK-TS1 Test Set is a portable instrument designed
2. Check phase sensor continuity.
for field checking the time-current characteristics and
pickup calibration of the SST's various trip elements. It can In the event that any component of the SST system does
verify the ability of the Flux-Shift Trip device to trip the not perform within the limits prescribed in test instructions
breaker and, in addition, includes means for continuity GEK-64454, it should be replaced.
checking the phase sensors.

54

Courtesy of NationalSwitchgear.com
SECTION 8-Type SST Overcurrent Trip Device

8.4.2-Resistance Values
For use in troubleshooting, the Common to Tap resistance to zero and no ground signal is developed. This current
for SST current sensors is given in Tables 9 and 10. These sum will be zero only if all three sensors have the same
values apply to both phase and neutral sensors. electrical characteristics. If one sensor differs from the
others (I.e., different rating or wrong tap setting), the
Table 9-Sensor Resistance Values differential transformer can produce output sufficient to
trip the breaker. Similarly, discontinuity between any
AKS 50 sensor and the programmer unit can cause a false trip
signal.
Breaker Resistance in ohms
Frame Ampere between COMMON
Size Tap and TAP Terminals If nuisance tripping is encountered on any breaker whose SST
components have previously demonstrated satisfactory perfor-
300 5.3-6.1 mance via the TAK·TS1 Test Set, the sensors and their connec-
400 7.2-8.2 tions should be closely scrutinized after disconnecting the
600 10.8-12.4
breaker from all power sources.
800 14.6-16.9
AKS-50
600 6.4-7.6 a. Check that all phase sensors are the same type
800 8.8-10.4 (ampere range).
1200 13.5-15.8
1600 19.4-22.8 b. Ensure that the tap settings on all 3-phase sensors
are identical.
800 10.2-12.0
AKST-50 1200 15.8-18.6
1600 22.0-25.9
2000 28.5-33.6
8.5-SST Cabling Diagrams
c. Verify that the harness connections to the sensors
Table 10-Sensor Resistance Values meet the polarity constraints indicated by the cabling
AKR 75/100 diagram, I.e., white wire to COMMON, black wire to TAP.
Resistance in ohms
Tap Tap between COMMON d. On Ground Fault breakers serving 4-wire loads, check
Breaker Terminal Lead terminal (white that the neutral sensor is properly connected (see cabling
(AMP) Color lead) and TAP diagram Fig. 72. In particular,
terminal
1. Verify that the neutral sensor has the same rating and
1200 Black 13.4-15.7
tap setting as the phase sensors.
1600 Yellow 18.3-21.5
AKR-75
2000 Red 23.5-27.6 2. Check continuity between the neutral sensor and its
3200 Green 42.1-49.5 equipment-mounted secondary disconnect block. Also
1600 Black 18.3-21.6 check for continuity from the breaker-mounted neutral
2000 Yellow 23.5-27.6 secondary disconnect block through to the female harness
AKR-100
3000 Red 37.7-44.3 connector (terminals Land N.).
4000 Green 53.4-62.6
3. If the breaker's lower studs connect to the supply
The coil resistance of the SST IECS Flux shifter device is source, then the neutral sensor must have its LOAD end
approximately 16 ohms. con nected to the sou rce.
4. Ensure that the neutral conductor is carrying only
that neutral current associated with the breaker's load
8.4.3-False Tripping-Breakers current (neutral not shared with other loads).

Equipped with Ground Fault e. If the preceding steps fail to identify the problem,
then the sensor resistances should be measured. Since the
When nuisance tripping occurs on breakers equipped with
phase and neutral sensors are electrically identical, their
the Ground Fault trip element, a probable cause is the
tap-to-tap resistance should closely agree. See Table 9 or
existence of a false "ground" signal. As indicated by the
Table 10.
cabling diagram of Fig. 71 each phase sensor is connected
in a series with a primary winding on the Ground Fault
differential transformer. Under no-fault conditions on 3-
wire load circuits, the currents in these three windings add

55

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 +A +B +C

,------
PROGRAMMER
AAA
$ $ ~
FLUX SHIFT
TRIP DEVICE
UNIT

- b- b-: I
BREAKER
BACK FRAME I-~, t----'-'R=ED=---t~_<~+oB+- (48V. de)
~ r==)==-=!:' ~B~L~AC:<:.K~>+-<:H-o-+- (TO SCR
LEFT POLE I l E ANODE)

I
CURRENT WHITE
SENSOR
A
BLACK C

WHITE

'-+----1f---=:;B","LA.:.::C:.:.:K'----t-<>-t-« f-I-<>-I----' III

WHITE

HARNESS
CONNECTOR
(AMP 201298-1)

LOAD
1 .....
PROGRAMMER
CONNECTOR
(AMP 201297 -1)

Fig. 70. Cabling diagram-SST without ground fault

+A .B tC

AAA
$ $ $
FLUX SHIFT
TRIP DEVICE
PROGRAMMER
UNIT
1------
1 1, - b- b-: I
BREAKER
BACK FRAME
~ r==)===)=1 t----'-'==-+<:o+-<: H-o-+-o (48V de)
r-=~-+<>-t-<~~-O-+-o (TO SCR
LEFT POLE I I ANODE)
CURRENT
WHITE
SENSOR
A
BLACK C
WHITE
D
BLACK F
WHITE
H
I,--_B::..:L::...A:.;::C.:..:.K_+c+-<: f-f-<K>-f--.
J
ttr LOAD
HARNESS
CONNECTOR
(AMP 201298-1)
PROGRAMMER
CONNECTOR
(AMP 201297-1)

Fig. 71. Cabling diagram-SST with ground fault on 3-wire load

56

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 ~A ~B tC

B:~~~~~~E
AAA
r1-1-t-,
FLUX SHIFT
TRIP DEVICE

B
,-----,
PROGRAMMER
UNIT

I
I
~
J-'-'=-+O-J-< ~:....j...o4-e (48V. de)
)===)===)= (TO SCR I
LEFT POLE I E ANODE)
CURRENT
SENSOR I 'rl--+--t---t--+_...:.W~H!.!..!IT-=.E_-+-O-l-<4o-t--.
1IIIL-...}o,,--,",,","-- I ,I
A

I
BLACK c
II WHITE
I A

NEUTRAL I BLACK F
SENSOR I W D
DISCONNECT I r+o-+-_-,-,-,-H,,-,IT-=.E_+<>+<~o-+--.

/
--1I
LINE
I
I BLACK
~
~i-I----.JIII

1\';r+~C:":::O~Mtoif7)+O+--+-l-~f-+-----:!..W:!.!:H!!..!ITE.E_-+O+-<~No.L.l----,
t BLACK
liN

r r t,
I 1 -'
HARNESS
CONNECTOR PROGRAMMER
EQUIPM1NT'---M-O-UN-T-ED-
(AMP 201298-1) (AMP
CONNECTOR
201297-1)
NEUTRAL SENSOR \~---~v .
4-WIRE LOAD

Fig. 72. Cabling diagram-SST with ground fault on 4-wire load

BREAKER PROGRAMMER
HARNESS GROUND FAULT DEFEAT CABLE
CONNECTOR
r \., .-- f -- -,
CAT. NO. TGFD
-"A~ \
UNIT

~~~~6~~ i ~ ~--O-+---ri---..-.c..-::.+-<: ~ ~ !:
$A F~-+--i~ : i ~:. 3 I ANY SST
PROGRAMMER

$B~~---L.-i~ : i ~ i' 3 ~
UNIT WITH
GROUND FAULT
ELEMENT

$Ct I~ ~~
~ ~: 3
NEU~
I
SENSOR ~
f-t-OI
~I
DISCONNECT 0-+--< ~ I
L_J L..----r--....J 1.._______ I L_ J
MALE FEMALE L __ --.J
END END

Fig. 73. Cabling diagram with ground fault defeat cable inserted
between breaker harness and SST programmer unit-for
use during single-phase, high current-low voltage testing

57

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 SECTION 9-Type ECS Overcurrent Trip Device

The ECS is a solid-state, direct-acting, self-powered trip

. device system. The ECS system consists of the ECS
programmer unit shown in Fig. 74, current sensors, and a
flux shifter trip device. Fig. 75 shows a block diagram of
the system.
The ECS trip system essentially duplicates the SST trip
system described in Section 8 except for the following:
1. Programmer units are limited to combinations of
Long Time, Short Time and Instantaneous trip elements
only. The Ground Fault element is not available.
2. Fault indicators (trip targets) are not available.
3. Phase sensors are not tapped. As listed in Table 11
each sensor has only a single ampere rating. A different
sensor is available for each of the tabulated ampere
ratings, which span the same range as SST, see Fig. 76.
4. Neutral sensors are not required because there is no
Ground Fault function.
In all other respects the ECS trip device system operates
and can be treated identically to SST. This includes
circuitry, size, construction, component location,
programmer unit set points, performance characteristics,
operating range, quality, reliability and the flux shift trip
device. Use the same troubleshooting and test procedures
for single-phase, high current-low voltage tests or those
employing the TAK-TS1 Test Set. The Ground Fault test
procedures, of course, do not apply. ECS phase sensor
resistance values are given in Table 12. Fig. 74. ESC programmer unit

1j)----

Fig. 75. ECS block diagram Fig. 76. ECS current sensor

58

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 Table 11-ECS Trip Characteristics

ECS PROGRAMMER ADJUSTMENT RANGE (Set Points)

Frame Long Time Short Time Instan-
Breaker Size Sensor Pickup taneous
Frame (Amperes) Ampere (L) Delay Pickup Delay Pickup
Type Size Rating (Multiple Band (Multiple Band (Multiple
Type (Amperes) (X) of X) (Seconds) of L) (Seconds of L)

300,400,600,800 .25, .3, A

AKS-4/4A-50 1600
1200, 1600 .5, .6, .7 (X)
800, 1200, .2, .25, .3, A,
AKST-4/4A-50 2000
1600, 2000 .5,.6 (X)
AK-4/4A-75 1200,1600, Maximum 1.75, 2, Maximum
3000 2.2~ 2.5, 0.35
AKR-4/4A-75 2000 3000 22 3, (L)
1200,1600, .6, .7, .8, Intermed. Intermed. 4,5,6,
AKR-4B/4C/4S-75 3200 2000,3000, .9, 1.0, 10 --or- 0.21 8, 10, 12 (L)
3200 1.1 (X)
AK-l00 1600,2000, Minimum 3,4,5, Minimum
400 4 6,8, 10 (L) 0.095
AKR-100 3000 4000
NOTES 1
• 3
• • •
, X= Sensor ampere rating = trip rating. 3 Time delay at lower limit of band @ 6L.
2 Pickup tolerance = ± 10% • Time delay at lower limit of band.

Table 12-
9.1-ECS Cabling Diagram Sensor Resistance Values
Resistance In Ohms
,A ,B ,C PROGRAMMER
Breaker
Type
Ampere
Rating Between Terminals
AAA FLUX SHIFT
TRIP DEVICE
UNIT
1------
BREAKER
BACK FRAME
~
r~,
~
-b- b:-:
~

)===)===)=
~
~R~ED~~-<~~B~(48V.de)
100
150
3.0 - 3.4
404 - 5.0
~B,,-,=L~AC~K4--<:>+-<~~-<>-+.... (TO SCR 225 4.8 - 5.6
LEFT POLE I 1 E ANODE) 300 6.4 - 7.2
CURRENT AKS50 6.7 - 7.8
SENSOR
WHITE 400
AKS750 600 604- 7.6
BLACK 800 8.8 - 10.4
1200 13.5-15.8
WHITE
1600 1904 - 22.8
2000 29.5 - 34.5
BLACK
WHITE
1200 13.4-15.7
BLACK 1600 18.3 - 21.5
2000 23.5 - 27.6
3000 37.7 - 44.3
\1_- --'
rrr
3200 42.1 - 49.5
HARNESS 4000 53.4 - 62.6
CONNECTOR PROGRAMMER
(AMP 201298-1) CONNECTOR
LOAD (AMP 201297-1)

Fig. 77. Cabling diagram for ECS trip device

59

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 SECTION 10-MicroVersaTri p TM Overcurrent Trip Device

The MicroVersaTrip is a solid-state, direct-acting, self- 10.1.1-Fault Trip Indicators

powered trip device system. The MicroVersaTrip system
consists of the MicroVersaTrip programmer, current The optional fault trip Indicators are similar to the SST in-
sensors, and a flux shifter trip device. Fig. 78 shows a dicators. They are mechanical pop-out type for identifying
block diagram of the system. overload or short circuit over-currents faults when breakers are
ordered without Integral ground fault protection. They are also
1O.1-Programmer Unit available to identify overload, short circuit and ground fault
trips for breakers supplied with integral ground fault protection.
Fig. 79 shows a typical MicroVersaTrip programmer unit.
Like the SST and ECS units, the MicroVersaTrip provides
Each target pops out when its associated trip element
the comparison basis for overcurrent detection and
operates to trip the breaker. After a trip, the popped target
delivers the energy necessary to trip the breaker. It
must be reset by hand. However, neglecting to reset does
contains a programmable microelectronic processor which
not affect normal operation of any trip element or prevent
incorporates nine adjustable time-current functions, three
the breaker from being closed.
mechanical fault indicators (local and remote), a long-time
pickUp LED indicator (local and remote) and a zone
selective interlocking function. All adjustable programmer
1O.1.2-Remote Fault Indication
functions are automatic and self-contained requiring no Remote fault indication is available in the form of a
external relaying, power supply or accessories. See Table mechanical contact which may be incorporated directly
13 for trip functions available and Table t4 for trip function into the customer's control circuitry. This is a Normally
characteristics. A detailed description of each trip function open contact which is activated when its associated target
is given in publication GEA 10265 and GEH 4657. pops out. When the target is reset. the contact is returned
to its open position. Each contact is rated
0.25 amp at 125 VDC and 1.0 amp (10 amp in rush) at 120
VAC. (Continued page 62)

I
1»-_ I
I

SHORT
,vr----.-----.- CIRCU IT
TARGET

GROUND
)}-+--ITARGET
NEUTRAL

Fig. 78. MicroVersaTrip block diagram Fig. 79. MicroVersaTrip programmer

60

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 Table 13-Trip Functions Available
Optional Features
BASIC FUNCTIONS ADD TO BASIC FUNCTIONS
STD.-or-S-or-H-or-M L T G-or-GR A 1-or-A2-or-A3-or-A Zl-or-Z2-or·Z
• Adjustable Currenl Selling X X X X I
I
• Adj Long-Time Pickup X X X X I I
LONG • Adj Long-Time Delay X X X X
TIME • Long-Time Timing Light X X X X
• Remote Long-Time Timing Light X
• Adj Short-Time Pickup X X X
SHORT • Adj Short-Time Delay X X X
TIME • Short-Time I't Switch(j) X
INSTANTA- • Adj Instantaneous Pickup X X
NEOUS • Adj High Range Instantaneous X
• Adl Ground Fault Pickup
GROUND --1 Ph. 2-W-3 PH. 3-W X I I
I
FAULT -Ground Return X
• Ad] Ground Fault Delay X X
• Tnp Indication Targets
-Overload & Short CircUit
OTHER -local only X
I IX
FUNCTIONS -local and remote
-0 L. S C and Ground Fault
I

r
-local only (2l X
-local and remote X
• Zone Selective Interlock
-Ground Faultq) X
-Short Tlme(j) IX X X

1 Shan- Time Delay IS required

2 Standard when Ground Fault specified
3 Ground Fault required

Table 14-MicroVersaTripTM Trip Characteristics

Lonq-Time Short-time Ground Feult
Current Adjustable
Setting Instantaneous Pickup
(X) (X) (MUltiple Pickup Pickup Pickup Short-time (Multiple
Fixed Tapped of Sensor (Multiple Delay (Multiple Delay (MUltiple 1'1 of sensor Delay
Maximum Sensors Sensors Current of Current (j) of Current ® of Sensor <D Current ®
Freme Retlng Rating) Rating) (Seconds) Rating) (Seconds) Retlng) (Seconds) Rating) (Seconds)
Size (Amps) Sensor Current Rating (X) (C) (C) (X) (X)
(Amps)

100. 150.
100,150. 225.300 .5.. 6..7. .B,9, 25.5, 1.5,2,25. 0.10. 1.5,2.2.5, .2. 25.. 3, 0.10.0.22 .
AKR-30 BOO 225,300, or .B, .B5.9, 1.0.11 10,21 3,4.5,7, 0.22. 3.4,6. B, OA 35. A, A5. 036
400.600, 300.400 .95, 1.0 (C) 9 (C) 036 10 (X) 5.. 6 (X)
BOO 600. BOO (XI

300.400.
300.400. 600. BOO
AKR-50 "
1600 600, BOO or
AKS-50 1200,1600 600. BOO
1200.1600
AKST-50 BOO, 1200. BOO. 1200
AKRT-50 2000 1600.2000 1600,2000

1200.1600, 1200. 1600 .2..22, .24,

AKR·75 3200 2000.3200 2000,3200 .26.. 2B..30. "
.34..37 (X)

1600.2000. 1600,2000 1.5, 2, 2.5, 3, .2..22 ..24.

AKR·IOO 4000 3000,4000 3000. 4000 " " 4,5.7.9 (XI " .26, .2B..3 (X)

1 Time delay shown al 600% of ampere setting al lower limit 01 each band. c ~ current setting
2 Time delay shown at lower limit of each band. X = sensor OJrrent
All pickup lolerances are ± 10%
Ground Fault pickup not to exceed 1200 amperes

61

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 SECTION 10-MicroVersaTrip TM Overcurrent Trip Device
10.1.2-(Cont.)
The remote fault indication switch leads are brought out
the bottom of the MicroVersaTrip programmer as shown in
Fig. 80. This switch lead harness is plugged into the
mating connector on the breaker, see Fig. 81.
The switch leads are brought out from the breaker through
the Programmer Secondary Disconnect shown in Fig. 82.
The zone selective interlocking function wiring is also
brought out through this disconnect. See Figs. 76 and 77
for the remote fault indication and zone selective
interlocking cable diagrams.

iJ

1. Remote fault indicator

disconnect

Fig. 81. Remote fault indicator disconnect

Fig. 80. MicroVersaTrip w/remote fault
indication harness

10.2-M icroVersaTrip Installation

The programmer is located on the left side of the breaker's
center channel as shown in Fig. 81. It mounts to the
bracket assembly shown in Figs. 83 or 84. Referring to
either Fig. 83 or 84, the guide pins mate with the holes on
either side of the programmer, connector. They provide the
necessary alignment for the connector engagement. The
locking lever engages with the pin which is assembled to
the programmer frame and secures the programmer to the
mounting bracket.

10.2.1-AKS 50 Installation
The AKS 50 mounting bracket is shown in Fig. 83.
Installation is as follows:
a. Insert the guide pins into the holes and push on the
programmer. This will engage the connectors and release
Fig. 82. Programmer secondary connector the locking lever which will move upwards.

62

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 b. Verify that the locking lever did engage the 10.2.2.-AKR 75/100 Installalion
programmer pin.
There are two programmer mounting designs in use. The
c. Connect remote fault indication harness, if equipped, difference in the designs is in the operation of the locking
see Fig. 81. lever, see Fig. 84.
To remove the programmer:
a. Disconnect remote fault indication harness, if
equipped.
b. Move locking lever to horizontal position, releasing
programmer pin.
c. Remove programmer.

ORIGINAL LATER
DESIGN DESIGN

Fig. 84. AKR 75/100 program mer

mounting

Installation using each design is as follows:

a. Insert the guide pins into the holes and push on the
programmer, engaging the connectors.
b. Original design-push in the locking lever, securing
the programmer.
Later design-the locking lever is released, securing
the programmer.
c. Verify that the locking lever did engage the
programmer pin.

1. Guide pin d. Connect remote fault indication harness, if equipped,

2. Locking/lever disengaged position see Fig. 81.
3. Engaged position To remove the programmer:
a. Disconnect the remote fault indication harness,
Fig. 83. AKS 50 programmer mounting if equipped.
(continued next page)

63

Courtesy of NationalSwitchgear.com
 SECTION 10-MicroVersaTrip TM Overcurrent Trip Device
10.2.2-AKR 75/100 Installation (Cont.)
b. Original design-push in locking 1ever, which will The tapped or fixed phase sensors are available with an
release the programmer pin. While holding the locking additional winding. This winding is brought out to separate
lever in, remove the programmer. flag terminals rather than the screw terminals. These phase
sensors are used when the hi-level instantaneous
c. Later design-pullout locking lever, which will
MicroVersaTrip option ('H'-option) is required. Fig. 86
release the programmer pin. Remove the programmer.
shows an 'H'-option phase sensor. When the 'H'-option
phase sensor is installed, there are four leads connected to
it. There is no polarity associated with the 'H'-option
10.3-Current Sensors windings. Fig. 95 shows the connections for the additional
The current sensors supply the power and signal input 'H'-option Windings.
necessary to operate the trip system. Like the SST system,
the MicroVersaTrip uses a phase and neutral sensor.
Fig. 85 shows the phase sensors. Tapped and fixed phase
sensors are available. The tapped sensors provide field
adjustment of the trip device's continuous ampere rating.
See Section 10.5 for cabling diagrams.
The tapped and fixed phase sensors have a polarity
associated with their windings. The COMMON terminal Of
the tapped sensor and of the AKS 50 fixed sensor is the
right hand terminal as shown in Fig. 85. A white wire with a
ring terminal will be connected to this COMMON terminal.
The AKR 75/100 fixed sensor uses push-on terminals, but
the right hand terminal is still the COMMON terminal and iI
uses a white wire.
All phase sensors must be correctly wired for the
programmer summing circuitry to function properly. Refer
to the cabling diagrams in Section 10.6

1. H-option terminals

Fig. 86. H-option phase sensor

Fig. 87 shows the neutral sensor. The neutral sensor is
required when integral ground fault protection is used on
single phase-three wire or three phase-four wire systems.
It is inserted into the neutral conductor and therefore is
separately mounted in the cable or bus compartment.
The outputs of the phase sensors and neutral sensor are
connected to a programmer circuit which sums these
values. The total value will remain zero as long as there is
no ground current flowing. See cable diagram in
Fig. 92.
The neutral sensor is an electrical duplicate of the phase
sensor, including taps. Therefore, when taps are changed
on the phase sensors, those on the neutral sensor must be
correspondingly positioned.
Since the neutral sensor is mounted separately from the
breaker, a disconnect means is required to connect its
output to the breaker. Fig. 88 shows the breaker and
equipment mounted 4th wire secondary disconnect used
Fig. 85. MicroVersaTrip phase sensors with the MicroVersaTrip system.

64

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 10.3.2-Replacement of Current
Sensors - AKR 75/100
The replacement of the AKR 75.100 MicroVersaTrip
current sensors follows the same procedure used for the
SST sensors, refer to Section 8.2.2

10.4-Flux Shifter Trip Device

The only difference between the MicroVersaTrip and SST
flux shifter trip devices is the solenoid winding. Refer to
Section 8.3 for details.
When replacing a MicroVersaTrip flux shifter, AMP
extraction tool Cat. No. 455822-2 is required to remove the
socket leads from the AMP connector.

10.5-Troubleshooting
When malfunctioning is suspected, the first step in
troubleshooting is to examine the circuit breaker and its
power system for abnormal conditions such as:
Fig. 87. Typical neutral sensor a. Breaker tripping in proper response to overcurrents
or incipient ground faults.
10.3.1-Replacement of Current
b. Breaker remaining in a trip-free state due to
Sensors - AKS 50 mechanical interference along its trip shaft.
The replacement of the AKS 50 MicroVersaTrip current c. Inadvertent shunt trip activations.
sensors follows the same procedure used for the SST
sensors described in Section 8.2.1. The only difference is
that the tap board is not a separate item but is integral with WARNING: DO NOT CHANGE TAPS ON THE
the sensor. CURRENT SENSORS OR ADJUST THE
PROGRAMMER UNIT SET KNOBS WHILE
THE BREAKER IS CARRYING CURRENT.

TYPICAL AKR 75/100-AKS 50 REAR MOUNTING EQUIPMENT MOUNTED MATING DISCONNECT

Fig. 88. Neutral sensor secondary disconnect

65

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SECTION 10-MicroVersaTrip rM Overcurrent Trip Device
10.5--(Cont.)
Once it has been established that the circuit breaker can Table 15-Tapped Sensor
be opened and closed normally from the test position,
attention can be directed to the trip device proper. Testing
Resistance Values
is performed by either of two methods: Breaker Resistance In ohms
1. Conduct high-current, single-phase tests on the Frame Ampere between Common
Size Vap 2nd Tap Terminals
breaker using a high current-low voltage test set.
300
400
NOTE: For these single-phase tests, special 600
800
connections must- be employed for AKS50
MicroVersaTrip breakers equipped with Ground 600
Fault. Any sing Ie-phase input to the 800
programmer circuit will generate an unwanted 1200
"ground fault" output signal which will trip the 1600
breaker. This can be nullified either by 800
1200 CONSUL T
a. Testing two poles of the breaker in series, AKST50 1600 FACTORY
or 2000
b. Using the Ground Fault Defeat Cable as AKR75 1200
shown in Fig. 94. This special test cable 1600
energizes the programmer circuit in a self- 2000
cancelling, series-parallel connection so that its 3200
output is always zero. 1600
AKR100 2000
3000
2. Test the components of the MicroVersaTrip system 4000
using portable Test Set Type TVS1 (Fig. 89). The
applicable test procedures are detailed in instruction Book
GEK-64464.

Table 16-Fixed Sensor

Resistance Values
Breaker Resistance In ohms
Frame CT between Common
Size Rating 2nd Tap Terminals
300
400
600
AKS50 800
1200
1600
800
AKST50 1200
1600
2000 CONSUL T
Fig. 89. Test set, cat. no. TVTS1 FACTORY
1200
AKR75 1600
2000
10.5.1-Resistance Values 3000
3200
For use in troubleshooting the MicroVersaTrip current
1600
sensors, the resistance of the tapped and fixed windings is
AKR100 2000
given in Tables 15 and 16 respectively. 3000
The coil resistance of the MicroVersaTrip flux shifter 4000
device is approximately 7 ohms.

66

Courtesy of NationalSwitchgear.com
 1O.5.2-False Tripping-Breakers 10.6-MicroVersaTrip Cabling
Equipped with Ground Fault Diagrams
When nuisance tripping occurs on breakers equipped with
the Ground Fault trip element, a probable cause is the
existence of a false "ground" signal. As indicated by the
cabling diagram of Fig. 91, each phase sensor is
OA oB OC PROGRAMMER
connected to summing circuitry in the programmer. Under
AAA FLUX SHIFT UNIT
no-fault conditions on 3-wire load circuits, the currents in
this circuitry add to zero and no ground signal is
developed. This current sum will be zero only if all three
B~~;~~~~E
~
11-1- t- i
r=+=:)=
TRIP DEVICE

RED
WHITE
32
1------

LEFT POLE f I 28
sensors have the same electrical characteristics. If one
sensor differs from the others (I.e., different rating or ~~%~~NRT ,'-.J':::'O::':c:+--+---+----+-<>-K.E-+<''"'8f--o
wrong tap setting), the circuitry can produce output I ~ 22

sufficient to trip the breaker. Similarly, discontinuity 'I

I A
between any sensor and the programmer unit can cause a I
I
false trip signal. I
If nuisance tripping is encountered on any breaker whose I
I
MicroVersaTrip ~ components have previously demonstrated I
satisfactory performance via the TVTS1 Test Set, the sensors 1-
\1_- -'
rrr
and their connections should be closely scrutinized after
disconnecting the breaker from all power sources. c~~~~~~gR PROGRAMMER
(AMP '-350356-9) CONNECTOR
LOAD
a. Check that all phase sensors are the same type
(ampere range).
b. Ensure that the tap settings on all 3-phase sensors
are identical. Fig, 90. Cabling diagram-MicroVersaTrip
c. Verify that the harness connections to the sensors without ground fault
meet the polarity constraints indicated by the cabling
diagram.
d. On Ground Fault breakers serving 4-wire loads, check
oA oB .c PROGRAMMER
that the neutral sensor is properly connected (see cabling
diagram Fig. 92). In particular,
BREAKER
AAA
,-.$--$-4'-,
FLUX SHIFT
TRIP DEVICE
UNIT
- 1-----1
1. Verify that the neutral sensor has the same rating and
BACK FRAME I ~, b b. I RED 32
I-W-!:H~'T~E+O-+-<~>-t--
I
~ r==)===}.o I
tap setting as the phase sensors, LEFT POLE I I 28 I
CURRENT
2. Check continuity between the neutral sensor and its SENSOR
18
equipment-mounted secondary disconnect block. Also 22
check for continuity from the breaker-mounted neutral
secondary disconnect block through to the female harness 19
23
connector.
3. If the breaker's lower studs connect to the supply 20
I 24
source, then the neutral sensor must have its LOAD end I I'------1-0+-< ~t-<>-t-
connected to the source. See Fig. 93. ,_ J 17

4. Ensure that the neutral conductor is carrying only

that neutral current associated with the breaker's load
current (neutral not shared with other loads).
'fr. LOAD
L ....
PROGRAMMER
e. If the preceding steps fail to identify the problem, CONNECTOR
then the sensor resistances should be measured. Since the
phase and neutral sensors are electrically identical, their
tap-to-tap resistances should closely agree. See Tables 15
and 16. Fig. 91. Cabling diagram-MicroVersaTrip
with ground fault on 3-wire load

67

Courtesy of NationalSwitchgear.com
SECTION 10-MicroVersaTripTM Overcurrent Trip Device

+A +B 'c
,-----,
PROGRAMMER

BREAKER
AAA
r $ --$-4'- I
FLUX SHIFT
TRIP DEVICE
UNIT

BACK FRAME ~,b b, I RED 32

~=--t-<>+-<f+C>-i
I
I
~ )===)===)= WHITE
28 I
LEFT POLE I I
CURRENT
SENSOR I
18 I
'111 22 I
I
19
I
23
I
I
I
20 I
24 I
I
I
21
I
I
17 I
I
......I

rr
1
HARNESS
CONNECTOR PROGRAMMER
EQUIPMENT -MOUNTED \ '( AMP 1-350356-9 CONNECTOR
NEUTRAL SENSOR L---~v
4-WIRE LOAD

Fig. 92. Cabling diagram-MicroVersaTrip with ground fault on 4-wire load

4-WIRE LOAD

,111 '
r -__~A,- ~

,-----,
PROGRAMMER
FLUX SHIFT
UNIT
TRIP DEVICE
BREAKER r $ --$- 4'- I
BACK FRAME ~,b ~,I RED 32 I
t--'-=--t-o+<. f+<H I
~ )===)===r WHITE
LEFT POLE I 28
CURRENT
SENSOR

:t
I,
18
22

I A
I
NEUTRAL I
SENSOR I
DISCONNECT I
~-1 I

EQUIPMENT -MOUNTED I LOAD\ I

NEUTRAL SENSOR I COM

~ {t"--++=-::~
\ IN >+ot--i----t----t--+-----------t-<>-KH-C>-i
1 ......
L
HARNESS
CONNECTOR PROGRAMMER
AMP 1-350356-9 CONNECTOR
LOAD

Fig. 93. Cabling diagram-MicroVersaTrip with ground

fault on 4-wire load-breaker reverse feed

68

Courtesy of NationalSwitchgear.com
SECTION 10-MicroVersaTripTMOvercurrent Trip Device

BREAKER PROGRAMMER

,
HARNESS
CONNECTOR

r ...,
GROUND FAULT DEFEAT MODULE
CAT, NO, TVTGD9
r----~A'---_ _~\
..--
1~-- ---~ ,--1
UNIT
,---,
I
0-+--< 'g ~I 1
~
0--+-< ~ I I
~ ~
o--t--<
4 4 ~ I I
0--+--<

~: i~
0-+-<
5 ~
Q 2
o---r-< 7 7 ~ I I
o-----t---< ~I
o-t-<
8 :a ~ I I
18
o---t-<
19
0
1 0 I I ANY MICROVERSATRIP
0--+--< 2'P
0 I 0 I I PROGRAMMER
~ I () UNIT WITH
0-+-<
17
0
0
I I GROUND FAULT
22
I 0 I ELEMENT
??
o.--l-<
23 23 ~I I
cr-t-< 24 24 ~ I I
o-t--<
2j 26 4-u I I
0--+-< ;!~ 28 ~+-o I I
0--+---< ~I
~ ~ 3) /
~J I I
L J ~
- - -- ~ L --l 1
L __ -l

Fig. 94. Cabling diagram with ground fault defeat module inserted between
breaker harness and MicroVersaTrip programmer unit-for use
during single-phase, high current-low voltage testing

PROGRAMMER
UNIT
1------
BREAKER
BACK FRAME r- - - -I
I
r-
'13
~ )===)===)=1
Partial
I E
LEFT POLE
CURRENT
I
I YELLOW

:t~
SENSOR
I 14

II
I A
I
I
YELLOW
YELLOW
10
-
,
t~
15
I 11
I YELLOW
:~ f-<>- ......
I

I I YELLOW
B I ......
:f-
~
f
I
I
1_ _ ___ I-.J
H
I
C
I YELLOW /
12

...... ,
rry
,,1/ '\l/

LOAD
,,1/
HARNESS
CONNECTOR PROGRAMMER
CONNECTOR
----~

Fig. 95. Partial cabling diagram: 'H'-option winding connections

69

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SECTION 10-MicroVersaTrip TM Overcurrent Trip Device

PROGRAMMER REMOTE FAULT MICROVERSATRIP

SECONDARY INDICATION PROGRAMMER
DISCONNECT CONNECTOR

EQUIPMENT BREAKER
------
9 9 YELLOW
I
I
OVERLOAD
{ YELLOW
I
RED
I
SHORT
CIRCUIT { RED I
GROUND J
13 13 GREEN I
14 14 GREEN
FAULT I
toE 15 15 BLUE I
OVERLOAD f 16 16 BLUE I
PICKUP
1 I
I------~
AMP AMP AMP AMP
1-350239-9 1-350246-9 1-350242-9 1-350235-9

Fig. 96. Cabling diagram-remote fault indication

PROGRAMMER MICROVERSATRIP
SECONDARY PROGRAMMER
DISCONNECT PROGRAMMER
HARNESS --I
EQUIPMENT BREAKER CONNECTOR

SHORT TIME { ~
INPUT - <E'----K.>-+--< <E'---_+_<J-t------t-

SHORT TIME { +
OUTPUT - <E'----f--CH--< ~_+_<)-t------H)+--<.

GROUND FAULT { +
INPUT _ <C---H.:)+--< ~+<}-f------+-

GROUND FAULT { +
OUTPUT - ~-I-Cr+--< ~+(}-+ -+-(

AMP AMP
1-350239-9 1-350246-9
--~

Fig. 97. Cabling diagram-zone selective interlock

70

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SECTION 11-RMS-9/Epic MicroVersaTripTM
The RMS-9/Epic MicroVersaTrip is a solid-state, direct-act-
ing, self-powered trip device system. The RMS-9 system
consists of the RMS-9 programmer, current sensors, and a
flux shifter trip device. Fig. 98 shows a block diagram of the
system.
11.1-Programmer Unit
Fig. 99 shows a typical RMS-9Epic MicroVersaTrip unit.
The RMS-9/Epic MicroVersaTrip provides the comparison
basis for overcurrent detection and delivers the energy nec-
essary to trip the breaker. It contains a programmable mi-
croelectronic processor which incorporates nine adjustable
time-current functions, three mechanical fault indicators, a
long-time pickup LED indicator and a zone selective inter-
locking function. All adjustable programmer functions are
automatic and self-contained requiring no external relaying,
power supply or accessories. See Table 17 for trip functions
available and Table 18 for trip function characteristics. A de-
tailed description of each trip function is given in publication
GEK 97367.
XFMR
N ---L}--~~~-,

AMPLIFIER
OA-{~

os----EJ
R8~ RATING PLUG ~~~;C~':STE

OCL~Jl~! r~c~L~'ER ~; TRIP

1.. ;RATING PLUG
~
ST

COMPARATOR TO
--+ ~ C~ '<2Cr,RIP 'FLUX
INST ~ SHIFTER
SWITCH FIG. 99
Fig. 98. RMS-9 Block Diagram RMS-9 & Epic MicroVersaTrip
11.1.1-Fault Trip Indicators Programmer
The optional fault trip indicators are similar to the
MicroVersaTrip indicators. They are mechanical pop-out
type for identifying overload or short circuit over-current Note Location
faults when breakers are ordered without integral ground of Pin #1
fault protection. They are also available to identify overload,
short circuit and ground fault trips for breakers supplied with
integral ground fault protection.
Each target pops out when its associated trip element
operates to trip the breaker. After a trip, the popped target
must be reset by hand. However, neglecting to reset does
not affect normal operation of any trip element or prevent
the breaker from being closed.
11.2-RMS-9 & Epic MicroVersaTrip
Installation
The programmer mounts to the lower left of the breaker
as shown in Fig. 101. It mounts to the bracket assembly
shown in Fig. 82. Referring to Fig. 82, the guide pins mate
with the holes on either side of the programmer connector.
They provide the necessary alignment for the connector
engagement. The locking lever engages with the pin which
is assembled to the programmer frame and secures the pro-
grammer to the mounting bracket
Installation using each design is as follows:
a. Insert the guide pins into the holes and push on the pro-
FIG. 100
grammer, engaging the connectors.
b. The locking lever is released, securing the programmer.
Programmer Secondary
c. Verify that the locking lever did engage the programmer ·pin. Connector Epic MicroVersaTrip
To remove the programmer: 71
a. Pull out locking lever, which will release the programmer
pin. Remove the programmer.
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SECTION 11-RMS-9 and Epic MicroVersaTrip Trip Device ™

11.3-Current Sensors
The current sensors supply the power and signal input nec-
essary to operate the trip system. The RMS-9 and Epic
MicroVersaTrip") use a phase and neutral sensor. Fig. 102
shows the phase sensors. See Section 11.5 for cabling dia-
grams.

Fig. 101
The fixed phase sensors have a polarity associated with their
windings. Their COMMON terminal is the right hand terminal
as shown in Fig. 102. A white wire with a push on terminal
will be connected to this COMMON terminal. All phase sen-
sors must be correctly wired for the programmer summing
circuit to function properly.
The phase sensors are available with an additional winding.
This winding is brought out to separate flag terminals. These
phase sensors are used when the hi-level instantaneous
RMS-9 option ('H'-option) is required. Fig. 102 shows an
'H'-option phase sensor. When the 'H'-option phase sensor
is installed, there are four leads connected to it. There is no
polarity associated with the special winding connection. Fig.
103 shows the connections for the additional 'H'-option
Windings.

72

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 TABLE 17. TRIP FUNCTIONS AVAILABLE

Optional Features
BASIC FUNCTIONS ADD TO BASIC FUNCTIONS
STD.-or-8-or-H-or-M L T G-or-GR A1-or-A2-or-A3-or-A Z1-or-Z2-or-Z
• Adjustable Current Selting X X X X
• Adj Long-Time Pickup X X X X
LONG • Adj Long-Time Delay X X X X
TIME • Long-Time Timing Light X X X X
• Remote Long- Time nming Light X
• Adj Short-Time Pickup X X X
SHORT • Adj Short-Time Delay X X X
TIME • Short-Time 12 t Switch <D X
INSTANTA- • Adi Instantaneous Pickup X X
NEOUS • Adj High Range Instantaneous X
• Adj Ground Fault Pickup
GROUND -1 PH, 2·W-3PH, 3/4-W X
FAULT -Ground Return X
• Adj Ground Fault Delay X X
• Trip Indication Targets
-Overload & Short Circuit
OTHER -local only X
FUNCTIONS -local and remote X
-OIL, SIC and Ground Fault
-local only(2) X
-local and remote X
• Zone Selective Interlock
-Ground Fault~ X X
-Short Time<D X X

1 Short· Time Delay is required

2 Standard wnen Ground Fault specified
3 Ground Fault required

TABLE 18. MICROVERSATRIP" TRIP CHARACTERISTICS

Long-Time Short· Time Ground Fault
Adjustable Adjustable
Current Instantan- Instantan~ High Range
Setting eo us eous Instantan- Triple Pickup
(Mult. Pick up Pick up Pick Up Pick Up eous Selective (Mult.
of (Mult. (Mult. w/o ST withST (Mult. of Trip of
Sensor Rating of of (Mult. of (Mult. of Frame Fixed High Sensor
Max. Rating Plug Current Current Rating Rating Short-time Range Amp Delay Delay'"
Frame Amp (Amps) Amps) Setting} Delay' Setting} Delay Plug Amps) Plug Amps) Rating) Instantaneous Rating) w/I'T w/o I'T
Size Rating (s) (Xl (C) (Sec.) (C) (Sec.) (X) (X) (HI 5 (5) (Sec.) (Sec.)

.2, .22,
.5, .6, Fixed at .24,
2 .44 at
.7, .8, 1.0 of 2.4,4.9, 1 T in: 1 1.5,2,3,5, 1.5.2,3,5, .26, .10, .21,
AKR-75 3200 3200 .4, .6, .8, 1.0 NA 200%
.9, .95, Current 9.8,20 .40 7,9,10 7.9,10,13 .28, .35
1.5,2.0. of pick
1.0,1.1 Setting .30,
2.5.3.0, up at
['T .34, .37
4.0,5.0, lower
out: 2
7.0,9.0 limit
.5, .6, Fixed al .10, .2, .22,
of
.7, .8. 1.0 of 2.4,4.9, .21,35 1.5,2,3,5, 1.5,2,3,5, .24, .10, .21,
AKR-100 4000 4000 .4, .6, .8, 1.0 NA band
.9..95, Current 9.8,20 7,9 7,9 .26, .35
1.0,1.1 Setting .28, .3

:1 Time delay shown at 600% elf Time delay shown at lower x = Rating plug amps Triple selective trip is '6; Time delay shown at lower
current setting at lower limit limit of each band. All pick S = Sensor amp rating standard when long- limit of each band.
of band. up tolerances are ± 10%. C = Current setting time/short-time only Ground fault pick up not
IS required. to exceed 1200 amps.

73

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SECTION 11-RMS-9 and Epic MicroVersaTrip Trip Device nl

Fig. 102. RMS-9 Phase Sensors Fig. 104. Typical Neutral Sensor

Fig. 104 shows the neutral sensor. The neutral sensor is re-
quired when integral ground fault protection is used on
single phase-three wire or three phase-four wire systems. It
is inserted into the neutral conductor and therefore is sepa-
rately mounted in the cable or bus compartment.
The outputs of the phase sensors and neutral sensors are
connected to a programmer circuit which sums these values.
The total value will remain zero as long as there is no ground
current flowing. See cable diagram in Fig. 108.
The neutral sensor is an electrical duplicate of the phase
sensor. Therefore, when phase sensors are changed, the
Fig. 103. 'H' Option Phase Sensor neutral sensor must be correspondingly changed.

74

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Since the neutral sensor is mounted separately The time-current characteristics for the RMS-9 & Epic
from the breaker, a disconnect means is required to MicroVersaTrip Trip Device are given in curves GES-6227
connect its output to the breaker. Fig. 88 shows the and GES-6228.
breaker and equipment mounted 4th wire secondary
disconnect used with the RMS-9 system.

11.3.1-Replacement of Current
Sensors
Referring to Fig. 88, replacement of RMS-9 & Epic
MicroVersaTrip® current sensors is accomplished by the
same procedure as the MicroVersaTrip® current sensors.

11.4-Flux Shifter Trip Device

The only difference between the RMS-9/Epic
MicroVersaTrip® and the SST flux shifter trip devices is the
solenoid winding. Refer to Section 8.3 for details.
When replacing a RMS-9/Epic MicroVersaTrip® flux shifter,
AMP extraction tool Cat. No. 455822-2 is required to remove
the socket leads from the AMP connector.

11.5--Troubleshooting
When malfunction ion is suspected, the first step in
troubleshooting is to examine the circuit breaker and its
power system for abnormal conditions such as:
a) Breaker tripping in proper response to overcurrents or
incipient ground faults.
b) Breaker remaining in a trip-free state due to
mechanical maintenance along its trip shaft. Fig. 105. Test Set, Cat. No. TVRMS
c) Inadvertent shunt trip activations. 11.5.1-Resistance Values
For use in troubleshooting the RMS-9 current sensors, the
WARNING: DO NOT ADJUST THE PROGRAMMER UNIT
resistance of the fixed windings is given in Table 19.
(KNOBS) WHILE THE BREAKER IS CARRYING CUR-

Once it has been established that the circuit breaker TABLE 19.
can be opened and closed normally from the test position, Ampere Resistance in Ohms
attention can be directed to the trip device proper. Testing Rating Between Terminals
is performed by either of two methods: 150 10-12
400 27-32
1. Conduct high-current, single-phase tests on the 800 58-68
breaker using a high current-low voltage test set. 1600 129-151
NOTE: For these single-phase tests, special connections 2000 207-243
must be employed for RMS-9 breakers equipped with The coil resistance of the RMS-9 & Epic MicroVersaTrip'" flux
Ground Fault. Any single-phase input to the programmer cir- shifter device is approximately 7 ohms.
cuit will generate an unwanted "ground fault" output signal
which will trip the breaker. This can be nullified either by
a) Using the Ground Fault Defeat Cable as shown in
Fig. 94 This special test cable energizes the pro-
grammer circuit in a self-cancelling, series-parallel
connection so that its output is always zero.
2. Test the components of the RMS-9 system using portable
Test Set Type. The applicable test procedures are detailed
in instruction Book 97367.

75

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SECTION 11-RMS-9 and Epic MicroVersaTripTM Trip Device

11.5.2- False Tripping-Breakers 11.6-Cabling Diagrams

Equipped With Ground Fault
cj>A cj>B cj>c PROGRAMMER
When nuisance tripping occurs on breakers equipped with
the Ground Fault trip element, a probable cause is the exist- BREAKER A A A FLUX SHIFT
TRIP DEVICE
UNIT
1------
ence of a false "ground" signal. As indicated by the cabling
diagram of Fig. 106, each phase sensor is connected to
~~~~E
~
-1-t- i
If)===)===)= RED
WHITE
32

summing circuitry in the programmer. Under no-fault condi-

tions on 3-wire load circuits, the currents in this circuitry add
LEFT I I 28
POLE COM
to zero and no ground signal is developed. This current sum CURRENT I ',.-1...:+:.4--+-+-----+0+< ~t<1O-8~
will be zero only if all three sensors have the same electrical SENSOR I t 22
characteristics. If one sensor differs from the others (i.e. dif- I I 4-<..-+--1-+---
ferent rating), the circuitry can produce output sufficient to I A

+I..J-o--+-+-----+<::+<. ~-o~;-t-
trip the breaker. Similarly, discontinuity between any sensor
and the programmer unit can cause a false trip signal. :
I
If nuisance tripping is encountered on any breaker whose I 20
RMS-9 or Epic MicroVersaTrip components have previously I 24
demonstrated satisfactory performance via the lVRMS Test I
Set, the sensors and their connections should be closely 1- \1_- -,
rrr
scrutinized. After disconnecting the breaker from all power
sources. HARNESS PROGRAMMER
CONNECTOR CONNECTOR
a) Check that all phase sensors are the same type (am- (AMP 1-350356-9)
LOAD
pere range).
b) Verify that the harness connections to the sensors Fig. 106. Cabling diagram-RMS-9 & Epic
meet the polarity constraints indicated by the cabling MicroVersaTrip without ground fault
diagram.
c) On Ground Fault breakers serving 4-wire loads,
check that the neutral sensor is properly connected (see cj>A cj>B .v PROGRAMMER
cabling diagram Fig.108). In particular, BREAKERA A A FLUX SHIFT
TRIP DEVICE
UNIT
1------
(1) Verify that the neutral sensor has the same rating ~~;~E'f -1-t-i RED 32
as the phase sensors. "": )= ==)= ==)= WHITE
LEFT I 1 28
(2) Check continuity between the neutral sensor and its POLE
'-+---+--+--+-----+<:>-+-< ~t-<1)-8t -
equipment-mounted secondary disconnect block. Also
check for continuity from the breaker-mounted neutral
CURRENTI
SENSOR I
I
t4-<_+--I-+-----t-<>-t-<
I
22
'E-+<>+-
secondary disconnect block through to the female harness
I A
connector.
I
(3) If The breaker lower studs connect to the supply I
I
source, then the neutral sensor must have its LOAD end I
connected to the source. See Fig. 109. I

(4) Ensure that the neutral conductor is carrying only I

th at neutral cu rrent associated with the breaker load cur- 1- J
rrr
( I
rent (neutral not shared with other loads).
HARNESS
e) If the preceding steps fail to identify the problem, then CONNECTOR
(AMP 1-350356-9)
the sensor resistances should be measured. Since the 1 -'
LOAD
phase and neutral sensors are electrically identical, their PROGRAMMER
tap-to-tap resistances should closely agree. See Table 19. CONNECTOR

Fig. 107. Cabling diagram-RMS-9 & Epic

MicroVersaTrip with ground fault on 3-wire load

76

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 PROGRAMMER
FLUX SHIFT UNIT
TRIP DEVICE 1------
RED 32
WHITE
28

:I ~
18
~2
I I..I--_+--+--+-----~>+_<~_k>_I
I A
19
I 23
NEUTRAL I
SENSOR I
DISCONNECT I

--1 I
I LINE I I
I COM
( ~ ";-'::=1-<>+7 )-+o+--I---f---+-+----+o+<

\ L+_-kl-A .>+<>t--J--I----+~----+_O_I_<
4:..+0-1
liN
~A~
rr1
1 ......
I
HARNESS
CONNECTOR PROGRAMMER
EQUIPM1NT -MOUNTED \ AMP 1-350356-9 CONNECTOR
NEUTRAL SENSOR '---~V
4-WIRE LOAD

Fig. 108. Cabling diagram-RMS-9 & Epic MicroVersaTrip'· with ground fault on 4-wire load

4-WIRE LOAD

BREAK
BACK FR
111
~~E r1-1-t-~
FLUX SHIFT
TRIP DEVICE

RED -
~
32
PROGRAMMER

,-----
UNIT

~ »=. =rr =),}- I WHITE

LEFT P OLE I I J 28
CURR ENT COM : ' ,
I I~
SENS
OR
I
'I
t r- I
I
18
22
I
I A

H~
19
I 23
RAL: I
OR I I

n
I
NECT
I
B ,~
-rc;
I
:f- ~
I

~I I I
EQUIPMENT -MOUNTED I C
NEUTRAL SENSOR I ! :f- ~
~{~~+<>+' I

- I 17
\
\IN

L ~N~
" L....
-
"
/-, /--..., _J
,/
HARNESS
CONNECTOR
"

PROGRAMMER
I- - - - - ......
AMP 1-350356-9 CONNECTOR
LOAD

Fig. 109. Cabling diagram-RMS-9 & Epic MicroVersaTrip with ground fault on 4-wire
load-breaker reverse feed

77

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SECTION 11-RMS-9 and Epic MicroVersaTripTM Trip Device

Socket

Class
No.
Note Location
5 + of Pin #1
Gnd .Fault
Zone 6 - Inputs
Selective
Interlock 7 +
Gnd. Fault
8 - Outputs

11 -
12 + Commnet

9 Spare

Epic 10 VC
MVT
1 V3

4 VA

2 24 Ret

3 + 24 VDC

Fig. 110. Programmer secondary connector pin locations for zone

selective interlock and Epic MicroVersaTrip Trip Device

78

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SECTION 12-MicroVersaTripTM Plus and
MicroVersaTripTM PM Trip Units
The MVT-Plus/MVT-PM is a solid-state, direct-acting, self- Power Requirements
powered trip device system. The system consists of the
MVT-Plus/MVT-PM programmer current sensors and a flux A small amount of power is necessary to energize the liquid
shifter trip device. Figure 111 shows location of features on crystal display (LCD) during setup, for viewing breaker status,
programmer. See user manual GEH-5891 A. and for metering displays. MicroVersaTrip PM trip units re-
quire external 24 Vdc control power for operation. The four
12.1-Trip Unit sources of such power are the following.

MicroVersaTrip Plus Trip Unit • Flow of current - Breaker current sensors provide
MicroVersaTrip Plus trip units utilize a digital, LCD display sufficient power to energize the LCD when at least
with a four-button keypad to provide local set-up and read- 20% of the sensor's ampere rating is flowing.
out of trip settings. A 3-phase ammeter and trip indicators • 24 Vdc control power - Breakers with MicroVersaTrip
are standard, as is a clear plastic cover with provisions for PM trip units are supplied with external 24 Vdc power
sealing to allow tamper resistant installation. The trip unit that, whenever present, energizes the LCD. Some
digitally measures the current waveform in each phase to de- breaker models that are configured for
termine the true RMS value of the current, regardless of the MicroVersaTrip Plus trip units may be optionally
waveshape. MicroVersaTrip@ Plus trip units provide accu- equipped to accept an external 24 Vdc supply.
rate, predictable overload and short circuit protection for dis- • MicroVersaTrip Test Kit - The MicroVersaTrip Test
tribution systems that include ac and dc variable speed Kit, Cat. No. TVRMS, contains a 24 Vdc power sup
drives, rectifiers, induction heating, and other loads that ply. The LCD is energized whenever the test kit jack
cause high harmonic distortion as well as standard circuit. is plugged into the test receptacle on the rating plug.
They provide maximum breaker-to-breaker selectivity and
custom load protection. Short time and ground fault func- • Micro Versa Trip battery pack - The portable
tions include the flexibility of coordination with or without an MicroVersaTrip battery pack contains a 24 Vdc
12t ramp and are also available with high range instanta- power source and a jack. The LCD is energized when
neous. the jack is plugged into the rating plug test receptacle.

MicroVersaTrip PM Trip Unit

MicroVersaTrip PM trip unit adds power management sys-
tem capability, advanced metering, and protective relays to
the basic functions of the MicroVersaTrip Plus.
MicroVersaTrip PM trip units communicate directly on the
GE POWER LEADER'" communications bus.

MicroVersaTrip PM Trip Unit

for Metering, Relaying, and Communication on
AKR Power Circuit Breakers

SELECT Key
chooses next item
for display
ENTER Key
stores options
VALUE Key
selects phase to
display or alter
setpoint values
Interchangeable
rating plug for
flexibility in matching
load requirements
LCD readout for
metered values, trip
settings, and fault trip
indication
FUNCTION Key
selects the mode
of display

79

Courtesy of NationalSwitchgear.com Fia. 111

SECTION 12-MicroVersaTrip Plus and ™

MicroVersaTrip PM Trip Units

12.2-Testing
Testing of MicroVersaTrip Plus and MicroVersaTrip PM trip CAUTION: Removal of a trip unit from its breaker must be
units may be performed with the trip unit installed in the cir- performed with the breaker in the OPEN or TRIPPED posi-
cuit breaker, the rating plug installed in he trip unit, and the tion. Draw-out breakers should be racked out first.
breaker carrying current. The test set catalog number is
CAUTION: Do not attempt to operate the breaker without its
TVRMS. The test set plugs into the test socket of the rating
assigned trip unit. Installation of an incorrect trip unit may
plug.
result in unsafe operation of the breaker.
Test set TVRMS may also be used for MicroVersaTrip RMS-
CAUTION: Removal of the rating plug while the breaker is
9 and Epic MicroVersaTrip trip units. Refer to the Mainte-
carrying current reduces the breaker's current-carrying ca-
nance and Troubleshooting section for additional details.
pacity to approximately 25% of the current sensor rating.
12.3-Product Structure This may result in undesired tripping.

MicroVersaTrip Plus and MicroVersaTrip PM trip units are NOTE: Trip units as received may have settings that are un-
removable. Figures 112 and 113 contain front and rear desirable for the specific application. Ensure that settings are
views of a MicroVersaTrip PM trip unit. appropriately adjusted before energizing.

Figure 113 shows the 36-pin plug that connects either trip
unit to the circuit breaker and equipment circuitry. This plug
is called the trip unit disconnect.

Fig. 112. Front view of MicroVersaTrip PM Fig. 113. Rear view of MicroVersaTrip PM
Trip Unit. Trip Unit.

80

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 12.4-Trip Unit Removal and
Replacement
The programmer mounts to the lower left of the breaker as
shown in Fig. 101. It mounts to the bracket assembly shown
in Figs. 83 and 84. Referring to Fig. 83, the guide pins mate
with the holes on either side of the programmer connector.
They provide the necessary alignment for the connector en-
gagement. The locking lever engages with the pin which is
assembled to the programmer frame and secure the pro-
grammer tot the mounting bracket. When a trip unit is re-
placed, the locking arm snaps back into place to indicate
proper engagement.
WARNING: Always de-energize Type AKR circuit breakers
before attempting to remove or replace the trip unit. Be-
cause of the exposed location of the trip unit, failure to ob-
serve this warning may result in equipment damage or per-
sonal injury, including death.

Socket

Class Fig. 114. Programmer secondary connector

No.
Note Location
S + of Pin #1
Zone
Zone 6 - Inputs
Selective
Interlock 7 +
Zone
8 - Outputs

11 -
12 + Commnet

9 Spare

10 VC
MVT-PM
1 VB

4 VA

2 24 Ret

3 + 24 VDC

Fig. 115. Programmer secondary connector pin locations for

zon~ selective interlock and MVT-PM

81

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SECTION 12-Microversatrip Plus and ™

Microversatrip PM Trip Units

12.5-Phase Current Sensors
The current sensors supply the power and signal input nec- The fixed phase sensors are available with an additional
essary to operate the trip system. Fig. 117 shows the fixed winding. This winding is brought out to separate flag termi-
phase sensors available. The sensors have a polarity associ- nals. These phase sensors are used when the hi-level in-
ated with their windings. The common terminal of the sensor stantaneous ('H'-option) is required. Fig. 118 shows an 'H'-
is the right hand terminal. A white wire with a push-on termi- option phase sensor. When the 'H'-option phase sensor is
nal will be connected to this common terminal. All phase installed, there are four leads connected to it. There is no
sensors must be correctly wired for the programmer sum- polarity associated with the 'H'-option windings.
ming circuitry to function properly.

AKR-9D-100
Fig. 116

Fig. 117. Phase Sensors Fig. 118. H-option phase sensor

82

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12.6-Neutral Current Sensors TABLE 20. Rating plug catalog numbers
CAUTION: Neutral current sensors are required for three- Sensor Plug Breaker
phase, four-wire systems. When the trip unit is connected to Cat No. Rating, Amps Rating Frames
a three-phase, three-wire system, the neutral sensor termi-
nals are left open. Do not short any neutral current sensor TR32B1200 1200
terminals in a three-phase, three-wire system, as this could TR32B1600 1600
3200 AKR75
result in damage to or malfunction of the electrical system. TR32B2400 2400
Fig. 119 shows the neutral sensor. The neutral sensor is re- TR3283200 3200
quired when integral ground fault protection is used on
single phase-three wire or three phase-four wire systems. It TR4081600 1600
is inserted into the neutral conductor and therefore is sepa- TR40B2000 2000
rately mounted in the cable or bus compartment. TR4082500 2500
4000 AKR100
TR40B3000 3000
The outputs of the phase sensors and neutral sensor are
TR4083600 3600
connected to a programmer circuit which sums these values.
TR40B4000 4000
The total value will remain zero as long as there is no ground
current flowing.
The neutral sensor is an electrical duplicate of the phase
12.8-Trip Unit Functions
sensor. Therefore, when phase sensors are changed, the MicroVersaTrip Plus and MicroVersaTrip PM trip units
neutral sensor must be correspondingly changed. have specific standard and optional functions. All trip units
share a series of interchangeable rating plugs. The standard
functions for both types of trip unit are as follows:
• Protection
- Long-time protection
- Instantaneous protection
• Status
- Trip target
• Metering display
- Phase current (selectable among phases)
The optional functions available on both types of trip unit are
as follows:
• Adjustable protection
- Switchable instantaneous and ground-fault protection
- High-range (fixed) instantaneous overcurrent
protection
- Short-time protection, with or without 12 T
Fig. 119. Typical neutral sensor - Ground-fault protection, with or without 12T
- Zone-selective interlock, with ground fault only or
12.7-Rating Plug Removal and with both ground fault and short time
Replacement Additional optional functions available only with PM style trip
CAUTION: Removal of the rating plug while the breaker is units are as follows. PM style trip units require the presence
carrying current reduces the breaker's current-carrrying ca- of external control power.
pacity to approximately 25% of the current sensor rating.
• Configurations
Interchangeable rating plugs are removed with a Rating Plug - Communication and metering
Extractor, Cat. No. TRTOOL. (Suitable equivalents are com- - Communication and protective relaying
mercially available as "integrated circuit (DIP) extractors. ") - Communicaiton, metering, and protective relaying
Grasp the rating plug tabs with the extractor and pull the
• Metering and protective-relaying functions
plug out. Be sure to grab the tabs and not the front cover of
- Voltage
the rating plug, or the plug may be damaged.
- Energy (kWh/MWh)
Rejection features are provided on all rating plugs to prevent - Real power (kW/MW)
application mismatches. Never force a rating plug into - Total power (kVAlMVA)
place. Refer to Table 20 to find the appropriate rating plugs - Frequency (Hz)
for each sensor rating and breaker frame. - Protective relays (undervoltage, overvoltage, voltage
If a replacement rating plug has a different rating than the unbalance, current unbalance, and power reversal)
plug that was removed, follow the appropriate setup proce-
dure in GEH"5891A to enter the new rating.
Do not attempt to use a rating plug from a Spectra RMS 83
breaker or a MicroVersaTrip·· RMS-9/MVT-4 function trip in a
MicroVersaTrip Plus or MicroVersaTrip PM trip unit.
Courtesy of NationalSwitchgear.com
SECTION 12- Microversatrip Plus and 1M

Microversatrip PM Trip Units

12.9-Trouble-Shooting Guide
The following guide is provided for trouble-shooting and iso-
lating common problems. It does not cover every possible
condition. Contact the Customer Support at 800-843-3742 if
the problem is not resolved by these procedures.

Symptom Possible Cause Corrective Action

1. The trip unit display Line current is below 20% At least 20% of the current sensor rating, S, must
is blank. of S (MicroVersaTrip Plus). be flowing through the breaker to activate the
display. If not, power the trip unit with the Test
Kit or external battery pack.
External 24 Vdc is absent Check that the control power supply is present
(MicroVersTrip' PM). and operational.

2. The trip unit display Can occur on Plus style trip Power the trip unit with the Test Kit or external
flashes. units when load current battery pack.
fluctuates near 20% of S.

3. The trip unit display The built-in self test has Replace the trip unit.
flashes ERR. detected an error.

4. The trip indication Trip unit is not in status Press FUNCTION until STATUS is displayed. Press
target will not clear. mode. SELECT and VALUE together to clear the target.

5. Unit does not comm- Commnet wires are shorted Locate and repair the short or the incorrect con-
municate with the or improperly connected. nection.
Monitor, POWER
LEADER Distribution FPU version is lower than 2.0 Update FPU to version 2.0 or higher.
Software, or FPU.
Trip unit address incorrect. Check that address assigned to trip unit, as in
Chapter 2, agrees with address at host.

6. Current readings are Rating plug value was Read the X value from the rating plug nameplate
incorrect. defined incorrectly. and enter this with the rating plug current
set point procedure in Chapter 2. 00 not enter
the sensor rating, S.

7. Voltage readings are Potential transformer (PD Read the PT ordinary rating from the PT name
incorrect. primary voltage was defined plate and enter this value with the PT primary
incorrectly. voltage procedure in Chapter 2.

PT connection was defined With the PT connection procedure in Chapter 2,

incorrectly. enter VL-N for a wye-connected PT primary or
VL-L for a delta-connected PT.

8. kW legend is flashing. Total power metering. Indicates that the total power is metered in kVA.

9. Overload target is Test Kit-initiated trip indication. Clear target as indicated above (Symptom 4).
flashing by itself.

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SECTION 13-Type EC Overcurrent Trip Device

Type EC overcurrent trip devices are magnetically The standard EC trip device for the AKS breaker frames is
operated, using a series coil or single conductor, and an the type EC-2A, see Fig. 120. An optional trip device for
associated magnetic structure to provide tripping force. these frames is the type EC-1, see Fig. 121.
There are three basic characteristics: long time delay, The EC trip device for the 4000 and 6000 amp AKA 75/100
short time delay and instantaneous, which can be used in frames is the EC-1 B shown in Fig. 122.
various combinations to suit the application.
The trip characteristics for the EC trip devices are listed in
AKA breakers with EC trips are for use on DC system Table 21.
voltages. One EC trip device is mounted per breaker pole.
This device contains its functional adjustments.

Fig. 120. EC-2A trip device Fig. 121. EC-1 trip device

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SECTION 13-Type EC Overcurrent Trip Device

1. Magnet 4. Short time adjustment

2. Connecting rod 5. Long time adjustment
3. Vibration damper 6. Adjustment for instantaneous pickup

Fig. 122. EC-1 B trip device

TABLE 21-EC Device Trip Characteristics

Trip Long Time Short Time

Instantaneous
Device Pickup CD Delay CD Pickup Delay ® Pickup

(1A) MAX. - adj 15~38 sec

or 4-9X.
80-160% X (18) INTER. - adj. 7.5-18 sec. 6-12X,
EC-2A (± 10%) or 9-15X or
(lC) MIN. - adj. 3.3-8.2 sec. 80-250%X CD
(1 A) MAX. ~- 30 sec. (2A) MAX. - .23 sec
or 2-5X, or High Set
80-160% X (18) INTER. - 15 sec. 3-7X or (28) INTER. - 15 sec. up to 15X,
EC-1 (± 10%) or 4-10X or Non-Adjustable
(1C) MIN. - 5 sec. (2C) MIN.- .07 sec

(2AA) MAX. -- 20 sec

80~160% X (188) MAX. - 4.5 sec. 2-5X, or 4-9X,
EC-18 (± 15%) or 3-7X or (2BB) INTER. -- 13 sec. 6-12X,
(1 CC) MIN. - 2 sec. 4-10X or 9-15X or
(2CC) MIN. - - .07 sec 80250% X 0
X = Trip device ampere rating. If trip devices are set above 100% 3 At lower limit of band at 2'/2 times fJlckup setting.
for coordination purposes, such settings do not increase the breaker's 4 Low set Instantaneous Not available In combination With long
continuous current rating. time delay.
2 At lower limit of band at 6 times pickup setting.

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13.1-Direct Acting Tripping Device EC-1B 13.1.3-lnstantaneous Tripping-High Set
The type EC-1 B overcurrent tripping device is a direct- Referring to Fig. 123 adjustable instantaneous tripping is
acting device that causes the power circuit breaker with accomplished by varying the amount of tensile force on
:VVhiQh it is associated to open within a predetermined time the high-set instantaneous spring (21). When a magnetic
range which depends upon the magnitude of the current force greater than the restraining spring force is produced
overload. The EC-1 B tripping device can be constructed to by an over-current condition, the armature (22) is pUlled
supply a variety of different types of time-current charac- upward against the magnet (24), thus tripping the breaker
teristics, either alone or in combination. These are long by the movement of the connecting rod (13) against the
time delay, short time delay, and instantaneous, and they trip paddle (14).
are identified respectively by numbers 1,2 and 3. Charac-
The pickup value of the device may have one of the
teristics are further broken down within each of the first
following ranges: 4 to 9, 6 to 12, or 9 to 15 times coil rating.
two of these general classifications into maximum,
Three calibration marks will appear on the calibration
intermediate and minimum values of the time delay period.
scale (18) and the value of these calibration marks will be
These are coded respectively as AA, BB and CC. Time and
indicated by stampings on the scale as follows: (4X-6.5X-
current relationships for the various device characteristics
9X) or (6X-9X-12X) or (9X-12X-15X). depending on the
are given by the curves listed in Table 18.
desired range. To set the device at a partiCUlar pickup
TABLE 22-Time-Current Curves value, loosen the clamping nut (20) and slide the index
pointer on the calibration washer (19) to a position which
Trip lines up horizontally with the desired pickup value on the
Trip Trip Characteristic
calibration scale (18).
Device EleCD"ts (EC Devices Curve
only)
13.1.4-lnstantaneous Tripping-Low Set
EC-1 LSI (See Curves) GES-6000A
Low-set instantaneous tripping is adjustable from 80
LI 1BB-3 GES-6003 percent to 250 percent of the continuous current rating of
EC-1B LI 1CC-3 GES-6004 the device. Whenever this is used, it is the only
(See Curves) GES-600S
characteristic of the device. Instantaneous tripping used in
LSI
conjunction with any other characteristic is always
LI 1A-3 GES-6010
high-set.
EC2/2A LI 1B-3 GES-6011
If the characteristic of the device is low-set, adjustable
LI 1C-3 9ES-6012 instantaneous, a link is installed in place of spring (21) and
the instantaneous calibration spring is located where
Q L = Long Time S = Short Time I = Instantaneous
spring (15) is shown in Fig. 26. Dashpot (17) is omitted
13.1.1-Long Time Delay Tripping from assembly. See Fig. 101.
Referring to Fig. 123, the long time delay is obtained
as follows:
13.2-Replacement
The EC-1 B device is replaced as follows, referring to
The long time delay armature (22) is restrained by the long
Fig. 123:
time delay calibration spring (15). After the magnetic force
produced by the overcurrent condition overcomes this 1. Remove stud (23).
restraint, the velocity of the armature movement is
2. Remove mounting clamp.
governed by the flow of oil through an orifice in the piston
of the dashpot (17). The time required to displace the 3. Remove two screws fastening magnet (11) to lower
piston i's inversely proportional to the force tending to stud.
close the magnetic circuit. 4. Device is now free of breaker. Reassembly is
accomplished by reversing the procedure.
13.1.2-Short Time Delay Tripping
When reassembling the magnet to the lower stud, be sure
Referring to Fig. 101 the short time delay is obtained to replace any spacing washers in the same location in
ciS follows:
which they were found during disassembly. If this is not
The short time delay armature (1) is restrained by a done. misalignment and consequent malfunction may result.
calibration spring (6). If the force tending to close the
armature against the magnet (11) is great enough to
overcome the spring force, the speed of movement is
governed by the mechanical escapement mechanism
consisting of parts (2). (3), (4) and (5).

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SECTION 13-Type EC Overcurrent Trip Device

13.3-Adjustments connecting rod (10). This is made by varying the amount

of thread engagement between the connecting rod and the
Before the EC-1 B overcurrent device is calibrated at the insulated coupling which ties onto the trip paddle (14). The
factory, the air gaps between magnet (11) and armatures approximate distance between the pivot centers on the
(1 and 22) are set. These gaps are measured at their widest ends of the connecting rod assembly is six inches. The
point, between the front edge of the armature and magnet. correct exact distance is that which will just cause tripping
The gap for the short time delay armature is 17/64 in., and of the breaker when the armature is closed to a point 1/32
for the long time delay armature is 17/64 in. Both have a in. short of contact with the magnet. A step-by-step
plus and minus tolerance of 1/64 in. procedure for making this adjustment follows.
The air gap setting is a factory adjustment and is not to be 1. Before mounting the trip device, set the center
attempted in the field. If any change occurs, the calibration distance between the pivot centers of the connecting rod
of the device will not be true. If any calibration difficulties at six inches.
are experienced, they may be due to the fact that the air
gap setting has been altered by rough handling or 2. Close the breaker and insert a feeler gage 1/32 in.
shipment damage. If a check of the air gap measurement thick between the armature and magnet. This should be
reveals that the setting is beyond the tolerance, the device done from the rear of the breaker. The feeler gage should
should be returned to the factory for recalibration. be no wider than 1/2 in. and at least 4 inches long.

The adjustment screw (7) is provided so that the short-time 3. Close the armature against the gage and magnet.
mechanism will pick up the trip link (8) at the same point at 4. If the breaker does not trip, form paddle 14 to obtain
which it is picked up by the long-time mechanism. This positive trip.
may be checked before the device is mounted by pulling
5. Check visually to make sure that the connecting rod
forward on the connecting link (10) and checking visually
does not restrict the engagement of the breaker trip latch
to see that trip link (8) contacts both the set pin in the long
when the breaker mechanism resets. It should always be
time linkage and the end of adjustment screw (7).
possible to adjust its length to a point where resetting is
After the device is mounted on the breaker, a final not interferred with and yet positive tripping by the
adjustment that must be made in the length of the overcurrent device is achieved.

+ +
+ +

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Long Time & High Set
Short Time Mechanism Inst. Mechanism
1. S.T.D. armature 9. Air gap adj. 17. Dashpot
2. Pallet 10. Connecting rod 18. Calibration scale
3. Pinion 11. Magnet 19. Calibration washer
4. Escape wheel 12. Lock nut 20. Clamping nut
5. Driving segment 13. Connecting rod 21. lnst. calibration spring
6. S.T.D. calibration spring 14. Trip paddle 22. L.T.D. armature
7. S.T.D. trip adj. 15. L.T.D. calibration spring 23. Stud
8. Trip link 16. Calibration clamp nut 24. Magnet

Fig. 123. Direct acting tripping device EC 1B

88
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 13.4-Series Overcurrent Tripping Time values are inversely proportional to the effective
length of the dashpot arm. Therefore, the linkage setting
Device EC-2A
that gives the shortest time value is the one at which
The Type EC-2A overcurrent tripping device is available in dimension "A", Fig. 123 is greatest. The time adjustment
three forms: screw (4) may be turned by inserting a Phillips head
screwdriver through the hole in the front of the case. If it is
1. Dual overcurrent trip, with long-time delay and high-
desired to relate the linkage setting to the index marks on
set instantaneous tripping.
the linkage it will be necessary to remove the case. This
2. Low-set instantaneous tripping. may be done by removing the two mounting screws, one
on each side of the case, which may be taken off without
3. High-set instantaneous tripping.
disturbing the trip unit itself.
The dual trip has adjustable long-time and instantaneous
pick-up settings and adjustable time settings. 80th forms 13.4.2-lnstantaneous low-Set Tripping
of instantaneous trip have adjustable pick-up settings.
The low-set instantaneous pick-up point may be varied by
Adjustment Note the adjustment knob (3). The calibration in this case
usually ranges from 80 percent ot 250 percent of the series
Before attempting any checks or adjustments on breaker with coil rating, with the calibration plate indexed at values of
EC trip devices, the breaker mechanism and trip latch should 80, 100, 150, 200, and 250 percent of the rating.
be checked to assure their proper functioning so that the
breaker trip shaft is free of high friction loads. The trip latch of 13.4.3-lnstantaneous High-Set Tripping
the breaker should also be checked for proper trip latch
engagement. See Section 6.3.1.
The high-set instantaneous pick-up value may have one of the
Refer to Fig. 124 for the discussions given below. following three ranges: (4 to 9), (6 to 12), (9 to 15) times coli
rating. The pick-up setting may be varied by turning the Instan-
13.4.1-long Time-Delay and High-Set taneous pick-up adjusting screw (12).
Instantaneous Tripping
Three calibration marks (15) will appear on the operating
By means of the adjustment knob (3), which can be arm (14) and the value of these calibration marks will be
manipulated by hand, the current pick-up point can be varied indicated by stampings on the arm as follows: (4X-6.5X-9X)
from 80 to 160 percent of the series coil rating. The Indicator or (6X-9X-12X) or (9X-12X-15X).
and a calibration plate (2) on the front of the case provide a
means of indicating the pick-up point setting In terms of
percentage of coil rating. The calibration plate Is indexed at At the factory, the pick-up point has been set at the name-
percentage settings of 80, 100, 120, 140, 160. plate value of the instantaneous trip current. (Usually
expressed in times the ampere rating of1he trip coil). The
As in the case of the EC-1 over-current trip, the long-time variation in pick-up setting is accomplished by varying the
delay tripping feature can be supplied with anyone of tensile force on the instantaneous spring (5). Turning the
three time-current characteristics which correspond to the adjustment screw changes the position of the movable nut
NEMA standards maximum, intermediate and minimum (11) on the screw. The spring is anchored to this movable
long-time delay operating bands. These are identified as nut so that when the position of the nut is changed, there
1A, 18 and 1C characteristics, respectively. Approximate is a corresponding change in the spring load. As the spring
tripping time for each of these, in the same order are 30, is tightened, the pick-up point is increased.
15, and 5 seconds at 600 percent of the pick-up value of
The top edge of the movable nut (11) serves as an index
current. (See time-current characteristic curves).
pointer and should be lined up with the center of the
desired calibration mark (15) to obtain the proper
The tripping time may be varied within the limits shown on the
instantaneous trip setting.
characteristic curves by turning the time adjustment screw (4).
Turning in a clockwise direction Increases the tripping time; The trip screw (6) on the end of the armature (7) should be
counterclockwise motion decreases it. The dashpot arm (8) Is set so. that it does not contact the trip paddle on the trip
indexed at four points, MIN-1/3-2/3-MAX, as Indicated In Fig. shaft'until the air gap between armature and pole piece is
124. When the Index mark on the connecting link (9) lines up reduced to 3/32 in. or less, measured at the rivet in the
with a mark on the dashpot arm, the approximate tripping time pole piece. Also, the armature must have a minimum of
as shown by the characteristic curve Is Indicated. The 1A and 1/32 in. of travel beyond the point in its motion at which
1B characteristic devices are shipped with this setting at the the breaker is tripped.
2/3 mark and the 1C characteristic at the 1/3 mark. Standard
characteristic curves are plotted at these settings.

89

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SECTION 13- Type EC Overcurrent Trip Device

Fig. 125. Time-adjustment indexing

1. Low set instantaneous spring 9. Connecting link

2. Calibration plate 10. Series coil
3. Adjustment knob 11. Movable nut
4. Time adjustment screw 12. Instantaneous pickup adj.
5. Instantaneous spring 13. Dashpot
6. Trip screw 14. Operating arm
7. Armature . 15. Calibration marks
8. Dashpot arm

Fig. 124. Overcurrent tripping device-EC-2A

90
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13.5 - Series Overcurrent Tripping movement is further retarded by an escapement
Device EC-1 mechanism which produces an inverse time delay
characteristic. The mechanism is shown on Fig. 126.
Each series overcurrent tripping device is enclosed in a
molded case and mounted by screws and a bracket to the 13.5.2-Long Time-Delay Tripping
lower part of the pole unit base.
The armature (10) is restrained by the calibration spring
Refer to Fig. 126 for the discussions below. (11) . After the magnetic force produced by an overcurrent
condition overcomes this restraining force, the armature
13.5.1-Short Time- Delay Tripping movement is further retarded by the flow of silicone oil in a
The armature (7) is restrained by calibrating spring (8). dash pot, which produces an inverse time delay
After the magnetic force produced by an overcurrent characteristic. The mechanism is shown on Fig. 126.
condition overcomes this restraining force, the armature

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Left Side View Showing
Short Time Delay Mechanism o !!J
Right Side View Showing
Long Time Delay Mechanism
Front View Showing
Mounting Bracket

1. Series coil 8. S.T.D. calibration spring 15. Plunger

2. Magnet 9. Trip paddle adjusting screw 16. Cylinder
3. Pallet 10. L.T.D. armature 17. Calibration plate
4. Pinion 11. L.T.D. or low-set inst. calibration spring 18. Trip paddle
5. Escape wheel 12. Inst. trip'spring (high set) 19. Trip arm
6. Driving segment 13. Spring holder 20. Clamping bracket
7. S.T.D. armature 14. Calibration clamp nut

Fig. 126. Series overcurrent tripping device EC-1

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SECTION 13-Type EC Overcurrent Trip Device

13.5.3-lnstantaneous Tripping 13.6-Positive Trip Adjustment

a. Adjustable instantaneous tripping takes place after Before attempting any checks or adjustments on breaker
the magnetic force produced by an overcurrent condition, with EC trip devices, the breaker mechanism and trip latch
overcomes the restraining force of the calibration spring should be checked to assure their proper functioning so
which can be adjusted by the calibration clamp nut (14). that the breaker trip shaft is free of high friction loads. The
trip latch of the breaker should also be checked for proper
b. Non-adjustable instantaneous tripping takes place
trip latch ~ngagement. See Section 6.3.1.
after the magnetic force produced by an overcurrent
condition overcomes the restraining force of a non- In addition to the pick-up settings and time-delay
adjustable spring. adjustments already described, overcurrent trip devices
must be adjusted for positive tripping. This adjustment is
13.5.4-EC-1 Adjustments made at the factory on new breakers, but must be made in
the field when the breaker mechanism or the overcurrent
Before attempting any checks or adjustments on breaker
trip devices have been replaced.
with EC trip devices, the breaker mechanism and trip latch
should be checked to assure their proper functioning so Positive tripping is achieved when adjustment screw (9)
that the breaker trip shaft is free of high friction loads. Figure 126 is in such a position that it will always carry the
trip paddle on the trip shaft beyond the point of tripping
EC-1 Devices may have their pick-up settings varied by
the mechanism, when the armature closes against the
changing the positions of the sliding calibration plates on
magnet.
the front of each device. The clamping nJ.Jt holding the
plate must be loosened to make the change, and then In order to make the adjustment, first unscrew trip screws
retightened. (9), Figure 126, until it will not trip the breaker even though
the armature is pushed against the magnet. Then, holding
I f a new device is installed, the adjusting screw on the
the armature in the closed position, advance the screw
tripping arm must be set to give 1/32nd of an inch
until it just trips the breaker. After this point has been
overt ravel in tripping. The method for making this check is
reached, advance the screw two additional full turns. This
demonstrated in Figure 127. The rod shown is used for
will give an overtravel of 1/16 of an inch and will make sure
pushing the armature of device closed. If this is done with
that activation of the device will always trip the breaker.
the device mounted on a closed breaker, it will simulate
the action which occurs when the device reacts to an Adjustment screw (9), Figure 126 can best be manipulated
overload condition. by an extended 1/4 inch hex socket wrench.

Fig. 127. Checking travel distance of

series overcurrent tripping device

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13.7-Reverse Current Tripping Device
The device is enclosed in a molded case and is mounted which tends to rotate the armature counterclockwise. The
on the right pole base similar to the series overcurrent calibr!ition spring also tends to rotate the armature in the
tripping device. same direction. This torque causes the armature to rest
The reverse current tripping device (see Fig. 128) consists against the stop screw (12) attached to a bearing plate on
of a series coil (2) with an iron core mounted between two the right side of the device.
pole pieces (9), also a potential coil (7) connected across a If the current through the series coil (2) is reversed, the
constant source of voltage and mounted around a rotary- armature (10) tends to move in the clockwise direction
type armature (10). Calibration spring (6) determines the against the restraint of the calibration spring (6). When the
armature pick-up when a reversal of current occurs. current reversal exceeds the calibration setting, the
As long as the flow of current through the breaker is in the armature revolves clockwise causing the trip rod (3) to
normal direction, the magnetic flux of the series coil and move upward engaging the trip paddle (1), thereby
the magnetic flux of the potential coil produce a torque tripping the breaker.

(+) c.t - - - - - - -----,

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A r - - - -
01 0 ' ·Ct 'iT :'5 ;" jl
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1. Trip paddle
2. Series coil
2A. Adjusting Nut
~ IE 28. Locking nut
3. Trip rod
~
lID 4. Trip crank
5. Setting sealing screw
fa 6. Calibration spring
7. Potential coil
m 8. Calibration nut
9. Pole pieces
10. Armature
mJ 11. Counter weight
12. Stop screw
9 13. Mounting screw
14. Screw

Fig. 128. EC-1 reverse currrent triping device

93

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 SECTION 13-Type EC Overcurrent Trip Device

13.7.1-Adjustments
The only adjustment to be made on the reverse current The switchette feature is available only in type EC-1
device is to make sure that the trip rod has a minimum devices.
overtravel of 1/32 in. beyond the point of tripping the
The switchette is used in one pole and EC-1 trips in the
breaker. This adjustment should have to be made only
other poles. For the alarm to be effective in indicating the
when an old device is being replaced by a new one.
overload before the other poles trip the breaker, the device
The new device will be factory adjusted so that the top end must have less time delay than the other two poles; this is
of the trip rod (3) will extend 1/2 in. above the top of the accomplished by using a lower characteristic on the alarm
device case, and no additional adjustments of the trip rod device than the other poles or setting the alarm devices
should be required. To obtain the proper 1/32 in. long time setting at 80%.
overtravel, close the breaker and proceed as follows:
1. Loosen the locking nut. (2B).
13.9-Trip Device Replacement
Overcurrent devices on the AKS50 breakers can be
2. Manually lift the trip rod and vary the position of the
replaced as follows:
adjusting nut (2A), this establishing the position of the
adjusting nut where the breaker is just tripped. a. Separate frames a~ described in Section 5.3
b. Referring to Fig. 126, remove bolts securing the series
NOTE: Be sure to keep clear of moving breaker
coil (1) to the lower stud.
parts when tripping the breakers.
c. Remove the clamping bracket (20).
. 3. With this position of the adjusting nut established, d. Before installing the replacement device, check the
advance the adjusting nut upward one and one-half turns. travel of trip arm as described in Section 11.5.4 and Fig.
4. Tighten the locking nut and the minimum 1/32-in. 127.
overtravel of the trip rod should be obtained. e. Replace new device in reverse order.
13.7.2-Replacement f. Adjust the new device as described in Section 11.5.4

After removing the wiring for the potential coil the reverse When replacing an EC-1 device with an EC-2 or EC-2A
current device can be removed and replaced by following device, it may be necessary to replace the trip paddles on
the procedure outlined for replacing the series overcurrent the trip shaft with slightly longer ones. If paddle
device. See Section 11.9. For wiring, see Fig. 128. replacement is required, new paddles are provided with the
replacement trip units.
13.8-Switchette Feature Pickup settings on the cover of the EC-2, EC-2A device are
The switchette is operated by the long-time delay function. calibrated for the specific device. When replacing covers,
Its purpose is to provide a set of contacts that will close replace on associated device.
before an overload occurs. This device will not trip the
breaker on overload it will trip on instantaneous only.

94

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SECTION 14- Electrical Characteristics
Table 23 Table 27
Charging and closing operating currents Charging times
Table 24 Table 28
Bell alarm contact-rating Shunt trip and undervoltage device
Table 25 Table 29
Auxiliary switch contact sequence Coil resistance
Table 26
Auxiliary switch contact ratings
TABLE 23-Charging and Closing Operating Currents
MOTOR CD
.
~c
u >-
Current (Amps)
ANTI-PUMP
RELAY"W"
CONTROL
RELAY "X"
CLOSING
SOLENOID z:
c
fti ...
u
c ... ~
!! Rated·Amps .I!l Rated Amps .I!l Rated Amps i=

.... ... .. co. Cco. Cco.

c ... N
.-E='"
. '"
=
CfI ...
CfI
"'::I: .~q;
Inrush Sealed Inrush Sealed Inrush Sealed wfrl
'" CfI
c ~~ /!..","
,,:>~. .
-
> '"0 -
> '"0 -
> '"0 en ...
::l w
z> ....~ >cc: ,~ c'"
iiii: Open Closed
._ u
c'"
::Eii: dpen Closed·
c'"
._ u
:lEii: Open Closed .... en

48V DC 38·56 40 10 38 .063 .063 30 4.1 4.1 38 2.7 2.7 20A

125V DC 100·140 27 5 85 .024 .024 90 1.05 1.05 100 1.3 1.3 20A
250V DC 200-280 13 3 170 .015 .015 180 .53 .53 200 .68 .68 20A
120V 60 .090 .052 1.0 1.4 2.6 .35 20A
120V 50 104-127 25 5 95 .090 .052 95 1.0 .15 98 2.2 .29 20A
120V 25 .047 .032 6.85 1.27 1.1 .17 20A
208V 60 .050 .029 .45 .063 1.5 .19 20A
208V 50 180·220 15 3.5 175 .050 .029 175 .55 .083 177 1.2 .16 20A
208V 25 .032 .018 3.86 .76 .60 .08 20A
250V 60 .064 .036 .50 .07 1.3 .17 20A
250V 50 208-254 12 3 190 .064 .036 190 .50 .08 196 1.1 .15 20A
250V 25 .035 .023 3.42 .64 .54 .08 20A
CD Values are typical and are given only as application information, and not intended to be maximum or minimum values.

Table 24-Bell Alarm Table 26-Auxiliary Switch

Contact Rating Contact Rating
Bell Alarm Contact' Auxiliary Switch
Control Rating (amperes) Interrupting Ratings
Voltage Control (Amperes)CD
Contin- Voltage
Inrush
uous Non·
Inductive
125 2.5 2.5 Inductive
Dc -
250 0.9 0.9 48 25
120 30 10 Dc 125 11 6.3
60 Hz. 250 2 1.8
Ac 240 15 5
480 7 3 115 75 50
Ac 240 50 25
480 25 12
CD Limited to 20A continuous rallng of
switch on all breakers and to 5A contin-
Table 25-Auxiliary Switch uous rating of # 16 wire on drawout
breakers.
Contact Sequence Table 27
Auxiliary Switch Position
CB Charging Times
Main "a" "b"
Contacts Contact Contact Nominal Time
Voltage (sec.) CD
Open 48VDC 2.0
or Open 'Closed 125VDC
Tr,ipped 1.7
250VDC
120VAC 1.5
Closed Closed Open 208VAC 1.7
240VAC 1.3
CD Closing spring charging times are
typical values. The maximum
95
permitted is 5 seconds.

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SECTION 14- Electrical Characteristics
TABLE 28-Shunt Trip and Undervoltage Device Operating Currents
e SHUNT TRIP UNDER VOLTAGE
C
0
U 01 0»
,.,u Current Current
-co _co c (Amps) (Amps)
0» N
c-
._ 0 ~p: Operating Inrush Sealed Inrush Sealed
E>
0 ~
LL
-- Operating
Z Voltage range Open Closed Voltage range Open Closed
24 DC 14 30 8.3 8.3 .38 .38
48 DC 28 60 4.5 4.5 .19 .19
125 DC 70 140 2.0 2.0 .08 .08
250 DC 140 280 1.0 1.0 .04 .04
OJ
70 60 59 132 - N/A N/A
-
- 0>
ro
120 60 95 127 12.3 10.8 <5 .66 .24
120 50 95 127 7.6 6.7 > .75 .25
OJ-
120 25 95 127 4.7 4.1
Ole
_ro-
c .31 .10
- 0
208 60 175 220 3.2 2.6 ~() .51 .17
208 50 175 220 3.8 3.1 (ij(ij
c c
.30 .10
208 25 175 220 2.1 1.9 'E 'E .14 .05
o 0
240 60 190 254 3.9 3.4 ZZ .37 .12
..........
240 50 190 254 4.7 4.1 o 0 .34 .11
240 40 190 254 5.8 5.1 ~PR N/A N/A
OJO
-CD
240 25 190 254 2.1 1.9 L.

o~
I
.16 .06
380 50 315 410 2.9 2.6 ;,Ro
~C')
.22 .08
480 60 380 508 3.4 3.1 co-
_ ro .23 .08
ro-
480 50 380 508 7.5 7.3 :J
0.0
.17 ..06
_-
480 25 380 508 3.5 3.3 :Jo.
.11 .05
ti
._ 0
L.
575 60 475 625 2.8 2.5 0.0 .16 .06
575 50 475 625 5.1 4.7 .14 .06
[ 575 25 475 625 3.1 3.0 See Table 30 .10 .05

TABLE 29-Coil Resistance-DC Ohms @ 25°

Nominal Control Antl·Pump Control Shunt
Voltage Frequency Hz Relay"W" Relay "X" Trip Undervoltage
24V DC N/A N/A 3 64
48V DC 802 12 11 240
125V DC 5000 119 64 1600
250V DC 16400 476 260 6700
120V 60 450 54 3.9 25.4
120V 50 450 75 7.15 33
120V 25 1450 75 25.4 146
208V 60 1450 216 25.4 64
208V 50 1450 300 25.4 146
208V 25 3900 300 64 580
240V 60 1450 300 25.4 100
240V 50 1450 300 25.4 146
240V 25 6000 300 64 580
380V 50 N/A N/A 64 370
480V 60 N/A N/A 64 370
480V 50 N/A N/A 32 580
480V 25 N/A N/A 100 1600
575V 60 N/A N/A 100 580
575V 50 N/A N/A 64 918
96
575V 25 N/A N/A 146 3200
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TABLE 30-lnstantaneous Undervoltage Device Settings
COIL MAXIMUM DROP OUT
RATING PICKUP VOLTAGE RANGE
24VDC 20 7-14

48VDC 41 14-29

125 VDC 106 38-75

155 VDC 132 47-93

250VDC 213 75-150

120 VDC 102 36-72

208 VDC 177 62-125

240 VDC 204 72-144

380 VDC 323 114-228

480 VDC 408 144-288

575 VDC 489 173-345

TABLE 31-Time-Delay Undervoltage Device Settings

DELAY PICK UP RANGE UVRINSTALLED
DROP OUT
UNIT UVR ONLY MECHANISM RESET
RANGE
VOLTAGE VDC NO PICK UP PICK UP
125 VDC 77 - 85 50 90 - 95
MINIMUM
250 VDC
208/240 VAC 125 - 140 90 160 - 165 POSSIBLE

97

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 These instructions do not purport to cover all details or variations in equipment nor to provide for every possihle
contingency to he met in connection with installation operation or maintenance. Should further information he
desired or should particular prohlems arise which are nOl covered sutnciently for the purchaser's purposes, the
matter should be referred to the GE Company.

GE Electrical Distribution & Control

General Electric Company

41 Woodford Ave., Plainville, CT 06062
GEK-64460A © 1993 General Electric Company

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