GE Consumer & Industrial Power Protection High Speed DC Circuit Breaker Gerapid 2607, 4207, 6007, 8007 with arc chutes 1X2, 1X4, 2X2, 2X3, 2X4 USER MANUAL 2010-06-07 S47183-E rev.
Design and specifications are subject to change without notice S47183e rev.
INDEX 1. WARNINGS........................................................................................... 4 2. GENERAL USAGE CONDITIONS ................................................... 4 2.1 Transportation and storing ..................................................... 4 2.2 Installation....................................................................................... 5 2.2.1 Operational environment................................................. 5 2.2.2 Installation and interfaces............
1. Warnings 2. General usage conditions 2.1 Transportation and storing • • Warnings: • During operation, electrical equipment carries dangerous voltages. In addition, circuit breaker emits hot, ionized gases when switching currents, especially short circuit currents. • The breaker is transported on wooden palette. It is fixed by shrunken plastic film. A cardboard box covers the breaker on the palette. Truck, railway, airplane and ship transport is possible.
2.2 Installation 2.3 Usage 2.2.1 Operational environment 2.3.1 Supply and load • • • • • • The breaker, as delivered, is IP00 (NEMA 1) protected. It is intended to work in indoor applications, without pollutions, with non-conductive dust, protected against high humidity and condensation. Low conductivity dust deposit due to frequent condensation of humidity is acceptable. General environmental conditions refer to EN 50123-1 - annex B, and IEC 60947, class PD3.
3. Technical information 3.2 Components and accessories 3.1 Introduction 3.2.1 Contact system • • • • • • • • • Gerapid is a high-speed DC circuit breaker. This is a single-pole DC breaker, primarily designed for use in railway power distribution systems with operating currents up to 8000 A (Code 1) and operating voltages up to 3600 V (Code 2). Additional applications are special industrial plants such as electrolysis, mining or steel mills.
3.2.3 Mechanism • • • • • • The Gerapid is equipped with a modular designed mechanism, which is wear-resistant and nearly maintenance-free. This mechanism ensures an extended electrical and mechanical endurance of the breaker as well as a high level of safety under all operation conditions. Breaker can operate 20 000 cycles when opened by the shunt trip or zero voltage release, and 1 000 operations by means of ED impulse coil or OCT releases.
• 3.2.5 ED impulse coil release (Code 12) • • • • • • ED impulse release requires an external protective relay for monitoring a current increase. This relay must be provided and installed by the customer. If a fault occurs, an external relay signal wired into the capacitors’ control unit (internal NEKO or external C-bank), causes NEKO unit to discharge its energy into ED coil [Fig. 8]. The coil trips the breaker’s quick latch and opens breaker’s contacts in less 3ms.
• With a correctly designed interlock in an enclosure, FT provides safety-tripping function. During withdrawal operation of the trolley, the breaker is tripped BEFORE its main terminals disconnect from the mains. Bottom view WARNING: Manual closing and opening – only during maintenance! Fig. 11b Opening operation by using hand lever • • Alternative manual closing and opening operation is possible by rotating the main shaft of the breaker mechanism, which is accessible from the side.
• 3.2.9 Auxiliary switch (Code 9) • • • ARC CHUTE INDICATOR (Code 17) – a potential free, NO contact mounted on the sidewall. Locks electrically the closing drive when arc chute is not installed on [Fig. 15]. Standard breaker can be equipped with 3, 5 or 10 isolated, form C, invertible auxiliary contacts (1 NO/NC each). The movable main arm activates the contacts. The contacts are wired to 15-pin control terminals: -X4 and -X5, with 5 switches to each terminal [Fig. 21].
3.2.13 Electronic control system 3.2.12 Current measurement system (Code 6) • All the control PCBs are installed in control box [Fig. 18]. Starting from the left, these are: The SEL current measurement system consists of the sensing component (1) and signal-processing unit (2) [Fig.17]. SEL sensor is integrated into a specially shaped upper terminal of the breaker and is connected by a shielded cable to the signal-processing unit. SEL control unit is placed in the control-box [Fig. 18]. Fig.
• (3) SU control unit – see point 3.2.11 • (5) EMPTY SLOT. – not used. • (6) SEL control unit – see point 3.2.12 Fig. 19-3 SU control unit. • (4) ST/UVR control unit – simple relay system. It controls operation of shunt trip or zero voltage release. Fig. 19-6a SEL control unit (T 35) Fig. 19-4a UVR control unit Fig. 19-6b SEL control unit (T 55) Fig. 19-4b- ST control unit Fig. 19-4c Extinguish capacitor for direct ST supply.
3.3 Technical data tables Breaker type Gerapid 2607 Arc chute type 1X2 Conventional thermal current Ith [A] Rated current [A] 1X4 (IEC/EN) 2X2 2X3 Gerapid 4207 2X4 1X2 1X4 2600 (ANSI/IEEE C37.
Control box terminals Closing solenoid drive1) Internal voltage converter 1) for Gerapid 2607, 4207, 6007, 8007 1x12-pole 4x15-pole Rated voltage Operating range Power consumption Gerapid 2607 / 4207 Power consumption Gerapid 6007 / 8007 Minimal CLOSING command duration min.
4. Electrical circuits 4.1 Controls layout Closing solenoid drive Shunt trip / Zero voltage release ED coil OCT device HS 1...HS 10 OCT trip target Arc chute-indicator Description Designation X2 X3 X4 X5 X6 X10 X11 X12 X13 X14 X16 X17 1.Connector: Auxiliary- and control circuits 2.Connector: Auxiliary- and control circuits 3.Connector: Auxiliary contacts HS1...HS5 4.Connector: Auxiliary contacts HS6...HS10 5.
+ SEL (4…20 mA) SEL ( +/- 20 mA) + SEL ( +/- 20 mA) SEL ( +/- 10V ) + SEL ( +/- 10 V ) - SEL (4…20 mA) HS 6 1 X3 16 5 6 7 8 9 10 11 12 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Arc chute indicator (Indicator switch) with OCT indicator (Indicates tripping by OCT) 1 2 2 4 3 5 4 Design and specifications are subject to change without notice 5 6 7 8 6 7 8 6 7 8 HS 5 HS 4 HS 3 3 5 HS 10 (+) (-) 4 HS 9 X4 3 HS 8 1 2 HS 2 HS 1 S3 ed-trip firing signal 6…24Vdc S2 (OPEN by UVR command )
4.3 Electrical diagrams 4.3.1 Wiring code • • • The main circuits are not shown in the wiring diagrams for transparency. The control circuit is presented as a typical circuit diagram and is a combination of numbered basic diagrams for drives, trips and indicators. Using the key numbers of the basic plan, you can derive the number of the complete diagram. WARNING: Some non standard electrical circuits do not comply with the diagrams in this instruction. Such circuits are coded with unique numbers i.
4.3.2 Controls supply circuit Breaker External power supply -X3 -X10 [4] [1] +DC 24 V ±2% [ 10 ] [9] [8] +/~ AC 115-240V ±10% DC 35-350V ±10% [7] [6] [5] -/N GND [3] Breaker External power supply -X3 -X11 [4] [1] +DC 24 V ±2% [ 10 ] [9] [8] + DC 24 V ±5% - [5] [3] [7] [6] GND 36/ X _ _ _ _ _ _ Key position - 2 Key number – 1: Voltage converter DC 35-85 V ; DC 88-145 V ; DC 125-353 V ;AC 115-240 V Key number – 2: Interface for direct external voltage DC 24 V +/- 5% connection. Fig.
4.3.3 ED coil with external capacity bank • In this option customer provides his own solution for releasing of the ED coil, by means of external capacitor trip device. The NEKO control unit is not furnished, and coil is connected directly to front panel of control box (X2 :10/:11). Breaker External C-bank -X2 [ 10 ] -S2 -Q1 ED impulse coil [ 11 ] U=300 V C=2000 uF 36/ _ X _ _ _ _ _ Key position - 3 Key number – 0: Without ED coil. Key number – 1: With ED coil and external C-bank. Fig.
4.3.4 NEKO control circuit -X16: NEKO PCB -X10/11 [ 8 ] (+) [1] Isolating Transformer (+) 24 Vdc [ 6 ] (-) (-) [2] Impulse switching Charging Control -X3 [6] C-bank charging signalization [7] [9] [ 10 ] Signals -K1 Charging Voltage Control [5] Closing STOP relay Cut-off contact -K2 [6] -X2 i.e. HS 10 provided by user ! [ 10 ] [3] Tripping signal 6V...
4.3.5 SU control circuit -Q1 Closing drive -X12: SU PCB Power supply -X2 +/~ [1] [2] [3] [1] AC 110-250V DC 48-220V [2] -/N [4] -X2 [8] Transforming of CLOSE signal [4] -S1 [5] -K1 [9] Closing control circuit -X10/11 [ 9 ] (+) [ 10 ] -K1 24 V DC [7] [ 6 ] (-) [5] Closing STOP -K2 [6] 36/ _ _ X _ _ _ _ Key position - 4 Key number – 20: Closing solenoid drive with SU control unit. Fig. 26 SU-control circuit 2010-06-07 S47183e rev.
4.3.6 Shunt trip control circuit Standard DC 24 V shunt trip with control PCB. -X13: ST PCB -X2 -S2 [6] [4] [7] [3] [5] -K1 -X10/11 [6] [ 7 ](-) Closing STOP relay [8] -K1 24 V DC [7] [ 9 ] (+) ST coil [ 10 ] [9] Cut-off contact [1] -HS11 [2] 36/ _ _ _ X _ _ _ Key position - 5 Key number - 00: Without shunt trip or zero voltage release. Key number - 10: With shunt trip. • • • The closing STOP signal is provided for resetting K2 on the SU-control circuit.
• Below, non-standard shunt trip with single winding, directly supplied from external DC voltage. -X2:6 + - 7 10 2 4 8 3 5 6 Breaker’s aux. -X2:7 • - Below, non-standard shunt trip with double winding, directly supplied from external DC voltage. 1st winding -X2:6 - 2nd winding + -X2:8 - 7 10 2 4 8 Breaker’s aux. -X2:7 • • • 3 5 1 3 2 4 6 + 7 10 2 4 8 3 5 6 Breaker’s aux.
4.3.7 Zero voltage release control circuit -X14: UVR PCB -X2 -S3 [9] [1] [8] [2] [3] [7] -K2 -S2 [6] [4] -K1 -X10/11 [ 7 ](-) [5] [6] Closing STOP relay [7] DC 24 V [8] [ 9 ] (+) -K1 UVR coil -K2 [9] U< [ 10 ] 36/ _ _ _ X _ _ _ Key position - 5 Key number - 00: Without shunt trip or zero voltage release. Key number - 20: With zero voltage release. • • • The closing STOP signal is provided for resetting K2 on the SU-control circuit.
4.3.8 Indicators -X3 OCT trip target [ 8] [ 9] Arc chute indicator [ 12 ] [ 13 ] 36/ _ _ _ _ X _ _ Key position - 6 Key number - 00: Without indicators. Key number - 01: With OCT trip target only. Key number - 02: With arc chute indicator only. Key number - 03: With OCT trip target and arc chute indicator. Fig. 29 OCT trip target and arc chute indicator 2010-06-07 S47183e rev.
4.3.9 Auxiliary switch 1 2 3 4 3 4 5 6 7 6 7 8 9 10 11 9 10 11 12 13 12 13 14 15 1 2 5 8 HS 5 HS 4 HS 3 HS 2 HS 1 X4 14 15 HS 10 HS 9 HS 8 HS 7 HS 6 X5 36/ _ _ _ _ _ X _ Key position - 7 Key number - 1: With 3 switches (HS1 thru HS3). Key number - 2: With 5 switches (HS1 thru HS5). Key number - 3: With 10 switches (HS1 thru HS10). Fig. 30 Auxiliary switch 26 Design and specifications are subject to change without notice S47183e rev.
4.3.10 SEL measuring system 1) 2) Signal Processing Unit 3) Voltage stabilizer Self check control DC 24 V DC 24 V 1) max. 500 Ω 2) max. 500 Ω 3) min. 300 kΩ 36/ _ _ _ _ _ _ X Key position - 8 Key number - S: With SEL measurement system. Fig. 31 SEL current measurement system 2010-06-07 S47183e rev.
5. Dimensions & safety distances Warnings During operation, all metallic parts of the breaker, except control box and closing solenoid drive, may carry dangerous voltages. Insulation covers are available as an option. For installation of the breaker into cubicle, top and side openings shall be provided, in order to reduce internal pressure rise during clearing short circuit. Ventilation openings in the breaker cubicle top cover shall not be less than 50% of total surface area.
5.1 Safety distances.
5.2 Outlined dimensions 5.2.1 Gerapid 2607,4207, 6007 with arc chute 1x_ Pay attention to legend, warnings and safety distances pages 26/27! Fig. 32 Gerapid 2607- 6007, arc chute 1X (dimensions in mm and inches) 30 Design and specifications are subject to change without notice S47183e rev.
5.2.2 Gerapid 2607, 4207, 6007with arc chute 2x_ Pay attention to legend, warnings and safety distances pages 26/27! Fig. 33 Gerapid 2607- 6007, arc chute 2x (dimensions in mm and inches) 2010-06-07 S47183e rev.
5.2.3 Gerapid 8007 with arc chute 1x_ Pay attention to legend, warnings and safety distances pages 26/27! Fig. 34 Gerapid 8007 with arc chute 1x (dimensions in mm and inches) 32 Design and specifications are subject to change without notice S47183e rev.
5.2.4 Gerapid 8007 with arc chute 2x_ Pay attention to legend, warnings and safety distances pages 26/27! Fig. 35 Gerapid 8007 with arc chute 2x (dimensions in mm and inches) 2010-06-07 S47183e rev.
5.2.5 Gerapid 2607, 4207 with H / H terminals It’s possible to combine horizontal and vertical connectors. Dimensions are corresponding. Note with SEL option, top connector is vertical only Fig. 36 Gerapid 2607, 4207 with horizontal terminals (dimensions in mm and inches) 34 Design and specifications are subject to change without notice S47183e rev.
5.2.6 Gerapid 2607, 4207 with V / V terminals It’s possible to combine horizontal and vertical connectors. Dimensions are corresponding. Fig. 37 Gerapid 2607, 4207 with vertical terminals (dimensions in mm and inches) 2010-06-07 S47183e rev.
5.2.7 Gerapid 6007 terminals Gerapid 6007 is available only with V / V terminals ! Fig. 38 Gerapid 6007 with vertical terminals (dimensions in mm) 36 Design and specifications are subject to change without notice S47183e rev.
5.2.8 Gerapid 8007 terminals Gerapid 8007 is available only with V / V terminals ! Fig. 39 Gerapid 8007 with vertical terminals (dimensions in mm and inches) 2010-06-07 S47183e rev.
6. Inspections and maintenance 6.1 List of inspections TYPE OF THE INSPECTION A. General visual inspection BY WHOM HOW OFTEN WHAT TO DO/CHECK -Customer -Trained technician Every 6-12 months • • • • • B. General functional inspection -Customer -Trained technician Every 6-12 months • • • • C. Inspection of the arc chute and contact system -Customer -Trained technician D. Inspection of the screw/bolt connections -Customer -Trained technician E.
• 6.1.1 General visual inspection • • • • • • • • Check out for damages or cracks of the frame, the adapter or the arc chute. Check out the black marks on the countersunk screws. These marks shall be aligned together. If any screw is loosening, shall be replaced with new one, using Loctite 222. Afterwards, mark the screw with black line to sign its position in nest. Check out for missing screws or caps. Check out for damaged labels. Clean and repair. Check out for corrosion.
4 1 Fig. 44 Checking the contact system C) Check the protective walls • [Fig. 44]. The material burn out on the protective walls (5) shall not exceed 1 mm [0.04 in] at any place. 2 3 D) Check the arc runners • [Fig. 44]. The arc runners should not be burned more than 30 % of its total cross section. Pay particular attention to the area around arc runner bend (3) and at contact point with arcing contact (2). Fig. 42 Inspection of the arc chute 6.1.
6.1.5 Inspection of contacts’ tilt and gap Pay attention to the warnings, Section 1! A) Remove the arc chute and adapter • See 6.1.4-A/B. B) Check the tilt of the main contacts • [Fig. 45]. Use the hand lever for slowly closing the main contacts. • [Fig. 46]. Once the arcing contact touches arc runner, check the air gap between main contacts. The gap between main contacts shall have more than 1 mm [0.04 in]. • In case of insufficient tilt (gap), replace the arcing contact with new one. See 6.2.1 and 6.2.
6.2 List of maintenance works TYPE OF THE WORK A. Arc chute changing B. Arcing contact and arc runners changing C. Protective walls changing D. Adjustment of the contacts E. Replacement of the control board F. Adjustment of the mechanism G. Flexband or fixed contact changing H. Mechanism changing I. Dumper(s) changing J. Trip unit changing & adjustment K. Auxiliary contacts adjustment and changing L. Drive changing M.
6.2.1 Contact system (after 11/2003). Pay attention to the warnings, Section 1! This section is valid for breakers manufactured after 11/2003. This section refers to maintenance works A, B, C from Table 4. 1 3 A) Remove the arc chute • [Fig. 49]. Loosen the screws (3) and (4), using SW5 hexagon wrench and take off the arch chute (1) from the adapter (2). B) Remove the arc chute adapter • [Fig. 48]. To dismantle the arc chute adapter, loosen and pull out the four upright screws (1) using SW5 tool.
6.2.2. Contact system (before 11/2003). Pay attention to the warnings, Section 1! 4 This section is valid for breakers manufactured before 11/2003. This section refers to maintenance works A, B, C from Table 4. 4 4a 5 6 5a A) Remove the arc chute and adapter • See 6.2.1-A/B. C) Changing the protective walls and arc runners • [Fig. 48]. Pull out two protective walls (3). • [Fig. 50]. Loosen screws (6a) with Torx® 30 and take out front wall (6). • [Fig. 50]. Loosen screw (5a) with tool (SW5). • [Fig.
D) Changing the arcing contact • • • • • • • Remove front and back arc runner. See 6.2.2-C. Close the breaker and secure the solenoid drive against unintended opening. See 1.2.2. Secure the contact area against parts falling inside the breaker. See 1.2.1. [Fig. 52-1]. Initially loosen two braid’s screws with tool, and unbolt them finally by hand. [Fig. 52-2]. Remove the safety ring from axis pin end. [Fig. 52-3]. Pull out the axis pin from contact. • • • • • • [Fig. 52-4].
6.2.3 Layout of control PCB inside control box Slot numbers: 1 2 3 6.2.4 Replacement of the control boards 4 5 6 1. OPEN the breaker. 2. Disconnect power supply, and pull out all the plugs from control box’s terminals. 3. If a NEKO control unit is installed, wait 1 minute until capacitors discharge. Fig. 53 Control box inside (w/o SEL unit) Slot Control board Z-No.
Fig. 55-4 Unscrew all the plugs from control boards Fig. 55-5 Pull out the plugs of the control boards. Pull out selected control board. Insert new control board • Listen that both, the isolation plate at the side of equipment and the isolation plate at the side of soldering, were inserted! Fig. 55-7 Pay attention, that no cables will be pinched between box and front cover during closing! Fig.
6.2.5 Adjusting the auxiliary switch 1 2 3 1. OPEN the breaker. 2. Disconnect power supply, and pull out all the plugs from control box’s terminals. 3. In case of NEKO control unit inside, wait 1 minute until capacitors discharge. • • • • • • • • • • • • Adjustment of the switches may be required if they fail to provide correct position indication. This condition can be caused by misalignment of the actuating plate (6) [Fig. 56-3], represented by dashed line.
6.3 Spare parts lists. Hints for parts identification: 6.3.1 Mechanical spare parts. NOTE: Gray-shaded parts are recommended for a maintenance stock, as applicable to your specific breaker configuration. Component Type Arc chute Part no. Service kit for replacing arcing components. (Before 11/2003). Service kit for replacing arcing components. (After 11/2003).
6.3.2 Electrical spare parts.
7. Customer support 7.1 Options overview. • • • • • • The coding system, introduced in 2008, is a catalog configuration tool based on Excel®. The catalogue code consists of 20 digits. Each digit represents specific rated value or component. Table 7 shows all available values, components and accessories for the Gerapid breaker family. Detailed descriptions are available in section 3. Please contact GE Sales representative in case of any questions.
7.2 Ordering. Gerapid with arc chute Quantity Catalogue no: Diagram no: => Customer's reference no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 52 Code Name Breaker type APN460437 rev03 09/2009 to Breaker number: => => Name Opt Unlock "On Request" options. Special ratings tested by customer.
7.2.1 Example of order no. 1 Line feeder breaker for LRT substation in Europe; comply with EN50123, with breaking capacity of 50 kA, configured as follows: 1. Load current of 4000 A. 2. Nominal voltage of 1500 V; 2x2 arc chute chosen due to high breaking capacity up to 70 kA. 3. Auxiliary supply voltage of 230 VAC for closing solenoid; 4. Vertical layout of both main terminals (V/V); 5. Breaker polarization not important; 6. Without SEL unit (not available with special terminals); 7.
7.2.2 Example of order no. 2 USA customer wants to buy Gerapid for DC drive application. The customer used to buy Gerapid 8007 according to company special ID code “GE80071x2R3”. The breaker shall comply with standard IEEE C37.14. Breaking capacity of 200 kA is required and configuration as follows: 1. Load current of 6000 A; 2. Nominal voltage of 800 V; 3. Available auxiliary voltage of 125 V DC; 4. With special design of main terminals as per customer drawing number “GE8007terR3”.
7.2.3 Example of order no. 3 Customer wants to use Gerapid as a field discharge breaker to commutate current from excitation system of synchronous machine to the discharge resistor circuit. Customer has previously tested one Gerapid breaker in a special test sequence using special ratings and internal standard “XXX 123”. Customer requests to put on the nameplate rated parameters that have been tested.
7.3 Glossary A a-release – see Shunt trip device; Activating magnet – see Closing drive; Anti-pumping device – see SU control PCB. Prevents reclosing after a close-open operation, as long as the device initiating closing is maintained in the position for closing Arc runners – (also: arc probes; arc horns). Provide safe arc leading into the arc chute. There are two arc runners mounted in Gerapid breaker, front and back. Arcing contact – – (also: pre-contact; arcing pre-contact).
7.4 Troubleshooting Breaker does not CLOSE. Breaker does not OPEN. A) Closing drive doesn't operate electrically but it is still possible to close the breaker manually by mean of the hand lever. WARNING! Below operations are done with control voltage connected. Only trained specialist or GE Service representative shall perform them. Risk of electric shock! 1) A) Shunt trip does not operate. Breaker is able to CLOSE and OPEN by means of hand lever. 1) Check points A2 to A5.
7.5 GE service teams 2010-06-07 S47183-E rev.
7.6 Notes 2010-06-07 S47183e rev.
GE Consumer & Industrial GmbH Berliner Platz 2-6 D-24534 Neumünster Germany Phone: ++49 4321-201-0 Fax : ++49 4321-201-444 60 Design and specifications are subject to change without notice S47183e rev.03 09/2009 S47183e rev.
