GE AK-1-50 User manual

Micro
Versa
Trip
Plus
and
MicroVersaTrip
PM
Conversion
Kits
For
GE
Types
AK
-
1
-
50
Low
-
Voltage
Power
Circuit
Breakers
INTRODUCTION
GE
Conversion
Kits
are
designed
to
upgrade
existing
GE
Low
Volt
-
age
Power
Circuit
Breakers
,
rather
than
replacing
the
entire
breaker
.
The
Conversion
Kits
contain enhanced
solid
-
state
MicroVersaTrip
Plus
or
MicroVersaTrip
PM
Trip
Units
,
representing
the latest techno
-
logical
advancement
in
GE
trip
systems
.
MicroVersaTrip
Plus
and
MicroVersaTrip
PM
Conversion
Kits
are
des
-
igned
and breaker
tested
to
conform
with
ANSI
Standard
C
37.59
,
allowing
the
retrofitter
to
properly
install
and
acceptance
test
’
the breaker
.
This
publication
covers
installa
-
tion
of
MicroVersaTrip
Plus
and
PM
Conversion
Kits
on
GE
Types
AK
-
1
-
50
Low
Voltage
Power
Cir
-
cuit Breakers
.
EacfvConversion
Kit
contains
all
appropriate
mate
-
rial
to convert
from
an
existing
GE
Type
ECFjxip
system
.
Courtesy of NationalSwitchgear.com

TABLE
OF
CONTENTS
«
SECTION
1
GENERAL
INFORMATION
3
SECTION
2
PRIOR
TO
INSTALLATION
3
SECTION
3
FRONT
AND
BACK
FRAME
DISASSEMBLY
AK
-
50
Frame
Separation
4
4
SECTION
4
BACK
FRAME
BREAKER
CONVERSION
Electromechanical
Trip
Device
Removal
.
.
.
Installing
the
Phase
Sensors
(
CT
’
s
)
5
5
5
-
6
SECTION
5
FRONT
FRAME
BREAKER
CONVERSION
Flux
Shifter
Installation
Programmer
Mounting
Bracket
Installation
.
Trip
Paddle
Installation
7
7
8
9
SECTION
6
BREAKER
ASSEMBLY
Frame
Assembly
Wire
Harness
Installation
Flux
Shifter
Adjustment
Programmable
Trip
Unit
Installation
10
10
10
11
11
SECTION
7
FOUR
-
WIRE
GROUND
FAULT
OPTION
Installing
the
Neutral
Sensor
12
12
13
-
15
SECTION
8
TESTING
AND
TROUBLESHOOTING
2
Courtesy of NationalSwitchgear.com

Preparatory
to
the
conversion
,
the
installer
should
verify
that
the
appropriate
current
sensors
and
programmer
unit
have
been
furnished
.
Whenever
the
ground
fault
trip
element
is
fur
-
nished
for
breakers
applied
on
4
-
wire
systems
,
note
that
an
associated
neutral
sensor
(
CT
)
is
re
-
quired
for
separate
mounting
in
the
equipment
.
Make
sure
that
retrofitted
breakers
are
applied
within
their
short
circuit
rating
.
For
example
,
when
the
trip
elements
of
the
breaker
are
to
be
changed
from
long
-
time
instantaneous
to
long
-
time
,
short
-
time
,
the
short
-
time
rating
would
gov
-
ern
the
application
.
As
a
service
-
related
consider
-
ation
,
the
installation
of
the
MicroVersaTrip
Plus
or
MicroVersaTrip
PM
kits
provides
an
excellent
opportunity
to
perform
normal
mainte
-
nance
on
the
breaker
,
particularly
when
the
front
and
back
frames
are
separated
.
Such
procedures
are
described
in
the
installation
and
maintenance
manuals
normally
supplied
with
the
Breakers
and
Equipment
.
SECTION
1
GENERAL
INFORMATION
GE
Conversion
Kit
installation
is
straightforward
,
but
does
require
careful
workmanship
and
atten
-
tion
to
these
instructions
.
Familiarity
with
the
breaker
itself
is
highly
desirable
.
The
general
ap
-
proach
is
to
first
strip
the
breaker
of
its
existing
trip
devices
,
then
install
the
MicroVersaTrip
Plus
or
MicroVersaTrip
PM
kit
components
.
Following
this
procedure
,
the
converted
breaker
is
performance
tested
,
prior
to
restoring
the
breaker
to
service
.
The
majority
of
breaker
kit
installations
do
not
re
-
quire
any
customized
assembly
work
.
However
,
some
conversions
may
involve
unusual
mounting
circumstances
or
accessory
combinations
which
necessitate
minor
modification
and
/
or
relocation
of
a
component
(
s
)
.
In
most
instances
this
supple
-
mentary
work
can
be
done
on
site
.
SECTION
2
PRIOR
TO
INSTALLATION
•
Turn
off
and
lock
out
the
power
source
feed
-
ing
the
breaker
prior
to
attempting
any
installation
,
maintenance
,
or
modification
.
Follow
all
lockout
and
tagging
rules
of
the
National
Electrical
Code
and
all
other
applicable
codes
.
•
Do
not
work
on
a
closed
breaker
or
a
breaker
with
the
closing
springs
charged
.
Trip
OPEN
the
breaker
and
be
sure
the
stored
energy
springs
are
discharged
avoiding
the
possibility
that
the
breakers
may
trip
OPEN
or
the
charg
-
ing
springs
discharge
,
causing
injuries
.
•
For
both
stationary
and
draw
out
breakers
,
trip
OPEN
,
then
remove
the
breaker
to
a
well
lighted
work
area
before
beginning
work
.
•
Do
not
perform
any
maintenance
including
breaker
charging
,
closing
,
tripping
,
or
any
other
function
which
could
cause
significant
movement
of
the
breaker
while
it
is
on
the
draw
out
extension
rails
.
•
Do
not
leave
the
breaker
in
an
intermediate
position
in
the
switchgear
compartment
.
Al
-
ways
leave
it
in
the
CONNECTED
,
TEST
,
or
DISCONNECTED
position
.
Failure
to
do
so
could
lead
to
improper
positioning
of
the
breaker
and
flashback
.
Before
starting
any
work
,
turn
off
and
lock
out
all
power
sources
leading
to
the
breaker
(
primary
and
secondary
)
.
Remove
the
breaker
to
a
clean
,
well
lighted
work
area
.
WARNING
:
Low
Voltage
Power
Circuit
Break
-
ers
utilize
high
speed
,
stored
energy
spring
operating
mechanisms
.
The
breakers
and
their
enclosures
contain
interlocks
and
safety
features
intended
to
provide
safe
,
proper
op
-
erating
sequences
.
For
maximum
personnel
protection
associated
with
installation
,
opera
-
tion
,
and
maintenance
of
these
breakers
the
following
procedures
must
be
followed
.
Fail
-
ure
to
follow
these
procedures
may
result
in
personal
injury
or
property
damage
.
•
Only
qualified
persons
,
as
defined
in
the
Na
-
tional
Electrical
Code
,
who
are
familiar
with
the
installation
and
maintenance
of
low
volt
-
age
power
circuit
breakers
,
and
switchgear
as
-
semblies
,
should
perform
any
work
associated
with
these
breakers
.
•
Completely
read
and
understand
all
instructions
before
attempting
any
breaker
installation
,
operation
,
maintenance
,
or
modification
.
Courtesy of NationalSwitchgear.com

SECTION
3
FRONT
AND
BACK
FRAME
DISASSEMBLY
!
'
w
The
conversion
of
a
GE
AK
-
1
-
50
breaker
requires
that
the
front
and
back
frames
be
disassembled
before
the
kit
can
be
installed
.
Follow
these
steps
to
disassemble
the
breaker
.
I
i
AK
-
50
Frame
Separation
Step
1
Remove
the
(
2
)
breaker
opening
springs
.
Save
them
to
be
re
-
installed
(
Fig
.
1
)
.
Step
2
Remove
the
crossbar
mechanism
pin
by
first
re
-
moving
the
external
retaining
clip
(
Fig
.
2
)
.
Save
the
pin
and
clip
.
Step
3
Remove
and
save
the
(
4
)
or
(
6
)
nuts
and
lock
washers
holding
the
front
and
back
frames
to
-
gether
.
Fig
.
3
shows
an
example
of
one
of
the
nuts
.
Four
nuts
are
used
on
manually
operated
breakers
and
six
on
electrically
operated
breakers
.
Step
4
OPENING
SPRINGS
Fig
.
1
.
AK
-
1
-
50
Circuit
Breaker
Carefully
separate
the
two
frame
halves
.
Fig
.
3
.
Frame
Mounting
Bolts
Courtesy of NationalSwitchgear.com

SECTION
4
BACK
FRAME
BREAKER
CONVERSION
Electromechanical
Trip
Device
Removal
Step
1
Remove
and
discard
the
(
2
)
screws
at
the
base
of
each
trip
device
.
Discard
the
“
C
”
shaped
metal
mounting
bracket
(
Fig
.
4
)
.
Step
2
Remove
and
discard
the
small
phillips
head
screw
at
the
top
of
each
trip
device
(
Fig
.
4
)
.
Step
3
Remove
and
discard
the
(
4
)
Yie
alien
head
bolts
fastening
each
trip
coil
.
The
trip
device
can
be
re
-
moved
and
discarded
(
Fig
.
5
)
.
Installing
the
Phase
Sensors
(
CT
’
s
)
Step
1
Mount
the
new
copper
CT
post
to
the
back
frame
using
the
(
2
)
%
-
16
x
llA
bolts
with
plain
and
lock
washers
provided
(
Fig
.
6
)
.
ALLEN
I
1
LAI
)
BOLLS
PHILLIPS
HEM
)
SCREW
#
BRACKET
Fig
.
4
.
EC
Trip
Device
Removal
NOTE
:
Occasionally
,
during
current
sensor
manufacturing
,
a
slight
separation
may
occur
between
the
epoxy
and
plastic
shell
.
This
may
amount
to
as
much
as
0.030
"
and
has
no
effect
on
performance
.
Additionally
,
slight
surface
imperfections
are
part
of
the
epoxy
curing
process
and
have
no
effect
on
performance
.
x
.
16
BOLTS
(
T
POST
Fig
.
6
.
CT
Post
Assembly
.
p
Courtesy of NationalSwitchgear.com

SECTION
4
BACK
FRAME
BREAKER
CONVERSION
Installing
the
Phase
Sensors
(
CT
’
s
)
(
Cont
’
d
)
Step
2
Fasten
the
(
3
)
small
insulated
wire
fasteners
to
the
back
frame
using
the
(
3
)
54
-
20
x
l
3
/
4
screws
with
plain
and
lock
washers
provided
.
One
fas
-
tener
is
mounted
under
each
CT
(
Fig
.
7
)
.
Step
3
Place
each
CT
over
the
copper
CT
posts
using
a
small
amount
of
RTV
or
an
equivalent
adhesive
to
prevent
the
CT
’
s
from
rotating
(
Fig
.
8
)
.
Step
4
Mount
the
top
copper
bus
over
each
CT
Using
the
!
4
-
13
x
114
alien
head
screw
with
a
plain
and
lock
washer
provided
(
Fig
.
8
)
.
Step
5
Insert
the
(
2
)
%
-
16
x
114
bolts
with
plain
and
lock
washers
provided
through
the
top
copper
bus
,
into
the
contact
arm
assembly
(
Fig
.
8
)
.
Step
6
Tighten
the
%
-
16
bolts
to
200
in
-
lbs
.
and
the
54
-
13
bolts
to
300
in
-
lbs
.
*
(
Fig
.
9
)
.
14
-
20
SCREW
WIRE
FASTENERS
Fig
.
7
.
Wire
Fastener
Installation
*
IMPORTANT
NOTE
:
Steps
designated
by
an
(
*
)
are
critical
electrical
integrity
connec
-
tions
.
They
must
be
correctly
tightened
for
proper
operation
.
Failure
to
tighten
prop
-
erly
will
cause
a
breaker
failure
resulting
in
property
damage
or
personal
injury
.
Fig
.
8
.
CT
Assembly
(
left
to
right
)
%
-
lb
BOLTS
fc
-
13
BOLTS
Fig
.
9
.
Electrical
Contact
Torques
Courtesy of NationalSwitchgear.com

SECTION
5
FRONT
FRAME
BREAKER
CONVERSION
Flux
Shifter
Installation
Step
1
Remove
and
discard
the
(
3
)
trip
paddles
on
the
common
trip
actuator
bar
(
Fig
.
10
)
.
Step
2
Install
the
flux
shifter
mounting
bracket
to
the
left
inside
of
the
front
frame
.
Remove
and
discard
the
grounding
strap
hardware
and
use
the
(
2
)
%
-
16
x
1
bolts
,
%
nuts
and
lock
washers
pro
-
vided
(
Fig
.
11
)
.
Step
3
Bolt
the
flux
shifter
assembly
to
the
bracket
using
the
(
2
)
*
/
4
-
20
x
V
2
bolts
and
lock
washers
provided
(
Fig
.
12
)
.
TRIP
PADDLES
Fig
.
10
.
Trip
Paddle
Removal
FLUX
SHIFTER
BRACKET
X
-
16
BOLTS
Fig
.
11
.
Flux
Shift
Mounting
Bracket
‘
/
«
-
20
BOLTS
FLUX
SHIFTER
Fig
.
12
.
Flux
Shifter
Installation
Courtesy of NationalSwitchgear.com

SECTION
5
FRONT
FRAME
BREAKER
CONVERSION
NOTE
LOCATION
OF
BEVELED
EDGES
ON
PLUG
BODY
4
Programmer
Mounting
Bracket
Installation
Step
1
The
wiring
harness
includes
a
36
-
pin
programmer
connector
which
must
be
pre
-
assembled
to
the
pro
-
grammer
mounting
bracket
.
Follow
step
1
through
5
in
Fig
.
13
to
mount
the
connector
(
Fig
.
14
)
.
Step
2
Fasten
the
programmer
mounting
bracket
to
the
side
of
the
flux
shifter
bracket
using
the
(
2
)
14
-
20
x
V
2
bolts
and
lock
washers
provided
(
Fig
.
15
)
.
ADAPTER
BRACKET
STEP
1
.
PUSH
BRACKET
OVER
NOTCHES
IN
END
OF
PLUG
BODY
v
/
J I
I U
A
r
4
STEP
5
.
HOLD
PLUG
BODY
TIGHT
TO
THE
ADAPTER
BRACKET
AND
BEND
OVER
(
2
)
LOCKING
TABS
CAUTION
:
Adapter
bracket
must
be
installed
onto
harness
plug
as
shown
in
Fig
.
13
.
Failure
to
do
so
will
result
in
harness
plug
failure
and
the
programmer
will
not
provide
protection
.
STEP
3
.
PRESS
ON
PUSH
NUTS
UNTIL
BRACKET
IS
HELD
FIRMLY
AGAINST
PROGRAMMER
BRACKET
O
OJD
A
oooooooo
*
00000000
00000000
oooooooq
,
PIN
1
STEP
4
.
HOLD
PLUG
FIRMLY
BEND
LOCKING
TABS
STEP
2
.
PULL
WIRE
HARNESS
BRACKET
ASSEMBLY
UP
OVER
GUIDE
PINS
AND
PUSH
ALL
THE
WAY
DOWN
4
GUIDE
PINS
>
.
A
a
n
J
]
lir
m
Fig
.
13
.
Harness
Connector
TRIP
UNIT
MOUNTING
BRACKET
K
-
20
BOLTS
Fig
.
14
.
Programmer
Mounting
Bracket
Fig
.
15
.
Programmer
Mounting
Bracket
Installed
8
Courtesy of NationalSwitchgear.com

SECTION
5
FRONT
FRAME
BREAKER
CONVERSION
Trip
Paddle
Installation
Step
1
Assemble
the
trip
paddle
and
the
threaded
back
plate
by
inserting
two
of
the
three
10
-
32
x
%
screws
and
lock
washers
provided
along
the
top
edge
.
Step
2
Slide
the
trip
paddle
over
the
common
trip
actua
-
tor
bar
approximately
1
”
from
the
side
frame
.
Use
the
remaining
10
-
32
x
3
/
i
screw
and
lock
washer
to
fasten
the
trip
paddle
in
place
(
Fig
.
16
)
.
Fig
.
16
.
Trip
Paddle
Installation
9
Courtesy of NationalSwitchgear.com

SECTION
6
BREAKER
ASSEMBLY
t
-
Frame
Assembly
Step
1
Follow
steps
1
-
4
on
page
4
in
reverse
to
reassemble
the
front
and
back
frames
.
IMPORTANT
NOTE
:
Use
extreme
caution
when
joining
the
frames
,
so
that
the
flux
shifter
reset
arm
is
not
damaged
.
The
reset
arm
must
be
assembled
so
that
it
rests
on
the
metal
contact
crossbar
on
the
underside
.
The
arm
will
fit
between
the
left
frame
side
lever
and
the
first
insulated
contact
actuator
lever
.
WIRE
TIES
Fig
.
17
.
Wire
Harness
Installation
Wire
Harness
Installation
Step
1
Connect
the
4
-
pin
flux
shifter
lead
plug
to
the
mating
plug
on
the
wire
harness
and
tie
the
leads
to
the
mounting
bracket
.
Step
2
Bring
the
CT
leads
of
the
wiring
harness
around
to
the
back
and
bottom
of
the
breaker
and
con
-
nect
to
the
CT
’
s
as
shown
in
Fig
.
17
.
Pay
special
attention
to
the
polarity
.
White
-
common
Black
-
tap
Step
3
Tie
the
wire
harness
to
the
insulated
fasteners
un
-
der
each
CT
using
the
wire
ties
provided
.
Make
*
t
certain
that
the
wire
harness
will
not
interfere
with
the
mechanism
of
the
breaker
(
Fig
.
17
)
.
Step
4
Loosen
the
(
2
)
%
-
16
mechanism
bolts
above
the
center
phase
CT
and
insert
the
insulated
barrier
provided
.
Do
not
remove
the
bolts
.
Retighten
the
bolts
,
fastening
the
barrier
in
place
(
Fig
.
18
)
.
Step
5
When
the
communications
portion
of
the
wiring
harness
is
installed
,
it
should
be
tied
to
the
frame
in
a
location
where
it
is
accessible
in
the
switchgear
.
Fig
.
19
shows
a
suggested
location
.
The
actual
location
is
dependent
on
the
configu
-
ration
of
the
equipment
and
may
be
determined
by
a
field
engineer
.
If
the
harness
is
not
used
,
it
may
be
removed
or
coiled
and
tied
to
the
frame
.
Fig
.
18
.
Center
Phase
Barrier
Installation
.
»
Courtesy of NationalSwitchgear.com