GE EntelliGuard G User manual

Installation, Operation,
and Maintenance Manual
Retain for Future Use.
EntelliGuard® G Circuit
Breaker
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2 ©2012 General Electric All Rights Reserved
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©2012 General Electric All Rights Reserved 3
HAZARD CATEGORIES
The following important highlighted information appears
throughout this document to warn of potential hazards or
to call attention to information that clarifies a procedure.
Carefully read all instructions and become familiar with
the devices before trying to install, operate, service or
maintain this equipment.
DANGER
Indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Failure to comply with these instructions may result in
product damage.
NOTICE
Indicates important information that must be
remembered and aids in job performance
TRADEMARKS
EntelliGuard™ G
EntelliGuard™ TU
WARRANTY
This document is based on information available at the
time of its publication. While efforts have been made to
ensure accuracy, the information contained herein does
not cover all details or variations in hardware and
software, nor does it provide for every possible
contingency in connection with installation, operation,
and maintenance. Features may be described herein that
are not present in all hardware and software systems. GE
Consumer & Industrial assumes no obligation of notice to
holders of this document with respect to changes
subsequently made. GE Consumer and Industrial makes
no representation or warranty, expressed, implied, or
statutory, with respect to, and assumes no responsibility
for the accuracy, completeness, sufficiency, or usefulness
of the information contained herein. No warrantees of
merchantability or fitness for purpose shall apply.
Contact your local sales office if further information is
required concerning any aspect of EntelliGuard G circuit
breaker operation or maintenance.
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EntelliGuard® G Circuit Breaker DEH-41304C
Table of Contents 13 March 2014
4 ©2012 General Electric All Rights Reserved
SECTION 1 –GENERAL INFORMATION
STORAGE......................................................................................................................................................................................................................... 7
INTRODUCTION ...........................................................................................................................................................................................................7
Quality Assurance ........................................................................................................................................................................................7
Options Check Sheet...................................................................................................................................................................................7
Product Serial Number............................................................................................................................................................................... 7
Measurement Units .....................................................................................................................................................................................7
PRODUCT DESCRIPTION .........................................................................................................................................................................................7
HAND TOOLS NEEDED FOR INSTALLATION ..................................................................................................................................................7
Table 1.1. Required Hand Tools ............................................................................................................................................................7
Figure 1.1. EntelliGuard G Power Circuit Breaker Features and Characteristics......................................................................8
SECTION 2 –PRODUCT SPECIFICATIONS
Table 2.1. Environmental Conditions...............................................................................................................................................................9
Table 2.2. EntelliGuard G Short Circuit and Interrupting Ratings: ANSI/UL1066 ......................................................................9
Table 2.3. EntelliGuard G Short Circuit and Interrupting Ratings: UL489 ..................................................................................... 9
Table 2.4. EntelliGuard G Non-Automatic Circuit Breaker: ANSI Version................................................................................... 10
Table 2.5. EntelliGuard G Non-Automatic Circuit Breaker/Molded Case Switch: UL Version ......................................... 10
Table 2.6. Key to Tables 2.2 Through 2.5.................................................................................................................................................... 10
Table 2.7. Agency Certification ........................................................................................................................................................................ 10
Table 2.8. Product Dimensions and Weights –ANSI/UL..................................................................................................................... 11
SECTION 3 –LIFTING, MOUNTING AND INSTALLATION
CIRCUIT BREAKER UNPACKING........................................................................................................................................................................ 12
BASIC CIRCUIT BREAKER CONSTRUCTION ............................................................................................................................................. 12
LIFTING AND MOUNTING .................................................................................................................................................................................... 13
Using a Lifting Truck................................................................................................................................................................................. 13
Drawout Cassette Lifting, Mounting and Installation............................................................................................................. 13
Circuit Breaker Installation in to the Cassette............................................................................................................................ 13
Drawout Circuit Breaker Installation into the Cassette......................................................................................................... 13
Circuit Breaker Removal from the Cassette ................................................................................................................................ 15
Fixed-Mounted Circuit Breaker Mounting .................................................................................................................................... 16
TRIP UNIT ................................................................................................................................................................................................................... 16
General Information................................................................................................................................................................................. 16
Trip Unit Installation ................................................................................................................................................................................. 16
WIRING ......................................................................................................................................................................................................................... 17
Table 3.1. Wiring Schematic for Block-A ....................................................................................................................................... 17
Table 3.2. Wiring Schematic for Block-B ....................................................................................................................................... 17
Table 3.3. Wiring Schematic for Block-C ....................................................................................................................................... 17
Table 3.4. Electronic Interlock ............................................................................................................................................................. 18
Table 3.5. Wiring Schematic Nomenclature Definitions........................................................................................................ 18
SECONDARY DISCONNECT BLOCKS .............................................................................................................................................................. 19
Table 3.6. Terminal Wiring..................................................................................................................................................................... 19
SELECTIVITY/BACKUP PROTECTION............................................................................................................................................................... 19
SECTION 4 –OPERATION
STORED ENERGY MECHANISM KEY FEATURES......................................................................................................................................... 20
Table. 4.1. Stored Energy Mechanism Sequences of Operation ....................................................................................... 20
Circuit Breaker Charging........................................................................................................................................................................ 20
Two Step Mechanism Design .............................................................................................................................................................. 20
CLOSING SPRING DISCHARGE PROCEDURE.............................................................................................................................................. 21
Table 4.2. Cassette Operating Positions ........................................................................................................................................ 21
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DEH-41304C EntelliGuard® G Circuit Breaker
13 March 14 Table of Contents
©2012 General Electric All Rights Reserved 5
CLOSING PROCEDURE .....................................................................................................................................................................................................21
CONDITIONS WHEN CLOSING CANNOT OCCUR ................................................................................................................................................21
CIRCUIT BREAKER OPENING PROCEDURE.............................................................................................................................................................21
SECTION 5 –LOCKS AND INTERLOCKS
GENERAL INFORMATION ................................................................................................................................................................................................22
CIRCUIT BREAKER FRONT PANEL LOCKING ..........................................................................................................................................................22
Pushbutton Locking ..........................................................................................................................................................................................22
Key Lock for Breaker Trip Free Condition ..............................................................................................................................................23
DRAWOUT CASSETTE FRONT PANEL LOCKING...................................................................................................................................................23
Security Locking..................................................................................................................................................................................................23
Isolation Shutters Locking (If Installed) ...................................................................................................................................................23
Door Interlock Installation .............................................................................................................................................................................24
KEY LOCKS AND INSTALLATION..................................................................................................................................................................................25
TWO-BREAKER CABLE INTERLOCK INSTALLATION ...........................................................................................................................................25
Vertical Mounting...............................................................................................................................................................................................25
Horizontal Mounting.........................................................................................................................................................................................26
SAFETY SHUTTERS INSTALLATION.............................................................................................................................................................................26
Table 5.1: Fixed-Mounted Circuit Breaker Locking...........................................................................................................................26
Table 5.2: Drawout Circuit Breaker Locking.........................................................................................................................................26
SECTION 6 –ACCESSORIES DESCRIPTION
GENERAL INFORMATION ................................................................................................................................................................................................27
INDIVIDUAL ACCESSORIES.............................................................................................................................................................................................27
Motorized Spring Charging Unit .................................................................................................................................................................27
Table 6.1. Motor Operators ..............................................................................................................................................................27
Circuit Breaker Closing Coils –Standard and Commanded........................................................................................................28
Table 6.2. Closing Coil Characteristics .......................................................................................................................................28
Command Operation Module......................................................................................................................................................................28
Shunt Trip (ST) ......................................................................................................................................................................................................28
Table 6.3. Extended Range Shunt Trip for UL Ground Fault and ANSI DC Rating Applications ...................28
Status Indication Switch (Coil Signaling Contact)..............................................................................................................................28
Table 6.4. Coil Signaling Contact Module .................................................................................................................................28
Under Voltage Release (UVR) with Fixed Time Delay.......................................................................................................................28
Table 6.5. UVR Operating Characteristics ................................................................................................................................29
Time Delay Module (TDM) for UVR (Externally Mounted) ...............................................................................................................29
Table 6.6. TDM Characteristics.......................................................................................................................................................29
Remote Operation Coil Combination.......................................................................................................................................................29
Table 6.7. Remote Operation Coil Combination....................................................................................................................29
Auxiliary Switches ..............................................................................................................................................................................................29
Table 6.8. Auxiliary Switches ...........................................................................................................................................................29
Table 6.9. Auxiliary Switch Ratings and Secondary Disconnect Points....................................................................29
Circuit Breaker –Key Interlock Facility....................................................................................................................................................30
Table 6.10. Key Interlocks and Door Interlocks .....................................................................................................................30
Carriage Position Switch (TOC) ....................................................................................................................................................................30
Table 6.11. Carriage Position Switches......................................................................................................................................30
Table 6.12. Carriage Position Switch Ratings (Common NO/NC Contact Configuration.................................30
Mechanical Interlocks (Cable/Rod)............................................................................................................................................................30
Table 6.13. Mechanical Interlocks (Cable/Rod)......................................................................................................................30
Cables.......................................................................................................................................................................................................................30
Table 6.14. Cables for Mechanical Interlocks.........................................................................................................................30
Table 6.15. Interlock Configurations ...........................................................................................................................................31
Bell Alarm with Lockout ..................................................................................................................................................................................31
Bell Alarm Switches...........................................................................................................................................................................................31
Table 6.16. Bell Alarm Switches........................................................................................................................................................31
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EntelliGuard® G Circuit Breaker DEH-41304C
Table of Contents 13 March 2014
6 ©2012 General Electric All Rights Reserved
Table 6.17. Bell Alarm Ratings (Common NO/NC Contact Configuration) ................................................................ 31
Charging Spring Status Indicator.............................................................................................................................................................. 32
Table 6.18. Spring Charged Contact (1 NO) ............................................................................................................................ 32
Secondary Disconnects (Factory-Installed/Field Installable) ..................................................................................................... 32
Table 6.19. Block Location ............................................................................................................................................................... 32
Table 6.20. Secondary Disconnect Parts.................................................................................................................................. 32
Ground Fault ........................................................................................................................................................................................................ 32
Table 6.21. Neutral Rogowski CTs.........................................................................................................................................32-33
Ready to Close Contact .................................................................................................................................................................................. 33
Table 6.22. Ready to Close Contacts (1NO) ............................................................................................................................. 33
Sealed Door Panel Escutcheon.................................................................................................................................................................. 33
Mechanical Operations Counter................................................................................................................................................................ 33
Table 6.23. Miscellaneous Accessories ..................................................................................................................................... 33
Cassette Substructure .................................................................................................................................................................................... 33
Position Indicators............................................................................................................................................................................................. 33
Rejection Device................................................................................................................................................................................................. 33
Front Flat Terminations .................................................................................................................................................................................. 33
Table 6.24. Optional Front Flat Terminations......................................................................................................................... 33
SECTION 7 –ACCESSORIES INSTALLATION
CIRCUIT BREAKER FRONT COVER REMOVAL ....................................................................................................................................................... 34
MOTOR OPERATOR –SPRING CHARGING UNIT INSTALLATION................................................................................................................. 34
SHUNT TRIP, CLOSING COIL AND UNDER VOLTAGE RELEASE DEVICE INSTALLATION .................................................................. 35
Closing Coil Installation .................................................................................................................................................................................. 35
Closing Coil Removal ....................................................................................................................................................................................... 35
NETWORK INTERLOCK INSTALLATION.................................................................................................................................................................... 35
Trip Alarm/Bell Alarm Switch Installation ............................................................................................................................................. 35
Ready to Close Switch Installation ........................................................................................................................................................... 35
SHUTTER PROP OPEN FEATURE ................................................................................................................................................................................. 35
CARRIAGE POSITION SWITCH INSTALLATION ..................................................................................................................................................... 36
BUSBAR/CABLE GROUNDING (OPTIONAL) ............................................................................................................................................................ 36
CLUSTERS .............................................................................................................................................................................................................................. 36
Upper Cluster Contact Set Grounding.................................................................................................................................................... 37
Lower Cluster Contact Set Grounding.................................................................................................................................................... 37
MECHANICAL TRIP ALARM INSTALLATION............................................................................................................................................................ 37
MECHANICAL OPERATIONS COUNTER INSTALLATION (OPTIONAL) ......................................................................................................... 38
REJECTION FEATURE........................................................................................................................................................................................................ 38
SECTION 8 –MAINTENANCE, TESTING AND TROUBLESHOOTING
MAINTENANCE .................................................................................................................................................................................................................... 39
Inspection Schedule......................................................................................................................................................................................... 39
Cleaning Procedure.......................................................................................................................................................................................... 39
Contact Wear Indicator Inspection (Optional).................................................................................................................................... 39
Circuit Breaker Main Mechanism Inspection ...................................................................................................................................... 40
Cassette Inspection.......................................................................................................................................................................................... 40
Isolating Contacts (Drawout Type) Inspection ................................................................................................................................... 40
Power Terminals and Busbar Inspection.............................................................................................................................................. 40
Lubrication ............................................................................................................................................................................................................ 40
TRIP UNIT TESTING............................................................................................................................................................................................................ 40
Trip Unit Testing .................................................................................................................................................................................................... 40
TROUBLESHOOTING......................................................................................................................................................................................................... 41
PUBLICATIONS .................................................................................................................................................................................................................... 42
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DEH-41304C EntelliGuard® G Circuit Breaker
13 March 14 Section 1 –General Information
©2012 General Electric All Rights Reserved 7
SECTION 1 –GENERAL INFORMATION
STORAGE
CAUTION
PRODUCT DAMAGE
Do not store circuit breaker in corrosive
environments above LC1 (sea salt mist) and G1 as
per ANSI/ISA-S71.04-1985.
Ensure circuit breakers and cassettes are stored in a
clean, dry location in their original packaging.
Failure to comply with these instructions may result
in product damage.
INTRODUCTION
Quality Assurance
All EntelliGuard G circuit breakers have been designed
and manufactured to the highest technical standards.
Strict procedures ensure first class product quality.
Options Check Sheet
Each circuit breaker comes with a detailed factory-
assembled side label that lists all optional features
included on both the circuit breaker and on the trip unit.
Product Serial Number
Please have the serial number available when
communicating about the circuit breaker. Each circuit
breaker has a unique serial number located on the left
side (viewed from front) of the front fascia.
Measurement Units
All data in this document is specified in conventional
metric/SI units.
All internal/external accessory and external
cable/bus bar connections are metric for both IEC
and UL/ANSI versions.
PRODUCT DESCRIPTION
The EntelliGuard G Circuit Breaker is suitable for
application on power systems up to 1000 Vac 50/60 Hz
systems and up to 750 Vdc as a main/source breaker,
feeder breaker, bus coupler or tie breaker. See Section 2
for complete product specifications.
Figure 1.1 shows a front view of the EntelliGuard G. The
indicated features are referenced in this document.
HAND TOOLS NEEDED FOR INSTALLATION
Table 1.1 provides a list of the hand tools required to
install, operate and maintain the EntelliGuard G Circuit
Breaker.
Table 1.1. Required Hand Tools
Tool Name
Function
Cluster pliers (two pairs, each with a different
gap, are supplied under Cat. No. GUNI)
To remove primary contacts for inspection and maintenance.
Screwdriver (8 mm)
To operate racking shutter drive.
Allen wrench (5 mm)
To remove arc chutes for inspection and maintenance.
To remove or adjust fixed and moving arcing contacts.
To remove mechanism.
Allen wrench key (4 mm)
To remove motor and gearbox mounting screws.
Metric feeler gauges
To check and adjust arcing contact gaps.
Pozidrive terminal screwdriver
To remove mechanical and electronic component mounting screws.
To connect wiring to secondary isolating contact terminals.
Pozidrive screwdriver (#1 and #3)
To remove front cover mounting screws.
To remove Rogowski coil and Power current transformer cover plate at the
rear of the circuit breaker moving portion.
Full Set of Metric Hex Allen Wrenches and
Socket Set
To remove PMU base, auxiliary switch assembly, etc.
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EntelliGuard® G Circuit Breaker DEH-41304C
Section 1 –General Information 13 March 14
8 ©2012 General Electric All Rights Reserved
Figure 1.1. EntelliGuard G Power Circuit Breaker Features and Characteristics
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DEH-41304C EntelliGuard® G Circuit Breaker
13 March 14 Section 2 –Product Specifications
©2012 General Electric All Rights Reserved 9
SECTION 2 –PRODUCT SPECIFICATIONS
WARNING
IMPROPER INSTALLATION, OPERATION AND
MAINTENANCE
Ensure only qualified personnel install, operate, service
and maintain all electrical equipment.
Failure to comply with these instructions could
result in death or serious injury.
Table 2.1. Environmental Conditions
Characteristic
Parameter
Temperature:
Operating
Ambient (surrounding circuit breaker)
Storage
-5 ºC to 70 ºC
-20 ºC to -5 ºC
-40 ºC to 70 ºC
Humidity
20% RH to 95% RH
Salt fog
per ASTM-B117
Vibration (random and sinusoidal)
1 G max., 50 Hz to 500 Hz in X, Y, Z directions
Fungus resistance
per ASTM G21
Voltage and current de-rating at altitude above sea level
per ANSI C37.20.1, Tables 2 and 3
Noise level
<30 dB
Endurance:
closing coil, Shunt trip
motor operator, under voltage release, accessories
20,000 operations
12,500 operations
Table 2.2. EntelliGuard G Short Circuit and Interrupting Ratings: ANSI/UL1066
Interrupting Rating Tier ANSI/UL1066 Devices, LVPCB
Envelope 1
Envelope 2
Envelope 3
Type
240 V
480 V
600 V
1/2S Withstand
400,
800,
1200
400, 800,
1600,
2000
3200
400-3200
3200
4000-5000
S
65,000
65,000
50,000
50,000
X
N
65,000
65,000
65,000
65,000
X
X
H
85,000
85,000
65,000
85,000
X
P
100,000
100,000
65,000
65,000
X
E
85,000
85,000
85,000
85,000
X
M
100,000
100,000
85,000
85,000
X
X
B
100,000
100,000
100,000
100,000
X
X
L
150,000
150,000
100,000
100,000
X
X
W
200,000
200,000
100,000
100,000
X
X
Table 2.3. EntelliGuard G Short Circuit and Interrupting Ratings: UL489
Interrupting Rating Tier ANSI/UL1066 Devices, LVPCB
Envelope 1
Envelope 2
Envelope 3
Type
240 V
480 V
600 V
1/2S Withstand
400-
1200
400-2000
2500-3000
400-3000
3000
4000
5000-
6000
S
65,000
65,000
50,000
42,000
X
N
65,000
65,000
65,000
42,000
X
X
H
85,000
85,000
65,000
50,000
X
X
P
100,000
100,000
65,000
50,000
X
M
100,000
100,000
85,000
65,000
X
X
X
L
150,000
150,000
100,000
85,000
X
X
X
W
200,000
200,000
100,000
85,000
X
X
X
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EntelliGuard® G Circuit Breaker DEH-41304C
Section 2 –Product Specifications 13 March 14
10 ©2012 General Electric All Rights Reserved
Table 2.4. EntelliGuard G Non-Automatic Circuit Breaker: ANSI Version*
Envelope
Type
Amps
Rated
Interrupting
Current
Rated Endurance
Minimum Mechanical
Endurance
Minimum Electrical
Endurance at 480 V
Minimum Electrical
Endurance at 600 V
1
S
800
42
12,500
10,000
7,500
1
N
800
42
12,500
10,000
7,500
1
N
1600
42
12,500
10,000
7,500
1
N
2000
42
12,500
7,500
5,000
2
M
3200
65
5,000
5,000
5,000
3
B
4000
100
5,000
3,000
2,000
3
B
5000
100
5,000
2,000
1,500
Table 2.5. EntelliGuard G Non-Automatic Circuit Breaker/Molded Case Switch: UL Version*
Envelope
Type
Amps
Short
Interrupting
Current (kA)
Rated Endurance
Minimum Mechanical
Endurance
Minimum Electrical
Endurance at 480 V
Minimum Electrical
Endurance at 600 V
1
S
800
42
12,500
10,000
7,500
1
S
1200
42
12,500
10,000
7,500
1
N
800
42
12,500
10,000
7,500
1
N
1600
42
12,500
10,000
7,500
1
N
2000
42
12,500
7,500
5,000
2
M
3000
65
5,000
5,000
5,000
3
B
4000
100
5,000
3,000
2,000
3
B
5000
100
5,000
3,000
1,500
3
B
6000
100
5,000
1,500
1,000
* GE internal quality testing requirements exceeded 20,000 mechanical and electrical operations.
Table 2.6. Key to Tables 2.2 through 2.5
Type
Description
Type
Description
E
Sq. Rated (ICW = ICU) 400 A to 2000 A, 85 kAIC at 480/508 V
H
85 kAIC at 480/508 V; 65 kAIC at 600/635 V
B
Sq. Rated (ICW = ICU) 3200 A to 6000 A, 100 kAIC at 480/508 V
M
100 kAIC at 480/508 V; 85 kAIC at 600/635 V
N
65 kAIC at 480/508/600/635 V
L
150 kAIC at 480/508 V; 100 kAIC at 600/635 V
W
200 kAIC at 480/508 V; 100 kAIC at 600/635 V
Table 2.7. Agency Certification (All industry standards referenced in this table are the latest version at the time the
product is sold.)
Standard Number
Title
ANSI C37.13,16,17, 20, 50
Low-voltage AC Power Circuit Breakers
NEMA SG 3, 5
Low-voltage Power Circuit Breakers
NEMA AB1

UL 1008*
Automatic Transfer Switches
UL 1066
Low voltage AC and DC Power Circuit Breakers Used in Enclosures
UL 489
Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures
CSA 22.2, No 5.1
Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures
IEC 60947 Part 1
Low Voltage Switchgear and Control Gear - General Rules
IEC 60947 Part 2
Low Voltage Switchgear and Control Gear - Circuit-Breakers
IEC 60947 Part 5
Low Voltage Switchgear and Control Gear - Accessories
IEC 60947 Part 3
Low Voltage Switchgear and Control Gear - Switches, Disconnects, Switch-Disconnects and
Fuse-Combination Units
IEC Environmental: 68-2-1,-2,-3,-6,-11,-
14,-14,-27,-29,-30,-31

IEC Environmental: 721

GB14048
China standards and CCC Mark
ABS (American Bureau of Shipping

Germanischer Lloyds

CUL
Low-voltage AC Power Circuit Breakers
*Suitable for use in UL1008 applications.
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