GE Gerapid 2607 User manual

S47183-e 01/2008 Design and specifications are subject to change without notice 1
GE Consumer & Industrial
Power Protection
High Speed DC Circuit Breaker
Gerapid 2607, 4207, 6007, 8007
with arc chute 1X2, 1X4, 2X2, 2X3, 2X4
USER`S GUIDE

2Design and specifications are subject to change without notice S47183-e 01/2008
INDEX
1. WARNINGS AND SAFETY HINTS..............................3
1.1 Warnings. ...........................................................................3
1.2 Safety hints.........................................................................4
1.2.1 Securing against falling parts........................................4
1.2.2 Maintenance with zero voltage release.........................4
2. GENERAL USAGE CONDITIONS...............................4
2.1 Transportation...................................................................4
2.2 Installation..........................................................................5
2.2.1 Operational environment..............................................5
2.2.2 Installation and interfaces.............................................5
2.3 Usage...................................................................................5
2.3.1 Supply and load. ...........................................................5
2.3.2 Adjusting the OCT........................................................5
3. TECHNICAL INFORMATIONS....................................6
3.1 Introduction. ......................................................................6
3.2 Components and accessories.............................................6
3.2.1 Contact system..............................................................6
3.2.2 Arc chute (code nr: 2)...................................................6
3.2.3 Mechanism....................................................................7
3.2.4 Over-Current Tripping device (code nr: 7)...................7
3.2.5 Electro-Dynamic tripping device (code nr: 12). ...........8
3.2.6 Auxiliary tripping devices (code nr: 11).......................8
3.2.7 Forced tripping release (code nr: 13)............................8
3.2.8 Hand lever (code nr: 16)...............................................9
3.2.9 Auxiliary switches (code nr: 9).....................................9
3.2.10 Indicators....................................................................9
3.2.11 Solenoid closing drive (code nr: 3)...........................10
3.2.12 Current measurement system (code nr: 6). ...............10
3.2.13 Electronic control system..........................................11
3.3 Technical data tables.......................................................12
4. ELECTRICAL CIRCUITS...........................................14
4.1 Controls layout.................................................................14
4.2 Terminals wiring system.................................................15
4.3 Electrical diagrams..........................................................16
4.3.1 Wiring coding system.................................................16
4.3.2 Voltage converter........................................................17
4.3.3 ED coil with external capacity bank...........................18
4.3.4 NEKO control unit......................................................19
4.3.5 SU control unit............................................................20
4.3.6 Shunt trip control unit.................................................21
4.3.7 Zero voltage release control unit.................................22
4.3.8 Indicators....................................................................23
4.3.9 Auxiliary switches. .....................................................24
4.3.10 SEL Measuring system 25
5. DIMENSIONS & SAFETY DISTANCES ....................26
5.1 Safety distances. ..............................................................27
5.2 Outlined dimensions........................................................ 28
5.2.1 Gerapid 2607,4207, 6007 with arc chute 1x_.............28
5.2.2 Gerapid 2607, 4207, 6007with arc chute 2x_.............29
5.2.3 Gerapid 8007 with arc chute 1x_. ..............................30
5.2.4 Gerapid 8007 with arc chute 2x_. ..............................31
5.2.5 Gerapid 2607, 4207 with H / H terminals. .................32
5.2.6 Gerapid 2607, 4207 with V / V terminals. .................33
5.2.7 Gerapid 6007 terminals.............................................. 34
5.2.8 Gerapid 8007 terminals.............................................. 35
6. INSPECTIONS AND MAINTENANCE.......................36
6.1 List of inspections............................................................36
6.1.1 General visual inspection. ..........................................37
6.1.2 General functional inspection.....................................37
6.1.3 Inspection of the arc chute. ........................................37
6.1.4 Inspection of the contact system. ...............................38
6.1.5 Inspection of contacts’ tilt and gap.............................39
6.1.6 Inspection of the screw connections...........................39
6.1.7 Inspection of the mechanic components..................... 39
6.2 List of maintenance works..............................................40
6.2.1 Maintenance of contact system (after 11/2003). ........ 40
6.2.2. Maintenance of contact system (before 11/2003)......42
6.2.3 Layout of control PCBs inside control box................ 44
6.2.4 Replacement of the control boards.............................44
6.2.5 Adjusting the auxiliary switches. ...............................46
6.3 Spare parts list.................................................................47
7. CUSTOMER SUPPORT.............................................48
7.1 PST coding system...........................................................48
7.2 Ordering Form. ...............................................................49
7.2.1 Example of order 1.....................................................50
7.2.1 Example of order 2.....................................................51
7.3 Glossary ...........................................................................52
7.4 Troubleshooting. .............................................................53

S47183-e 01/2008 Design and specifications are subject to change without notice 3
1. Warnings and Safety Hints
1.1 Warnings
During operation, electrical equipment carries dangerous
voltages. In addition, circuit breaker emits hot, ionized
gases when switching currents, especially short circuit
currents.
Installing, commissioning, maintaining, changing or refit-
ting of this equipment must be carried out only by quali-
fied and suitably trained personnel and under strict ob-
servation of national and international applicable safety
regulations.
During their operation, circuit breakers must be equipped
with appropriately fitted covers, e.g. in suitable enclosures
or panel boards. Safety distances must be preserved.
Suitably trained service personnel shall only carry out cer-
tain works.
Non-compliance with these warnings may result in death,
and/or severe physical damage and extensive damage to
equipment.
Prior to carrying out maintenance, inspection or checks,
the circuit breaker must be open, the both terminals must
be grounded, the circuit breaker must be switched off and
the control plugs removed.
During breakers’ operation, manually activation of the
breaker is forbidden. Manual activation must only be used
for maintenance and inspection purposes, when breaker
is power off and grounded.
The circuit breaker consists of high energy moving com-
ponents. Do not touch the circuit breaker while it is being
switched ON (closing) or OFF (opening). There is a high risk
of major injury.
The control circuits may be equipped with capacitors
bank, which may be charged with dangerous voltages.
Work on this section must be carried out carefully.

4Design and specifications are subject to change without notice S47183-e 01/2008
1.2 Safety hints
1.2.1 Securing against falling parts
Hint 1: Place a cloth into the lower area of the pre-arcing
contact [Fig. 1]. Remember to secure the closing drive
according to Hint 3.
Fig.1 Protecting of the arcing area aginst falling parts
1.2.2 Maintenance with zero voltage release
Hint 2: In case, when the zero voltage release is installed
in, it shall be energized to enable closing of the breaker.
Only then maintenance of the pre-arcing contacts is
possible.
Hint 3: To prevent the risk of injury, it is recommended to
secure the close position of the breaker with a mechani-
cal interlock device [Fig. 2]. The tube shall have ~50mm
[~2in] length and inner diameter of minimum 14mm
[0,55in]. The outer diameter of the locking rod shall be
less 8mm [0,3in]. GE does not offer this locking device.
Fig. 2 Securing closing drive against opening
2. General usage conditions
2.1 Transportation
•The breaker is transported on wooden palette. It is fixed
by shrunken plastic film. A paper cardboard box covers
the breaker on the palette. Truck, railway, airplane and
ship transport is possible. In case of sea transport, spe-
cial protection against salty and humid environment is
used.
•The circuit breaker must always be transported to the
installation site vertically and fully packed. The packag-
ing protects the device against damage and dust; it
should only be removed prior to installation.
•If the packaging is damaged, the breaker and the arc
chute must be inspected for damage. Ensure that all
packaging materials have been carefully removed prior
to breaker installation.
•For handling the unpacked breaker [Fig. 3], use a trans-
portation belts and reach them below the closing drive
(a)and below the lower terminal (b).
•Listen, that the basement isolation of the unpacked
breaker during handling will not be damaged (for exam-
ple don’t push the breaker back and forth at rough sur-
face).
Fig. 3 Handling the breaker and setting of the OCT unit
Closing drive
Secure tube
Locking rod
SW 6
a
b

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2.2 Installation
2.2.1 Operational environment
•The breaker, as delivered, is IP00 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. Gen-
eral environmental conditions refer to EN 50123-1 -an-
nex B, and IEC60947, class PD3.
•The breaker can operate within ambient temperature
range of –5°C…+40°C (23...104°F). With decreased nomi-
nal current, breaker can operate up to +60°C (140°F).
•The breaker can operate at altitude up to 2000m
(~6500ft).
•The breaker shall not be subjected to strong vibrations.
Vibrations of 0.5g per 30sec in vertical and horizontal di-
rections are allowed.
•Air shall be clean and its relative humidity shall be not
more than 50 % r.h. at the maximum temperature of
+40°C (104°F). Relative humidity may be higher if the
temperatures are lower, for example, 90 %r.h. at +20°C
(68°F). Slight condensation might occur during variations
of temperature
2.2.2 Installation and interfaces
•The lower and upper connections (code nr: 4) must be
connected directly to the main cables or bus bars. The
breaker must only be used in an upright operation po-
sition with the arc chute in place and fully secured.
•After installation, both the arc chute and special
threaded joints must be checked for tightness.
•The safety distances as shown in the dimensional draw-
ings must be maintained to grounded or insulated parts.
Suitable measures must be taken to protect personnel
from arcs.
•Strong, external magnetic fields, caused by improperly
located supply conductors or tray fields from other de-
vices, can lead to a shift of the trip setting thresholds.
This may result in premature tripping, or no tripping at
al, during low-level short circuit current events. This has
to be accounted for when installing and operating the
device with shielding added if appropriate.
•The control wires must be connected to the control ter-
minals (code nr: 19), as shown in the schematic circuit
diagram (Page 14). The protective grounding wire must
be connected at the marked contact.
2.3 Usage
2.3.1 Supply and load
•In accordance with its type, the breaker has been de-
signed for the current and voltage listed in Table 1, sec-
tion 3.3.
•During cont
inuous operation, breaker must be loaded
with its rated current at maximum. Load currents in ex-
cess of breaker nameplate rating are al
lowable for brief
periods. Refer to the short time currents listed in
Tables
1a/1b.
•Do not exceed the rated operating volt
age shown on the
breaker’s nameplate.
•
The drive and the auxiliary tripping devices (code nr: 8).
shall be supply within the specified control voltage
range. The auxiliary-
tripping devices must be loaded
with the values listed in Table 2a at maximum.
•Plugging or removing the auxiliary current con
nectors
are only allowed at zero potential, no voltage (-
X2
:1/:2) (-X3 :4/:5) !
2.3.2 Adjusting the OCT
•OCT is an over-
current tripping device (code nr: 7), which
trips a breaker in case of overload or short circu
it. This is
fully adjustable, instantaneous and direct tripping de-
vice.
•OCT adjustment [Fig.3], within a specific range, is real-
ized by turning the screw 1.
•
Adjusting procedure requires an SW6 hexagon wrench
2.
•The adjustment must only be carried out after
the
breaker has been disconnected from the main circuit
and has been grounded.
•
Turning the adjustment screw clockwise increased the
trip threshold, turning the screw counter-clockwise de-
creased the tripping threshold.
•Aligning the arrow and the marking into one line 3 per-
forms adjustment.

6Design and specifications are subject to change without notice S47183-e 01/2008
3. Technical informations
3.1 Introduction
•Gerapid is a high-speed DC circuit breaker. This is a sin-
gle-pole DC breaker, primarily designed for use in rail-
way propulsion-power distribution systems with operat-
ing currents up to 8000A (code nr: 1) and operating volt-
ages up to 3600V (code nr: 2). Additional application ar-
eas are special industrial plants as electrolysis plants,
mines or steel mills.
•The breaker type Gerapid has a very high interruption
capacity combined with a current limiting characteristic.
The arc chute works on the basis of an asbestos-free arc
splitting principle.
•A wide variety of accessories and spares are available
for maintenance, repair, or as a possible extension. The
breaker shall be configured by using PST coding sys-
tem, available at the end of this instruction or as an ex-
cel file, free of charge.
•Closing of the circuit breaker is performed through a
high-power solenoid drive (code nr: 3).
•During inspections, opening and closing may be carried
out by means of a hand lever (code nr: 16), which is
mounted onto the armature of the closing drive.
•Overload tripping is obtained directly via OCT device
(code nr: 7) or, optionally by electro-dynamic coil (code
nr: 12). Indirect remote tripping can be achieved by
means of a shunt trip or exclusively, by a zero voltage
release (code nr: 11).
•Gerapid breakers have a compact and enclosed con-
struction [Fig. 4]. They are IP 00 protected. All parts are
mounted on thick-walled, non-breakable and fireproof
insulation panels.
Fig. 4 Modular construction overview
3.2 Components and accessories
3.2.1 Contact system
•Gerapid breakers are equipped with a two-stage con-
tact system [Fig. 5], consists of a main contact and an
arcing contact. With this proven design of the contact
system, the main contact is not subjected to any wear or
tear.
•The main contacts are coated with a silver, composite
material. The arcing contact and link braid are made
from copper and can be easily replaced.
•The flexible bend is linked to the arcing contact by
means of very tight braid.
Fig. 5 Contact system: new (upper) and old (lower) type
3.2.2 Arc chute (code nr: 2)
•Compact and modular design of the arc system requires
no additional magnetic support and allows smaller
safety distances with high breaking capacity.
•Because of the new compact dimensions these breakers
can be installed in extremely small enclosures (from
600mm; 2ft) and offers a cost-effective solution for re-
placements.
•An adaptor is used to mount the various arc chutes for
different operating voltages to the breakers.
•The arc chutes consist of a highly durable, arc-proof ma-
terial, wherein the arc plates have been integrated.
•The arc plates split the arc into partial arcs and increase
the arcing voltage by multiplying the anode and cath-
ode voltage drop. Because of their high heat capacity,
the plates and arc chute walls absorb a large amount of
the arc’s energy.
Arcing contact
Arc ru
n
ner
Main co
n
tact
Flexible band
Braid

S47183-e 01/2008 Design and specifications are subject to change without notice 7
3.2.3 Mechanism
•The Gerapid is equipped with a modular designed
mechanism, wear-resistant and nearly maintenance-
free. This mechanism ensures an extended electrical
and mechanical endurance of the breaker as well as a
high amount of safety for all operation conditions.
•This mechanism is mechanically latched in CLOSE posi-
tion. The principle of a mechanical latch mechanism of-
fers the big advantage, contrary to often used holding
magnet system. No auxiliary control power source is re-
quired to keep close.
•The mechanism is provided with two latches [Fig. 6]. One
of the latches, “slow latch”, is used for opening under
normal conditions, like actuation of shunt trip or zero-
voltage release. The other one, “quick latch”, de-clutches
the main contact arm from the mechanism and open
contacts with an extremely short delay. This is used in
case of short-circuit or overloads. All safety releases op-
erate onto this latch.
Fig. 6 Latching and tripping system
3.2.4 Over-Current Tripping device (code nr: 7)
•
The OCT device is a release magnet with twin magnet
circuits, optimizing the twin magnetic field principle [Fig.
7]. This technology ensures an equally fast tripping in
both current directions.
•The magnetic system does not require an auxiliary con-
trol voltage to operate. It uses magnetic energy from the
main circuit.
•The system consists of the holding circuit [6], the mov-
able armature [3] and the tripping circuit [7]. The holding
and the tripping magnetic circuits are both excited by
main current [1]. Until the static overload release’s re-
sponse threshold has been reached, the armature [3] is
held in position by the holding flux (Φ
H) [2] and the
counter spring’s force [4]. Once the main current ex-
ceeds the set static response threshold, the attraction
flux (ΦA) [2] takes over and pulls rapidly down the flexi-
ble armature [3]. During this operation, the armature hit
the
seesaw, which releases the quick latch in the
mechanism. The latch and contacts are opened imme-
diately.
•The response threshold can be easily adjusted by turn-
ing the adjustment nut with a SW6 hexagon wrench as
described in point 2.3.2.
•In combination wit
h the transparent side protection
covers (code nr: 15), a fixed mounted insulated knob is
available to enable OCT adjusting [Fig. 16].
1. Current flow direction.
2. Magnetic core with two fluxes (holding flux ΦH and attracting flux ΦA).
3. Movable anchor.
4. Pressure spring for movable anchor.
5. Short circuit rings.
6. Holding magnetic circuit.
7. Tripping magnetic circuit.
Fig. 7 OCT device
6
7

8Design and specifications are subject to change without notice S47183-e 01/2008
3.2.5 Electro-Dynamic tripping device (code nr: 12)
•ED tripping device requires an external protective re-
lay/system for monitoring a current increase. This re-
lay/system belongs to customer’s installation.
•If a fault occurs, an external relay, releases signal into
the capacitors’ control unit (internal NEKO or external),
which discharges abruptly its energy into ED coil [Fig. 8].
The coil trips the breaker’s quick latch and cause open-
ing within time of less 3ms.
•ED tripping device is offered as an option. Standard set
consist of ED coil and electronic control unit with C-bank
installed in (NEKO). The external release signal shall have
6V to 24V DC, and shall be fed at (-X2 :10 / :11).
•Customer may use it’s own C-bank unit. Rated voltage of
300VDC and capacity of 2000uF is required. In this case
only ED coil will be installed into the breaker.
•Be sure, that voltage level is between 6V…24V and
there are no spikes on signal with duration <3msec.
This can lead to major defect of the NEKO board!
•Maximum duration of the firing signal must not ex-
ceed ~1sec. Longer signal will lead to NEKO failure! It
is highly recommended to use an internal auxiliary con-
tact in serial connection with firing circuit (-X2 :10/:11). It
will automatically cut off the firing circuit after contacts
are opened.
Fig. 8 ED tripping coil with seesaw interface
3.2.6 Auxiliary tripping devices (code nr: 11).
•The breaker can be equipped with either a shunt trip (ST)
or a zero voltage release (UVR). It is not possible to have
both devices installed in the same breaker.
•In standard configuration, internal voltage converter
(code nr: 8), supply the devices with 24VDC. This con-
verter transforms any externally connected voltage, into
internal 24VDC, required by breaker’s controls.
•Optionally, it’s possible to supply both devices with direct
external 24VDC ±5%. In this case release signal for ST
shall not be longer 100ms.
•Both devices are tripped by potential free contact con-
nected accordingly.
•Both devices are interchangeable.
•The ST is used for remote actuation. It is designed for
short time operation with maximum duty cycle of 9%.
ST’s supply is connected through the auxiliary contact,
which cut off supply voltage after breaker’s opening.
This protects ST against overheating.
•The UVR [Fig. 9] is used for remote actuation and, in
combination with an internal electronic control, for volt-
age control.
•The UVR releases at voltage interruption or voltage loss
>3V. In these cases UVR trips the breaker. It is therefore
possible to use this device in combination with the elec-
tronic trip unit for voltage monitoring, i.e. for motor
switches, where an unintended re-start of machines af-
ter a temporary voltage breakdown is to be prevented.
•The UVR is intended for continuous operation. Its rated
power is 40W.
•Due to their operational mode, UVR is self-monitoring
device, i.e. when the breaker is tripped upon a break of
the pilot wire (EMERGENCY-OFF principle).
Fig. 9 Zero voltage release
3.2.7 Forced tripping release (code nr: 13)
•Optionally, the forced tripping release (FTU) can be in-
stalled in the breaker [Fig. 10a]. This unit is used for me-
chanical tripping of the breaker, by means of pressing
the pin at the bottom plate. Force required to trip the
breaker is about 300N (~67,5 lbf).
•The tripping pin position is as on Fig. 10b.
Fig. 10a Forced tripping release
(~0,6 in)
(~0,3 in)

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With correctly designed interlock in enclosure, FTU provides
safety-tripping function. The breaker is tripped BEFORE its
terminals are disconnected from mains, during withdraw
operation of the trolley.
Fig. 10b Positioning of the forced tripping pin
3.2.8 Hand lever (code nr: 16)
•Optionally, hand lever for manual closing and opening
operation during maintenance is available. This tool
must not be use while breaker is alive!
•To close the contacts, install hand lever on the drive’s
rod, and pull it smoothly until latches snap [Fig. 11a].
•To open the contacts, install the tool into the ring and
push it hard against the drive’s rod until breaker opens
[Fig. 11b].
Fig. 11a Closing operation by using hand lever
Fig. 11b Opening operation by using hand lever
3.2.9 Auxiliary switches (code nr: 9)
•The breaker can be equipped with 3, 5 or 10 iso
lated,
form C, auxiliary switches (1 NO/NC each). The movable
main arm activates the contacts.
•The contacts are wired to 15-pin control terminals: -
X4
and -X5; 5 switches to each terminal.
•Maximum electrical
ratings for switches are 5A/230VAC
and 0.3A/220VDC. Utilization category AC/DC 12 and 13.
Fig. 12 Auxiliary contacts layout in control box
3.2.10 Indicators
Optionally, the circuit breaker can be equipped with follow-
ing indicators:
•POSITION INDICATOR (code nr: 14) -
is mounted at the
front of the closing drive. It’s mechanically switched by
means of drive’s rod position. It indi
cates position of the
main contacts. “O” –means contacts are open; “I” –
means contacts are closed [Fig. 13].
•OCT INDICATOR (code nr: 10) –
electrical switch, the
same type as in 3.2.7, mounted at the top of OCT [Fig.
14]. It’s potential free, NO contact, which provides sig-
nalization of the OCT tripping.
•ARC CHUTE INDICATOR (code nr: 17) –
electrical switch,
the same type as in 3.2, mounted on the sidewall. Indi-
cates presence of the arc chute and blocking closing
drive until arc chute is installed [Fig. 15].
ring
Bottom view
(~45 lbf)

10 Design and specifications are subject to change without notice S47183-e 01/2008
Fig. 13 Position indicator
Fig. 14 OCT indicator
Fig. 15 Arc chute indicator
3.2.11 Solenoid closing drive (code nr: 3)
•For normal closing operations, the breaker is fitted with
a high power solenoid coil. The drive is mounted at the
front of the breaker and is equipped with a grounded
casing.
•Closing drive is supplied independently from other con-
trols (-X2 :1/:2), and directly from power source. Voltage
level shall be defined at the order. Rated power depends
of breaker type is between 1,8kW and 2,6kW.
•CLOSING command is enable by potential free contact
at (-X2 :4/:5) the signal durations shall be ~300ms.
•The closing drive system always includes a self-interrupt
control circuit (SU unit). This circuit enables a short acti-
vation with a time of ~150ms. SU unit switches power to
the solenoid and automatically switched it off after
~400ms.
•SU unit prevents also repeated drive activation (anti-
pumping), during continuous operation, due to an exist-
ing short circuit.
Fig. 16 Solenoid closing drive and control box
•In addition, the switch-in mechanism is electrically
blocked for approximately 8sec. or 14sec. after activa-
tion (see Table 2a “Activating magnet”). This prevents
premature activation following a short circuit.
3.2.12 Current measurement system (code nr: 6)
•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. 17 SEL current measurement system
•SEL may be used for recording DC currents in selected
measurement ranges of 6kA or 12kA. Measurement of
rated current values and of the current rise may now be
made directly at the breaker.
Position’s indic
a
tor
Drive’s rod
Control box
Closing drive
Side protection
cover
Knob
(2) SEL control
unit
(1) SEL sensor

S47183-e 01/2008 Design and specifications are subject to change without notice 11
•The sensor includes Hall-probes and delivers a propor-
tional signal-output to the SEL control. The signal-
processing unit transforms input signal, into standard
output signals shown in the table below.
•The outputs are insulated from the main voltage. The in-
sulation withstands voltages up to 4kV RMS and up to
40kV in peak.
•Two versions are available. Standard model (T35) for
ambient temperature -5°C…+35°C and the model for
higher temperature (T55) -5°C…+55°C.
•More details can be found in separate instruction for SEL
usage.
Type SEL 06-106-206-412-112-212-4
Input -6kA…+6 kA -12kA…+12kA
UNe[V] 1000 2000 4000 1000 2000 4000
T35 for ambient temperature of the breaker
-5°C…+35°C / +23°F…+95°F
T55 for ambient temperature of the breaker
-5°C…+55°C / +23°F...+131°F
INe Relating to the rated current of the breaker
Output 4...20mA
-20...20mA
-10...10V
UNi[kV] 12 18 40 12 18 40
3.2.13 Electronic control system
All the control units are installed in control box [Fig. 18].
Starting from the left, these are:
Fig. 18 Control box with control units
•(1) NEKO control unit [Fig. 19-1] –internal control unit
with capacitors’ bank. It releases firing signal for ED coil
(-X2 :10/:11) and enable signalization of the capacitors’
charging (-X3 :6/:7). NEKO control unit also blocks the fir-
ing signal until C-bank is fully charged (~15sec).
•NEKO unite requires high quality firing signal. Be sure,
that voltage level is between 6V…24V and there is no
short spikes on signal (<3msec). This can lead to major
defect of the NEKO control unit!
Fig. 19-1 NEKO control unit
•(2) internal voltage converter (code nr: 8) -converts ex-
ternal supply voltage (-
X3 :4/:5) to the internal 24VDC,
required by controls (except for the drive supply).
Fig. 19-2 Voltage converter 110V/24V DC
•(3) SU control unit –see point 3.2.11.
Fig. 19-3 SU control unit
•(4) ST/UVR control unit –
simple relays’ system. It controls
operation of shunt trip or zero voltage release.
Fig. 19-4 ST/UVR control unit
•(5) SEL control unit –see point 3.2.12 [Fig. 17].

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-e 01/2008 Design and specifications are subject to change without notice 12
3.3 Technical data tables
Breaker type
Arc chute type 1X2 1X4 2X2 2X3 2X4 1X2 1X4 2X2 2X3 2X4 1X2 1X4 2X2 2X3 2X4 1X2 2X2
Conventional thermal current Ith [A] (IEC/EN)
Rated current [A] (ANSI) 2600 4150 5000
Rated voltage Ue[V] 1000 2000 2000 3000 3600 1000 2000 2000 3000 3600 1000 2000 2000 3000 3600 1000 2000
Rated insulation voltage U
i
[V]
2000 2000 2000 3000 4000 2000 2000 2000 3000 4000 1000 2000 2000 3000 4000 1000 2000
Short time current 120 min [A]
Short time current 2 min [A]
Short time current 20 sec [A]
Impulse withstand voltage 1,2/50 µs Ui [kV] 18 18 18 30 30 18 18 18 30 30 12 18 18 30 -1) 12 18
according to EN 50124-1:1997
Power frequency withstand voltage 50 Hz Ua [kVeff] 10 10 10 15 15 10 10 10 15 15 710 10 15 -1) 710
according to EN 50124-1:1997
Rated short circuit making capacity ÎNss [kA] 70 50 100 50 42 70 50 100 50 42 70 50 80 50 -1) 70 - 1)
Rated short circuit breaking capacity INss [kA] 50 35 71 35 30 50 35 71 35 30 50 35 56 35 -1) 50 50
according to EN 50123-2
Rated service short circuit breaking current Ics [kA] 60 40 50 40 40 60 40 50 40 40 60 40 50 40 -1) 60 - 1)
according to IEC 947-2
Short circuit current [kA] at Une=800 VDC 200 200 200
Short circuit current [kA] at Une=1600 VDC -1) 100 -1) -1)
ANSI C37.14
Maximum short circuit current [kA] 244 120 100 52 244 120 100 52 200 240
tested at customer request
Maximum arc voltage Uarc [kV] 2 4 4 5,6 7 2 4 4 5,6 7 2 4 4 5,6 7 2 4
Weight ca. [kg] 120 120 160 160 160 120 120 160 160 160 150 150 165 165 165 190 210
Weight ca. [lbs] 265 265 352 352 352 265 265 352 352 352 331 331 364 364 364 419 463
Gerapid 4207 Gerapid 6007
3150
2600 4200 6000
Gerapid 8007
7800 12600
8500
5000
5200 7200 12000
18000
Gerapid 2607
9600
16000
24000
8000
6000
Table 1: Technical data of Gerapid 2607, 4207, 6007, 8007.

S47183-e 01/2008 Design and specifications are subject to change without notice 13
Control box terminals 1x12-pole AC 400V, 20A
4x15-pole AC 250V, 8A
Closing solenoid drive
1)
Rated voltage AC 48V…230V and DC 48V…220V
Operating range 80%...115% of rated voltage
Power consumption Gerapid 2607 / 4207 1750W / 2000W
Power consumption Gerapid 6007 / 8007 2600W / 2600W
Minimal CLOSING command duration 100ms
min.interval between two "CLOSE" operations ~8s with NEKO installed; ~14s w/o NEKO
Internal voltage converter
1)
Input: Voltage range DC 33...85V
for Gerapid 2607, 4207, 6007, 8007 Output: Voltage range DC 24V (±5%)
Current 6A permanent
Model description PCMD 150 48 S24W-GE
Input: Voltage range DC 88...145V
Output: Voltage range DC 24V (±5%)
Current 6A permanent
Model description nr. PCMD 150 110 S24W-GE
Input: Voltage range AC 115...290V, DC 125...353V
Output: Voltage range DC 24V (±5%)
Current 3A permanent, 5A/100ms
Model description nr. PCMA 70 S24W-GE
External power supply with plug and socket unit requires extrnal 24V (±5%) DC
Aux. contact HS 1…HS 10, Rated operational voltage Ue/AC 230V
OCT- and Arc chute- indicators Rated operational current Ie/AC-15 1A
Rated operational current Ie/AC-12 (Ith) 10A
Rated operational voltage Ue/DC 110V
Rated operational current Ie/DC-13 0,5A
Contact duty (min. value) DC 10V/2 mA
ST
1)
Rated voltage Uc 24V
(Shunt trip) Operating range: OFF 21.6V…26.4V
Power consumption ~ 150W
UVR
1)
Rated voltage Uc 24V
(Zero voltage release) Operating range: OFF < 3V
Operating range: ON 24V (±10%)
Power consumption ~ 40W
ED-tripping device
1)
Energie source: Capacity 2000µF
Charging voltage 300V
Switching interval max. 2/min with 10 consecutive operations
Endurance 1000 operations with 1operation per 180s
Firing signal
2)
level / duration 6…24V / 100…1000ms
1) Standard ambient conditions acc. to EN 123-1 Attachement B. For meeting outside of this standard range, please call back.
Table 2a: Technical data of auxiliary circuits
Components Technical datas of control circuits
Us / In
SU-Control CLOSE-push-button -S1 DC 24V / approx. 10mA
ST releasing push-button-S2 DC 24V / approx. 4A
UVR releasing push-button -S2 ( -X2 :6 / :7) DC 24V / approx. 10mA
push-button -S2 ( -X2 :8 / :9 ) DC 24V / approx. 450mA
ED-coil tripping w/o NEKO(R = 4Ohm) push-button -S3 DC 300V / 750A / 3ms
ED-coil tripping with NEKO Connect "Firing signal" at ( -X2 :10 / :11 ) DC 6V…24V / approx.20mA
Table 2b: Control circuits ( directional values to rate the components )

14 Design and specifications are subject to change without notice 01/2008
4. Electrical circuits
4.1 Controls layout
Closing solenoid drive
Shunt trip / Zero voltage release
ED coil
OCT device
HS 1...HS 10
OCT indicator
Arc chute-indicator
Description
Designation
X2 1.Connector: Auxiliary-and control circuits
X3 2.Connector: Auxiliary-and control circuits
X4 3.Connector: Auxiliary contacts HS1...HS5
X5 4.Connector: Auxiliary contacts HS6...HS10
X6 5.Connector: Current measure system SEL
X10 Control board: Voltage converter
X11 Control board: Interface for external DC 24V supply (OPTION)
X12 Control board: SU control unit
X13 Control board: Shunt trip control unit
X14, X15 Control board: Zero voltage release (X15: with modified UVR)
X16 Control board: NEKO control unit for ED coil control
X17 Control board: Current measure system SEL
Fig. 20 Control system’s layout

S47183-e 01/2008 Design and specifications are subject to change without notice 15
4.2 Terminals wiring system
Closing drive supply (~,+) (S3) Closing drive supply (N,-) PE S1 ( CLOSE-Command) S2 ( OPEN by ST command) S2 (OPEN by UVR command ) ed-trip +( 6,5…24V ) ed-trip - ( 0V )
1 2 3 4 5 6 7 8 9 10 11 12
X2
12345678910 11 12 13 14 15
X3
NEKO charging indicator (indicates C-bank charging) with OCT indicator (Indicates tripping by OCT) Arc chute indicator (Indicator switch)
Fig. 21 Terminals wiring system.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
X4
HS 1 HS 2 HS 3 HS 4 HS 5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
X5
HS 6 HS 7 HS 8 HS 9 HS 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
X6
SEL (4…20 mA) + SEL (4…20 mA) - SEL ( +/- 20 mA) + SEL ( +/- 20 mA) - SEL ( +/- 10V ) + SEL ( +/- 10 V ) -
SEL (self check)

16 Design and specifications are subject to change without notice 01/2008
4.3 Electrical diagrams.
4.3.1 Wiring coding system.
The main circuits are not shown in the wiring diagrams
due to clarity. 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.
Key position:
1 /
2345678
Breaker type
Aux. voltage supply
ED tripping device
Closing drive
Aux. tripping device
Indicators
Aux. switches
SEL system
EXAMPLE:
Key number:
36 /
1220 10 01 2S
Gerapid
With voltage converter
With ED coil and NEKO
With closing drive
Wtih shunt trip
With OCT indicator
With 5 aux. switches
With SEL system
Fig. 22 Example of wiring code for AEG type labels.
Key
position Key number Designation
Type
136 Gerapid
Auxiliary voltage
21Voltage converter
2DC 24V external supply
Tripping coil
30Without ed-trip coil
1With ed-trip coil
2With ed-trip coil and NEKO
control unit
Drive
420 Solenoid drive with
SU control unit
Tripping device
500 Without trip unit
10 With shunt trip
20 With zero voltage release
Indication device
600 Without indicators
01 OCT indicator
02 Arc chute indicator
03 OCT + arc chute indicator
Auxiliary contacts
713 auxiliary switches
25 auxiliary switches
310 auxiliary switches
Current-measurement system
8Swith SEL
Indication of components
Q1 Circuit breaker
S1 Push button „CLOSE“
S2 Push button „OPEN“"
SU control unit:
K1 Closing relay
K2 Internal emergency STOP relay1)
Shunt trip, zero voltage release:
K1 Internal emergency STOP relay1)
HS11 Auxiliary contact
ED-tripping device with internal NEKO unit:
K1 Voltage monitoring relay
1) These relays are part of internal emergency STOP circuit. It
is a 24VDC closed circuit, through all the control units in the
box. Serial connection of all emergency relays is realized
through connections ( :5/:6) in every PCB’s terminal. In case
of control voltage lost or unit’s damage, circuit is locking
possibility to switch ON the breaker.

S47183-e 01/2008 Design and specifications are subject to change without notice 17
4.3.2 Voltage converter
Fig. 23 Voltage converter and direct external supply (DC 24V ±5%)
Input DC 33V…85V DC
DC 88…145V DC
DC 125…353V DC
AC 115…290V AC
Output DC 24V ±5%
Voltage converter
33V...353VDC / 115V...290VAC
~ / +
N /
-
4
5
1
3
-X10
-X3
-X3
6
7
8
9
10
+24V
-24V
Key position -2
Key number –1: Voltage converter 33..85V DC; 88..145V DC; 125..353V DC; 115..290V AC
Key number
–
2: Interface for direct external voltage 24VDC +/
-
5% connection.
36/ X _ _ _ _ _ _
External voltage supply
24V DC +/-5%
5
-24 V
-X3
-X3
4
1
3
-X11
10
9
8
7
6
Emergency STOP circuit
Emergency STOP circuit

18 Design and specifications are subject to change without notice 01/2008
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 capacity bank. In this
case NEKO control unit is not installed, and coil’s connected directly to front panel of control box (-X2 :10/:11).
Fig. 24 ED coil with external C-bank
:11
:10
-S3
-X2
-X2
-Q1
ed
Capacity
bank:
U ~300V
F ~2000µF
Key position -3
Key number –0: Without ED coil.
Key number
–
1: With ED coil and external C
-
bank.
36/ _ X _ _ _ _ _

S47183-e 01/2008 Design and specifications are subject to change without notice 19
4.3.4 NEKO control unit
•Releasing signal at (-X2 :10/:11) is processed by optocoupler, pay attentions to the polarity !
•Emergency STOP signal is provided to lock CLOSE command, until capacitors will be charged.
•Be sure, that voltage level is between 6V…24V and there is no interfere spikes (<3ms) on firing signal. This can lead to
major defect of the NEKO control unit!
•Maximum duration of the firing command must not exceed ~1sec. Longer signal will lead to NEKO failure! It is highly
recommended to use an internal auxiliary contact in serial connection with firing circuit (-X2 :10/:11). It will automatically
cut off the firing circuit after contacts are opened.
Fig. 25 ED coil with internal NEKO control unit
Output signal
-
bank charged
-X10, 11
-
X10, 11
Charging control
Voltage control
Firing circuit
Pulse circuit
Insulating Transformer
Firing signal control
and transforming
Meldeschalter
Power supply
24VDC
Q1
„ED coil”
Firing signal
6
-24V
+
-
+
-
-X16
3
4
5
6
9
10
1
2
11
12
-X3
-X3
-X2
-X2
:8
:6
:6
:7
:10
:11
Emergency
STOP signal
Capacity and firing thyristor
Key position -3
Key number –2: With ED coil and internal NEKO control unit.
36/ _ X _ _ _ _ _

20 Design and specifications are subject to change without notice 01/2008
4.3.5 SU control unit
Fig. 26 SU-control circuit
+
-
~
~
Power circuit
CLOSE signal circuit
Closing control
Emergency STOP
relay
1
2
3
4
9
8
10
7
5
6
-X12
-X2
-X2
-X2
-X2
-X10, 11
-X10, 11
:1
:2
:5
:4
:9
:6
+ / ~
N / ~
-S1
-S3
„CLOSE“
signal
External power sup-
ply for the drive.
Emergency
STOP signal
-
Q1 Drive
Key position -4
Key number –20: Closing solenoid drive with SU control unit.
36/ _ _ X _ _ _ _
K2