GE MicroVersaTripPlus AK-50 User manual

Micro
Versa
Trip
Plus
and
MicroVersaTrip
PM
Conversion
Kits
TM
For
GE
Types
AK
-
50
,
AKU
-
50
,
AKS
-
50
,
AKT
-
50
,
AK
-
75
,
AK
-
100
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
designed
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
-
50
,
AKU
-
50
,
AKS
-
50
,
AKT
-
50
,
AK
-
75
,
and
AK
-
100
Low
Voltage
Power
Circuit
Breakers
.
Each
Conversion
Kit
contains
all
ap
-
propriate
material
to
convert
from
an
existing
GE
Type
EC
,
Power
Sensor
,
ECS
or
SST
trip
system
.
Courtesy of NationalSwitchgear.com

TABLE
OF
CONTENTS
SECTION
1
GENERAL
INFORMATION
3
PRIOR
TO
INSTALLATION
SECTION
2
3
SECTION
3
FRONT
FRAME
BREAKER
CONVERSION
.
.
Relocating
,
Remounting
W
and
X
Relays
Installing
the
Flux
Shifter
Installing
the
Programmer
Mounting
Bracket
Installing
the
Programmer
Harness
Installing
the
Communications
Harness
4
-
11
4
5
-
8
9
10
11
SECTION
4
BACK
FRAME
CONVERSION
Modifying
the
Crossbar
Installing
Phase
Sensors
12
-
14
12
13
-
14
SECTION
5
FOUR
-
WIRE
GROUND
FAULT
OPTION
Stationary
Breaker
Conversion
Draw
Out
Breaker
Conversion
Installing
Neutral
Sensors
15
-
18
15
16
-
17
18
SECTION
6
EQUIPMENT
CONVERSION
Installing
Mounting
Brackets
..
19
-
20
19
-
20
SECTION
7
INSTALLING
THE
PROGRAMMER
21
SECTION
8
TESTING
AND
TROUBLESHOOTING
Cabling
Diagrams
22
-
24
24
Courtesy of NationalSwitchgear.com

SECTION
1
GENERAL
INFORMATION
grammer
unit
have
been
furnished
.
Whenever
the
ground
fault
trip
element
is
furnished
for
breakers
applied
on
4
-
wire
systems
,
note
that
an
associated
neutral
sensor
(
CT
)
is
required
for
separate
mount
-
ing
in
the
equipment
.
Make
sure
that
retrofitted
breakers
are
applied
within their
short
circuit
rat
-
ing
.
For
example
,
wThen
the
trip
elements
of
the
breaker
are
to
be
changed
from
long
-
time
instanta
-
neous
to
long
-
time
,
short
-
time
,
the short
-
time
rating
would
govern
the
application
.
As
a
service
-
related
consideration
,
the installation
of
the
MicroVersaTrip
Plus
or
PM
kits
provides
an
excel
-
lent
opportunity
'
to
perform
normal
maintenance
on
the breaker
,
particularly
when
the
front
and
back
frames
are
separated
.
Such
procedures
are
de
-
scribed
in
the installation
and
maintenance
manu
-
als
supplied
with the Breakers and
Equipment
.
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
PM
Kit
components
.
Following
this
procedure
,
the
con
-
verted breaker
is
performance
tested
,
prior
to
re
-
storing
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
accessor
)
'
combinations
which
ne
-
cessitate minor modification and
/
or
relocation
of
a
component
(
s
)
.
In
most
instances this
supplemen
-
tary
work
can
be done
on
site
.
Preparatory
to
the conversion
,
the installer
should
verify
that
the
appropriate
current
sensors
and
pro
-
SECTION
2
-
PRIOR TO
INSTALLATION
•
Turn
off
and lock
out
the
power
source
feeding
the breaker
prior
to
attempting
any
installation
,
maintenance
,
or
modification
.
Follow
’
all
lock
-
out
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
move
-
ment
of
the breaker
while
it
is
on
the
draw
out
extension
rails
.
•
Do
not
leave
the
breaker
in
an
intermediate
po
-
sition
in
the
switchgear
compartment
.
Always
leave
it
in
the
CONNECTED
,
TEST
,
or
DIS
-
CONNECTED
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
op
-
erating
mechanisms
.
The breakers and their
enclosures
contain
interlocks
and
safety
7
fea
-
tures
intended
to
provide
safe
,
proper
operat
-
ing
sequences
.
For
maximum
personnel
pro
-
tection associated with installation
,
operation
,
and
maintenance
of
these
breakers
the follow
-
ing
procedures
must
be
followed
.
Failure
to
fol
-
low these
procedures
may
result
in
personal
in
-
jury
or
property
damage
.
•
Only
qualified
persons
,
as
defined
in
the
Na
-
tional
Electrical
Code
,
who
are
familiar
with the
installation
and
maintenance
of
low
voltage
power
circuit
breakers
,
and
switchgear
assem
-
blies
,
should
perform
any
work associated
with
these
breakers
.
•
Completely
read
and
understand
all
instructions
before
attempting
any
breaker installation
,
op
-
eration
,
maintenance
,
or
modification
.
3
Courtesy of NationalSwitchgear.com

SECTION
3
FRONT
FRAME
BREAKER
CONVERSION
FRONT
VIEWS
OF
BREAKER
The
front
frame
conversion
consists
of
the
following
:
1
.
Separation
of
the
front
and
back
breaker
frames
.
Refer
to
the
appropriate
installation
and
maintenance
manuals
supplied
with
the
break
-
ers
and
equipment
for
instructions
on
accom
-
plishing
the
separation
.
Copies
of
these
publica
-
tion
may
be
obtained
from
your
local
GE
sales
office
.
NOTE
that
AK
-
75
and
AK
-
100
breakers
do
not
need
to
be
separated
to
complete
the
conversion
.
2
.
Relocating
and
remounting
the
W
and
X
relays
on
AK
-
50
,
AK
-
75
,
AK
-
100
electrically
operated
breakers
with
EC
trip
devices
.
3
.
Installing
the
flux
shifter
and
trip
paddle
.
4
.
Installing
the
programmer
mounting
bracket
.
5
.
Installing
the
programmer
wire
harness
.
6
.
Installing
the
communication
wire
harness
(
when
required
)
.
X
/
a
cz
:
\
w
V
1
—
^
/
x
/
i
I
BEFORE
I
\
\
\
CD
CD
Relocating
,
remounting
W
and
X
Relays
a
.
Remove
the
W
Relay
and
install
the
mounting
bracket
supplied
with
the
conversion
kit
to
the
upper
left
side
of
the
front
frame
.
See
Fig
.
3
-
1
.
b
.
Remove
the
X
Relay
and
its
mounting
bracket
.
Use
the
new
bracket
supplied
with
the
conver
-
sion
kit
to
remount
the
X
Relay
in
its
existing
position
.
See
Fig
.
3
-
1
and
3
-
2
.
AFTER
Fig
.
3
-
1
.
Relocating
W
Relay
and
Remounting
X
Relay
Fig
.
3
-
2
.
New
W
and
X
Relay
Mounting
Bracket
Installation
4
Courtesy of NationalSwitchgear.com

SECTION
3
FRONT
FRAME BREAKER
CONVERSION
Installing
the Flux
Shifter
The
installation
procedure
of
the flux shifter
will
vary
depending
on
the
type
of
breaker
and
trip
de
-
vice
involved
.
In
some cases
mounting
holes
must
be
added
,
terminal
blocks
relocated
or
breaker
side
rails removed
.
BREAKERS
WITH
EC OR POWER
SENSOR
TRIP
SYSTEMS
1
.
Add the
flux
shifter
mounting
holes
to
the left
side
of
the
front frame
.
The drill
pattern
for
the
required
three
(
3
)
%
2
M
diameter
holes is
given
in
Fig
.
3
-
4
.
2
.
Install
the
new
flux
shifter
,
position
the
insula
-
tor
and
programmer
connector
bracket
as
shown
in
Fig
.
3
-
10
.
BREAKERS
WITH
A
SIDE
BRACKET
Drill
a
hole diameter
,
into the
mounting
base
(
Fig
.
3
-
3
)
.
This
will
provide
the
necessary
clearance
for
the
bracket
.
The
hole
locations
are
given
in
Fig
.
3
-
5
.
Remove
the
side
bracket
from
the
frame
and
drill holes
as
shown
in
Fig
.
3
-
4
.
Return
the side
bracket
to
its
original
location
upon
completion
of
this
step
.
Install
the
new
flux shifter
device
.
The bottom
screw
must
be inserted
in
the
reverse
direction
,
i
.
e
.
,
the
screw
must
be fed
from
the
inside
of
the
frame
to
the
outside
.
Use
tape
to
hold the
nut
on
the
wrench
.
1
.
2
.
3
.
Fig
.
3
-
3
.
Flux
Shifter
$
O
t
-
1.1
-
45
—
o
T
.
75
*
1.275
o
O
Side View
Mounting
Base
Fig
.
3
-
4
.
Mounting
Hole
Pattern
Fig
.
3
-
5
.
Mounting
Base
Adjustment
5
Courtesy of NationalSwitchgear.com

SECTION
3
FRONT
FRAME
BREAKER
CONVERSION
Installing
the
Flux
Shifter
(
Cont
’
d
)
AKU
-
50
BREAKERS
ONLY
1
.
For
easier
installation
of
AKU
-
50
breakers
,
the
Open
Fuse
Lock
Out
(
OFLO
)
device
may
be
separated
from
the
breaker
to
allow
insertion
of
the
flux
shifter
.
To
do
this
,
remove
the
three
bolts
attaching
it
to
the
base
.
2
.
The
terminal
block
must
be
remounted
on
the
upper
left
hand
side
of
the
breaker
.
Certain
parts
,
(
not
provided
with
the
conversion
kit
)
,
and
tools
are
required
to
complete
this
task
:
•
Six
strips
of
14
AWG
wire
•
Wire
splice
•
12
butt
splices
•
Wire
labels
•
Drill
and
size
“
F
”
drill
bit
•
/
is
-
18
tap
•
Flathead
screwdriver
•
Two
r
/
i
6
-
18
bolts
and
lock
washers
To
remount
the
terminal
block
:
Step
1
.
Drill
and
tap
two
(
2
)
holes
for
the
Yi
6
-
18
nuts
.
See
Fig
.
3
-
6
for
hole
locations
.
Step
2
.
Separate
the
Open
Fuse
Lock
Out
(
OFLO
)
device
by
removing
the
three
bolts
shown
in
Fig
.
3
-
7
.
Step
3
.
Remove
the
wires
that
connect
the
(
OFLO
)
device
to
the
terminal
block
.
Step
4
.
Cut
the
wires
that
connect
to
the
coils
where
they
join
and
label
the
wires
.
Attach
butt
splices
to
all
twelve
open
ends
(
Fig
.
3
-
8
)
.
Fig
.
3
-
6
.
Terminal
Block
Mounting
Hole
Pattern
Fig
.
3
-
7
.
OFLO
Removal
Bolts
Fig
.
3
-
8
.
Wire
Connectors
with
Butt
Splices
6
Courtesy of NationalSwitchgear.com

SECTION
3
FRONT
FRAME
BREAKER
CONVERSION
Installing
the
Flux
Shifter
(
Cont
’
d
)
Step
5
.
Connect
the
strands
of
wire
to
the
(
OFLO
) (
Fig
.
3
-
9
)
.
Mount
the terminal
block
to
its
new
location
.
DO NOT
complete
the wire connections
until the
flux shifter is installed
.
Step
6
.
Install the
new
flux shifter
,
positioning
the insulator
and
programmer
connector
bracket
as
shown
in
Fig
.
3
-
10
.
Step
7
.
Connect
cables attached
to
terminal block and
tie
together
as
shown
in
Fig
.
3
-
11
.
Fig
.
3
-
9
.
Wire
Connected
to
(
OFLO
)
ECS
OR
SST
TRIP
SYSTEMS
Step
1
.
Remove
the
ECS
or
SST
Programmer
.
Step
2
.
Remove
the
existing
flux shifter device
and the
pro
-
grammer
control harness
.
Step
3
.
Install the
new
flux
shifter device
,
positioning
the
insulator and
programmer
connector
bracket
as
shown
in
Fig
.
3
-
10
.
EC OR POWER
SENSOR
TRIP
SYSTEMS
Step
1
.
Drill
the flux shifter
mounting
holes
at
the
left
side
of
the
front frame
.
The drill
pattern
for
the
re
-
quired
three
(
3
)
%
2
n
diameter
holes
is
shown
in
Fig
.
3
-
4
.
Step
2
.
Install
the
new
flux
shifter
,
positioning
the
insulator
and
programmer
connector
bracket
as
shown
in
Fig
.
3
-
10
.
Fig
.
3
-
10
.
Flux
Shifter
Installed
Fig
.
3
-
11
.
Relocated
Terminal
Block
and
Wire
Harness
7
Courtesy of NationalSwitchgear.com

SECTION
3
FRONT
FRAME
BREAKER
CONVERSION
Installing
the
Flux
Shifter
(
Cont
’
d
)
INSTALLING
THE
FLUX
SHIFTER
TRIP
PADDLE
L
For
breakers
equipped
with
an
ECS
or
SST
sys
-
tem
,
the
existing
flux
shifter
trip
paddle
will
be
used
with
the
new
flux
shifter
.
For
all
other
breakers
,
the
flux
shifter
trip
paddle
must
be
assembled
to
the
trip
shaft
as
shown
in
Fig
.
3
-
12
.
FLUX
SHIFTER
ADJUSTMENTS
Once
the
flux
shifter
and
trip
paddle
are
installed
and
the
breaker
frames
are
reassembled
,
the
follow
-
ing
adjustments
must
be
made
:
1
.
With
the
breaker
in
the
OPEN
position
and
the
mechanism
charged
,
set
the
gap
between
the
trip
paddle
and
the
end
of
the
flux
shifter
rod
at
0.100
inches
.
Use
a
0.100
-
inch
diameter
rod
,
not
supplied
,
as
shown
in
Fig
.
3
-
12
.
Set
the
adjuster
end
of
the
trip
rod
and
lock
it
in
place
with
the
jam
nut
.
Note
that
removal
of
the
buffer
stud
will
make
the
trip
paddle
easier
to
install
and
adjust
.
2
.
As
the
crossbar
travels
between
the
breaker
CLOSED
and
the
breaker
OPEN
positions
,
the
tang
of
the
actuator
bracket
must
clear
the
buffer
stud
.
If
insufficient
clearance
exists
,
loosen
the
two
mounting
screws
and
rotate
the
bracket
clockwise
to
take
up
mounting
hole
slack
.
Retighten
screws
.
3
.
OPTIONAL
TEST
:
The
flux
shifter
assembly
may
be
tested
by
closing
the
breaker
and
apply
-
ing
a
9
V
dc
power
source
to
the
flux
shifter
leads
.
The
red
wire
is
the
positive
lead
.
The
breaker
should
trip
.
8
Courtesy of NationalSwitchgear.com

SECTION
3
FRONT
FRAME BREAKER
CONVERSION
Installing
the
Programmer
Mounting
Bracket
MicroVersaTrip
Plus and
PM
programmers
mount
to
the
left side
of
the
front
channel
.
A
mounting
bracket
is
shock
-
mounted
to
a
plate
that
is
as
-
sembled
to
the
front
channel
as
shown
in
Fig
.
3
-
14
.
Use
Loctite
*
or
an
equivalent
retaining
material
on
the
mounting
screws
for
the
plate
assembled
to
the
front
channel
.
ECS
OR
SST
TRIP
SYSTEM
Replace
the
existing
plate
and
mounting
bracket
with the
new ones
provided
.
Assemble the
mount
-
ing
bracket
to
the
plate
using
the holes
closest
to
the
front of
the breaker
(
See
Fig
.
3
-
14
)
.
If
the
manual
indicator
assembly busing
on
AJK
-
50
manual
breakers
interferes with the
mounting
bracket
installation
(
Fig
.
3
-
14
)
,
then the
bracket will
have
to
be
modified
.
This is
accomplished
by
cut
-
ting
off
a
K
"
x
1
V
2
'
section
off
the
right
front of
the
plate
as
shown
in
Fig
.
3
-
15
.
EC
OR
POWER
SENSOR
TRIP
SYSTEMS
The
holes
for
the
new
plate
may
have
to
be
added
to
the
front
channel
.
The
drill
pattern
for
these
holes
is
given
in
Fig
.
3
-
16
.
Once
the
plate
is
in
-
stalled
,
assemble
the
mounting
bracket
to
the
plate
using
the holes
closest
to
the
front of
the
breaker
(
See
Fig
.
3
-
14
)
.
Fig
.
3
-
14
.
Plate
Assembled
to
Channel
*
Trademark
of
the
Loctite
Corp
Fig
.
3
-
16
.
Mounting
Plate
Hole
Pattern
l
Fig
.
3
-
15
.
Programmer
Mounting
Bracket and Plate
on
a
Type
AK
-
50
Breaker
9
Courtesy of NationalSwitchgear.com

SECTION
3
FRONT
FRAME
BREAKER
CONVERSION
CAUTION
:
Adapter
bracket
must
be
installed
onto
harness
plug
as
shown
in
Fig
.
3
-
17
.
Failure
to
do
so
will
result
in
harness
plug
failure
and
the
programmer
will
not
provide
protection
.
Installing
the
Programmer
Harness
The
programmer
harness
consists
of
the
mating
36
-
pin
programmer
connector
and
the
16
-
pin
front
frame
half
of
the
front
/
back
frame
connector
.
Re
-
fer
to
Fig
.
3
-
18
.
Assemble
the
adapter
bracket
to
the
36
-
pin
programmer
connector
(
with
bevels
to
right
side
)
by
pushing
bracket
over
notches
in
ends
of
plug
body
(
Step
1
)
.
Follow
Steps
2
-
5
of
Fig
.
3
-
18
to
complete
assembly
of
programmer
harness
to
pro
-
grammer
bracket
.
The
15
-
pin
connector
is
inserted
into
the
program
-
mer
connector
bracket
which
is
part
of
the
flux
shifter
assembly
.
See
Fig
.
3
-
10
.
Insert
the
connector
so
that
the
Number
1
pin
is
toward
the
breakers
'
top
,
right
-
hand
side
.
Route
the
harness
under
the
flux
shifter
base
.
At
-
tach
the
harness
to
this
base
using
the
wire
keepers
provided
.
Install
the
programmer
harness
as
shown
in
Fig
.
3
-
10
.
Include
the
flux
shifter
leads
with
this
harness
.
Join
the
4
-
pin
connector
on
the
programmer
har
-
ness
to
the
4
-
pin
connector
on
the
flux
shifter
.
Assemble
the
programmer
bracket
to
the
mounting
bracket
as
shown
in
Fig
.
3
-
17
.
NOTE
LOCATION
OF
BEVELED
EDGES
ON
PLUG
BODY
|
—
Oio
0000000
0
'
Hooooooooo
°
N o
oooooooo
_
JOO
o o
0
0 0
0 4
ADAPTER
BRACKET
o
STEP
1
.
PUSH
BRACKET
OVER
NOTCHES
IN
END
OF
PLUG
BODY
ffO
STEP
5
.
HOLD
PLUG
BODY
TIGHT
TO
THE
ADAPTER
BRACKER
AND
BEND
OVER
(
2
)
LOCKING
TABS
STEP
3
.
PRESS
ON
PUSH
NUTS
UNTIL
BRACKET
IS
HELD
FIRMLY
AGAINST
PROGRAMMER
BRACKER
v
oooooooo
o
'
ooooooooo
ooooooooo
ooooooooo
,
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
A
-
GUIDE
PINS
Lmnm
•
•
Fig
.
3
-
17
.
Programmer
Plate
Installation
Fig
.
3
-
18
.
Harness
Connector
10
Courtesy of NationalSwitchgear.com