GE GEH-6294 User manual

•
ft
nstallation
Instructions
MicroVersaTrip
®
Plus
and
PM
Conversion
Kits
For
I
-
T
-
E
®
Types
K
-
225
,
K
-
600
,
K
-
800
,
K
-
1600
,
K
-
2000
Low
-
Voltage
Power
Circuit
Breakers
INTRODUCTION
GE
Conversion
Kits
are
designed
to
upgrade existing
I
-
T
-
E
-
Low
Voltage
Power
Circuit
Breakers
,
rather
than
replacing
the
entire
breaker
.
The
Conversion
Kits
contain enhanced solid
-
state
MicroVersa
Trip
Plus
or
MicroVersaTrip
-
PM
Trip
Units
,
representing
the latest
technological
advancement
in
GE
trip
systems
.
MicroVersaTrip
Plus
and
MicroVersaTrip
PM
Conversion
Kits
are
designed
and
breaker
tested
to
conform
with
ANSI Stan
-
dard
C
37.59
,
allowing
the
retrofltter
to
properly
install
and
acceptance
test
the
breaker
.
This
publication
covers
installa
-
tion
of
MicroVersaTrip
Plus
and
PM
Conversion
Kits
on
I
-
T
-
E
Type
K
-
225
,
K
-
600
,
K
-
800
,
K
-
1600
,
and
K
-
2000
Low
Voltage
Power
Circuit
Breakers
.
Each
Conversion
Kit
contains
all
the
appropriate
material
to convert
from
an
existing
I
-
T
-
E
electro
-
mechanical
trip
system
.
Courtesy of NationalSwitchgear.com

TABLE
OF
CONTENTS
GENERAL
INFORMATION
SECTION
1
3
SECTION
2
PRIOR
TO
INSTALLATION
3
SECTION
3
DISASSEMBLING
THE
BREAKER
I
-
T
-
E
®
225
-
800
Amperes
I
-
T
-
E
®
1600
-
2000
Amperes
4
-
6
4
-
5
6
INSTALLING
THE
CONVERSION
KIT
Phase
Sensors
(
CT
’
s
)
I
-
T
-
E
®
225
-
800
Amperes
I
-
T
-
E
®
1600
-
2000
Amperes
Installing
the
Flux
Shifter
Mounting
the
Programmer
Bracket
Programmer
Wiring
Harness
Communications
Wiring
Harness
Programmable
Trip
Unit
SECTION
4
7
-
16
7
-
10
7
-
8
9
-
10
11
-
12
13
-
14
14
15
16
)
SECTION
5
FOUR
-
WIRE
GROUND
FAULT
OPTION
17
-
18
SECTION
6
TESTING
AND
TROUBLESHOOTING
Cabling
Diagram
19
-
21
21
9
Courtesy of NationalSwitchgear.com

SECTION
1
GENERAL
INFORMATION
Whenever
the
ground
fault
trip
element
is
fur
-
nished
for
breakers
applied
on
4
-
wire
systems
,
note
that
,
an
associated
neutral
sensor
(
CT
)
is
re
-
quired
for
separate
mounting
in
the
equipment
.
Make
sure
that
retrofitted breakers
are
applied
within
their
short
circuit
ratings
.
For
example
,
when the
breaker
’
s
trip
elements
are
to
be
changed
from
long
-
time
instantaneous
to
long
-
time
,
short
-
time
,
the short
-
time
rating
would
gov
-
ern
the
application
.
As
a
service
-
related
consideration
,
the installation
of
the
MicroVersaTrip
Plus
or
PM
kit
provides
an
excellent
opportunity
to
perform
normal
mainte
-
nance
on
the breaker
,
particularly
while
the
front
and back
frames
are
separated
.
Such
procedures
are
described
in
installation and
maintenance
manuals
normally
supplied
with
breakers
and
equipment
.
Conversion
kit
installation is
straightforward
.
However
,
careful
workmanship
and
attention
to
these instructions
should
be
maintained
.
Famil
-
iarity
with the
breaker
will
prove
helpful
.
The
general
approach
is
to
first
strip
the
breaker
of
its
existing
trip
devices and then
install
the
program
-
mable
trip
unit
MicroVersaTrip
®
Plus
or
PM
components
.
Following
this
,
the converted
breaker
is
performance
-
tested
prior
to
being
restored
to
service
.
The
majority
of
breaker
kit
installations
do
not
re
-
quire
any
customized
assembly
work
.
However
,
some
conversions
may
involve unusual
mounting
circumstances
or
accessory
combinations which
necessitate
minor
modification
and
or
relocation
of
a
component
(
s
)
.
In
most
instances
,
this
supple
-
mentary
work
can
be done
on
site
.
Preparatory
to
the
conversion
,
the
installer
should
verify
that
the
correct
kit
,
current
sensors
and
programmable
trip
unit have
been
furnished
.
SECTION
2
-
PRIOR TO
INSTALLATION
•
Turn
off
and lock
out
the
power
source
feed
-
ing
the
breaker
prior
to
attempting
any
installation
,
maintenance
,
or
modification
.
Follow
all
lockout and
tagging
rules
of
the
National
Electrical
Code
and
all
other
appli
-
cable
codes
.
•
Do
not
work
on
a
closed
breaker
or
a
breaker
with
the
closing
springs
charged
.
Trip
OPEN
the
breaker
and
be
sure
the stored
energy
springs
are
discharged
avoiding
the
possibility
that
the
breakers
may
trip
OPEN
or
the
charg
-
ing springs
discharge
,
causing
injuries
.
•
For
both
stationary
and draw
out
breakers
,
trip
OPEN
,
then
remove
the
breaker
to
a
well
lighted
work
area
before
beginning
work
.
•
Do
not
perform
any
maintenance
including
breaker
charging
,
closing
,
tripping
,
or
any
other
function
which could
cause
significant
movement
of
the
breaker while
it
is
on
the
draw
out
extension
rails
.
•
Do
not
leave
the breaker
in
an
intermediate
position
in
the
switchgear
compartment
.
Al
-
ways
leave
it
in
the
CONNECTED
,
TEST
,
or
DISCONNECTED
position
.
Failure
to
do
so
could
lead
to
improper
positioning
of
the
breaker
and
flashback
.
Before
starting
any
work
turn
off
and lock
out
all
power
sources
leading
to
the breaker
(
primary
and
secondary
)
.
Remove
the breaker
to
a
clean
,
well
lighted
work
area
.
WARNING
:
Low
Voltage
Power
Circuit
Break
-
ers
utilize
high
speed
,
stored
energy
spring
operating
mechanisms
.
The
breakers
and
their enclosures contain interlocks
and
safety
features
intended
to
provide
safe
,
proper
op
-
erating
sequences
.
For
maximum
personnel
protection
associated
with
installation
,
opera
-
tion
,
and
maintenance
of
these
breakers the
following
procedures
must
be followed
.
Fail
-
ure
to
follow
these
procedures
may
result
in
personal
injury
or
property
damage
.
•
Only
qualified
persons
,
as
defined
in
the
Na
-
tional
Electrical
Code
,
who
are
familiar
with
the
installation
and
maintenance
of
low
volt
-
age
power
circuit
breakers
,
and
switchgear
as
-
semblies
,
should
perform
any
work
associated
with these breakers
.
•
Completely
read
and
understand
all
instructions before
attempting
any
breaker
installation
,
operation
,
maintenance
,
or
modification
.
3
Courtesy of NationalSwitchgear.com

SECTION
3
DISASSEMBLING
THE
BREAKER
The
I
-
T
-
E
®
K
-
Series
Breakers
do
not
need
to
be
separated
,
front
and back
,
for
installation
of
the
Conversion
Kit
.
The
general
procedure
is
to
re
-
move
and
disassemble
the
trip
unit
housing
,
then
install the
kit
.
First
,
remove
the
breaker
to
a
clean
,
well
lighted
work bench and
place
it
in
the
upright
position
,
so
both
the
front
and back
are
easily
accessible
.
I
-
T
-
E
225
-
800
Ampere
Breakers
Step
1
.
The
electro
-
mechanical
trip
units
are
contained
in
a
common
,
insulated
housing
(
Fig
.
1
)
.
To
re
-
move
these
units
,
unscrew
the
(
5
)
Philip
’
s
head
screws
at
the back
of
the
breaker
holding
the
housing
in
place
.
Save
the
hardware
.
NOTE
:
On
some
I
-
T
-
E
breakers
,
the
load
side
draw
out
fingers
must
also
be
removed
ARM
SCREWS
Step
2
.
Remove
and
discard the
(
2
)
Philip
’
s
head
screws
per
phase
above
the
copper
load terminals
hold
-
ing
the
trip
units
to
the
contact
arm
(
Fig
.
1
)
.
Step
3
.
Remove
the
trip
unit
housing
assembly
from
the
back
of
the
breaker
(
Fig
.
2
)
.
Fig
.
1
.
Insulated
housing
removal
on
K
-
800
/
600
/
225
Fig
.
2
.
K
-
800
/
600
/
225
with
the
trip
unit
housing
removed
4
Courtesy of NationalSwitchgear.com

SECTION
3
DISASSEMBLING
THE
BREAKER
I
-
T
-
E
®
225
-
800
Ampere
Breakers
(
cont
’
d
)
Step
4
.
Remove
the
electro
-
mechanical
trip
units
by
care
-
fully
drilling
out
the
(
4
)
10
-
32
screws
per
phase
holding
the
trip
units
to
the
housing
(
Fig
.
3
)
.
Step
5
.
Remove
and
save
the
(
1
)
%
”
x
2
”
bolt
,
nut
and
lock
washer
per
phase
holding
the
trip
units
to
the
bus
(
Fig
.
4
)
.
The
trip
units
can
be
removed
and
discarded
.
The
breaker
is
now
ready
for
conversion
.
I
-
T
-
E
1600
-
2000
Ampere
Breakers
DRILL
OUT
EACH
PHASE
On
I
-
T
-
E
1600
-
2000
ampere
breakers
,
each
electro
-
mechanical
trip
unit
is
contained
in
its
own
insulated
housing
.
Step
1
.
On
draw
out
breakers
with
electrical
operators
,
remove
the
draw
out
contact
block
assembly
by
removing
the
(
4
)
screws
holding
it
to
the
back
frame
(
Fig
.
5
)
.
Save
the
hardware
.
Step
2
.
Remove
the
(
2
)
top
and
(
2
)
bottom
Philip
'
s
head
screws
at
the
breaker
back
holding
the
insulated
trip
unit
housing
to
the
breaker
frame
(
Fig
.
6
)
.
Save
the
hardware
.
Fig
.
3
.
Electro
-
mechanical
trip
unit
disassembly
K
-
800
/
600
/
225
REMOVE
AND
SAVE
Fig
.
4
.
Load
side
stab
removal
,
K
-
800
/
600
/
225
TOP
HOUSING
SCREWS
p
CONTACT
BLOCK
SCREWS
(
2
)
EACH
SIDE
TTOM
HOUSING
SCREWS
Fig
.
5
.
Draw
Out
Contact
Block
removal
K
-
2000
/
1600
Fig
.
6
.
Trip
unit
housing
removal
,
K
-
2000
/
1600
5
Courtesy of NationalSwitchgear.com

SECTION
3
DISASSEMBLING
THE
BREAKER
hf
I
-
T
-
E
1600
-
2000
Ampere
Breakers
(
cont
’
d
)
1
m
L
*
f t
f
NOTE
:
On
some
I
-
T
-
E
breakers
,
the
load
-
side
draw
out
fingers
must
also
be
removed
.
Step
3
.
Remove
the
(
4
)
Philip
’
s
head
screws
above
the
copper
load
terminals
,
connecting
,
each
trip
unit
to
the
contact
arm
(
Fig
.
7
)
.
The
trip
unit
assem
-
blies
can
be
removed
by
pulling
them
out
of
the
back
of
the
breaker
frame
.
Discard
the
hardware
.
Step
4
.
Carefully
drill
out
the
(
4
)
10
-
32
screws
holding
each
trip
unit
in
its
housing
(
Fig
.
8
)
.
Step
5
.
Remove
and
save
the
(
2
)
Philip
’
s
head
screws
at
the
back
and
under
the
load
terminals
of
each
trip
unit
housing
holding
the
copper
terminal
extensions
in
the
insulated
housing
.
Step
6
.
Remove
and
discard
the
hardware
holding
each
copper
load
terminal
to
the
metal
mounting
brackets
.
Separate
each
trip
unit
from
its
housing
.
Discard
the
trip
units
and
save
the
insulated
hous
-
ing
and
mounting
brackets
(
Fig
.
9
)
.
CONTACT
ARM
SCREWS
Fig
.
7
.
Contact
Arm
Connections
,
K
-
2000
/
1600
REMOVE
AND
SAVE
\
\
.
1
A
,
e
.
l l
,
:
If
Fig
.
8
.
Electro
-
mechanical
trip
unit
disassembly
K
-
2000
/
1600
Fig
.
9
.
Trip
Unit
Housing
,
K
-
2000
/
1600
6
Courtesy of NationalSwitchgear.com

SECTION
4
INSTALLING
THE
CONVERSION
KIT
s
/
«
"
X
2
VA
BOLT
Installing
Phase
Sensors
(
CT
’
s
)
I
-
T
-
E
225
-
800
AMPERE
BREAKERS
Step
1
.
Mount
the
new
copper
load
terminals
to
the
trip
unit
housing
using
the
(
4
)
10
-
32
x
VA
"
screws
,
nuts
,
and
plain
and
lock washers
supplied
for
each
phase
.
At
the
top
of
each
bus
assembly
,
reinstall
the
%
-
16
x
2
"
bolt saved
in
step
5
,
page
5
(
Fig
.
10
)
.
Step
2
.
Place
each
CT
,
one
at
a
time
,
on
the
phase
bus
post
over
the
spacer
.
Place
an
insulated
barrier
over
the
end
of
the bus
post
and
mount
the
as
-
sembly
to
the
load
terminal
(
Fig
.
11
)
.
Insert
the
%
-
16
x
1
”
bolt
with
a
lock
and
flat
washer
and
tighten finger
tight
(
Fig
.
12
)
NEW
C
LEAD
TERMINAL
Fig
.
10
.
Copper
Load
Terminal
Installed
,
K
-
800
/
600
/
225
BUS
POST
BUS
BOLT
INSULATED
BARRIER
Fig
.
11
.
CT
Assembly
Installation
BUS
POST
SPACER
Fig
.
12
.
Converted
Trip
Unit
Housing
7
Courtesy of NationalSwitchgear.com

SECTION
4
INSTALLING
THE
CONVERSION
KIT
Installing
Phase
Sensors
(
CT
’
s
)
I
-
T
-
E
225
-
800
AMPERE
BREAKERS
(
CONT
’
D
)
Step
3
.
Reassemble
the
back
and
front
breaker
frames
by
reinstalling
the
(
5
)
Philip
’
s
head
screws
that
hold
the
housing
in
place
(
Fig
.
13
)
.
See
step
1
on
page
4
.
Then
install
the
(
2
)
Vir
,
-
18
x
WH
"
Philip
’
s
head
screws
with
a
lock
washer
and
a
plain
washer
connecting
the
copper
load
terminals
to
the
con
-
tact
arms
.
Refer
to
step
2
,
page
4
.
Tighten
them
,
finger
tight
for
now
.
Step
4
.
Torque
the
bolts
inserted
in
step
2
to
200
in
-
lbs
.
*
(
Fig
.
14
)
.
Step
5
.
Torque
the
(
2
)
screws
in
each
phase
connecting
the
load
terminals
to
the
contact
arms
to
100
in
-
lbs
.
*
The
screws
were
inserted
in
step
3
.
Fig
.
13
.
Installed
CT
Assemblies
*
IMPORTANT
NOTE
:
Steps
designated
by
an
(
*
)
are
critical
electrical
integrity
connec
-
tions
.
They
must
be
correctly
tightened
for
proper
operation
.
Failure
to
tighten
properly
will
cause
a
breaker
failure
resulting
in
prop
-
erty
damage
or
personal
injury
Fig
.
14
.
CT
Assembly
Torques
8
Courtesy of NationalSwitchgear.com

SECTION
4
INSTALLING
THE
CONVERSION
KIT
Installing
The
Phase
Sensors
(
CT
’
s
)
I
-
T
-
E
1600
-
2000
AMPERE
BREAKERS
Step
1
.
Mount
the
brackets
removed
from
the
old
copper
terminals
in
step
6
on
page
6
on
the
insu
-
lated
housings
,
using
the
hardware
removed
in
steps
5
,
page
6
.
Step
2
.
Mount
a
new
copper
load
terminal
extension
to
each
insulated
housing
using
the
(
2
)
%
-
16
x
1
”
bolts
with
plain
and
lock
washers
provided
.
Fig
.
15
.
Terminal
Assembly
K
-
2000
/
1600
NOTE
:
The
K
-
2000
breaker
uses
(
l
)
5
/
ir
,
-
18
x
1.5
”
bolt
(
Fig
.
15
)
.
Step
3
.
Insert
the
(
2
)
10
-
32
x
1
V
\
"
screws
with
a
plain
and
lock
washer
and
nut
provided
through
the
insu
-
lated
housing
.
Step
4
.
Assemble
the
copper
CT
post
,
spacer
,
CT
and
in
-
sulated
barrier
provided
onto
each
insulated
housing
(
Fig
.
16
)
.
Insert
the
!
4
-
13
x
Wi
"
bolt
with
a
plain
and
lock
washer
provided
into
the
CT
post
.
Tighten
the
bolts
finger
tight
for
now
.
NOTE
:
For
a
K
-
2000
breaker
,
the
assembly
is
held
together
by
a
14
-
13
x
7
"
bolt
through
the
center
of
the
CT
post
.
Fig
.
16
.
CT
Assembly
K
-
2000
/
1600
9
Courtesy of NationalSwitchgear.com

SECTION
4
INSTALLING
THE
CONVERSION
KIT
Installing
The
Phase
Sensors
(
CT
’
s
)
I
-
T
-
E
1600
-
2000
AMPERE
BREAKERS
(
CONT
’
D
)
Step
5
.
Cut
and
remove
the
“
CT
shaped
projection
on
the
insulated
phase
barrier
inside
the
breaker
frame
.
Remove
all
but
Z
\
of
the
projection
to
allow
clearance
of
the
CT
bus
post
(
Fig
.
17
)
.
Step
6
.
Return
the
CT
assembly
housing
to
the
breaker
frame
.
Use
the
hardware
removed
in
step
2
on
page
5
.
The
(
4
)
Vi
6
-
18
x
TK
"
screws
provided
are
inserted
with
a
plain
and
lock
washer
into
the
contact
arm
.
They
should
be
finger
tight
for
now
.
Step
7
.
Torque
the
CT
bolts
inserted
in
step
3
to
300
in
-
lbs
.
*
Step
8
.
Torque
the
contact
arm
screws
above
each
load
terminal
to
100
in
-
lbs
.
*
Fig
.
17
.
“
C
”
Shaped
Barrier
Modification
TOP
HOUSINGS
SCREWS
Ji
NOTE
:
Ocassionally
,
during
current
sensor
manufacturing
,
a
slight
separation
occurs
of
the
epoxy
from
the
plastic
shell
.
This
may
amount
to
as
much
as
0.030
"
and
has
no
effect
on
performance
.
Additionally
,
slight
surface
imperfections
are
part
of
the
epoxy
curing
process
and
have
no
effect
on
performance
.
*
IMPORTANT
NOTE
:
Steps
designated
by
an
(
*
)
are
critical
electrical
integrity
connec
-
tions
.
They
must
be
correctly
tightened
for
proper
operation
.
Failure
to
tighten
properly
will
cause
a
breaker
failure
resulting
in
prop
-
erty
damage
or
personal
injury
Fig
.
18
.
Assembled
K
-
2000
/
1600
10
Courtesy of NationalSwitchgear.com

SECTION
4
INSTALLING
THE
CONVERSION
KIT
Installing
The
Flux
Shifter
I
-
T
-
E
®
225
-
800
AND
1600
-
2000
AMPERE
BREAKERS
An
I
-
T
-
E
600
ampere
breaker
is
shown
as
an
example
for
the
instructions
that
follow
.
These
instructions
are
essentially
the
same
for
all
breaker
ratings
.
Step
1
.
Carefully
rotate
the
breaker
onto
its
back
so
that
the
breaker
bottom
is
accessible
.
NOTE
:
If
the
breaker
has
already
been
con
-
verted
to
solid
state
,
the
existing
trip
actuator
and
linkage
must
be
removed
and
discarded
.
Step
2
.
Remove
the
left
front
rack
mounting
bolt
on
the
breaker
frame
.
The
head
of
the
bolt
has
a
radial
slot
cut
in
it
.
Slide
the
new
flux
shifter
assemblv
in
through
the
bottom
of
the
breaker
.
Align
the
bracket
with
the
hole
in
the
frame
where
the
mounting
bolt
was
removed
(
Fig
.
19
)
.
Reinsert
the
mounting
bolt
through
the
hole
in
the
frame
.
Then
insert
the
14
-
20
x
]
A
"
bolt
and
lock
washer
pro
-
vided
through
the
hole
above
the
mounting
bolt
.
Step
3
.
Make
sure
the
reset
arm
linkage
is
on
the
inside
of
the
crossbar
arm
.
Line
up
the
hole
in
the
reset
arm
with
the
hole
in
the
crossbar
(
Fig
.
20
)
.
Insert
the
(
14
"
x
14
"
)
pin
provided
through
the
large
hole
in
the
side
of
the
breaker
frame
.
Place
the
(
2
)
washers
and
cotter
pin
provided
on
the
other
end
of
the
pin
.
Fig
NOTE
:
If
an
auxiliarv
switch
is
mounted
on
the
left
side
of
the
breaker
,
the
auxiliarv
switch
operating
arm
must
be
modified
.
Drill
out
the
pin
that
is
connected
to
the
crossbar
arm
using
a
0.257
"
diameter
drill
.
Place
the
end
of
the
link
over
the
pin
inserted
through
crossbar
arm
and
reset
link
.
Use
only
one
washer
and
the
cotter
pin
provided
.
11
Courtesy of NationalSwitchgear.com

SECTION
4
INSTALLING
THE
CONVERSION
KIT
ADJUSTMENT
SCREW
Installing
The
Flux
Shifter
FLUX
SHIFTER
ADJUSTMENT
Once
the
flux
shifter
and
trip paddle
are
in
-
stalled
,
the
following
adjustments
must
be
made
:
With
the
breaker
upright
in
the
CLOSED
posi
-
tion
,
the
gap
between
the
trip
paddle
and
the
flux
shifter
adjustment
screw
should be
I
62
of
an
inch
.
Use
a
lA
"
wrench
or
nut
driver
to
adjust
the
screw
.
It
may
help
gauge
the
air
gap
with
1
/
32
"
diam
-
eter
rod
or
drill
(
not
provided
)
.
The best
ap
-
proach
is
to
adjust
the breaker
in
the
open
posi
-
tion
,
then check
it
in
the closed
position
.
Make
sure
the
trip
paddle
play
is
eliminated
by
gently
pushing
on
the
paddle
while
adjusting
the
screw
(
Fig
.
21
)
.
1
RIP
PADDL
IMPORTANT NOTE
:
Extreme
caution
must
be used when
working
on
a
closed breaker
.
DO NOT
reach
your
hands
into the
mecha
-
nism while
adjusting
the
flux shifter
.
OPTIONAL TEST
:
The
flux shifter
assembly
can
be tested
at
this
point
by
applying
a
9
volt dc
power
source
to
the flux shifter leads
.
The
red
lead is the
positive
.
The breaker
should
trip
.
12
Courtesy of NationalSwitchgear.com

SECTION
4
INSTALLING
THE
CONVERSION
KIT
NOTE
LOCATION
OF
BEVELED
EDGES
ON
PLUG
BODY
JU
oooooooo
ooooooooo
ooooooooo
ooooooooo
.
Mounting
the
Programmer
Bracket
The
programmer
bracket
and
programmer
wiring
harness
are
provided
but
,
must
be
assembled
(
Fig
.
23
)
.
Step
1
.
Assemble
the
adapter
bracket
to
the
36
-
pin
pro
-
grammer
connector
(
with
bevels
to
right
side
)
by
pushing
the
bracket
over
the
notches
in
the
ends
of
the
plug
body
.
Follow
Steps
2
-
5
of
Fig
.
22
to
complete
assembly
of
programmer
harness
to
pro
-
grammer
bracket
.
Step
2
.
Rotate
the
breaker
to
the
upright
position
.
Remove
the
Philip
’
s
head
screws
at
the
front
of
the
top
cover
(
Fig
.
24
)
.
ADAPTER
BRACKET
o
STEP
1
.
PUSH
BRACKET
OVER
NOTCHES
IN
END
OF
PLUG
BODY
urn
A
STEP
5
.
HOLD
PLUG
BODY
TIGHT
TO
THE
ADAPTER
BRACKET
AND
BEND
OVER
(
2
)
LOCKING
TABS
STEP
3
.
PRESS
ON
PUSH
NUTS
UNTIL
BRACKET
IS
HELD
FIRMLY
AGAINST
PROGRAMMER
BRACKET
O
°
i
3
CAUTION
:
Adapter
bracket
must
be
installed
onto
harness
plug
as
shown
in
Fig
.
22
.
Failure
to
do
so
will
result
in
harness
plug
failure
and
the
programmer
will
not
provide
protection
.
cc
000000000
s
ooooooooo
ooooooooo
ooooooooq
,
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
-
GUIDE
PINS
'
-
J
Fig
.
22
.
Harness
Connector
Fig
.
23
.
Wire
Harness
attached
to
the
Programmer
Bracket
Fig
.
24
.
Top
Cover
Screw
Removal
13
Courtesy of NationalSwitchgear.com

SECTION
4
INSTALLING
THE
CONVERSION
KIT
PROGRAMMER
BRACKET
WIRE
TIES
INSULATED
BARRIER
Mounting
the
Programmer
Bracket
(
Cont
’
d
)
Step
3
.
Install
the
programmer
bracket
and
wiring
har
-
ness
assembly
to
the
top
cover
.
Include
the
insu
-
lating
barrier
between
the
arc
chutes
and
the
bracket
.
Use
(
3
)
wire
ties
to
fasten
the
barrier
to
the
programmer
bracket
(
Fig
.
25
)
.
Programmer
Wiring
Harness
The
programmer
harness
consists
of
the
mating
of
the
36
-
pin
programmer
connector
and
the
as
-
sociated
wires
.
Step
1
.
Connect
the
wire
harness
leads
to
the
screw
ter
-
minals
on
each
CT
.
Make
sure
they
are
properly
connected
.
The
white
wire
must
be
connected
to
the
terminal
marked
white
.
Step
2
.
Use
the
wire
ties
provided
to
tie
the
harness
back
against
the
frame
.
The
harness
should
be
tied
to
the
holes
in
the
fiber
barrier
at
each
CT
.
Make
sure
that
the
harness
will
not
interfere
with
any
moving
parts
.
See
Fig
.
26
.
WIRE
HARNESS
Fig
.
25
.
Programmer
Bracket
Installed
Fig
.
26
.
Programmer
Harness
Installation
14
Courtesy of NationalSwitchgear.com

SECTION
4
INSTALLING
THE
CONVERSION
KIT
Communications
Harness
(
When
Required
)
The
communications
harness
is
provided
with
every
kit
,
preassembled
to
the
programmer
har
-
ness
.
On
MicroVersaTrip
Plus
kits
,
when
there
is
no
expectation
to
upgrade
to
a
PM
kit
in
the
fu
-
ture
,
the
communications
harness
can
be
re
-
moved
or
coiled
and
tied
to
the
breaker
frame
.
When
the
communications
harness
is
installed
,
it
should
be
tied
to
the
frame
in
an
accessible
loca
-
tion
in
the
switchgear
.
Fig
.
27
shows
a
suggested
location
.
However
,
actual
location
of
the
commu
-
nications
disconnect
plug
will
dictate
routing
of
the
harness
.
It
is
dependent
on
the
configuration
of
the
equipment
and
may
be
determined
by
a
field
engineer
.
Fig
.
27
.
Communications
Harness
15
-
Courtesy of NationalSwitchgear.com

SECTION
4
INSTALLING
THE
CONVERSION
KIT
Programmable
Trip
Unit
The
programmer
is
attached
to
the
programmer
mounting
bracket
.
The
guide
pins
on
this
bracket
mate
with
the
holes
on
either
side
of
the
pro
-
grammer
box
.
The
guide
pins
provide
the
neccessary
alignment
for
the
connector
engagement
.
The
locking
lever
engages
with
the
pin
which
is
assembled
to
the
programmer
frame
,
and
secures
the
programmer
to
the
mounting
bracket
.
TO
INSTALL
THE
PROGRAMMER
:
Step
1
.
Insert
the
guide
pins
into
the
hole
and
push
on
the
programmer
.
This
will
engage
the
connectors
,
and
release
the
locking
lever
which
will
move
up
-
wards
(
Fig
.
28
)
.
Step
2
.
Verify
that
the
locking
lever
actually
engaged
the
programmer
pin
.
To
remove
the
programmer
,
pull
the
locking
lever
out
,
releasing
the
programmer
pin
.
Then
,
remove
the
programmer
.
Fig
.
28
.
Programmer
Trip
Unit
,
:
/
Fig
.
29
.
Completed
Breaker
Assembly
16
Courtesy of NationalSwitchgear.com

SECTION
5
FOUR
-
WIRE
Step
3
.
Route
the
wire
through
the
equipment
and
con
-
nect
to
the
2
-
pin
connector
on
the
programmer
harness
.
The
wire
should
be
tied
to
the
breaker
frame
in
an
easily
accessible
location
.
It
may
be
located
with
the
communications
harness
.
See
Fig
.
27
on
page
15
.
GROUND
FAULT
OPTION
The
ground
fault
option
in
all
four
-
wire
systems
requires
an
additional
neutral
sensor
.
The
neutral
sensor
is
installed
in
the
neutral
bus
in
the
equip
-
ment
and
is
connected
to
the
programmable
trip
unit
through
the
communications
wiring
harness
provided
.
Step
1
.
Mount
the
neutral
sensor
in
the
outgoing
neutral
lead
,
normally
in
the
equipment
’
s
bus
or
cable
compartment
(
Fig
.
30
and
31
)
.
Step
2
.
Connect
the
neutral
sensor
wire
harness
to
the
correct
taps
on
the
sensor
.
The
top
setting
on
the
neutral
sensor
must
match
the
phase
sensors
.
Maintain
the
following
color
code
:
White
—
Common
,
Black
-
Tap
Fig
.
30
.
Neutral
Sensor
Oudine
for
K
-
600
,
K
-
225
17
Courtesy of NationalSwitchgear.com

SECTION
5
FOUR
-
WIRE
GROUND
FAULT
OPTION
s
1
LOAD
LINE
.
562
DIA
.
HOLES
MAX
.
STRAP
1.25
MAX
.
STRAP
3.33
ref
.
1.25
r
—
If
.
i
1
S
i
i
h
V I
I
.
625
I
.
625
•
i
i
i
*
1.18
ref
.
TERMINAL
BLOCK
1.75
.
88
1.75
i
6.00
i
]
.
75
©
—
©
-
©
i
:
ei
t
I
:
EI
3.75
MAX
.
m
\
1.75
3.25
re
i
9
—
©
-
-
©
—
I
i
:
ei
11.25
Fig
.
31
.
Neutral
Sensor
Outline
for
K
-
800
,
1600
,
2000
18
Courtesy of NationalSwitchgear.com

SECTION
6
TESTING
AND
TROUBLESHOOTING
WARNING
:
Do
not
change
taps
on
the
current
sensors
or
adjust
the
programmer
trip
unit
set
-
tings
while
the
breaker
is
carrying
current
.
Once
the
breaker
has been
converted
,
but before
it
is
energized
,
it
must
be
tested
.
See
below
for
troubleshooting
details
.
TESTING
Before
installing
a
converted breaker back into
service
,
perform
the
following
steps
:
Step
1
.
Verify
that
the
programmable
trip
unit
is
securely
installed
.
The
phase
sensors
must
not
be
ener
-
gized
if
they
are
open
-
circuited
.
Step
2
.
Megger
the breaker
primary
circuit
using
a
1
,
000
-
Volt
Megger
.
Step
3
.
Measure
the
resistance
across
the line and load
terminals
for
each
phase
using
a
Micro
-
Ohmeter
or
Milli
-
Volt
tester
.
Also
,
measure
the resistance
across
the
CT
assembly
.
If
the
resistance
differs
considerably
from
phase
to
phase
,
the electrical
points
may
not
be
properly tightened
.
Also
,
it
may
indicate
improper
contact
wipe
.
Step
4
.
To
verify
that
the breaker
has been
properly
ret
-
rofitted
,
a
primary
injection
test
should
be
per
-
formed
on
each
phase
.
This
test
will check the
CTs
,
bus
,
wiring
harness
,
flux
shifter
,
and
trip
unit
as
a
complete
system
.
A
high
current
,
low
voltage
power
supply
should be
connected
across
each
line and load terminal
to
simulate
an
overcurrent
fault
.
The
long
-
time
may
be
set
at
0.5
to
minimize
the breaker
stress
.
When
ground
fault is
installed
,
the
test
can
be
performed
by
wiring
two
adjacent
poles
in
series
.
This
will
prevent
the
breaker
from
tripping
due
to
an
unbalance
current
flow
.
Do
not
attempt
to
use
GE
test
kit
Cat
.
No
.
TVTS
1
or
TVRMS
on
this
programmer
.
Troubleshooting
When
malfunctioning
is
suspected
,
first
examine
the
circuit
breaker and
its
power
system
for
ab
-
normal conditions
such
as
:
1
.
Breaker
not
tripping
in
proper
response
to
overcurrents
or
incipient
ground
faults
.
2
.
Breaker
remaining
in
a
trip
-
free
state
due
to
mechanical interference
along
its
trip
shaft
.
3
.
Inadvertent
shunt
trip
activations
.
False
Tripping
Breakers
Equipped
with
Ground
Fault
When
nuisance
tripping
occurs
on
breakers
equipped
with
the
ground
fault
trip
element
,
a
probable
cause
is the
existence
of
a
false
“
ground
”
signal
.
Each
phase
sensor
is
connected
to
summing circuitry
in
the
programmer
.
Under
no
-
fault
conditions
on
3
-
wire
load
circuits
,
the
currents
add
to
zero
,
and
no
ground
signal
is
de
-
veloped
.
This
current
sum
will
be
zero
only
if
all
three
sensors
have
the
same
electrical
characteris
-
tics
.
If
one sensor
differs
from
the others
(
i
.
e
.
,
dif
-
ferent
rating
or
wrong
tap
setting
)
,
the
circuitry
can
produce
output
sufficient
to
trip
the
breaker
.
Similarly
,
discontinuity
between
any
sensor
and
the
trip
unit
can
cause
a
false
trip
signal
.
The
sensors
and their connections should be
closely
examined
if
nuisance
tripping
is
encoun
-
tered
on
any
breaker
whose
MicroVersaTrip
®
Plus
or
PM
components
have
previously
demonstrated
satisfactory
performance
.
.
After
disconnecting
the
breaker
from
all
power
sources
,
perform
the
following
steps
:
Step
1
.
Check
that all
phase
sensors are
the
same
type
(
ampere
range
)
.
Step
2
.
Make
sure
that
the
tap
settings
on
all
three
-
phase
sensors
are
identical
.
Step
3
.
Verify
that
the
harness
connections
to
the
sensors
meet
the
polarity
constraints indicated
by
the
ca
-
bling diagram
in
Fig
.
32
.
19
Courtesy of NationalSwitchgear.com

Table
6
-
1
.
Resistance
Values
SECTION
6
TESTING
AND
TROUBLESHOOTING
Ampere
CT
Rating
FALSE
TRIPPING
BREAKERS
EQUIPPED
WITH
GROUND
FAULT
(
CONT
’
D
)
Breaker
Resistance
in
Ohms
K
-
225
9
-
12
150
A
Step
4
.
On
ground
fault
breakers
serving
four
-
wire
loads
,
check
that
the
neutral
sensor
is
properly
con
-
nected
.
See
cabling
diagram
Fig
.
32
.
In
particular
,
the
following
:
Verify
that
the
neutral
sensor
has
the
same
rating
and
tap
setting
as
the
phase
sensors
.
Check
continuity
between
the
neutral
sensor
and
its
equipment
-
mounted
secondary
disconnect
block
.
Also
check
for
continuity
from
the
breaker
-
mounted
neutral
secondary
disconnect
block
through
to
the
female
har
-
ness
connector
.
If
the
breaker
'
s
lower
studs
connect
to
the
supply
source
,
then
the
neutral
sensor
must
have
its
load
end
connected
to
the
source
.
See
Fig
.
32
.
Make
sure
that
the
neutral
conductor
is
carrv
-
ing
only
that
neutral
current
associated
with
the
breaker
’
s
load
current
(
neutral
not
shared
with
other
loads
.
)
2
25
A
14
-
18
K
-
600
225
A
14
-
18
600
A
40
-
50
150
A
K
-
800
9
-
12
400
A
27
-
32
A
.
80
0
A
58
-
79
58
-
79
K
-
1600
800
A
B
.
1600
A
130
-
154
K
-
2000
2000
A
210
-
246
C
.
D
.
Step
5
.
If
the
preceding
steps
fail
to
identify
the
problem
,
then
measure
the
sensor
resistances
.
Since
the
phase
and
neutral
sensors
are
electrically
identi
-
cal
,
their
resistance
should
closely
agree
.
20
Courtesy of NationalSwitchgear.com