GE BreakMaster Instruction Manual

imagination at work
GE Consumer & Industrial
Electrical Distribution
BreakMaster™Load
Interrupter Switch
Installation and Maintenance

1
Overview
This instruction book is expressly intended to cover the installation, operation and maintenance of GE’s BreakMaster Load
Interrupter Switch. This manual does not cover all possible contingencies, variations and details that may arise during
installation, operation or maintenance of this equipment.
If the user has questions regarding a particular installation, contact the local GE sales office. For application information,
consult your nearest GE sales office and refer to the appropriate ANSI standards.
Contents
Page
Section 1 - Introduction 2
1.0 Basic Description and Application
1.1 Switchgear Identification
1.2 Safety Features
1.3 Safe Practices
Section 2 - Receiving 4
2.0 Receiving
2.1 Handling
2.2 Storage
2.3 Lifting Instructions
Section 3 - Feature Identification 5
Section 4 - Installation 6
4.0 Joining BreakMaster Enclosures
4.1 Connection of Switchgear to Transformer
4.2 Bolting Torque Valves
4.3 Electrical Clearances
4.4 Grounding
4.5 Medium Voltage Electrical Connections
4.6 Connection to Metal Clad Switchgear Assembly
4.7 Connection of Customer Power Cables
4.8 Field Taping of Electrical Connections
4.9 Securing Switchgear to Foundation
4.10 Connection of Space Heaters to Customer’s Source
4.11 Switch Inspection Before Startup
Section 5 - Operation 13
5.0 Mechanical Safety Interlocks
5.1 Switch Operation
5.2 Fuse Replacement Steps
5.3 Shunt Trip Operating Guidelines
5.4 Motor Operator
Section 6 - Maintenance 21
6.0 General Requirements
Section 7 - Selector Switch Configuration 23
Section 8 - Duplex Configuration 23
Section 9 - Auto Transfer Switchgear (LIS-ATS) Configuration 24
Section 10 - Troubleshooting 26
Section 11 - How to Contact GE 27
11.0 GE RESOLVE
11.1 www.geelectrical.com
BreakMaster Load Interrupter Switch

2
Section 1 – Introduction
1.0 Basic Description and Application
GE’s BreakMaster Load Interrupter Switch consists of an air insulated, three pole, gang-operated, quick-make,
quick-break, load interrupter switch in a floor mounted metal enclosure. It can be applied with power fuses and
many other protective devices to provide safe, economical switching and circuit protection where infrequent
disconnecting means is required. The BreakMaster is designed for medium voltage circuit applications ranging
from 2.4kV through 15kV in 600 or 1200 load ampere interrupting ratings. The switch is operated externally
from the front of the cubicle and is equipped with a quick make, quick break mechanism to open and close the
switch independent of the speed with which the operating handle is moved, manually or power operated. The
switchgear meets or exceeds all applicable ANSI, NEMA and IEEE standards and the Seismic requirements of the
UBC zone 4 and CBC zone 4 building codes and UL listed switches are available as an option.
1.1 Switchgear Identification
A data nameplate is located beneath the switch operating handle of each BreakMaster vertical switch section
(see Figure 1). Contained on this nameplate are the GE order number, serial number, drawing number, and switch
style number. This information should be given to the GE sales office if a question should arise concerning the
switchgear or if renewal parts are required. These numbers allow the factory to completely identify the
switchgear. Also located on the nameplate are voltage and current ratings for the switch and switchgear.
1.2 Safety Features
GE’s BreakMaster Load Interrupter Switch meets or exceeds all of the following standards:
GE’s BreakMaster Load Interrupter Switch has several built in
features to reduce hazards and to provide proper operating
sequences.
1. Door interlock prevents opening the enclosure front doors
while the switch is in the closed position.
2. Switch interlock prevents manual operation of the handle
mechanism with the doors open.
3. A viewing window is provided to verify each switch contact
position.
4. Facilities are provided for padlocking the switch in the open
or closed position.
5. Mechanical indicators show whether the switch mechanism
is open or closed.
6. Key interlocks, when provided, force a sequence of operation.
WARNING
Exceeding nameplate ratings of the
switchgear could cause property damage,
severe injury, or death. Switchgear must
be operated within its nameplate ratings.
!
BREAKMASTER LOAD
INTERRUPTER SWITCH
REQ. NO.
FACTORY ORDER NO.
SWITCH PART NO.
MANUFACTURE DATE
190B9965P1 ASSEMBLED IN MEXICO
XXXXXXX
XXXXXXXX
XXXXX-X
28-JUN-00
FUSE/RATING
FUSE CATALOG NO.
INTEGRATED SWITCH & FUSE
SHORT CIRCUIT CURRENT
175
9F62FDD175
40KA ASYM
MAIN BUS AMPACITY
MAIN BUS BRACING
ENCLOSURE TYPE
N/A
50
INDOOR
A
KA ASYM
CATEGORY B
RATED MAXIMUM VOLTAGE
IMPULSE WITHSTAND (BIL)
NORM. FREQ. WITHSTAND
FREQUENCY
CONTINUOUS CURRENT
LOAD INTERRUPTING CURRENT
MOMENTARY CURRENT
SHORT TIME – CURRENT
– TIME
FAULT CLOSING CURRENT
15
95
36
60
600
600
40
25
2
40
KV
KV
KV
HZ
A SYM
A SYM
KA ASYM
KA SYM
SEC
KA ASYM
imagination at work
Standards
C37.20.3
ANSI/IEEE C37.20.4
C37.22
NEMA SG-6
UL UL 1008A (LIS-ATS only)
See ANSI standards
CSA C22.2, No. 31
C22.2, No. 193
IEEE 693-1997
BreakMaster Load Interrupter Switch
Figure 1

3
1.3 Safe Practices
Only qualified electrical workers with training and experience on high voltage circuits should be permitted to work
on this equipment. They should be familiar with the work to be performed, the safety equipment required and
hazards involved.
Read and understand these instructions before attempting any assembly, operation, or maintenance of this
switchgear. Exceeding nameplate ratings of switchgear could cause property damage, severe injury, or death.
1. Make sure all power sources are disconnected before making any adjustments or performing maintenance.
2. After opening the switch and before opening the door, use viewing window to insure that all three switch
blades are open. If necessary, use a flashlight to verify.
3. Never energize the switch without the arc chutes and barriers installed.
4. Always be sure that all hardware is in place and bolted tightly before putting switch into operation.
5. Before replacing covers, carefully inspect buswork and phase barriers to insure that no tools or other
objects are accidentally left inside the unit.
WARNING
There are several interlocks on the switches. They are for personnel and/or
equipment protection. Under no circumstances should they be made
inoperative when switch is in service. To do so could cause bodily injury
or property damage.
!
NOTE
Any work done on this equipment must
conform to the appropriate OSHA and
NFPA standards.
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Section 2 – Receiving
2.0 Receiving
A visual inspection – inside and out – should be performed immediately upon receipt of the switchgear and before
removing it from the truck. Shipping papers should be checked to ensure all boxes or other accompanying pieces
have been received. If any damage or shortages are evident, a claim should be filed at once with the carrier and
the nearest GE sales office.
The data nameplate for each switch assembly is located beneath the switch operating handle. The order
number, serial number, and drawing number are located on this nameplate and should be given to the GE repre-
sentative whenever identification of the assembly is required.
2.1 Handling
Removable lifting plates are provided on the top of the BreakMaster structure for insertion of hooks to lift the
complete structure. This is the only recommended method of moving the BreakMaster structure. Extreme care
should be used not to damage or deform the unit if other moving methods are employed.
2.2 Storage
If it is necessary to store the equipment before installation, keep it in a clean, dry location with ample air
circulation and heat to prevent condensation. Like all electrical apparatus, these units contain insulation that must
be protected against dirt and moisture. OUTDOOR UNITS MAY BE STORED OUTSIDE ONLY IF ROOF CAPS ARE
INSTALLED, SPACE HEATERS ENERGIZED AND ANY OPENINGS ARE COVERED.
2.3 Lifting Instructions
1. Do not pass cables or ropes through support holes.
2. Always use load rated shackles or safety hooks in support holes.
3. Rig so that legs of sling (Figures 2 and 3) are no less than 45 degrees from horizontal.
NOTE:
Figure 2 – Using lifting slings, spreader and blocking which are not furnished with equipment.
Figure 3 – Using lifting plates, angles or beams which are furnished with equipment.
Figures 2 and 3
45 Degrees Minimum
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Section 3 – Feature Identification
3.0 Front View with Top Door Open
3.2 Side View with Covers Removed
3.1 Front View with Lower Door Open
Louvers –
Front and
Rear
Switch
Mechanism
Safety Mechanical
Interlock
Oversize
Inspection
Window
Top Door
Lifting Angles Provided
on All Sections
Louvers –
Front and
Rear
Highly Visible
Warning SIgn
Lower
Door
Oversize
Inspection
Window
Safety Mechanical
Interlock
Lower Fuse
Compartment
Ground Bus
Data Label
Key Interlock
(when required)
Data Label
Glass Polyester
Insulators
Porcelain Available
as an option
Full Height
Phase Barrier
Large Cable
Pulling Space
Ground Bus
Copper Bus Standard
Switch Mechanism
Rigid Bolted Frame
Construction
Heavy-duty
Chain Drive
All Covers 11 Gauge Steel
Tough Polyester
Paint 2-mil Baked
Coating Thickness
BreakMaster Load Interrupter Switch

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Section 4 – Installation
4.0 Joining BreakMaster Enclosures
4.0.0 Access to BreakMaster Vertical Sections Containing Switches
Each BreakMaster load interrupter switch is shipped from the factory in the closed position to maintain alignment
during shipping and handling. The safety interlocking prevents opening of the door of the vertical section when the
switch is closed. In order to gain access to the interior, be sure the switchgear is on a true and level surface. To
open a manually operated BreakMaster switch, pull the release button and rotate the handle to the open position.
When handling the BreakMaster enclosure and moving switches, be sure the switches are in the closed position. Do
not operate switches unless they are setting on true and level surfaces.
4.0.1 Identification of Shipping Splits
Refer to the front view drawing. Below this drawing, shipping splits will be identified in relation to group numbers
for each cubicle. Normally shipping sections will not exceed 90 inches in width.
4.0.2 Procedures for Joining BreakMaster Enclosures at Shipping Splits
The joining of sections consists of 2 bolted connections on the top and bottom of each depth frame member. In
addition, 2 bolted connections are made on each vertical frame member. The vertical connections are located 1⁄3
and 2⁄3up from the bottom of the BreakMaster Load Interrupter Switch (if 90” high switch, then connections are
made at 30” and 60” off the ground).
Make any main and ground bus connections using splice plates and hardware furnished. Bus bars are usually tin
or silver plated. To insure a proper electrical connection, care should be taken to protect the plating from
damage. DO NOT use joint compound.
4.1 Connection of Switchgear to Transformer
4.1.1 Indoor Assemblies
Holes are pre-drilled in the side of the BreakMaster structure to match holes provided in the transformer.
4.1.2 Outdoor Throat Connection
a. Switch and transformer should be brought together to give spacing of 1⁄2inch between throat flanges.
b. Apply double bead of caulking material supplied with Breakmaster switchgear to outside surfaces of
both flanges.
c. Move switch and transformer together to compress caulking material.
WARNING
Wipe surfaces with clean, dry cloth to clean.
Cleaning bus joints with abrasive or chemical cleansers may
remove plating, which may cause joint overheating.
!
BreakMaster Load Interrupter Switch

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4.2 Bolting Torque Values
BreakMaster Load Interrupter switches are furnished with medium carbon steel hardware having a high tensile
strength of 120,000 psi. SAE 5 or better hardware should be used for any additional bolting. The use of a torque
wrench is recommended to assure the following torques. These torques apply to aluminum or copper
connections. When torquing bolts the following values are nominal:
1⁄4”bolts – 4 lb. ft.
5⁄16” bolts – 9 lb. ft.
3⁄8” bolts – 16 lb. ft.
1⁄2” bolts – 39 lb. ft.
5⁄8” bolts – 80 lb. ft.
Flat washers and lock washers should be used for all connections. Washers should not be included under the
heads of carriage bolts.
4.3 Electrical Clearances
The following minimum clearances should be maintained after field modifications:
2.4 kV - 5kV 7.2 kV - 15kV
Between live parts of adjacent phases:
Through air: 3 1⁄2”5
3⁄4”
Over Surface: 3 1⁄2”5 3⁄4”
Between live parts and grounded
metal through air over surface: 3 1⁄2”5 3⁄4”
4.4 Grounding
The ground bus is bolted to the uprights of the frame structure. It is arranged so that connections to
the station ground can be made in any unit. A ground bus is included in each section for connecting the
BreakMaster equipment to the station ground.
4.5 Medium Voltage Electrical Connections
4.5.1 Connection by Cable Supplied with BreakMaster Switch
a. Cables are not factory pre-cut to proper length. Installer must cut to fit.
b. Since factory cables are unshielded, they must be properly separated from each other, from all grounded
metal parts, and from transformer bushing/terminals of other phases.
c. BreakMaster conforms to ANSI standards concerning phasing. Phases are arranged A, B, C, front to rear,
top to bottom, and left to right at connection points unless otherwise noted on the drawings. The installer
is responsible for maintaining continuity of phasing throughout the system.
d. Lugs are provided with the switchgear for terminating cable to the transformer bushings/terminals.
4.5.2 Connection by Bus Bar
a. Flexible bus straps or splice plates and hardware are furnished with the BreakMaster Load
Interrupter Switch.
b. Copper bus bar is tin or silver plated.
WARNING
It is very important that the equipment be adequately grounded to insure that all
parts of the equipment, other than live parts, need to be at ground potential.
!
BreakMaster Load Interrupter Switch

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4.6 Connections to Metal Clad Switchgear Assembly
4.6.1 Indoor Switchgear
Holes are predrilled in the side of the BreakMaster Load Interrupter Switch structure to match holes provided in
Metal Clad switchgear. Bolt together using hardware furnished with BreakMaster Load Interrupter Switch.
4.6.2 Outdoor Switchgear
a. Position units side by side. Holes in BreakMaster switch side sheet around bus cutout will match holes in metal
clad switchgear flange.
b. Press weather stripping putty on to flange for weather-tight seal.
c. Join enclosures using bolts supplied with BreakMaster switch. Opposite side of metal clad switchgear flange
has nuts welded in place for ease of connection.
4.7 Connection of Customer Power Cables
Cable termination space is provided in the cubicle for top or bottom cable entry as shown on the outline draw-
ings. Adequate electrical clearance must be maintained between cables, energized parts, and grounded metal
parts. It is also the installer’s responsibility to adequately support cables such that insulators or bus bars do not
carry the strain of the cables.
Tin-plated aluminum clamp type terminals are suitable for acceptance of copper or aluminum cable. If potheads
or other special terminations are supplied, termination should be made according to the terminator manufactur-
er’s instructions.
4.7.1 Installation Procedure for Main Cables when Cable Brace is Provided
Align conduit holes in a linear orientation directly over or as close as possible to the braces. Consideration should
be given to installing conduits or sleeves which might be required for future connections.
Run and bend the main cable in a most convenient orientation, making sure the main cable has been located
directly up against the cable braces before it connects to the main cable terminals. Lash the main cable accord-
ing to Figure 4 above, using a 3/8” nominal nylon rope, or a polyester braided rope having a tensile strength of
2000 lbs. minimum, making 6 revolutions around the “A” and “B” phase main cables and 6 revolutions around the
“B” and “C” phase main cables. Continue wrapping the cord around the main cable lashing and around the cable
braces (if applicable), in between the phases, tying a knot to the cable brace or cable as you complete your last
revolution. All revolutions should be made as tight as possible so as to prevent whipping during short circuits. The
nylon rope is not provided.
6"
Maximum
Main Cable Terminals
Cable Brace
Figure 4
BreakMaster Load Interrupter Switch

9
4.8 Field Taping of Electrical Connections
4.8.1 Materials
a. Filler – insulation putty – GE Part #: 55A213957
b. Insulating tape – black, linerless H.V. EPR tape – GE Part # MMC#130C1 (1”) or MMC#130C2 (2”)
4.8.2 Procedure
a. Clean area of dirt and foreign matter per Section 6.0.2
b. Apply filler – installation putty – over bare conductor and hardware to cover and smooth out the surface.
Blend contour into preinsulation surfaces. Cover conductors and hardware with at least 1⁄8” of filler.
c. Apply insulating tape, lapping and layering as specified in chart below. Tape must overlap factory installed
insulation by 1". Elongate insulating tape 10 to 25 percent during application to insure a smooth, tight fit.
Should a tape roll be used up, start the new roll by overlapping any previous end by 1⁄2turn.
4.9 Securing Switchgear to Foundations
All anchoring hardware and necessary devices are to be supplied by the installer.
Indoor and outdoor units can be secured to the foundation using 1⁄2" diameter anchor bolts (SAE Grade 5 or
stronger). The four 5⁄8" holes in the base for these bolts are shown on the floor plan included with the drawings.
4.10 Connection of Space Heaters to Customer Source
Space heaters, when supplied, must be energized to prevent condensation. Heaters are supplied for 120 or 240
volt sources as shown on drawings.
For lineups or units with heater control devices, heaters will be internally wired and brought to a terminal block. A
wiring diagram will be furnished with the drawings showing connection points for power.
4.11 Switch Inspection Before Setup
The following procedure should be performed to insure proper operation of the switch. Open and close the switch
2-5 times in succession. Do not attempt to grind the blades with powdered emery or other abrasives. Such prac-
tice inevitably results in poor contact and overheating.
Switch contact adjustment should be checked as follows:
1. Operate the switch several times checking for main blade and arcing blade alignment with the stationary con-
tacts and arc chute.
2. Check switch resistance by using a low resistance ohm meter connected between the jaw spade terminal and
the hinge spade terminals. Do this measurement of each pole of the assembly.
Any low resistance meter capable of measurements in the micro-ohm range may be used.
Suitable meters include:
Valhalla Scientific, Inc. Biddle Instruments
Model 4150 ATC Cat. No. 247350
Digital Ohmmeter Digital Low Resistance Ohmmeter
If the switch does not move freely or the resistance is over 80 micro-ohms then the switch must be readjusted
using the following switch alignment procedure and adjustment procedure (see Section 4.11.1).
Chart 1: Taping Chart
Lap of Tape No. of Layers
Up to 5 kV 1⁄21
Over 5 kV to 15 kV 2⁄32
CAUTION
The hinge and jaw contacts are sliding joints and overtightening can cause
the switch not to open and severely damage the mechanism.
!
BreakMaster Load Interrupter Switch