GE Power Break User manual

DEH40391 Installation Instructions R01
g
Power Break®Circuit Breakers
Power Management Upgrade
Application
These kits provide the wiring and switches required for a
Power Break circuit breaker to use power management
trip unit features. The kit catalog numbers are TPSP for
800–2000 A stationary breakers, TCSP for 800–2000 A
draw-out breakers, TPLP for 2500–4000 A stationary
breakers, and TCLP for 2500–4000 A draw-out breakers.
The parts included in these kits are listed in Table 1,
Table 2, Table 3, and Table 4.
The numbers in brackets in the following instructions and
figures refer to the item numbers in these tables.
Item Part No. Description Qty.
1 10086637G1 Terminal board assembly 1
2 N701P1708B6 Thread-forming screw,
#10-16 x 1/2
2
3 286A8112P1 Barrier (not used) 1
4 567B262G36 Auxiliary switch 1
5 793A765P2 Wire tie, small 6
6 793A765P3 Wire tie, large 8
Table 1. List of parts in the power management upgrade kits for 800–
2000 A stationary breakers, catalog number TPSP.
Item Part No. Description Qty.
1 10086637G1 Terminal board assembly 1
2 N701P1708B6 Thread-forming screw,
#10-16 x 1/2
2
3 286A8112P1 Barrier 1
4 567B262G42 Auxiliary switch 1
5 793A765P2 Wire tie, small 6
6 793A765P3 Wire tie, large 8
Table 2. List of parts in the power management upgrade kits for 2500–
4000 A stationary breakers, catalog number TPLP.
Item Part No. Description Qty.
1 10086523G1 Terminal board assembly 1
2 N701P1708B6
Thread-forming screw,
#10-16 x 1/22
4 567B262G36 Auxiliary switch 1
5 793A765P2 Wire tie, small 6
6 793A765P3 Wire tie, large 8
7 N722P16006B6
Thread-forming screw,
#10-32 x 3/82
8 TDOSVD907F Trip unit disconnect, breaker 1
9 TDOSVD12
Trip unit disconnect,
substructure 1
10 Incl. with [9] Spring 1
Table 3. List of parts in the power management upgrade kit for 800–
2000 A draw-out breakers, catalog number TCSP.
Item Part No. Description Qty.
1 10086637G1 Terminal board assembly 1
2 N701P1708B6 Thread-forming screw,
#10-16 x 1/24
3 286A8112P1 Barrier 1
4 567B262G42 Auxiliary Switch 1
5 793A765P2 Wire tie, small 6
6 793A765P3 Wire tie, large 8
7 N722P16006B6 Thread-forming screw,
#10-32 x 3/82
8 TDOSVD907F Trip unit disconnect, breaker 1
9 TDOSVD12
Trip unit disconnect,
substructure 1
10 Incl. with [9] Spring 1
Table 4. List of parts in the power management upgrade kit for 2500–
4000 A draw-out breakers, catalog number TCLP.
Installation
WARNING: Before beginning this procedure,
turn the breaker OFF, disconnect it from all
voltage sources, and discharge the closing
springs.
AVERTISSEMENT: Mettre le disjoncteur à OFF,
le débrancher de toutes les sources de tension et
déclencher les ressorts de fermeture avant
d'entamer cette procédure.
Preparing the Breaker
1. Turn the breaker off and discharge the closing
springs. Verify that the breaker indicator shows OFF.
2. Remove the breaker from its cubicle or substructure
and place it on a suitable working surface.
3. Remove the cover from the breaker according to the
instructions in GEH-4693 (800–2000 A applications)
or GEH-4694 (2500–4000 A applications).
4. On draw-out breakers, remove the side plate on the
side with the terminal board.
Installing the Kit
5. Disconnect the leads to the terminal board and
bracket assembly, shown in Figure 1.
6. Remove the two screws securing the terminal board
and bracket assembly to the breaker, then remove the
old terminal board. On 2500–4000 A breakers, also
remove the fiber insulation barrier.

2
Figure 1. Old terminal board mounted on the breaker (2500–4000 A
shown).
7. Push in the locking lever on the side of the trip unit
mounting plate and carefully lift off the trip unit.
8. Remove the trip unit mounting plate as follows for
the appropriate breaker frame size:
• 800–2000 A: Remove the two mounting screws on
the trip unit plate and loosen the 1/4-20 screw on
the side of the assembly, as shown in Figure 2.
Remove the trip unit mounting plate assembly.
• 2500–4000 A: Remove the two screws securing the
trip unit mounting plate to the center-phase sensor
shell, as shown in Figure 3. Lift off the trip unit
mounting plate. Take care that the two nuts in the
slots in the top of the CT don’t fall out.
9. Use pliers to bend the two locking tabs that secure
the large plug to the trip unit mounting plate, as
shown in Figure 4. Slide the plug off the mounting
plate, then remove and save the plug mounting
bracket.
10. Connect the leads from the new terminal board [1]
to the large plug, as shown in Figure 5, according to
the wiring diagram in Figure 6. Use AMP tool
455822-2 to remove incorrectly placed pins from the
plug.
Figure 2. Trip unit mounting plate on an 800–2000 A breaker.
Figure 3. Trip unit mounting plate on a 2500–4000 A breaker.
Figure 4. Bending the locking tabs to remove the large plug from the
trip unit mounting plate.
Figure 5. Connecting the leads from the new terminal board to the trip
unit plug.
1
/
4-20
Mounting
Screw
Mounting
Screws
Mounting
Screws

11. If an auxiliary switch is present, remove it as follows:
• 800–2000 A breaker, Figure 7: Remove the two
mounting screws.
• 2500–4000 A breaker, Figure 8: Remove the bolt,
lock washer, and flat washer securing it to the C
phase contact assembly.
If no auxiliary switch is present in a 2500–4000 A
breaker, remove and save the inner bolt, lock washer,
and flat washer on the C phase contact assembly, as
shown in Figure 9.
3
Figure 6. Wiring diagram for terminal board and trip unit plug.
Mounting
Bar
Figure 7. Old auxiliary switch in an 800–2000 A breaker.
Figure 8. Old auxiliary switch in a 2500–4000 A breaker.
Figure 9. Removing the inner bolt on the C phase contact assembly to
install the auxiliary switch in a 2500–4000 A breaker.

12. Install the new auxiliary switch [4] as follows:
• 800–2000 A breaker: Insert the new switch into the
breaker base and secure with the two screws [2]
supplied, as shown in Figure 10.
• 2500–4000 A breaker: Place the new switch over the
C phase contact assembly and secure with the bolt,
lock washer, and flat washer removed in the
previous step, as shown in Figure 11. Tighten the
bolt to 180–250 in.-lb.
In both cases, use small wire ties [5] to dress the wire
bundles.
13. Insert the two white wires in the small auxiliary
switch cable into the trip unit plug in positions 31
and 34 (see the wiring diagram in Figure 6), as
shown in Figure 12.
4
14. File three slots in the breaker base, as shown in
Figure 13, to accommodate the auxiliary switch wires.
15. Run the five remaining auxiliary switch cables out
through the slots in the breaker base. Secure the
cables in position with large wire ties [6] for strain
relief, as shown in Figure 14.
Figure 10. New auxiliary switch [4] installed in an 800–2000 A
breaker.
Figure 11. New auxiliary switch [4] installed in a 2500–4000 A
breaker.
Figure 12. Auxiliary switch wires inserted into the trip unit plug.
Auxiliary Switch
Wires to Trip
Unit Plug
Figure 13. Filing slots in the breaker base for exit of the auxiliary
switch wires (2500–4000 A shown).
Figure 14. Auxiliary switch wires exiting the breaker (2500–4000 A
shown).
Wire Exit
Slots
Trip Unit
Wires
Large Wire
Tie [6]
Small Wire
Tie [5]
Small Wire
Tie [5]

16. Attach the new terminal board and bracket assembly
[1] to the breaker as follows:
• 800–2000 A breaker: Secure the bracket with the
two #10-16 screws [2] supplied, as shown in Figure
15 for a stationary breaker and in Figure 16 for a
draw-out installation. File two additional slots in the
side of the breaker base for wires to pass through to
the terminal board.
• 2500–4000 A breaker: Install the bracket with the
two #10-16 screws [2] and barrier [3] supplied, as
shown in Figure 17.
5
17. Connect the wires to the new terminal board
according to the wiring diagram in Figure 6.
18. Arrange the wires neatly into the slot in the breaker
case, between the CTs, as shown in Figure 18. Use
small wire ties [5] as shown to dress the wire bundles.
19. Slide the mounting bracket onto the large trip unit
plug and slide the bracket over the two pins on the
trip unit mounting plate, as shown in Figure 19.
20. Use a thin screwdriver to bend the two locking tabs
on the trip unit mounting plate into the slots on the
plug bracket to hold the plug in position, as shown in
Figure 20.
Figure 15. New terminal board [1] installed on an 800–2000 A
stationary breaker.
Figure 16. New terminal board [1] installed on an 800–2000 A draw-
out breaker.
Barrier [3]
Mounting
Screws [2]
Figure 17. New terminal board [1] installed on a 2500–4000 A breaker.
Figure 18. Completed terminal board installation (shown with breaker
cover in place).
Figure 19. Reinstalling the large plug on the trip unit mounting plate.
Mounting
Screws [2]
Small Wire
Tie [5]
Plug
Bracket
Mounting
Screws [2]

6
Figure 20. Bending the locking tabs to secure the trip unit plug to the
mounting plate.
21. Attach the trip unit mounting plates to the breaker as
follows:
• 800–2000 A breaker: Slide the tab of the mounting
plate under the 1/4-20 screw shown in Figure 2.
Insert the two mounting screws removed in step 8
into the holes in the plate and secure to the
mounting bar shown in Figure 7. Tighten all the
screws.
• 2500–4000 A breaker: Insert the two #8-32 x3/8
screws removed in step 8into the holes in the
mounting plate, as shown in Figure 3. Tighten the
screws into the nuts installed in the slots in the top
of the B phase CT, shown in Figure 21.
22. Reinstall the trip unit as follows:
a. Push in and hold the locking lever on the side of
the trip unit mounting plate.
b. Carefully line up the guide pins on the mounting
plate with the holes in the rear of the trip unit, as
shown in Figure 22. Align the pins in the
connector on the rear of the trip unit with the plug
on the mounting plate. The alignment pin on the
rear of the trip unit must fit in the hole in the
locking lever.
b. Push the trip unit against the mounting plate until
it is securely in position. Release the locking lever.
Draw-Out Breakers Only
23. Install the new trip unit disconnect plug [8] on the
breaker side plate with the two thread-forming screws
[7] supplied, as shown in Figure 23. Run the wires
through the hole in the plate to the terminal board.
24. Connect the wires from the breaker-mounted trip
unit disconnect [8] to the terminal board according
to the chart on the terminal board mounting bracket.
The pin arrangement of the trip unit disconnect
plug is shown in Figure 24. The wires from the trip
unit disconnect are grouped in sleeves as listed in
Table 5. If zone-select interlocking is not installed on
the breaker, those four wires (in two sleeves) may be
cut off or tucked out of the way.
Trip Unit
Mounting Plate
Screw Slots
Bend the
Locking
Tab
Figure 21. Trip unit mounting slots in the B phase CT on 2500–4000 A
breakers.
Figure 22. Installing the trip unit (800–2000 A breaker shown).
25. Run the wires from the substructure-mounted trip
unit disconnect [9] through the slot in the side of the
substructure. Place the enlarged portions of the slots
in the disconnect slide over the two shoulder studs in
the side panel, as shown in Figure 26.
26. Slide the trip unit disconnect forward in the slot,
then connect the spring [10] between the hole in the
slide and the anchor tab on the substructure, as
shown in Figure 26.
27. Connect the wires from the substructure-mounted
trip unit disconnect [9] to the appropriate external
sources. The wire colors and groupings are the same
as those listed in Table 5. The pin arrangement of
the trip unit disconnect plug is shown in Figure 27.
Mounting
Plate
Guide Pin
Trip Unit
Alignment
Pin

7
Figure 23. New trip unit disconnect [8] installed on the side plate of a
2500–4000 A breaker.
Figure 24. Pin layout of the breaker-mounted trip unit disconnect, as
seen from the rear.
Wire Color Function
Sec. Disc.
Pin No.
Terminal
Board Point
green
white
zone-select
interlock
11
12
74
73
red
white
zone-select
interlock
13
14
76
75
green
yellow
power
management
2
6
105
106
red
white
blue
power
management
3
7
10
107
108
109
black
red
power
management
4
8
110
111
Table 5. Wire groupings from the trip unit disconnect.
Spring
Mounting
Hole
Figure 25. Placing the trip unit disconnect [9] on the mounting studs on
the substructure side panel.
Figure 26. Trip unit disconnect [9] installed on the draw-out
substructure.
Figure 27. Pin layout of the substructure-mounted trip unit disconnect,
as seen from the rear.
Trip Unit
Disconnect [8]
Disconnect
Mounting Studs
Mounting
Spring [10]
Wire Slot in
Side Panel
Spring
Anchor Tab
Mounting
Screws [7]

Returning the Breaker to Service
28. Replace the cover on the breaker according to the
instructions in GEH-4693 (800–2000 A) or GEH-4694
(2500–4000 A).
29. For a draw-out installation, reinstall the side plate on
the breaker.
30. Test the breaker at high current with primary current
injection before returning it to service.
31. Reinstall the breaker into its cubicle or substructure.
g
These instructions do not cover all details or variations in equipment nor do they provide for every possible contingency that
may be met in connection with installation, operation, or maintenance. Should further information be desired or should
particular problems arise that are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the
GE Company.
GE Industrial Systems
General Electric Company
41 Woodford Ave., Plainville, CT 06062
DEH40391 R01 0702 © 2002 General Electric Company