catalogo gerapid ge.pdf

1. 1

GE Energy

Industrial Solutions

GerapidHigh Speed DC BreakerApplication Guide

g imagination at work

1. 2

Contents Pages

Gerapid introduction 3Gerapid applications 4Gerapid key features and construction 5Gerapid options and accessories 7Gerapid breaker ratings 14Gerapid controls data 15Gerapid wiring diagrams and connections 16Gerapid catalog numbering system / breaker selection 26 Gerapid outline drawings 30Gerapid guideform spec 42Glossary 46

1. 3

IntroductionGerapid is a DC single pole, high-speed, air circuit breaker available in either fixed-mounted or drawout versions, designed for traction market applications. Both feeder and rectifier breaker types are offered, utilizing a common com-pact modular design. Current ratings from 2600A to 8000A, and voltage ratings up to 3600V are available. Gerapid em-ploys a 2-stage contact system (main and arcing contacts) for prolonged contact life and simple contact replacement. Tripping is via a spring energy trip mechanism with me-chanical latch. A powerful solenoid with integrated control unit provides closing energy. Primary terminals can be configured in vertical or horizontal arrangements. Extensive accessory options are available.

The Gerapid is tested to relevant IEC 60947, EN 50123 and ANSI/IEEE C37 Standards.

Other related publications:Gerapid FCB Users GuideS47183e

Gerapid RCB Users Guide..DTR01807

Gerapid BrochureDEA-379

Gerapid Guide Form Specification..DEE-425

Gerapid 4207FCB with 1X2 Arc Chute Gerapid 4207FCB with 2X2 Arc Chute

1. 4

Applications

In addition to traction substation applications, Gerapid can be used as a feeder breaker in various other installations, such as industrial plants (metals industry), as field breakers for motor and generator field applications, and as discon-nects for DC Drives to name a few. The breaker, as deliv-ered, is NEMA 1 protected. It is intended for service in indoor applications, without pollution, with non-conductive dust, protected against high humidity and heavy condensation. Low conductivity dust deposit due to frequent condensation of humidity is acceptable. For general environmental condi-tions, refer to EN 50123-1 -annex B, and IEC 60947, class PD3. The breaker can operate at rated current within ambi-ent temperature range of 5C to +40C (23F to 104F).

Maximum operating ambient temperature is +55C (130F) with continuous current derated by 10%. The breaker can operate at altitudes up to 2000m (~6500ft) without derat-ing. The breaker shall not be subjected to strong vibra-tions. Maximum vibrations of 0.5g per 30sec in vertical and horizontal directions are allowed. Air shall be clean and its relative humidity shall be not more than 50% r.h. at the maxi-mum temperature of +40C (104F). Relative humidity may be higher if the temperatures are lower, for example, 90%r.h. at +20C (68F). Slight condensation might occur during vari-ations of temperature.

The lower and upper main terminals must be connected directly to the main cables or bus bars. The breaker must only be used in an upright operation position with the arc chute in place and fully secured. The safety distances as listed in section page 31 shall 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 stray fields from other devices, can lead to a shift of the trip setting thresholds. This may result in premature tripping, or no tripping at all during low-level short cir-cuit current events. This has to be accounted for when installing and operating the breaker with shielding added if appropriate. The control wires must be connected to the control terminals as shown in the schematic circuit diagrams. During continuous operation, breaker must only be loaded up to its maximum rated current. Load currents in excess of breaker nameplate rating are allowable for brief periods only. Refer to the short time currents listed in tables on page 14.

Manual closing of the breaker while energized is forbid-den. Manual closing must only be used for maintenance and inspection purposes, when breaker power is off and grounded. The circuit breaker consists of high energy mov-ing components. Do not touch the circuit breaker while it is being opened or closed. There is a high risk of major injury. The control circuits may include capacitor banks, which can be charged with dangerous voltages. Work on this section must be carried out carefully.

1. 5

Key Features and Construction

Mining and traction compliant (ANSI C37.14, IEC 947-2,EN 50123-2) High speed TRIP (opening delay

1. 6

Arc Chutes and Adapter

Arc chute variations are based on system voltage and interrupting rating requirements. The compact and modular design of the arc containment system requires no additional magnetic support and allows small safety clearances with high interrupting capacity. Because of the compact dimen-sions, these breakers can be installed in extremely small enclosures and offer a cost-effective solution for replace-ments. An arc chute adaptor is used to mount the various arc chutes for different operating voltages on the breakers. The arc chutes consist of a highly durable, arc-proof material, in which 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 cathode voltage drop. Because of their high heat capacity, the plates and arc chute walls can absorb a large amount of the arcs energy.

Gerapid 2607/4207/6007 Fig. 6.1 1x_Arc Chutes

Gerapid 8007

Gerapid 8007

Fig. 6.2 2x_Arc Chutes

Gerapid 2607/4207/6007

1. 7

Mechanism

The Gerapid is equipped with a modular mechanism design, which is wear-resistant and nearly maintenance-free. This mechanism ensures an extended electrical and mechanical endurance of the breaker as well as a high level of safety under all operating conditions. Breaker can operate 20,000 cycles without major maintenance when opened by the shunt trip or zero voltage release coils, and 1,000 opera-tions by means of ED impulse coil or OCT releases. This mechanism is mechanically latched in the CLOSED posi-tion. A mechanically latched mechanism offers advantages compared to often used electro magnet holding systems since no auxiliary control power source is required to keep the breaker closed.

The mechanism is provided with two tripping latches. One latch, called slow latch, is used for opening under normal conditions, like actuation from shunt trip or zero-voltage release. The second one, quick latch, de-clutches the main contact arm from the mechanism and opens the contacts with an extremely short delay. This is used when interrupt-ing short-circuit or overloads. All safety releases operate onto the quick latch. Different main springs are used in mechanisms for different breaker frames. Therefore mecha-nisms cannot be exchanged between breakers of different frames. Note too, that the 8007R and 10007R rectifier break-ers utilize dual contact assemblies and mechanisms for increased interruption and withstand capabilities, required of rectifier applications.

Fig. 7.1 Operating Mechanism

1. 8

Overcurrent Trip Device (OCT & POCT)

The OCT release is a magnet with two magnetic circuits, optimizing the twin magnetic field principle. This technology ensures equally fast tripping in both current directions. This system does not require auxiliary control voltage to oper-ate. It is a direct acting and instantaneous tripping device. The OCT consists of the holding circuit, the movable arma-ture and the tripping circuit. The holding and the tripping magnetic circuits are both excited by load current. Until the static overload releases response threshold has been reached, the armature is held in position by the holding flux and the counter springs force. Once the load current exceeds the set static response threshold, the attraction flux takes over and rapidly pulls down the flexible armature. During this operation, the armature hits the seesaw, which releases the quick latch in the mechanism. The latch and contacts are opened immediately. The OCT is available in either a fixed setting or adjustable over specific ranges. On the adjustable OCT, the response threshold can be easily adjusted by turning the adjustment nut with a SW6 hexagon wrench. The available ranges are described in the table in Figure 8.2. Other ranges might be possible on request.

On Gerapid rectifier (RCB) type breakers, the OCT is polarized (POCT) so that it provides fast tripping in reverse current di-rection and no tripping on forward current (normal) direction. This is intended to provide protection of the rectifiers, against internal faults. Downstream faults are cleared by the feeder breakers. The blocking system of the POCT consists of main magnet circuit, permanent magnet oscillator and blockades. If the main current in forward direction exceeds 300A, the blocking system starts to operate and counteracts tripping.

Fig. 8.1 Overcurrent Trip Device (OCT)

Table 8.2 Available Tripping Bands for the OCT

Gerapid Feeder Circuit Breaker OTC Bands 9-2009Gerapid Feeder Circuit Breaker OCT Bands 9-2009Frame Size

Trip Band (kA) 2607 4207 6007 8007

1.5-2.5

1.5-3 1.5-4

1.5-5 2-6 2-7 2-8

2.5-5.5 3-7 3-8 3-9

3-12 5-10 6-14 7-15 8-18

10-16 12-24

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Closing Solenoid (drive)A high power solenoid is used to perform fast closing opera-tions. This drive is mounted at the front of the breaker and is enclosed in a grounded metal casing. Closing solenoid pow-er is supplied from a external power source, independent from the breaker internal controls. Voltage level must be de-fined at order placement. Rated power, depends on breaker type, but is between 1.8kW and 2.6kW. Closing is enabled by external dry contact closure. Minimum close signal duration should be 100ms. The closing drive system always includes a self-interrupt control circuit (SU circuit board).

This circuit enables short activation with a time of ~150ms. The SU switches power to the solenoid and automatically disconnects it after ~400ms. This feature protects the drive from possible overheating, and increases service life. The SU unit also prevents repeated drive closing, due to an ex-isting and continuous short circuit condition and provides an anti-pumpingsafety feature. After a closing attempt, the close mechanism is electrically blocked for approxi-mately 8sec. Lock time increases to 14 sec, if internal C-bank (NEKO) is present. This prevents premature closing following a short circuit.

Fig. 9.1 Closing Solenoid

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ED Trip CoilED (electrodynamic) impulse release is a high speed trip coil, and is intended to be used with external protective relays or systems monitoring current increase. External relays must be provided and installed by the customer. The ED coil must be energized by a capacitor storage trip device. An optional internal capacitor trip and control (NEKO), can be furnished with the breaker or must be sup-plied by the user externally. Rated voltage of 300V and capacitance of 2000F is required. If a fault is detected by the external relay, a firing signal must be sent to the capacitorscontrol unit (internal NEKO) causing NEKO unit to discharge its energy into ED coil. If the capacitor and controls are external, then user must supply the 300V directly to the ED coil. The coil releases the quick latch and opens breakers contacts in 3-4 ms. ED trip coil is an optional accessory. It can be selected as a complete set consisting of ED coil and electronic control unit with C-bank called NEKO, or just the ED coil with user supplied capacitor trip unit .

WARNING: Firing signal voltage of 6VDC to 24VDC must be filtered. There should be no spikes on the signal with a du-ration less than 3ms. This can lead to failure of the NEKO board. Maximum duration of the firing signal must not exceed ~1sec. Longer duration can cause the NEKO board to overheat. It is recommended to use an auxiliary breaker contact in series connection with firing circuit. It will auto-matically cut off the firing circuit after breaker opening.

Fig. 10.1 ED Trip Coil (with seesaw trip linkage

Shunt Trip & UVR CoilsThe 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. Both devices are in-terchangeable. In normal configuration, the internal voltage converter transforms the external supply voltage into 24VDC, which is required by the standard ST or UVR. Both devices can be activated by a dry contact connected as shown in section on pages 21-24 wiring diagrams.

Optionally, the ST can be ordered for connection directly to an external 24VDC ( 5%), 125VDC or 220VDC supply. A double winding shunt trip coil is also available with this op-tion for 125/220VDC external control supply, for back-up or redundancy. The ST is used for remote actuation and normal opening operations. It is designed for short time operation with max duty cycle of 9%. STs supply is connected through breaker auxiliary contacts, which cut off supply voltage after opening. This protects the ST against overheating.

The UVR can be used with remote actuation, and in combi-nation with an internal electronic control, for voltage control.The UVR releases at voltage interruption or supply voltage drop below 20V. In these cases UVR trips the breaker. It is therefore possible to use this device in combination with the electronic trip unit for voltage monitoring, where an unin-tended re-start of machines after a temporary voltage loss is to be prevented. The UVR is intended for continuous opera-tion. Its rated power is 10W. Due to its operational mode, the UVR is a self-monitoring device, i.e. when the breaker is tripped upon a break of the pilot wire (EMERGENCY-OFF prin-ciple). NOTE: Manual closing of the breaker with ST installed, while pushbutton OPEN is pressed and control power ap-plied, might lead to ST coils overheating and damage.

Fig. 10.2 Shunt Trip or UVR Coil

1. 11

Forced Tripping ReleaseFor drawout installations or as an manual trip interlock, the forced tripping release (FT) can be installed in the breaker. This unit, which mounts in the breaker base plate, mechanically trips the breaker, by pressing the pin against the seesaw link-age. Force required to trip the breaker is about 30N (~7ft-lb). The tripping pin position is shown below. With a correctly designed interlock in an enclosure, FT provides safety-tripping function. During withdrawal operation of the trolley, the break-er can be tripped BEFORE its main terminals disconnect from the mains.

Fig. 11.1 Forced Tripping Release (side view)

Arc Chute Indicator Arc Chute Indicator is a potential free, N.O. contact mounted on the sidewall. It electrically blocks the closing solenoid when the arc chute is not installed.

Fig. 11.3 Forced Tripping Release (bottom view)(2607-6007)

Fig. 11.2 Arc Chute Interlock Indicator

Front

5

Front

5

1. 12

Auxiliary SwitchStandard breaker is equipped with 3 isolated, form C, aux-iliary contacts (1 NO/NC each). Maximum available is 10. The movable main arm activates the contacts. The con-tacts are wired to the 15-pin control terminals (X4 & X5) on the front of the control box. Conventional thermal current rating is 10A. Maximum electrical ratings for switches are 1A@230VAC and 0.5A@110VDC, 0.3A/220VDC.

Fig. 12.1 Auxiliary Switch Assembly (inside control box)

Position IndicatorOptional position Indicator is mounted at the front of the closing solenoid. It is mechanically switched by the sole-noids shaft, and indicates position of the main contacts.O (or Green) indicates contacts are openI (or Red) indicates contacts closed

Fig. 12.2 Position Indicator

Overcurrent Trip TargetIndicator OC TRIP TARGET is a potential free, NO contact mounted at the top of the OCT. Provides contact closure when OCT operates.

Fig. 12.3 OCT Trip Target

Manual Operation LeverA hand lever for manual closing and opening operation dur-ing maintenance is available. This tool must not be use while breaker is energized. To close the contacts, install hand lever on the drives rod, and pull it out smoothly until latches snap.To open the contacts, install the tool into the ring and push it hard against the drives rod until breaker opens. Alternative manual closing and opening operation is possible by rotat-ing the main shaft of the breaker mechanism, which is ac-cessible from the side. Use 10mm hexagon-socket wrench.

Fig. 12.4 Feeder Breaker Manual Operating Handle

1. 13

SEL Current Measuring SystemThe SEL current measurement system is available on the 2607 and 4207 frame breakers, and consists of the sensing component and signal-processing control board. 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 mounted in the control-box. 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.

Fig. 13.1 SEL Sensor

The sensor includes Hall-effect 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 in Fig. 13.2. The outputs are insulated from the main voltage. The insulation withstands voltages up to 4kV RMS and up to 40kV in peak. Two versions are available. Standard model (T35) for ambient temperature 5C to +35C and a model for higher temperature (T55) 5C to +55C. Note top terminal must be vertical orientation only.

Table 13.2 SEL Ratings

Type SEL 06-1 06-2 06-4 12-1 12-2 12-4Input

Une (V) 1000 2000 4000 1000 2000 4000

Ine

Uni (kV) 12 18 40 12 18 40

for ambient temperature 5C to +35C / +23F to +95F

-6kA to +6kA -12kA to +12kA

5C to +55C / +23F to +131F

T35

T55

Output4 to 20 ma

-20 to +20 ma -10 to +10V

Related to the rated current of the breaker

for ambient temperature

1. 14

Ratings

Table 14.1 2607-8007 Ratings

Table 14.2 8007R & 10007R Ratings

2607 thru 8007 Technical Data

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/IEEE C37.14) 2600 4150 N/A

Rated voltage UNe [V] (EN 50123 / IEC 60947) 1000 2000 2000 3000 3600 1000 2000 2000 3000 3600 1000 2000 2000 3000 3600 1000 2000

Rated maximum voltage [V] (ANSI/IEEE C37.14) 800 N/A N/A N/A N/A 800 N/A 1600 N/A N/A N/A N/A N/A N/A N/A 800 N/ARated insulation voltage Ui [V] (EN 50123 / IEC 60947) 2000 2000 2000 3000 4000 2000 2000 2000 3000 4000 1000 2000 2000 3000 4000 1000 2000

Short time current 120 min [A] (EN 50123 / IEC 60947)

Short time current 2 min [A] (EN 50123 / IEC 60947)Short time current 20 sec [A] (EN 50123 / IEC 60947)

Impulse withstand voltage 1,2/50 s Ui [kV] 18 18 18 30 30 18 18 18 30 30 12 18 18 30 -1) 12 18according to EN 50124-1:1997

Power frequency withstand voltage 50 Hz Ua [kVeff] 10 10 10 15 15 10 10 10 15 15 7 10 10 15 -1) 7 10according to EN 50124-1:1997

Rated short circuit making capacity Nss [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 according to IEEE C37.14 [kA] 120 120 60 120 -1)

Peak current according to IEEE C37.14 [kA] 200 200 100 200 -1)

Maximum short circuit current [kA] 244 120 100 52 244 120 100 52 200 240

tested at customer request

Maximum arc voltage Uarc [kV] (EN 50123 / IEC 60947) 2 4 4 5.6 7 2 4 4 5.6 7 2 4 4 5.6 7 2 4Weight ca. [kg] 120 120 160 160 160 120 120 160 160 160 150 150 165 165 165 190 210Weight ca. [lbs] 265 265 352 352 352 265 265 352 352 352 331 331 364 364 364 419 463

9600

1600024000

8000

6000

Gerapid 8007

7800 126008500

5000

5200

7200

1200018000

Gerapid 2607 Gerapid 4207 Gerapid 6007

3150

2600 4200 6000

1) Test data available at customer request

2607 thru 8007 Breaker Charaertstics

2010/01/28 Design and specifications are subject to change without notice

1

8007R & 10007R Technical data

Parameter Reference Gerapid 8007 R Gerapid 10007 R Arc chute type N/A 1x2 1x3 1x2 1x3 Rated continuous current [A] ANSI C37.14 p.5.3 6.000 6.000 8.000 8.000 2 hours current [A] N/A 7.200 7.200 9.600 9.600 2 minutes current [A] N/A 12.000 12.000 16.000 16.000 20 seconds current [A] N/A 18.000 18.000 24.000 24.000 Rated short-time current (250ms) [kA] ANSI C37.14 p.5.5 90 (149 peak) 60 (100 peak) 90 (149 peak) 60 (100 peak) Rated maximum voltage [V] ANSI C37.14 p.5.2 800 1200 800 1.200 Rated insulation voltage - UNm [V] EN 50124-1 p.1.3.2.4 2.000 2.000 2.000 2.000 Rated impulse voltage - UNi [kV] EN 50124-1 p.1.3.2.7 18 [1,2/50 s] 18 [1,2/50 s] 18 [1,2/50 s] 18 [1,2/50 s] Power frequency voltage Ua [kV] EN 50124-1 a.B 2.2 10 [1 minute 50 Hz] 10 [1 minute 50 Hz] 10 [1 minute 50 Hz] 10 [1 minute 50 Hz] Mechanical endurance [cycles] a) N/A 10.000 10.000 10.000 10.000 Rated short circuit peak / sustained current [kA] b),c) ANSI C37.14 p.5.4 200 / 120 132 / 80 200 / 120 132 / 80 Short-circuit characteristic Tests a, b, c, d acc. ANSI C37.14 annex A High-speed High-speed High-speed High-speed Maximum arc voltage [V] N/A 2.500 2.500 2.500 2.500 Mass ca. N/A 220 kG 220 kG 220 kG 220 kG

a) 10.000 cycles without parts replacement. Inspection after 5.000 cycles. Max. 5.000 cycles by means of ED impulse coil or POCT release. b) Tested for high and low frequency impedance bonds. c) Trip by means of POCT (direct-acting, instantaneous, electromechanical and polarized OC release) or by means of ED impulse coil with no intentional delay.

8007R & 10007R Breaker Characteristics

1. 15

Controls Data

Table 15.1 Controls Data

1. 16

Standard Gerapid Wiring Diagrams

The internal wiring for Gerapid breakers is composed of several standard typical diagrams, for such components as trip-ping devices and indicators. These basic diagrams are shown on the following pages. The power circuit is not shown in the diagrams for clarity. Using the key numbers and codes shown below, the complete wiring diagram number can be obtained or deciphered.

Note: Some special, non-standard circuit requirements may not comply with the wiring diagram coding shown below. In such cases, the diagram will be assigned a unique number, for example: 36/0033. For breakers with special wiring diagrams, a copy of the special diagram is shipped with the breaker.

Example: Wiring Diagram 36/102020011

Fig. 16.1 Wiring Codes

Wiring Diagram Number 1 / 2 3 4 5 6 7 8

36 S37

11 22 3

ED Tripping Device0 0 Without Indicators1 01 OTC Trip Indicator2 02 Arc Chute Installed Indicator

03 OTC and Arc Chute Indicator

200 None

10 With Shunt Trip20 With Zero Voltage Release

Gerapid Wiring Diagram Code Positions

SEL System

Auxiliary Contacts

Solenoid with SU Control

With SEL System

3 Form C Contacts5 Form C Contacts10 Form C Contacts

With ED Coil & NECO

24VDC External Supply

Gerapid RCB

Indication Devices

Auxiliary Tripping Device

Breaker Type

Closing Solenoid

Gerapid FCB

Voltage Converter

With ED CoilWithout ED Coil

Auxiliary Voltage Supply

1. 17

Breaker Internal Control Power Supply

Fig. 17.1 Supply with voltage converter or with direct external 24 V DC 5%.

1 (+)

3 (-)

-X3

4 (+ or ~)

5 (- or N)

+24VDC +/- 2% to other PCBs

-X10: PCB

User SuppliedControl Power

Source115-240VAC +/- 10%

or35-350VDC +/- 10%

8

9

10

67

Ground

1 (+)

3 (-)

-X3

4 (+)

5 ( - )

+24VDC +/- 2% to other PCBs

-X11: PCB

User SuppliedControl Power

Source24VDC +/- 5%

8

9

10

67

Ground

Breaker

Breaker

- User external connection point

- Factory internal connection point

PCB - Printed Circuit Board

Breaker Internal Control Power Supply

Fig. xx Supply with voltage converter or with direct external 24 V DC 5%.

*

*

*

Note: Rectifier Breakers Contain Two(2) X10 or X11 PCBs

1. 18

ED Coil With Internal NECO Control Circuit

Fig. 18.1 ED Coil with Internal NEKO control unit

1 (+)

2 (-)

3 (+)

4 (+)

5

6

9

10

11

12

-X10/X11: PCB -X16 : NECO PCB

8 (+)

6 (-)

24VDC

-X2:

10 (+)

11 (-)

User ExternalTripping Signal6-24VDC, 20ma

Internal Close StopInterlocking To

Other PCBs

-X3:

6

7

-Q1

EDImpluseCoil

Capacitor BankCharged Signal

N.O. Contact

NEC

O P

rinte

d C

ircui

t Boa

rd

Breaker


ED Coil With Internal NECO Control Circuit



Fig. xx ED coil with internal NEKO control unit

*

*

*

* Note: Rectifier Breaker contains two (2) Ed coils and NECO PCBS, both connected to -X2, terminals 10 and 11. Second NECO charged signal is connectedto -X3, terminals 10 and 11.

1. 19

ED Coil With External User Furnished Capacitor Trip Supply

Fig. 19.1 ED coil with external capacitor trip device

ED Coil With External User Furnished Capacitor Trip Supply



-X2:

10

11

-Q1

EDImpluse Coil

User FurnishedExternal Capacitor

Tripping Device300V - 2000uf

Breaker

Fig. xx ED coil with external capacitor trip device

**

Rectifier breakers contain two(2) ED Coils, and require a 4000uf external capacitor bank. Both are con-nected to -X2, Terminals 10 and 11.

*

1. 20

SU Control Circuit for Closing Solenoid

Fig. 20.1 SU-control circuit

4

3

1

2

5

6

8 (+)

7 (-)

9

10

-X10/X11: PCB

-X13 : ST PCB

9 (+)

6 (-)

24VDC

External TripSignal, N.O.

Contact


Other PCBs

ShuntTrip Coil

Shun

t Trip

Prin

ted

Circ

uit

Boa

rd

Breaker

Standard 24VDC Shunt Trip Circuit

-X2:

6

7

Coil Cut-offContact-HS11

PCB - Printed Circuit Board- User external connection point - Factory internal connection point

1. 21


Fig. 21.1 Standard Shunt Trip control circuit

***

*

* NOTE: Rectifier breakers contain two (2) shunt trip coils and PCBs. Second shunt trip coil is connected to -X2, terminals 8 and 9, and requires an additional N.O. Trip Contact,

*

4

3

1

2

5

6

8 (+)

7 (-)

9

10

-X10/X11: PCB

-X13 : ST PCB

9 (+)

6 (-)

24VDC


Contact


Other PCBs

ShuntTrip Coil

Shun

t Trip

Prin

ted

Circ

uit

Boa

rd

Breaker


-X2:

6

7

Coil Cut-offContact-HS11

PCB - Printed Circuit Board- User external connection point - Factory internal connection point

1. 22

Optional Shunt Trip Circuit - External DC

Fig. 22.1 Special version of shunt trip with single winding coil, directly supplied from external DC source. Not available on RCBs.

4 (-)

10

2

7 (+)

3

8

-X13 : ST PCB

External User Supplied DCTrip Supply and N.O. Contact

110VDC, 125VDC, 220VDC

ShuntTrip Coil

Shun

t Trip

Prin

ted

Circ

uit

Boa

rd

Breaker


Optional Shunt Trip Circuit - External DC

- User external connection point- Factory internal connection point

-X2:

6

7

Coil Cut-offBkr AuxContacts

Fig. xx Special version of shunt trip with single winding coil, directly supplied from external DC source.

1. 23

Optional Shunt Trip Circuit - External DC, Dual Winding Coil

Fig. 23.1 Special version of shunt trip with double winding coil directly supplied from external DC source. Not available on RCBs.

Fig. xx Special version of shunt trip with double winding coil directly supplied from external DC source.

4 (-)

10

2

7 (+)

3

8

-X13 : ST PCB



ShuntTrip Coil #1

Shun

t Trip

Prin

ted

Circ

uit

Boa

rd #

1

Breaker

-X2:

6 (+)

7 (-)


4 (-)

10

2

7 (+)

3

8

-X13 : ST PCB

Shun

t Trip

Prin

ted

Circ

uit

Boa

rd #

2

-X2:

8 (+)

9 (-)




1

2

ShuntTrip Coil #2

3

4

Optional Shunt Trip Circuit - External DC, Dual Winding Coil

1. 24

Zero Voltage Release Circuit

Fig. 24.1 UVR control circuit

1

2

3

4

5

6

8 (+)

7 (-)

9

10

-X10/X11: PCB

-X14 : UVR PCB

9 (+)

7 (-)

24VDC

External TripSignal, N.C.

Contact


Other PCBs

UVR Coil

Und

ervo

ltage

Rel

ease

Dev

ice

Prin

ted

Circ

uit B

oard

Breaker


Zero Voltage Release Circuit



-X2:

9

8


Contact

7

6

Fig. xx UVR control circuit

*

*

*

* NOTE: Rectifier breakers contain two(2) UVR coils and PCBs. Second UVR coil is connected to -X2, ter-minals 6 and 7, for external trip from N.C. contact. Option for N.O. trip contact is not available

1. 25

Typical Gerapid FCB External Connections

X2 through X5 Plug connectors viewed from the front, and located on front of control box.Auxiliary switch contacts are shown with breaker open. Check breaker documentation for actual quantity.Some connections or output contacts present only when optional feature is installed in breaker.

Typical Gerapid FCB External Connections

X2 through X5 Plug connectors viewed from the front, and located on front of control box. Auxiliary switch contacts are shown with breaker open. Check breaker documentation for actual quantity. Some connection or output contacts present only when optional feature is installed in breaker.

1 2 3 4 5 6 7 8 9 10 11 12X2

(-) /

N

(+) /

~

GR

D

Clo

sing

Driv

e S

uppl

yIn

put

Clo

se S

igna

l(N

.O.)

Trip

Sig

nal t

oS

hunt

Trip

or

UV

R (N

.O.)

Trip

Sig

nal t

oU

VR

(N.C

.)

(-)(+)

ED

Firi

ngS

igna

l6-

24V

DC

Pul

se

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15X3(-)

/ N

(+) /

~B

reak

erC

ontro

l Pow

erIn

put

NE

KO

Cap

acito

rsC

harg

ed O

utpu

t Con

tact

Trip

ped

by O

CT

Out

put C

onta

ct

Arc

Chu

te In

stal

led

Indi

catio

n C

onta

ct

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15X4

Auxiliary BreakerContacts

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15X5

Auxiliary BreakerContacts

Fig. 25.1 FCB Connections

1. 26

1 2 3 4 5 6 7 8 9 10 11 12X2

(-) /

N

(+) /

~

GR

D

Clo

sing

Driv

e S

uppl

yIn

put

Clo

se S

igna

l(N

.O.)

Trip

Sig

nal

to D

ual S

hunt

Trip

s (N

.O.)

(-)

(+)

ED F

iring

Sig

nal

6-24

VD

CP

ulse

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15X3

(-) /

N

(+) /

~B

reak

erC

ontro

l Pow

erIn

put

1st N

EK

OC

apac

itors

Cha

rged

Out

put C

onta

ct

Trip

ped

by P

OC

TO

utpu

t Con

tact

Arc

Chu

te In

stal

led

Indi

catio

n C

onta

ct

2nd

NE

KO

Cap

acito

rs C

harg

edO

utpu

t Con

tact

1 2 3 4 5 6 7 8 9 10 11 12X2

(-) /

N

(+) /

~

GR

D

Clo

sing

Driv

e S

uppl

yIn

put

Clo

se S

igna

l(N

.O.)

Trip

Sig

nal

to D

ual U

VR

Coi

ls (N

.C.)

(-)

(+)

ED F

iring

Sig

nal

6-24

VD

CP

ulse

RCB -X2 wiring with Shunt Trips installed

RCB -X2 wiring with UVR Trips installed

RCB -X4 & -X5 wiring same as FCB

Typical Gerapid RCB External Connections

X2 through X5 Plug connectors viewed from the front, and located on front of control box.Auxiliary switch contacts are shown with breaker open. Check breaker documentation for actual quantity.Some connections or output contacts present only when optional feature is installed in breaker.

Fig 26.1 RCB Connections

1. 27

Gerapid Breaker Configuration and Catalog Number Coding System

The Gerapid Breaker coding system (PST), introduced in 2008, is a catalog configuration tool based on Excel. The cata-log code consists of 20 digits. Each digit represents specific rated value or component. The table below shows all available values, components and accessories for the Gerapid breaker family. Not all of the options from the Table are compatible. To avoid improper configurations use the Gerapid configuration tool for ordering. The coding system is valid for Gerapid feeder type (F), rectifier type (R) and disconnector type (DS).

Language1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 0

Breaker type Code 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Code 20 Target standards1 Gerapid 2607 5 Gerapid 8007R LV DC acc. IEC60947-2 4 Railway DC acc. EN50123-2 12 Gerapid 4207 6 Gerapid 10007R On Request R LV DC acc. IEEEC37.14 23 Gerapid 6007 7 Gerapid 8007DS China acc. IEC947-2 & GB14048.2 34 Gerapid 8007

code 19 Control connectors typeArc chute type Code 2 Gearapid SE retrofit 3 Railway & Industry applications 1

1 1X2 (1000V) 4 2X2 (2000V) S 2X2 S (1500V) Heavy Industry type 4 Military type acc. MIL-C-5015G 22 1X3 (1500V) 5 2X3 (3000V) E EF4-12 (3600V) R3 1X4 (2000V) 6 2X4 (3600V)

Code 18 CounterClosing solenoid supply voltage Code 3 Mechanical Counter 1 Without 0

1 48 V DC 5 220 V DC 9 125 V AC2 60 V DC 6 250 V DC A 230 V AC3 110 V DC 7 110 V AC B 240 V AC Code 17 Arc chute position switch4 125 V DC 8 120 V AC R On Request With 1 Without 0

Main terminals orientation (Top / Bottom) Code 4 Code 16 Lever for manual operating1 H/H - (H)orizontal 4 V/V B Balfour Beatty type With 1 Without 02 H/V - (V)ertical 5 For SEL 6kA S Siemens type3 V/H 6 For SEL 12kA R On Request

Code 15 Protection optionsMain terminals polarization Code 5 Sidewalls protection panels 1 Without 0

1 Top connector '+' 2 Top connector '-' 0 Not apply Rodent proofing 2

SEL operation temperature Code 6 Code 14 Contacts position indicator1 Ta = 35C 0 without SEL With 1 Without 02 Ta = 55C

Code 13 Forced tripping unitOver current trip unit (OCT) Code 7 With 1 Without 0

1 Fixed setting up to 15kA 5 Polarized adj. 0,4kA-1,2kA 02 Adjustable up to 15kA 6 Polarized adjust. 0,8kA-2,5kA Code 12 Impulse coil3 Fixed setting up to 24kA 7 Polarized adjust. 2kA-6kA Impulse coil with internal C-bank and control PCB (NEKO) 2 Without 04 Adjustable up to 24kA 8 Polarized adjust. 4kA-8kA - 3 Impulse coil w/o internal C-bank 1

Control circuits supply voltage Code 8 Code 11 Auxiliary tripping device1 external 24V DC5% 4 88 .. 145V DC Shunt Trip - external 125 Vdc 4 Without 02 24V/24V (DC stabilizer) 5 125 .. 353 V DC / 115 .. 240V AC Shunt Trip - external 220 Vdc 5 - 13 33 .. 85V DC R On request Zero Voltage Release 6 Standard Shunt Trip - 24Vdc 2

On request R Shunt Trip - external 110 Vdc 3

Auxiliary contacts quantity - changeover type Code 9 Code 10 OCT trip target (aux. contact)1 3 convertible contacts 3 9 convertible contacts R On Request With 1 Without 02 5 convertible contacts 4 10 convertible contacts

APN460437 rev.03 2008.10.07 Codes

Without OCT

Fig. 27.1 PST Code System

1. 28

Gerapid Breaker Selection

Breaker Type (Code 1)The breaker type is usually selected based on the required continuous current, and by application, either feeder or recti-fier protection. The continuous current rating of each breaker type is determined by the specific standards to which it is tested. The Ratings Tables on page 14 and the table be-low show the continuous current rating available for each breaker type, based on IEC/EN or ANSI test standards.

Arc Chute Configuration (Code 2)The type of arc chute utilized is dictated by the required system voltage and interrupting rating. Arc chutes are either one section (1X_) or two section (2X_), and can have up to four dividers. For most applications, select the arc chute with voltage rating closest to, but still greater than your system voltage. Make sure your available fault current does not exceed the breaker type and arc chute configuration noted in the Ratings Tables on page 14. For Field Application and Discharge Breaker applications, please contact GE Applica-tion Support.

Solenoid Drive Voltage (Code 3)The closing solenoid (drive) has a control power input sepa-rate from the rest of the Gerapid breaker controls. Select the voltage rating that matches the voltage source that will be used for breaker closing, from the options listed.

Main Terminal Configuration (Code 4)Main terminals on breaker types 2407 and 4207 can be furnished in either vertical or horizontal orientation, or in combination. Main terminals on breaker types 6007, 8007, 8007R and 10007R can only be furnished in vertical orienta-tion. Note that if the SEL (current monitoring module) option is selected (only available on the 2407 and 4207 breakers), the top terminal must be vertical and the bottom terminal horizontal.

Polarization Markings (Code 5)When the SEL option is selected, or when the breaker type is a 8007R or 10007R and includes a POCT (polarized over-current trip device), the intended current flow direction is needed to make sure the SEL or POCT are properly installed. Select the polarity of the top connector.

SEL Current Monitoring Module (Code 6)The SEL current monitoring module is calibrated to operate in two different ambient temperatures, either 35 degrees C or 55 degrees C. If you have selected the SEL in code 4, choose the appropriate ambient for your application.

Trip Device (Code 7)Gerapid breakers offer an internal, direct acting, instantane-ous overcurrent trip device (OCT). For 8007R and 10007R rectifier breakers a polarized overcurrent trip device (POCT) is used, which trips for current flow in only one direction, to protect the rectifier. The trip devices are available with either a specified fixed trip setting or an adjustable band within the listed ranges (1.5-12kA, 12-24kA). Actual trip setting or trip band must identified at order entry. Available trip bands for 2407, 4207, 6007 and 8007 breaker types are shown below.

Gerapid Feeder Circuit Breaker OCT Bands 9-2009

Breaker Type Standard 2607 4207 6007 8007 8007R 1007R IEC/EN 2600A 4200A 6000A 8000A N/A N/A ANSI 2600A 4150A N/A 6000A 6000A 8000A

ANSI C37-14, ANSI C37-16EN 50123/ IEC60947

Gerapid Feeder Circuit Breaker OCT Bands 9-2009Frame Size

Trip Band (kA) 2607 4207 6007 8007

1.5-2.5

1.5-3 1.5-4

1.5-5 2-6 2-7 2-8

2.5-5.5 3-7 3-8 3-9

3-12 5-10 6-14 7-15 8-18

10-16 12-24

Table 28.1 Continous Current Ratings

Table 28.2 OCT Bands

1. 29

Gerapid Breaker Selection, Contd

Internal Voltage Converter/Supply (Code 8)

Gerapid breaker internal controls utilize 24VDC. If filtered 24VDC control power is available, select option (2) -24VDC Filtered, otherwise select option (1) -24VDC +/-5%. If a differ-ent control voltage is planned to be used, select appropriate range from those listed. Note for 125VDC, select option (4) 88-143VDC.

Auxiliary Contact Assembly (Code 9)

Standard breaker comes equipped with 3 form C auxiliary contacts, so option (1) should be selected at a minimum. Optionally, auxiliary contacts can be increased to 5 or 10. Note that on 8007R and 10007R breakers, maximum auxil-iary contact quantity is 9.

Additionally, if the MIL type external connector is selected (Code 19), number of available auxiliary contacts is limited to 3.

OC Indicator (Code 10)

OC Indicator is an optional normally open, auxiliary output contact, that operates when the OCT or POCT trips the breaker.

Standard Operators/Trip Devices (Code 11)

For normal opening operations, or low-speed tripping (20-40 ms), a Shunt Trip should be selected. The standard Shunt Trip is powered from the internal 24VDC control, and actuated from an external dry contact. Optionally, exter-nally powered Shunt Trips can be provided, for use with 110VDC, 125VDC or 220VDC control power. As an alternate to the Shunt Trip, the breaker can be equipped with a Zero Voltage Release (UVD) coil. This coil monitors the internal 24VDC control supply, and will trip the breaker upon loss of voltage. The UVD coil can also be actuated by an external dry contact, acting much like a Shunt Trip.

Electro Dynamic Trip, High Speed (Code 12)

The Electro Dynamic (ED) trip coil is used for high speed tripping (3 -5 ms) of the breaker, triggered from external protective relays or systems (furnished by user). The power to energize the ED coil comes from a capacitor trip device (NECO) and controls, which can be furnished with the ED coil, or user can furnish their own external capacitor trip device (requires 300V output, 2000 f).

Forced Tripping Assembly (Code 13)

The Forced Tripping Assembly is mounted in the base plate of the breaker, and will mechanically trip the breaker when pressed upward. This is typically used as an interlock for drawout breaker designs.

Position Indicator (Code 14)

The Position Indicator displays the position of the main contacts and is located on the front of the closing solenoid. This indicator is required for breakers rated to ANSI C37.14 Standards.

Sidewall Protection/Rodent Proofing (Code 15)

Breaker types 2407, 4207 and 6007 can be fitted with either Lexan sidewall covers, to provide additional operator safety, or screening over all openings to prevent entrance of vermin into the breaker.

Hand Lever (Code 16)

To manually open and close the breaker for maintenance purposes, select this option to include the Hand Lever. Note: the Gerapid breaker is electrically operated, and has no pro-visions for manual operation while energized!

1. 30

Gerapid Breaker Selection, Contd

Arc Chute Indicator (Code 17)

Arc Chute Indicator is an optional normally open, auxiliary output contact that is closed if the arc chute is not installed. This feature is not available on 2X type are chutes.

Mechanical Operations Counter (Code 18)

A mechanical, non-resetable operations counter is available on 8007R and 10007R rectifier breakers.

Control Terminal Type (Code 19)

External control connections are brought out to the front of the breaker control box. The standard connectors utilize Phoenix type plug and socket connectors (plugs included), option (1). Other connector options include Military style plug, option (2), or Hartingstyle industrial plugs, options (3) and (4).

Relevant Standard (Code 20)

Select the specific governing standard to which the breaker is to be rated. This must match the breakerconfiguration selection restrictions as noted under the Breaker Type (Code 1) and Arc Chute (Code 2) and will es-tablish the values stamped on the breaker nameplate.

Standard Phoenix Connectors

Harting Connector

MIL-C-5015G Connector

1. 31

Gerapid Outline DrawingsWhen Gerapid breakers are mounted in enclosures, the following recommended safety clearances should be followed.

Gerapid Outline DrawingsWhen Gerapid breakers are mounted in enclosures, the following recommended safety clearances should be followed.

Safety distances - To Insulated Surfaces.Units in mm (inches)

Type Arc chute Main- Additional DeflectorGerapid Connection isolation

E A B C D1x2 H or V 10 (0.4) 700 (27.6) 150 (5.9) 150 (5.9) 120 (4.7)1x4 H or V 150 (5.9) 700 (27.6) 150 (5.9) 150 (5.9) 120 (4.7)2x2 H or V 80 (3.15) 1000 (39.4) 180 (7.1) 180 (7.1) 180 (7.1)2x3 H or V 80 (3.15) 1000 (39.4) 180 (7.1) 180 (7.1) 180 (7.1)2x4 H / H Plate 150 (5.9) 1000 (39.4) 180 (7.1) 180 (7.1) 180 (7.1)2x4 H / H Sidewalls 150 (5.9) 1000 (39.4) 180 (7.1) 180 (7.1) 180 (7.1)2x4 SEL / H Pan 150 (5.9) 1000 (39.4) 180 (7.1) 180 (7.1) 180 (7.1)1x2 V / V Heat sink 10 (0.4) 1000 (39.4) 300 (11.8) 300 (11.8) 180 (7.1)1x4 V / V Heat sink 150 (5.9) 1000 (39.4) 300 (11.8) 300 (11.8) 180 (7.1)2x2 V / V Heat sink 80 (3.15) 1000 (39.4) 180 (7.1) 180 (7.1) 180 (7.1)2x3 V / V Heat sink 80 (3.15) 1000 (39.4) 180 (7.1) 180 (7.1) 180 (7.1)2x4 1) 1) 1) 1) 1) 1) 1)1x2 V / V Heat sink 10 (0.4) 1000 (39.4) 300 (11.8) 300 (11.8) 180 (7.1)1x4 1) 1) 1) 1) 1) 1) 1)2x2 V / V Heat sink 80 (3.15) 1000 (39.4) 180 (7.1) 180 (7.1) 180 (7.1)2x3 V / V Heat sink 80 (3.15) 1000 (39.4) 180 (7.1) 180 (7.1) 300 (11.8)2x4 1) 1) 1) 1) 1) 1) 1)1x2 V / V n/a n/a 600 (23.6) 280 (11.0) 280 (11.0) 190 (7.5)1x3 V / V n/a n/a 600 (23.6) 281 (11.0) 281 (11.0) 191 (7.5)1x2 V / V n/a n/a 600 (23.6) 282 (11.0) 282 (11.0) 192 (7.5)1x3 V / V n/a n/a 600 (23.6) 283 (11.0) 283 (11.0) 193 (7.5)

1) Can be tested on customers orderHHorizontal terminal V...Vertical terminal SEL...Current measurement system type SEL

Safety distances - To Grounded Surfaces.Units in mm (inches)

Type Arc chute Main- DeflectorGerapid Connection

E A B C D1x2 H or V 10 (0.4) 1000 (39.4) 300 (11.8) 300 (11.8) 300 (11.8)1x4 H or V 150 (5.9) 1350 (53.2) 450 (17.7) 450 (17.7) 200 (7.9)2x2 H or V 80 (3.15) 1350 (53.2) 450 (17.7) 450 (17.7) 300 (11.8)1x2 V / V n/a 600 (23.6) 530 (20.9) 530 (20.9) 190 (7.5)1x3 V / V n/a 600 (23.6) 531 (20.9) 531 (20.9) 191 (7.5)1x2 V / V n/a 600 (23.6) 532 (20.9) 532 (20.9) 192 (7.5)1x3 V / V n/a 600 (23.6) 533 (20.9) 533 (20.9) 193 (7.5)

Safety distances - Grounded Surfaces

2607 / 4207

8007

Safety distances - Insulated Surfaces

2607 / 4207

6007

8007R

10007R

8007R

10007R

Table 31.1 Safety Clearances

1. 32

Legend for FCB Dimensional DrawingsLegend for FCB Dimensional Drawings

K Heat sink (for Gerapid 6007) L Ventilation openings in the breaker cubicle top cover shall not be less than 50% of total surface area. M Solenoid closing drive P Diameter 9 mm [0.35 in], Countersunk screw M8 S Control box Z Main Connector

K L M P S Z *) **) ***)

Gerapid 8007R, 10007R with arc chute 1X

Fig.XX Gerapid 8007R, 10007R with arc chute 1X; dimensions in mm [inches].

Legend for RCB Dimensional DrawingsK Additional heat sinks for Gerapid 10007RL Ventilation openings in the breaker cubicle top cover shall not be less than 50% of total surface area.M Solenoid closing driveP Diameter 9 mm [0.35in], Countersunk screw M8S Control boxZ Main Connector*) Dimensions valid only for Gerapid 8007R version.**) Dimensions valid only for Gerapid 10007R version.***) Lifting eye diameter 25 mm [ ~ 1 in]

Legend for RCB Dimensional Drawing

Table 32.1 Drawing Legends

1. 33

Gerapid 2607,4207, 6007 with arc chute 1x

Fig.33.1 Gerapid 2607-6007, arc chute 1X (dimensions in mm and inches)

1. 34

Gerapid 2607, 4207, 6007with arc chute 2x_

Fig.34.1 Gerapid 2607-6007, arc chute 2x (dimensions in mm and inches)

1. 35

Fig.34.1 Gerapid 2607-6007, arc chute 2x (dimensions in mm and inches)

Gerapid 8007 with arc chute 1x_

Fig. 35.1 Gerapid 8007 with arc chute 1x (dimensions in mm and inches)

1. 36

Gerapid 8007 with arc chute 2x_


1. 37


Gerapid 2607, 4207 with H / H terminals

Its possible to combine horizontal and vertical connectors. Dimensions are corresponding. Note with SEL option, top connector is vertical only.

Fig. 37.1 Gerapid 2607, 4207 with horizontal terminals (dimensions in mm)

1

1. 38

Gerapid 2607, 4207 with V / V terminalsIts possible to combine horizontal and vertical connectors. Dimensions are corresponding.

Fig. 38.1 Gerapid 2607, 4207 with vertical terminals (dimensions in mm)

2

1. 39

Fig. 38.1 Gerapid 2607, 4207 with vertical terminals (dimensions in mm)

Gerapid 6007 terminals

Gerapid 6007 is available only with V / V terminals!

Fig. 39.1 Gerapid 6007 with vertical terminals (dimensions in mm)

3

1. 40

Gerapid 8007 terminals

Gerapid 8007 is available only with V / V terminals!

Fig. 40.1 Gerapid 8007 with vertical terminals (dimensions in mm)

4

1. 41


Fig. 41.1 Gerapid 8007R, 10007R with arc chute 1X; dimensions in mm [inches].

Printed on 26, Mar 2010 at 12:23PM.

1. 42


Fig. 42.1 Gerapid 8007R, 10007R with arc chute 1X; dimensions in mm [inches].

Frontview Rearview

Printed on 26, Mar 2010 at 12:23PM.Printed on 26, Mar 2010 at 12:23PM.

1. 43

Gerapid High Speed DC Circuit BreakersGuide Form Specification

1. GeneralThis specification establishes the functional, environmental, and material requirements and conformance levels for high speed, high energy DC circuit breakers. The specification covers both feeder type and rectifier type breakers suitable for use in DC switchgear. The breakers can be used as main circuit breakers (MCBs), feeder circuit breakers (FCBs) and rectifier circuit breakers (RCBs) to protect semiconductors (converters/rectifiers). The specified high speed, high-energy DC circuit breakers shall be suitable for service in, but not limited to, the following applications:

Traction Power (light rail, trolley, tram, subway, maglev, ect.) Industrial plant protection (electrolysis plants, iron and steelmills, etc.,) Mining, Chemical, and Petrochemical processes Electric Power Generation (solar panel, wind, field breakers) Research/experimental (e.g., physics, particle accelerator protection)

MCBs, FCBs and RCBs shall be furnished by the same manufacturer. MCBs, FCBs and RCBs shall be based on similar or iden-tical designs to ensure commonality in spare parts, commonality in control power circuits and a common operator knowl-edge base.

FCBs shall be available with rated operating currents up to 8,000A (6000A ANSI) and operating voltages up to 3600VDC. RCBs shall be available with rated operating currents up to 8,000A and operating voltages up to 1200VDC.

Breakers shall have very high interrupting capacities combined with current limiting characteristics. Gerapid circuit breakers Models 2607 through 10007R, manufactured by the General Electric Company (GE), are acceptable. No equals or substitu-tions shall be acceptable.

2. Scope and ApplicationsThe breakers covered under this specification must meet the minimum ratings defined herein. FCBs shall be available with rated operating currents up to 8,000A (6000A ANSI) and operating voltages up to 3600VDC. RCBs shall be available with rated operating currents up to 8,000A and operating voltages up to 1200VDC.

The breakers shall be of a compact, modular design suitable for both new equipment applications and as replacement breakers for existing equipment.

3. Environment, Standards, Testing Indoor/enclosed IP 00 or NEMA 1 Ambient Temperature: -5 to +40C (55C @ 0.8 In) Humidity: 90% relative humidity (ANSI C37.14) Pollution: PD3A per EN50124-1 Vibration: 0.5g, 30s Altitude: -120m to 2000m above sea level

1. 44

All breaker types shall be type tested in accordance with ANSI/IEEE, EN and IEC standards regulating electric power systems supply to public transportation systems. Gerapid breakers comply with the Standards listed below.

ANSI/IEEE C37.14ANSI/IEEE C37.16 ANSI/IEEE C37.17ANSI/IEEE C37.20EN 50123-1EN 50123-2EN 50124-1EN 50121IEC 947-1IEC 947-2

4. Operation and ControlBreakers shall be Gerapid Type 2607, 4207, 6007, 8007, 8007R and 10007R manufactured by the General Electric Com-pany (GE). Breakers shall be equipped with a 2 -stage contact system and mechanically latched operating mechanisms. Latching shall not require external energy. Breakers shall be furnished with solenoid type closing mechanism and integrat-ed control units. Solenoid shall be front-mounted and enclosed in a grounded casing. Solenoid mechanism shall include a self-interrupt control module (SU) with anti-pumping and signal blocking, to protect the unit from repeated activation due to a short circuit condition.

The FCB mechanism shall close the breaker in 150ms or less, and the power consumption shall not exceed 2kW. The RCB mechanism shall close the breaker in 150ms or less, and the power consumption shall not exceed 5kW.

The mechanism shall be capable of operating on all standard control voltages as defined by the applicable standards.

FCBs shall have the option for an internally mounted, fixed or adjustable, over-current trip (OCT) device. Opening time shall not exceed 5ms. Electronic type trip units are not acceptable.

RCBs shall be equipped with an internally mounted, adjustable, polarized over-current trip (POCT) device. The internal over-current trip devices shall operate without imported energy (self-powered). The energy to operate the OCT or POCT and open the breaker, shall be derived from short circuit current. The POCT device shall have design characteristics specific to forward and reverse current flow. Only reverse current flow exceeding the over-current trip setting shall trip the circuit breaker. The trip units shall be integral to the circuit breaker. Bolt-on or remotely mounted OCT or POCT units are not acceptable. Trip units shall have provisions for optional trip indication. RBCs equipped with a POCT device shall be fitted with a high-speed auxiliary trip unit. The trip unit shall be electro-dynamic type, powered by internal or external capacitors and operated by an external over-current (OC) relay. The external OC relay must be specified and supplied by others.

1. 45

Breakers shall be capable of being equipped with either shunt trip (ST), or zero voltage trip (UVR) devices.

a) Shunt Trip operating voltage: 24V +/-5%b) Zero Voltage Trip operating voltage: 24V +/-5%

Breakers shall have provisions for up to ten isolated form C auxiliary contacts (1 NO/NC each) activated by the movable main contact. Contact ratings shall be 5A/230vac, 0.1A/220VDC

5. Ratings and Protection

RCBs shall be rated 6000A and 8000A with operating voltages either 800VDC or 1200VDC. Breakers shall comply with the relevant US and IEC standards (ANSI/IEEE C37.14, ANSI C37.16, ANSI C37.17, C37.20, IEC947). RCBs shall be fully rated and able to withstand rectifier short circuit conditions and reverse over-current conditions due to line side short circuits. RCBs shall be selective with FCBs, and have a very high transient over current withstand rating as listed below:

200kA short-circuit current @ 800VDC (per ANSI/IEEE C37.14) 132kA short-circuit current @ 1200VDC (per ANSI/IEEE C37.14) 8kA rated continuous current (per ANSI/IEEE C37.14)

FCBs shall be rated 2600-8000A (6000A max ANSI) with operating voltages up to 3600VDC 800VDC ANSI). Rated short circuit breaking capacity shall be in accordance with ANSI/IEEE C37.14, EN 50123-2 and IEC 942-2.

6. Materials and Construction

Rectifier and feeder breakers shall have a compact and enclosed construction. They shall be IP 00 (NEMA 1) protected. All parts shall be mounted on thick-walled, non-breakable and fireproof insulation panels with large covers protecting the breaker mechanism from damage. Optional transparent plastic side covers are available on types 2607, 4207 &, 6007 to further protect connection points.

RCBs shall use similar, proven technology as that used by the FCBs. Spare parts between the RCBs and FCBs shall be identical or very similar in design, construction and material.

RCB dimensions shall not exceed 425mm W x 960mm L x 900mm H. FCB dimensions shall not exceed 270mm W x 825mm L x 900mm H.

7. Service

The suggested breaker maintenance is based on normal use in an indoor switchgear-type enclosure. Recommended maintenance includes visual inspection, observation of open/close operations, cleaning, lubrication and replacement of arcing parts. Visual inspection may reveal conditions that require additional service.

For standard environmental conditions, with recommended or reduced maintenance, the life of the breaker shall be no less than 10 years. The breaker shall be designed for a minimum number of 10,000 mechanical operations (C-O) prior to major service and repair. Inspection intervals shall be a minimum of once per year.

For heavy use (high short circuit currents or a high number (>50) of over current operations (

1. 46

7.3 Glossary

A

a-release see Shunt trip device;

Activating magnet see Closing drive;

Anti-pumping device see SU control PCB. Prevents reclos-ing after a close-open operation, as long as the device initiat-ing closing is maintained in the position for closing

Arc probes (also: arc runners; arc horns). Provide safe arc leading into the arc chute. There are two arc probes mounted in Gerapid breaker, front and back.

Arcing contact (also: pre-contact; arcing pre-contact). An arcing contact on which the arc is intended to be estab-lished, to avoid wearing and burning of the main contacts. It is mounted at the top of flexible band. It is easy to replace. Spring loaded to maintain proper contact force.

Auxiliary contact (also: make/break contact; a-/b-contact, changeover contact, convertible contact). A contact included in an auxiliary circuit and mechanically operated by the breaker.

Auxiliary switch (also: auxiliary switch; make/break contact; a-/b-contact). A switch block containing up to 10 auxiliary contacts. Mechanically operated by the mechanism of the breaker during switching operations. Auxiliary switch block is mounted in lower compartment of the control box. Every contact can be either NO or NC, configured by appro-priate wiring.

C

Closing drive (also: activating magnet; closing solenoid; so-lenoid drive). High power, black solenoid coil, mounted at the front of the breaker, below the control box. Use for electric and remote closing of the main contacts. Power consump-tion is up to 2.6kW. Closing time is ~150ms.

Closing operation (also: switching ON; CLOSE operation). It is operation, by which the breaker is brought from the OPEN position to the CLOSED position.

Closing solenoid - see Closing drive;

Control circuit terminals (also: control sockets/plugs). Fully insulated sockets at the front cover of control box. Intended for external connection to the auxiliary and control circuits.

E

ED coil (also: electro-dynamic coil). An impulse coil release. Actuating element of ED impulse release, mounted on the base, under the mechanism.

Electro-Dynamic impulse release (also: ED tripping; impulse release). Release device, consist of actuator (ED coil) and control circuit (NEKO PCB with C-bank). This is an auxiliary release, activated by high-energy impulse of cur-rent. The impulse is shaped by internal (NEKO) or external C-bank. Opening time is less 3ms. Time to charge capacitors is ~15sec.

L

Lever for manual operating (also: hand lever). Hand lever can be used for both, closing and opening manual operation. It is intend for use only during maintenance.

M

Main circuit (also: mains; primary circuit; current path). All the conductive parts of the breaker included in the circuit, which is intend to close or open. It consists of: main terminals (upper and lower), fixed contact, flexible band and lower bus bar.

Main terminals (also: main connections). Two conduc-tive bars provided for electrical connection to external main circuit. Different configurations are available.

N

NEKO control PCB (also: ED coil control unit; internal C-bank control). Control circuit PCB to supervise the operation of the ED coil. It consists of control circuit and bank of capacitors. Required to energize the ED impulse coil.

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O

Opening operation(also: switching OFF; OPEN operation). An operation by which the breaker is brought from the CLOSEDposition.

P

POCTAn instantaneous, polarized and direct acting mechani-cal release. Tripping the breaker in case of fault backward currents, starting from 400A threshold. It is adjustable within predetermined ranges. Opening time depends on short circuit conditions and shall not exceed 7ms. POCT is activated by means of magnetic energy from main circuit. Requires no external control power.

Polarized breakeris a breaker, which trips only in case of spe-cific direction of a current flow, by means of POCT release. The breakers main connections are marked with plus and minus. These marks show normal current flow, at which the breaker does not trip.

Position indicator(also: position indicating device). A me-chanical device mounted at the front of closing drive. Indicates whether the breaker is in the open or closed position.CLOSED position is marked as I, or Red ColorOPEN position is marked as O, or Green Color

Pre-contactsee Arcing contact;

R

r-releasesee Zero voltage release;

S

Self cut-off functionA safety feature provided to avoid over-stressing of the closing drive and shunt trip release. Closing drive is automatically cut-off from power source after 500ms. Shunt trip coil is connected in series with auxiliary contact(s), which cause cut-off after breakers opening.

Shunt trip (also: ST; shunt release; a-release). Instantane-ous release energized by means of voltage signal. Within 50ms trips the breakers mechanism. Use for remote OPEN operation. ST can be activated by potential free contact or by directly applied voltage from external source. ST can have a single or double winding.

Solenoid drive-see Closing drive;

ST control PCBcontrol circuit PCB supervising the operation of shunt trip release.

SU control PCBcontrol circuit PCB supervising the remote closing operation by means of solenoid drive. Presents in every breaker, and placed in control box. Provides also anti-pumping and self cut-off functions.

Switching ONsee Closing operation;

Switching OFFsee Opening operation;

T

Trip-free deviceA mechanical switching device, the moving contacts of which return to and remain in the open position when the opening operation is initiated after the initiation of the closing operation, even if the closing command is main-tained. To ensure proper breaking of the current, which may have been established, it may be necessary that the contacts momentarily reach the closed position.

U

UVR control PCB-control circuit, designed as a single PCB, for supervising the zero-voltage release device.

Z

Zero-voltage release(also: under-voltage; UVR; r-release). An auxiliary tripping device. Trips the breaker open on control voltage loss. Opening time is less than 75ms. It is used for remote OPEN operation or control voltage supervision. Inter-changeable option with shunt trip release. Activated by means of auxiliary potential free, NO or NC contact.

catalogo gerapid ge.pdf

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