GE Gerapid 2607 User Manual

High speed dc circuit breaker with arc chutes 1x2, 1x4, 2x2, 2x3, 2x4

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2009-09-02

S47183e rev.03

High Speed DC Circuit Breaker

Gerapid 2607, 4207, 6007, 8007

with arc chutes 1X2, 1X4, 2X2, 2X3, 2X4

USER MANUAL

Design and specifications are subject to change without notice

GE Consumer & Industrial

Power Protection

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Summary of Contents for GE Gerapid 2607

Page 1 GE Consumer & Industrial Power Protection High Speed DC Circuit Breaker Gerapid 2607, 4207, 6007, 8007 with arc chutes 1X2, 1X4, 2X2, 2X3, 2X4 USER MANUAL 2009-09-02 S47183e rev.03 Design and specifications are subject to change without notice...
Page 2 5.2.3 Gerapid 8007 with arc chute 1x_....... 32 5.2.4 Gerapid 8007 with arc chute 2x_....... 33 5.2.5 Gerapid 2607, 4207 with H / H terminals.... 34 5.2.6 Gerapid 2607, 4207 with V / V terminals .... 35 5.2.7 Gerapid 6007 terminals........36 5.2.8 Gerapid 8007 terminals........37 Design and specifications are subject to change without notice S47183e rev.03...
Page 3 1. Warnings 2. General usage conditions 2.1 Transportation and storing • The breaker is transported on wooden palette. It is fixed by shrunken plastic film. A cardboard box covers the breaker on the palette. Truck, railway, airplane and ship transport is possible. In case of sea transport, special pro- tection against salty and humid environment is provided.
Page 4 2.2 Installation 2.3 Usage 2.2.1 Operational environment 2.3.1 Supply and load • The breaker, as delivered, is IP00 (NEMA 1) protected. It is • In accordance with its type, the breaker has been de- intended to work in indoor applications, without pollu- signed for the current and voltage listed in Table 1, sec- tions, with non-conductive dust, protected against high tion 3.3.
Page 5 3. Technical information 3.2 Components and accessories 3.1 Introduction 3.2.1 Contact system • Gerapid is a high-speed DC circuit breaker. This is a sin- • All Gerapid breakers are equipped with a two-stage con- gle-pole DC breaker, primarily designed f or use in railway tact system [Fig.
Page 6 • position by the holding flux (ΦH) [2] and the c ounter 3.2.3 Mechanism spring’s force [4]. Once the load c urrent exceeds the set • The Gerapid is equipped with a modular designed static response threshold, the attraction flux (ΦA) [2] mechanism, which is wear-resistant and nearly mainte- takes over and rapidly pulls down the flexible armature nance-free.
Page 7 supply is connected through auxiliary contacts, which cut 3.2.5 ED impulse coil release (Code 12) off supply voltage after opening. This protects ST against overheating. • The UVR [Fig. 9] is used for remote actuation and, in com- • ED impulse release requires an external protective relay bination with an internal electronic c ontrol, for voltage for monitoring a current inc rease.
Page 8 With a correctly designed interlock in an enclosure, FT pro- vides safety-tripping f unction. During withdrawal operation of the trolley, the breaker is tripped BEFORE its main terminals disconnect f rom the mains. Bottom view Fig. 11b Opening operation by using hand lever •...
Page 9 3.2.9 Auxiliary switch (Code 9) • Standard breaker can be equipped with 3, 5 or 10 iso- lated, form C, invertible auxiliary contacts (1 NO/NC each). The mov able main arm activates the c ontacts. • The contacts are wired to 15-pin control terminals: -X4 and -X5, with 5 switc hes to each terminal [Fig.
Page 10 3.2.12 Current measurement system (Code 6) 3.2.13 Electronic control system • The SEL current measurement system consists of the All the control PCBs are installed in control box [Fig. 18]. Start- sensing c omponent (1) and signal-processing unit (2) ing f rom the left, these are: [Fig.17].
Page 11 • (3) SU control unit – see point 3. 2.11 Fig. 19-4c Extinguish capacitor for direct ST supply. Fig. 19-3 SU control unit. • (5) Empty slot. – not used in control box. • (4) ST/UVR control unit – simple relay system. It controls •...
Page 12 M aximum a rc voltage U arc [kV] W eig ht ca . [kg] W eig ht ca . [lbs ] Table 1: Technical data of Gerapid 2607, 4207, 6007, 8007. 1) Rating tests at customer request Design and specifications are subject to change without notice S47183e rev.03...
Page 13 AC 48 V - 230 V and DC 48 V - 220 V Operating range 80 % - 115 % of rated voltage Power consumption Gerapid 2607 / 4207 1750 W / 2000 W Power consumption Gerapid 6007 / 8007...
Page 14 4. Electrical circuits 4.1 Controls layout Closing solenoid drive Shunt trip / Zero voltage release ED coil OCT device HS 1...HS 10 OCT trip target Arc chute-indicator Description Designation 1.Connector: Auxiliary- and control circuits 2.Connector: Auxiliary- and control circuits 3.Connector: Auxiliary contacts HS1...HS5 4.Connector: Auxiliary contacts HS6...HS10 5.Connector: Current measure system SEL Control board: Voltage converter...
Page 15 8 9 10 11 12 13 14 15 4.2 Terminals wiring system (+) (-) 3 4 5 8 9 10 11 12 13 14 15 9 1 0 11 12 9 1 0 1 1 1 2 1 3 1 4 1 5 SEL (self check) 3 4 5 6 7 8 9 10 11 12 13 14 15...
Page 16 4.3 Electrical diagrams Designation position number Type 4.3.1 Wiring code Gerapid Auxiliary voltage The main circ uits are not shown in the wiring diagrams Voltage converter DC 24 V external supply for transparency. The control circuit is presented as a Tripping coil typical circuit diagram and is a combination of numbered Without ed-trip coil...
Page 17 4.3.2 Controls supply circuit Breaker External -X10 power supply +DC 24 V ±2% [ 4 ] [ 1 ] [ 10 ] + / ~ [ 9 ] [ 8 ] AC 115-240V ±10% DC 35-350V ±10% [ 7 ] [ 6 ] - / N [ 5 ]...
Page 18 4.3.3 ED coil with external capacity bank • In this option customer provides his own solution for releasing of the ED coil, by means of external capacitor trip device. The NEKO control unit is not f urnished, and coil is connected directly to front panel of control box (-X2 : 10/:11). Breaker External C-bank...
Page 19 4.3.4 NEKO control circuit -X16: NEKO PCB -X10/11 [ 1 ] Isolating Transformer [ 8 ] 24 Vdc [ 6 ] [ 2 ] Charging Control Impulse switching [ 9 ] Signals [ 6 ] C-bank charging [ 10 ] signalization [ 7 ] Charging Voltage...
Page 20 4.3.5 SU control circuit Closing drive -X12: SU PCB Power supply [ 3 ] + / ~ [ 1 ] AC 110-250V DC 48-220V [ 2 ] - / N [ 4 ] [ 8 ] Transf orming of CLOSE signal [ 4 ] [ 5 ] [ 9 ]...
Page 21 4.3.6 Shunt trip control circuit Standard DC 24 V shunt trip with control PCB. -X13: ST PCB [ 4 ] [ 6 ] [ 3 ] [ 7 ] [ 5 ] Closing -X10/11 STOP relay [ 6 ] [ 7 ](-) [ 8 ] 24 V DC [ 7 ]...
Page 22 Below, non-standard shunt trip with single winding, directly supplied from external DC v oltage. -X2:6 -X13a Breaker’s aux. contacts -X2:7 Below, non-standard shunt trip with double winding, directly supplied from external DC voltage. 1st winding 2nd winding -X2:6 -X2:8 -X13a -X13b Breaker’s Breaker’s...
Page 23 4.3.7 Zero voltage release control circuit -X14: UV R PCB [ 9 ] [ 1 ] [ 8 ] [ 2 ] [ 3 ] [ 7 ] [ 6 ] [ 4 ] [ 5 ] Closing STOP relay [ 6 ] -X10/11 [ 7 ](-)
Page 24 4.3.8 Indicators OCT trip target [ 8] [ 9] Arc chute indicator [ 12 ] [ 13 ] 36/ _ _ _ _ X _ _ Key position - 6 Key number - 00: Without indicators. Key number - 01: With OCT trip target only. Key number - 02: With arc chute indic ator only.
Page 25 4.3.9 Auxiliary switch 36/ _ _ _ _ _ X _ Key position - 7 Key number - 1: With 3 switc hes (HS1 thru HS3). Key number - 2: With 5 switc hes (HS1 thru HS5). Key number - 3: With 10 switches (HS1 thru HS10). Fig.
Page 26 4.3.10 SEL measuring system Signal Processing Unit Voltage stabilizer Self check control DC 24 V DC 24 V max. 500 Ω max. 500 Ω min. 300 kΩ 36/ _ _ _ _ _ _ X Key position - 8 Key number - S: With SEL measurement system. Fig.
Page 27 5. Dimensions & safety distances Warnings During operation, all metallic parts of the breaker, except control box and closing solenoid drive, may carry dangerous voltages. Insulation covers are available as an option. For installation of the breaker into cubicle, top and side openings shall be provided, in order to reduce internal pres- sure rise during clearing short circuit.
Page 29 5.1 Safety distances. Units call in mm (inches) Type Arc chute Main- additional De flector Sa fety distance s / Insula ted pla tes S afe ty dista nces / Earthed pla tes Gera pid Connection isol ation a ction 2607 / 4207 10 (0,4) 700 (27,6)
Page 30 5.2.1 Gerapid 2607,4207, 6007 with arc chute 1x_ Pay attention to legend, warnings and safety distances pages 26/27! Fig. 32 Gerapid 2607- 6007, arc chute 1X (dimensions in mm and inches) Design and specifications are subject to change without notice S47183e rev.03...
Page 31 5.2.2 Gerapid 2607, 4207, 6007with arc chute 2x_ Pay attention to legend, warnings and safety distances pages 26/27! Fig. 33 Gerapid 2607- 6007, arc chute 2x (dimensions in mm and inches) 2009-09-02 S47183e rev.03 Design and specifications are subject to change without notice...
Page 32 5.2.3 Gerapid 8007 with arc chute 1x_ Pay attention to legend, warnings and safety distances pages 26/27! Fig. 34 Gerapid 8007 with arc chute 1x (dimensions in mm and inches) Design and specifications are subject to change without notice S47183e rev.03 2009-09-02...
Page 33 5.2.4 Gerapid 8007 with arc chute 2x_ Pay attention to legend, warnings and safety distances pages 26/27! Fig. 35 Gerapid 8007 with arc chute 2x (dimensions in mm and inches) 2009-09-02 S47183e rev.03 Design and specifications are subject to change without notice...
Page 34 It’s possible to combine horizontal and vertical connectors. Dimensions are corresponding. Note with SEL option, top conne ctor is vertical only Fig. 36 Gerapid 2607, 4207 with horizontal terminals (dimensions in mm and inches) Design and specifications are subject to change without notice S47183e rev.03...
Page 35 5.2.6 Gerapid 2607, 4207 with V / V terminals It’s possible to combine horizontal and vertical connectors. Dimensions are corresponding. Fig. 37 Gerapid 2607, 4207 with vertical terminals (dimensions in mm and inches) 2009-09-02 S47183e rev.03 Design and specifications are subject to change without notice...
Page 36 5.2.7 Gerapid 6007 terminals Gerapid 6007 is available only with V / V terminals ! Fig. 38 Gerapid 6007 with vertical terminals (dimensions in mm) Design and specifications are subject to change without notice S47183e rev.03 2009-09-02...
Page 37 5.2.8 Gerapid 8007 terminals Gerapid 8007 is available only with V / V terminals ! Fig. 39 Gerapid 8007 with vertical terminals (dimensions in mm and inches) 2009-09-02 S47183e rev.03 Design and specifications are subject to change without notice...
Page 38 6. Inspections and maintenance 6.1 List of inspections TYPE OF THE INSPECTION BY WHOM HOW OFTEN WHAT TO DO/CHECK A. General visual inspec- • -Customer Every 6-12 months Check for damages or cracks of the tion -Trained technician frame, adapter or arc c hute •...
Page 39 • Pay attention to the warnings, Section 1! Check out for corrosion. In case of significant c orro- sion, please c ontact GE representative f or assistance. A) Remove the arc chute • Check out for distinct manifestations of flame or •...
Page 40 Fig. 44 Checking the contact system C) Check the protective walls • [Fig. 44]. The material burn out on the protective walls (5) shall not exceed 1 mm [0.04 in] at any place. Fig. 42 Inspection of the arc chute D) Check the arc runners •...
Page 41 This check must be carried out prior to commissioning and after maintenance. 6.1.7 Inspection of the mechanical components Only GE Service Team or its representative shall perform this inspection. These require major disassembly and ad- justment of the breaker. Customer, without supervision of Fig.
Page 42 The outer diameter of the locking rod shall be less Hint 1 Place a cloth into the lower area of the arcing 8 mm [0,3 in]. GE does not offer this locking device. contact [Fig. a]. Remember to secure the closing drive according to Hint 3.
Page 43 6.2.1 Maintenance of contact system (after 11/2003) Pay attention to the warnings, Section 1! This section is valid for breakers manufactured after 11/2003. This section refers to maintenance works A, B, C from Table 4. A) Remove the arc chute •...
Page 44 6.2.2. Maintenance of contact system (before 11/2003) Pay attention to the warnings, Section 1! This section is valid for breakers manufactured before 11/2003. This section refers to maintenance works A, B, C from Ta- ble 4. A) Remove the arc chute and adapter •...
Page 45 • D) Changing the arcing contact [Fig. 52-4]. Replace arcing c ontact with new one. Use • Remove front and back arc runner. See 6.2.2-C. old contact to lift up two washers, and slip the new • Close the breaker and secure the solenoid drive contact under these.
Page 46 6.2.3 Layout of control PCB inside control box 6.2.4 Replacement of the control boards Slot numbers: • OPEN the breaker. • Disconnect power supply, and pull out all the plugs from control box’s terminals. • If a NEKO control unit is installed, wait 1 minute un- til capacitors discharge.
Page 47 Fig. 55-7 Pay attention, that no cables will be pinched Fig. 55-4 Unscrew all the plugs from control boards between box and front cover during closing! Fig. 55-8 Carefully replace the control box front cover and attach the with the four screws Fig.
Page 48 Gerapid in "OFF“ position: Main contacts closed. Main contacts open. If re-adjustment does not help, please contact GE Service Aux. swit ches not actuated Auxiliar y switch es actuated Team. It might be required to install switch block again or to move switches to center of the block for better per- Fig.
Page 49 6.3 Spare parts lists. Hints for parts identification: 6.3.1. Mechanical spare parts. Component Type Arc chute Part no. Ver. 128 122 R02 128 121 2607 / 4207 / 6007 APN340110 R01 2607 / 4207 / 6007 APN340110 R02 Service kit for replacing arcing components.
Page 50 Spring bar cap 128 058; Materials: Transparent silicone E-COLL 310ML; glue Locktite 222; thermo paste WLP500; grease Beacon EP3 by ESSO. 1) F or substitute materials please consult GE representative. 2009-09-02 S47183e rev.03 Design and specifications are subject to change without notice...
Page 51 Table 7 shows all av ailable values, components and accessories for the Gerapid breaker family. Detailed descriptions are available in section 3. Please contact GE Sales repre- sentative in case of any questions. • The coding system is valid f or Gerapid feeder type (F), rectifier type (R) and disconnector type (DS).
Page 52 7.2 Ordering. 2009-09-02 S47183e rev.03 Design and specifications are subject to change without notice...
Page 53 7.2.1 Example of order no. 1 Line feeder breaker for LRT substation in Europe; comply with EN50123, with breaking c apacity of 50 kA, configured as follows: Load c urrent of 4000 A. Nominal voltage of 1500 V; 2x2 arc chute chosen due to high breaking capacity up to 70 kA.
Page 54 20-digit catalogue code. • Modifications of main terminals according to c ustomer’ s drawings are possible after agreement with GE and after positive tests results. • Choosing a double winded shunt trip will limit your available auxiliary contacts number to maximum 8 units.
Page 55 “XXX 123”. Customer requests to put on the nameplate rated parameters that have been tested. After agreement with GE both parties decided to create special version of the breaker and assign to it a letter “a” as extension of standard name.
Page 56 7.3 Glossary OCT – see Over-Current rel ease; Opening operation – (also: switching OFF; OPEN operation). An operation by which the breaker is brought from the CLOSED a-release – see Shunt trip device; Over-Current release – (also: OCT). An instantaneous and direct Activating magnet –...
Page 57 Check the continuity of shunt trip coil (-X14 : 9/:10). Check continuity of the control connections. Replace the ST PCB or ST c oil if necessary. Contact GE Service in case of problem is not solved. Open the control box: WARNING ! Following operations are done with control voltage connected.
Page 58 GE Consumer & Industrial GmbH Berliner Platz 2-6 D-24534 Neumünster Germany Phone: ++49 4321-201-0 : ++49 4321-201-444 S47183-e rev.03 08/2009 Design and specifications are subject to change without notice S47183e rev.03 2009-09-02...

This manual is also suitable for:

Gerapid 4207 Gerapid 6007 Gerapid 8007