GE Energy Industrial Solutions. Gerapid High Speed DC Breaker Application Guide 1. 1

Transcription

1 GE Energy Industrial Solutions Gerapid High Speed DC Breaker Application Guide g imagination at work 1. 1

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

3 Introduction Gerapid 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 compact modular design. Current ratings from 2600A to 8000A, and voltage ratings up to 3600V are available. Gerapid employs 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 mechanical 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 and ANSI/IEEE C37 Standards. Other related publications: Gerapid FCB Users Guide S47183e Gerapid RCB Users Guide..DTR01807 Gerapid Brochure DEA-379 Gerapid Guide Form Specification..DEE-425 Gerapid 4207FCB with 1X2 Arc Chute Gerapid 4207FCB with 2X2 Arc Chute 1. 3

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 disconnects for DC Drives to name a few. The breaker, as delivered, 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 conditions, refer to EN annex B, and IEC 60947, class PD3. The breaker can operate at rated current within ambient temperature range of 5 C to +40 C (23 F to 104 F). Maximum operating ambient temperature is +55 C (130 F) with continuous current derated by 10%. The breaker can operate at altitudes up to 2000m (~6500ft) without derating. The breaker shall not be subjected to strong vibrations. 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 maximum temperature of +40 C (104 F). Relative humidity may be higher if the temperatures are lower, for example, 90%r.h. at +20 C (68 F). Slight condensation might occur during variations 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 circuit 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 forbidden. 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 moving 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. 4

5 Key Features and Construction Mining and traction compliant (ANSI C37.14, IEC 947-2,EN ) High speed TRIP (opening delay <3ms) Internal, self-powered direct acting instantaneous and adjustable trip unit Trip Unit is available as bidirectional (for line feeder) or unidirectional (for rectifier breaker) High speed CLOSE (approximately 150 ms) Solenoid close (integral control unit, mechanically latched) Mechanical forced tripping High Speed Electrodynamic trip device (with or without capacitor and charging unit) Shunt trip or Zero-voltage release 10 Form C Auxiliary contacts Variable main terminal configurations Plug connectors for auxiliary circuits Hand lever for manual actuation from front (for maintenance purposes) Contact Position indication Internal power supply with a wide range of input supply voltage options Integrated SEL current measurement unit (optional) Standard dimensions from 2,600A to 6,000A (feeder models ) Operating voltages from 1,000 to 3,600VDC 2-stage main contact system Compact, enclosed construction Modular, serviceable design Easily accessible control and auxiliary connections Fixed and draw-out versions Control Box Containing Circuit Boards and Auxiliary Switch Arc Runner Arcing Contact Main Contacts SEL Current Sensor (optional) Upper Terminal Control Connectors Lower Terminal OCT Device Closing Solenoid Shunt Trip/UVR Coil Mechanism Module ED Trip Coil Seesaw Trip Linkage OTC Trip Band Adjustment Fig. 5.1 Key Features 1. 5

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 dimensions, these breakers can be installed in extremely small enclosures and offer a cost-effective solution for replacements. 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 arc s energy. Gerapid 2607/4207/6007 Fig x_Arc Chutes Gerapid 8007 Gerapid 2607/4207/6007 Gerapid 8007 Fig x_Arc Chutes 1. 6

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 operations by means of ED impulse coil or OCT releases. This mechanism is mechanically latched in the CLOSED position. 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 interrupting short-circuit or overloads. All safety releases operate onto the quick latch. Different main springs are used in mechanisms for different breaker frames. Therefore mechanisms cannot be exchanged between breakers of different frames. Note too, that the 8007R and 10007R rectifier breakers utilize dual contact assemblies and mechanisms for increased interruption and withstand capabilities, required of rectifier applications. Fig. 7.1 Operating Mechanism 1. 7

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 operate. It is a direct acting and instantaneous tripping device. The OCT consists of the holding circuit, the movable armature and the tripping circuit. The holding and the tripping magnetic circuits are both excited by load current. Until the static overload release s response threshold has been reached, the armature is held in position by the holding flux and the counter spring s 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 direction 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. Gerapid Feeder Circuit Breaker OTC Bands Gerapid Feeder Circuit Breaker OCT Bands Frame Size Trip Band (ka) Table 8.2 Available Tripping Bands for the OCT Fig. 8.1 Overcurrent Trip Device (OCT) 1. 8

9 Closing Solenoid (drive) A high power solenoid is used to perform fast closing operations. This drive is mounted at the front of the breaker and is enclosed in a grounded metal casing. Closing solenoid power is supplied from a external power source, independent from the breaker internal controls. Voltage level must be defined 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 existing and continuous short circuit condition and provides an anti-pumping safety feature. After a closing attempt, the close mechanism is electrically blocked for approximately 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 1. 9

10 ED Trip Coil ED (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 supplied by the user externally. Rated voltage of 300V and capacitance of 2000μF is required. If a fault is detected by the external relay, a firing signal must be sent to the capacitors control 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 breaker s 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 duration 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 automatically cut off the firing circuit after breaker opening. Shunt Trip & UVR Coils The 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 interchangeable. 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 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 option 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%. ST s 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 combination 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 unintended re-start of machines after a temporary voltage loss is to be prevented. The UVR is intended for continuous operation. 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 principle). NOTE: Manual closing of the breaker with ST installed, while pushbutton OPEN is pressed and control power applied, might lead to ST coil s overheating and damage. Fig ED Trip Coil (with seesaw trip linkage Fig Shunt Trip or UVR Coil 1. 10

11 Forced Tripping Release For 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 linkage. 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 breaker can be tripped BEFORE its main terminals disconnect from the mains. Front Fig Forced Tripping Release (side view) Fig Forced Tripping Release (bottom 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 Arc Chute Interlock Indicator 1. 11

12 Auxiliary Switch Standard breaker is equipped with 3 isolated, form C, auxiliary contacts (1 NO/NC each). Maximum available is 10. The movable main arm activates the contacts. The contacts 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. Overcurrent Trip Target Indicator OC TRIP TARGET is a potential free, NO contact mounted at the top of the OCT. Provides contact closure when OCT operates. Fig OCT Trip Target Fig Auxiliary Switch Assembly (inside control box) Position Indicator Optional position Indicator is mounted at the front of the closing solenoid. It is mechanically switched by the solenoid s shaft, and indicates position of the main contacts. O (or Green) indicates contacts are open I (or Red) indicates contacts closed Manual Operation Lever A hand lever for manual closing and opening operation during maintenance is available. This tool must not be use while breaker is energized. To close the contacts, install hand lever on the drive s 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 drive s rod until breaker opens. Alternative manual closing and opening operation is possible by rotating the main shaft of the breaker mechanism, which is accessible from the side. Use 10mm hexagon-socket wrench. Fig Position Indicator Fig Feeder Breaker Manual Operating Handle 1. 12

13 SEL Current Measuring System The 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 signalprocessing unit. SEL control unit is mounted in the controlbox. 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 SEL Sensor The sensor includes Hall-effect probes and delivers a proportional signal-output to the SEL control. The signal-processing unit transforms input signal, into standard output signals shown in the table in Fig 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 5 C to +35 C and a model for higher temperature (T55) 5 C to +55 C. Note top terminal must be vertical orientation only. Type SEL Input -6kA to +6kA -12kA to +12kA Une (V) T35 T55 for ambient temperature 5 C to +35 C / +23 F to +95 F for ambient temperature 5 C to +55 C / +23 F to +131 F Ine Related to the rated current of the breaker 4 to 20 ma Output -20 to +20 ma -10 to +10V Uni (kv) Table 13.2 SEL Ratings 1. 13

14 Ratings 2607 thru 8007 Breaker Charaertstics Breaker type Gerapid 2607 Gerapid 4207 Gerapid 6007 Gerapid 8007 Arc chute type 1X2 1X4 2X2 2X3 2X4 1X2 1X4 2X2 2X3 2X4 1X2 1X4 2X2 2X3 2X4 1X2 2X2 Conventional thermal current I th [A] (IEC/EN) Rated current [A] (ANSI/IEEE C37.14) N/A Rated voltage UNe [V] (EN / IEC 60947) 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/A Rated insulation voltage U i [V] (EN / IEC 60947) Short time current 120 min [A] (EN / IEC 60947) Short time current 2 min [A] (EN / IEC 60947) Short time current 20 sec [A] (EN / IEC 60947) Impulse withstand voltage 1,2/50 µs Ui [kv] ) according to EN :1997 Power frequency withstand voltage 50 Hz Ua [kveff] ) 7 10 according to EN :1997 Rated short circuit making capacity Î Nss [ka] ) 70-1) Rated short circuit breaking capacity I Nss [ka] ) according to EN Rated service short circuit breaking current Ics [ka] ) 60-1) according to IEC Short circuit current according to IEEE C37.14 [ka] ) Peak current according to IEEE C37.14 [ka] ) Maximum short circuit current [ka] tested at customer request Maximum arc voltage Uarc [kv] (EN / IEC 60947) Weight ca. [kg] Weight ca. [lbs] ) Test data available at customer request Table Ratings 8007R & 10007R Breaker Characteristics Parameter Reference Gerapid 8007 R Gerapid R Arc chute type N/A 1x2 1x3 1x2 1x3 Rated continuous current [A] ANSI C37.14 p hours current [A] N/A minutes current [A] N/A seconds current [A] N/A Rated short-time current (250ms) [ka] ANSI C37.14 p (149 peak) 60 (100 peak) 90 (149 peak) 60 (100 peak) Rated maximum voltage [V] ANSI C37.14 p Rated insulation voltage - UNm [V] EN p Rated impulse voltage - UNi [kv] EN p [1,2/50 µs] 18 [1,2/50 µs] 18 [1,2/50 µs] 18 [1,2/50 µs] Power frequency voltage Ua [kv] EN a.b [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 Rated short circuit peak / sustained current [ka] b),c) ANSI C37.14 p / / / / 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 Mass ca. N/A 220 kg 220 kg 220 kg 220 kg a) cycles without parts replacement. Inspection after cycles. Max 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. Table R & 10007R Ratings 1. 14

15 Controls Data Table 15.1 Controls Data 1. 15

16 Standard Gerapid Wiring Diagrams The internal wiring for Gerapid breakers is composed of several standard typical diagrams, for such components as tripping 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. Gerapid Wiring Diagram Code Positions Wiring Diagram Number 1 / Breaker Type Gerapid FCB Gerapid RCB Auxiliary Voltage Supply Voltage Converter 24VDC External Supply 36 S With SEL System SEL System Auxiliary Contacts 3 Form C Contacts 5 Form C Contacts 10 Form C Contacts ED Tripping Device Without ED Coil With ED Coil With ED Coil & NECO Closing Solenoid Solenoid with SU Control Indication Devices 0 0 Without Indicators 1 01 OTC Trip Indicator 2 02 Arc Chute Installed Indicator 03 OTC and Arc Chute Indicator 20 Auxiliary Tripping Device 0 None 10 With Shunt Trip 20 With Zero Voltage Release Example: Wiring Diagram 36/ Fig Wiring Codes 1. 16

17 Breaker Internal Control Power Supply Breaker -X3 -X10: PCB * User Supplied Control Power Source VAC +/- 10% or VDC +/- 10% 4 (+ or ~) 5 (- or N) 1 (+) 3 (-) VDC +/- 2% to other PCBs Ground Breaker User Supplied Control Power Source 24VDC +/- 5% -X3 4 (+) 5 ( - ) -X11: PCB 8 1 (+) (-) 6 7 * +24VDC +/- 2% to other PCBs Ground - User external connection point - Factory internal connection point PCB - Printed Circuit Board Fig Supply with voltage converter or with direct external 24 V DC ±5%. * Note: Rectifier Breakers Contain Two(2) X10 or X11 PCB s 1. 17

18 ED Coil With Internal NECO Control Circuit Breaker -X10/X11: PCB -X16 : NECO PCB * * 8 (+) 1 (+) 24VDC 6 (-) 2 (-) User External Tripping Signal 6-24VDC, 20ma Capacitor Bank Charged Signal N.O. Contact Internal Close Stop Interlocking To Other PCBs -X2: 10 (+) 11 (-) -X3: (+) 4 (+) NECO Printed Circuit Board -Q1 * ED Impluse Coil User external connection point - Factory internal connection point PCB - Printed Circuit Board Fig 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 connected to -X3, terminals 10 and

19 ED Coil With External User Furnished Capacitor Trip Supply Breaker User Furnished External Capacitor Tripping Device 300V uf * -X2: Q1 * ED Impluse Coil - User external connection point - Factory internal connection point Fig ED coil with external capacitor trip device * Rectifier breakers contain two(2) ED Coils, and require a 4000uf external capacitor bank. Both are connected to -X2, Terminals 10 and

20 SU Control Circuit for Closing Solenoid Breaker -X13 : ST PCB External Trip Signal, N.O. Contact -X2: Coil Cut-off Contact -HS11 Internal Close Stop Interlocking To Other PCBs -X10/X11: PCB 6 (-) 24VDC 9 (+) (-) 8 (+) Shunt Trip Printed Circuit Board Shunt Trip Coil User external connection point - Factory internal connection point PCB - Printed Circuit Board Fig SU-control circuit 1. 20

21 Standard 24VDC Shunt Trip Circuit * External Trip Signal, N.O. Contact Breaker * -X2: 7 6 -X13 : ST PCB 3 4 * Coil Cut-off Contact -HS11 Internal Close Stop Interlocking To Other PCBs -X10/X11: PCB 6 (-) 24VDC 9 (+) (-) 8 (+) Shunt Trip Printed Circuit Board * Shunt Trip Coil User external connection point - Factory internal connection point PCB - Printed Circuit Board Fig Standard Shunt Trip control circuit * NOTE: Rectifier breakers contain two (2) shunt trip coils and PCB s. Second shunt trip coil is connected to -X2, terminals 8 and 9, and requires an additional N.O. Trip Contact, 1. 21

22 Optional Shunt Trip Circuit - External DC Breaker -X13 : ST PCB External User Supplied DC Trip Supply and N.O. Contact 110VDC, 125VDC, 220VDC Coil Cut-off Bkr Aux Contacts -X2: (+) 4 (-) Shunt Trip Printed Circuit Board Shunt Trip Coil 8 - User external connection point - Factory internal connection point PCB - Printed Circuit Board Fig Special version of shunt trip with single winding coil, directly supplied from external DC source. Not available on RCB s

23 Optional Shunt Trip Circuit - External DC, Dual Winding Coil Breaker -X13 : ST PCB External User Supplied DC Trip Supply and N.O. Contact 110VDC, 125VDC, 220VDC Coil Cut-off Bkr Aux Contacts Shunt Trip Coil #1 -X2: 6 (+) 7 (-) (+) 4 (-) Shunt Trip Printed Circuit Board #1 -X13 : ST PCB External User Supplied DC Trip Supply and N.O. Contact 110VDC, 125VDC, 220VDC Coil Cut-off Bkr Aux Contacts Shunt Trip Coil #2 -X2: 8 (+) 9 (-) (+) 4 (-) Shunt Trip Printed Circuit Board #2 Fig Special version of shunt trip with double winding coil directly supplied from external DC source. Not available on RCB s

24 Zero Voltage Release Circuit Breaker * External Trip Signal, N.C. Contact -X2: 9 8 -X14 : UVR PCB 1 2 External Trip Signal, N.O. Contact Internal Close Stop Interlocking To Other PCBs 7 6 -X10/X11: PCB 9 (+) * (+) Undervoltage Release Device Printed Circuit Board 24VDC 7 (-) 7 (-) UVR Coil * User external connection point - Factory internal connection point PCB - Printed Circuit Board Fig UVR control circuit * NOTE: Rectifier breakers contain two(2) UVR coils and PCB s. Second UVR coil is connected to -X2, terminals 6 and 7, for external trip from N.C. contact. Option for N.O. trip contact is not available 1. 24

25 Typical Gerapid FCB External Connections X Closing Drive Supply Input Close Signal (N.O.) Trip Signal to Shunt Trip or UVR (N.O.) Trip Signal to UVR (N.C.) ED Firing Signal 6-24VDC Pulse (+) / ~ (-) / N GRD (+) (-) X Breaker Control Power Input NEKO Capacitors Charged Output Contact Tripped by OCT Output Contact Arc Chute Installed Indication Contact (+) / ~ (-) / N X Auxiliary Breaker Contacts X Auxiliary Breaker Contacts Fig FCB 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

26 Typical Gerapid RCB External Connections X Closing Drive Supply Input Close Signal (N.O.) Trip Signal to Dual Shunt Trips (N.O.) ED Firing Signal 6-24VDC Pulse (+) / ~ (-) / N GRD (+) (-) RCB -X2 wiring with Shunt Trips installed X X Breaker Control Power Input 1st NEKO Capacitors Charged Output Contact Tripped by POCT Output Contact 2nd NEKO Capacitors Charged Output Contact Arc Chute Installed Indication Contact (+) / ~ (-) / N Closing Drive Supply Input Close Signal (N.O.) Trip Signal to Dual UVR Coils (N.C.) ED Firing Signal 6-24VDC Pulse (+) / ~ (-) / N GRD (+) (-) RCB -X2 wiring with UVR Trips installed RCB -X4 & -X5 wiring same as FCB Fig 26.1 RCB 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

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 catalog 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). APN rev Codes Language Breaker type Code Code 20 Target standards 1 Gerapid Gerapid 8007R LV DC acc. IEC Railway DC acc. EN Gerapid Gerapid 10007R On Request R LV DC acc. IEEEC Gerapid Gerapid 8007DS China acc. IEC947-2 & GB Gerapid 8007 code 19 Control connectors type Arc 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 2 2 1X3 (1500V) 5 2X3 (3000V) E EF4-12 (3600V) R 3 1X4 (2000V) 6 2X4 (3600V) Code 18 Counter Closing solenoid supply voltage Code 3 Mechanical Counter 1 Without V DC V DC V AC 2 60 V DC V DC A 230 V AC V DC V AC B 240 V AC Code 17 Arc chute position switch V DC V AC R On Request With 1 Without 0 Main terminals orientation (Top / Bottom) Code 4 Code 16 Lever for manual operating 1 H/H - (H)orizontal 4 V/V B Balfour Beatty type With 1 Without 0 2 H/V - (V)ertical 5 For SEL 6kA S Siemens type 3 V/H 6 For SEL 12kA R On Request Code 15 Protection options Main 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 indicator 1 Ta = 35 C 0 without SEL With 1 Without 0 2 Ta = 55 C Code 13 Forced tripping unit Over current trip unit (OCT) Code 7 With 1 Without 0 1 Fixed setting up to 15kA 5 Polarized adj. 0,4kA-1,2kA 0 Without 2 Adjustable up to 15kA 6 Polarized adjust. 0,8kA-2,5kA OCT Code 12 Impulse coil 3 Fixed setting up to 24kA 7 Polarized adjust. 2kA-6kA Impulse coil with internal C-bank and control PCB (NEKO) 2 Without 0 4 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 device 1 external 24V DC±5% V DC Shunt Trip - external 125 Vdc 4 Without V/24V (DC stabilizer) V DC / V AC Shunt Trip - external 220 Vdc V 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 convertible contacts 4 10 convertible contacts Fig PST Code System 1. 27

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 rectifier 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 below show the continuous current rating available for each breaker type, based on IEC/EN or ANSI test standards. Breaker Type Standard R 1007R IEC/EN 2600A 4200A 6000A 8000A N/A N/A ANSI 2600A 4150A N/A 6000A 6000A 8000A ANSI C37-14, ANSI C37-16 EN 50123/ IEC60947 Table 28.1 Continous Current Ratings 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 Application Support. 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 overcurrent 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, instantaneous 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 Solenoid Drive Voltage (Code 3) The closing solenoid (drive) has a control power input separate 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 orientation. 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. Frame Size Trip Band (ka) Table 28.2 OCT Bands 1. 28

29 Gerapid Breaker Selection, Cont d 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 different control voltage is planned to be used, select appropriate range from those listed. Note for 125VDC, select option (4) VDC. 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 auxiliary 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, externally 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 μf). 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 provisions for manual operation while energized! 1. 29

30 Gerapid Breaker Selection, Cont d 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) Relevant Standard (Code 20) Select the specific governing standard to which the breaker is to be rated. This must match the breaker configuration selection restrictions as noted under the Breaker Type (Code 1) and Arc Chute (Code 2) and will establish the values stamped on the breaker nameplate. 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 Harting style industrial plugs, options (3) and (4). Standard Phoenix Connectors MIL-C-5015G Connector Harting Connector 1. 30

31 Gerapid Outline Drawings When 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 Deflector Gerapid Connection isolation 2607 / 4207 Safety distances - Insulated Surfaces E A B C D 1x2 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) x2 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) x2 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) 8007R 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) 10007R 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 order H Horizontal terminal V...Vertical terminal SEL...Current measurement system type SEL Safety distances - To Grounded Surfaces. Units in mm (inches) Type Arc chute Main- Deflector Safety distances - Grounded Surfaces Gerapid Connection E A B C D 1x2 H or V 10 (0.4) 1000 (39.4) 300 (11.8) 300 (11.8) 300 (11.8) 2607 / x4 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) 8007R 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) 10007R 1x3 V / V n/a 600 (23.6) 533 (20.9) 533 (20.9) 193 (7.5) Table 31.1 Safety Clearances 1. 31

32 Legend for FCB Dimensional Drawings K Heat sink (for Gerapid 6007) L M P S Z Ventilation openings in the breaker cubicle top cover shall not be less than 50% of total surface area. Solenoid closing drive Diameter 9 mm [0.35 in], Countersunk screw M8 Control box Main Connector Legend for RCB Dimensional Drawing K Additional heat sinks for Gerapid 10007R 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 *) Dimensions valid only for Gerapid 8007R version. **) Dimensions valid only for Gerapid 10007R version. ***) Lifting eye diameter 25 mm [ ~ 1 in] Table 32.1 Drawing Legends 1. 32

33 Gerapid 2607,4207, 6007 with arc chute 1x Fig.33.1 Gerapid , arc chute 1X (dimensions in mm and inches) 1. 33

34 Gerapid 2607, 4207, 6007with arc chute 2x_ Fig.34.1 Gerapid , arc chute 2x (dimensions in mm and inches) 1. 34

35 Gerapid 8007 with arc chute 1x_ Fig Gerapid 8007 with arc chute 1x (dimensions in mm and inches) 1. 35

36 Gerapid 8007 with arc chute 2x_ Fig Gerapid 8007 with arc chute 2x (dimensions in mm and inches) 1. 36

37 Gerapid 2607, 4207 with H / H terminals It s possible to combine horizontal and vertical connectors. Dimensions are corresponding. Note with SEL option, top connector is vertical only. Fig Gerapid 2607, 4207 with horizontal terminals (dimensions in mm) 1. 37

38 Gerapid 2607, 4207 with V / V terminals It s possible to combine horizontal and vertical connectors. Dimensions are corresponding. Fig Gerapid 2607, 4207 with vertical terminals (dimensions in mm) 1. 38

39 Gerapid 6007 terminals Gerapid 6007 is available only with V / V terminals! Fig Gerapid 6007 with vertical terminals (dimensions in mm) 1. 39

40 Gerapid 8007 terminals Gerapid 8007 is available only with V / V terminals! Fig Gerapid 8007 with vertical terminals (dimensions in mm) 1. 40

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

42 Gerapid 8007R, 10007R with arc chute 1X Frontview Rearview Fig Gerapid 8007R, 10007R with arc chute 1X; dimensions in mm [inches]

43 Gerapid High Speed DC Circuit Breakers Guide Form Specification 1. General This 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 identical designs to ensure commonality in spare parts, commonality in control power circuits and a common operator knowledge 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 substitutions shall be acceptable. 2. Scope and Applications The 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 +40 C ( In) Humidity: 90% relative humidity (ANSI C37.14) Pollution: PD3A per EN Vibration: 0.5g, 30s Altitude: -120m to 2000m above sea level 1. 43

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 C37.14 ANSI/IEEE C37.16 ANSI/IEEE C37.17 ANSI/IEEE C37.20 EN EN EN EN IEC IEC Operation and Control Breakers shall be Gerapid Type 2607, 4207, 6007, 8007, 8007R and 10007R manufactured by the General Electric Company (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 integrated 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. RBC s 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