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AC-PRO Retrofit Kit
Retrofit Kit Instructions for
GE
AKR-30/50
Low Voltage Breaker
Instructions for:
Manual Reset Actuator
Mechanical Reset Actuator
Including Instructions for
+
AC-PRO
Utility Relay Co.
Chagrin Falls, Ohio 44023
Phone: 888-289-2864
www.utilityrelay.com
I-ACM-AKR-30/50
Communications
January, 2008
Fax: 440-708-1177
Rev. 0
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Table of Contents
Related Manuals for Utility Relay Company AC-PRO AKR-30
Summary of Contents for Utility Relay Company AC-PRO AKR-30
- Page 1 AC-PRO Retrofit Kit Retrofit Kit Instructions for AKR-30/50 Low Voltage Breaker Instructions for: Manual Reset Actuator Mechanical Reset Actuator Including Instructions for AC-PRO Communications Utility Relay Co. Chagrin Falls, Ohio 44023 Phone: 888-289-2864 Fax: 440-708-1177 www.utilityrelay.com I-ACM-AKR-30/50 January, 2008 Rev. 0...
- Page 2 “product”) shall be free from defects in material and workmanship, and will perform as described in Utility Relay Company’s sales literature and Instruction Manuals, under normal use and service for a period of (2) two years from date of invoice. EXCEPT AS SET...
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Page 3: Table Of Contents
TABLE OF CONTENTS Section PAGE General ..........1 Inspection ........1 Initial Breaker Tests ........ 2 Remove Existing Trip Unit ......2 Install CTs .......... 3 Remove Existing CTs ......3 Install New CTs ......... 3 Reusing Existing Actuator ......4 Install Trip Paddle ........ - Page 4 ILLUSTRATIONS Figure Front View, "Blue" Front Breaker.....16 Trip Unit Mounting, "Blue" Front Breaker.....17 Front View, "Black" Front Breaker....18 Trip Unit Mounting, "Black" Front Breaker....19 CT Installation........20 Manual Reset Actuator Installation....21 Mechanical Reset Actuator Pre-Assembly....22 Mechanical Reset Actuator Installation....23 Wiring Diagram........24 10 Front View “Blue Front”...
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Page 5: General
AC-PRO Retrofit...................AKR-30/50 GE AKR-30 & AKR-50 "Blue" Front & "Black" Front 1.0 General All possible contingencies which may arise during the installation, operation or maintenance, and all details and variations of this equipment are not necessarily covered by these instructions. 1.1 Inspection Carefully inspect the retrofit kit on arrival. -
Page 6: Initial Breaker Tests
AC-PRO Retrofit...................AKR-30/50 2.0 Initial Breaker Tests Before starting the retrofit, perform a visual/mechanical inspection and an electrical test of the breaker to determine its condition. Refer to the breaker manufacturer's instruction manual and accepted test standards such as the NETA Maintenance Specifications or PEARL reconditioning standards to verify that the breaker is in acceptable mechanical and electrical operating condition. -
Page 7: Install Cts
AC-PRO Retrofit...................AKR-30/50 4.0 Install CTs 4.1 Remove Existing CTs Remove the existing CTs on each pole as follows: Remove two (2) 3/8-16 X 2 socket head cap screws from the rear of the breaker. Tip the breaker back and loosen the top shunt clamp screw. Remove the top shunt. -
Page 8: Reusing Existing Actuator
AC-PRO Retrofit...................AKR-30/50 5.0 Reusing Existing Actuator Either the existing actuator will be reused or a new actuator was ordered. If a new actuator is being installed, skip this section. Check the condition of the existing actuator and verify that it operates freely and resets properly. -
Page 9: Manual Reset Actuator
AC-PRO Retrofit...................AKR-30/50 7.0 Manual Reset Actuator The actuator is installed on the lower left side of the breaker. Skip this section and go to section 8.0 if the mechanical reset actuator will be installed. On a “blue front” breaker, if the Actuator has to be mounted on the right side of the breaker the AC-Pro must be installed on the upper left side of the breaker as described in section 9.2 for the “black front”... -
Page 10: Adjust Actuator
AC-PRO Retrofit...................AKR-30/50 7.2 Adjust Actuator With the breaker closed, and the actuator reset, adjust the position of the actuator rod by screwing it in or out until the end of the rod is about 1/64" from the trip paddle. Trip the breaker. Trip the actuator by striking the reset knob. -
Page 11: Mechanical Reset Actuator Assembly
AC-PRO Retrofit...................AKR-30/50 8.0 Mechanical Reset Actuator Installation Skip this section if the manual reset actuator was installed in Section 7. 8.1 Install Mechanical Reset Actuator Assembly A-300C-AKR Actuator assembly has been pre-assembled. See Figure 7 for reference. Final adjustments will be made in Section 8.2 Refer to Figure 8 for the following: Using existing holes, attach the actuator assembly to the breaker using two (2) 10-32 X 1/2 Phillips screws and lock... -
Page 12: Verify Trip Free Operation
AC-PRO Retrofit...................AKR-30/50 8.3 Verify Trip Free Operation of Mechanical Reset Actuator Assembly It is very important to verify that the trip adjustment of the mechanical reset actuator assembly will keep the breaker trip free if the actuator fails to reset properly on breaker opening. Close the breaker. -
Page 13: Ac-Pro Installation
AC-PRO Retrofit...................AKR-30/50 9.0 AC-PRO Installation 9.1 “Blue Front” Breaker The “standard” mounting is on the lower right (see Figures 1 and 2), the “alternate” location is shown in Section 9-2. Attach the mounting bracket BR-048-1 to the back of the trip unit with the short leg of the bracket pointing towards the rear. -
Page 14: Alternate Mounting Behind Closing Spring
AC-PRO Retrofit...................AKR-30/50 9.3 Alternate Mounting for “Black Front” Breaker The trip unit mounts vertically on the upper left side of the frame behind the closing spring as shown in Figure 15. Attach the Trip Unit Shield BR-094 to the BR-059 bracket using two (2) 10-32 X 1/2 Pan head nylon screws. -
Page 15: Wiring
AC-PRO Retrofit...................AKR-30/50 10.0 Wiring Use the wiring harness provided to make the connections to the CTs and the actuator. See Figure 9 for the wiring diagram. The wiring harness plugs into the side of the AC-PRO. Be sure to tighten the two plug retaining screws after the wiring is complete. -
Page 16: Neutral Current Transformer
AC-PRO Retrofit...................AKR-30/50 10.3 Neutral Current Transformer A neutral CT is only required on a 4-wire system with the ground fault function on. On a 3-wire system, a neutral CT is not required even if the ground fault function is on. The neutral CT and neutral wiring assembly are provided with the neutral CT kit. -
Page 17: Communications
AC-PRO Retrofit...................AKR-30/50 12.0 Communications The following instructions are for the communications option using the AC-PRO 12.1 Install PT Module - “Blue Front” Breaker The PT Module mounts on the lower left of the “blue front” breaker as shown in Figures 10 and 11. Attach the BR-081 bracket to the PT Module using two (2) 8-32 X 3/8 Phillips screws and lock washers. -
Page 18: Install Fuse Block For Pt Module
AC-PRO Retrofit...................AKR-30/50 12.3 Install Fuse Block for PT Module CAUTION: When selecting a mounting location for fuse block check the breaker cell for interference from existing devices. Check all cells for variations in applications where breakers may be “swapped”. Install the 3-pole fuse block on the back of the breaker as follows: Find a suitable location close to the rear stabs that will be tapped. -
Page 19: Communications Wiring
AC-PRO Retrofit...................AKR-30/50 12.4 Communications Wiring Refer Figure 14 for the following: Voltage Input Determine the line side of the breaker and drill and tap a 10-32 hole in each of the three line side poles. Use #14 SIS wire from the bus taps to the 3-pole fuse block. -
Page 20: Figure 1
AC-PRO Retrofit...................AKR-30/50 FIGURE 1 Front View "Blue" Front Breaker Page 16... -
Page 21: Trip Unit Mounting "Blue" Front Breaker
AC-PRO Retrofit...................AKR-30/50 FIGURE 2 Trip Unit Mounting "Blue" Front Breaker Page 17... -
Page 22: Front View "Black" Front Breaker
AC-PRO Retrofit...................AKR-30/50 FIGURE 3 Front View "Black" Front Breaker Page 18... -
Page 23: Trip Unit Mounting "Black" Front Breaker
AC-PRO Retrofit...................AKR-30/50 FIGURE 4 Trip Unit Mounting "Black" Front Breaker Page 19... -
Page 24: Ct Installation
AC-PRO Retrofit...................AKR-30/50 FIGURE 5 CT Installation Page 20... -
Page 25: Manual Reset Actuator Installation
AC-PRO Retrofit...................AKR-30/50 FIGURE 6 Left Side View “Blue” & “Black” Front Breakers Manual Actuator Installation Page 21... -
Page 26: Mechanical Reset Actuator Pre-Assembly
AC-PRO Retrofit...................AKR-30/50 FIGURE 7 Mechanical Reset Actuator Pre-Assembly Page 22... -
Page 27: Mechanical Reset Actuator Installation
AC-PRO Retrofit...................AKR-30/50 FIGURE 8 “Blue” & “Black” Front Breakers Mechanical Reset Actuator Installation Page 23... -
Page 28: Wiring Diagram
AC-PRO Retrofit...................AKR-30/50 FIGURE 9 Wiring Diagram Page 24... -
Page 29: Front View "Blue Front" With Communications
AC-PRO Retrofit...................AKR-30/50 FIGURE 10 Front View - “Blue Front” Breaker With Communications Page 25... -
Page 30: Module Installation "Blue Front" Breaker
AC-PRO Retrofit...................AKR-30/50 FIGURE 11 PT Module Installation “Blue Front” Breaker Page 26... -
Page 31: Front View "Black Front" With Communications
AC-PRO Retrofit...................AKR-30/50 FIGURE 12 Front View - “Black Front” Breaker With Communications Page 27... -
Page 32: Module Installation "Black Front" Breaker
AC-PRO Retrofit...................AKR-30/50 FIGURE 13 PT Module Installation “Black Front” Breaker Page 28... -
Page 33: Wiring Diagram For Communications
AC-PRO Retrofit...................AKR-30/50 FIGURE 14 Wiring Diagram For Communications Page 29... -
Page 34: Side View Alternate Mounting Behind Closing Spring
AC-PRO Retrofit...................AKR-30/50 FIGURE 15 Side View Alternate Mounting Trip Unit behind closing spring Page 30... -
Page 35: Side View
AC-PRO Retrofit...................AKR-30/50 FIGURE 16 Side View Alternate Mounting Using MicroVersa Trip Bracket Page 31... -
Page 36: Top View
AC-PRO Retrofit...................AKR-30/50 FIGURE 17 Top View Alternate Mounting Using MicroVersa Trip Bracket Page 32... -
Page 37: Microversa Trip Bracket
AC-PRO Retrofit...................AKR-30/50 FIGURE 18 TEMPLATE: Modification to Existing MicroVersa Trip Bracket Page 33...
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