GE Industrial Systems Plainville, CT USAgg

Instruction Manual Gerapid 2607/4207/6007/8007

S47185 us - Revision 5/2000 Page 3 Design and specifications are subject to change without notice

User’s Guide High Speed DC Circuit Breaker Type Gerapid 2607-4207 with Arc chute 1X2 and 1X4

Table of Contents Page

1 General ........................................................ 3

1.1 Warnings 3

1.2 Technical Data 4

1.3 Short Description 4

1.4 Structure and Components 4

2 Installation and Operation ........................... 6

2.1 Transportation 6

2.2 Installation 6

2.3 Setting the Overload Release 6

2.4 Operation 6

3 Inspection and Maintenance ........................ 7

3.1 General 7

3.2 General Visual and Functional Check 7

3.3 Inspecting the Arc Chute 8

3.4 Checking the Condition of Contacts,

Arc Probes and Protective Walls 8

3.5 Checking the chute and the probe

screwed connections for tightness 9

3.6 Checking the Latch Mechanism and Drive 9

4 Instructions for Maintenance and Refit......... 9

4.1 Changing the Protective Wall 9

4.2 Changing the Arc Chute 9

4.3 Changing Probes 10

4.4 Changing the Arc Contacts 10

5 Dimensional Drawings............................... 12

6 Circuit Diagram.......................................... 20

7 Spare Parts* ............................................... 26

8 Catalog No ................................................. 27

1 General

1.1 Warnings

During operation, electrical appliances carry dangerous voltages. In addition, circuit breakers can emit hot, ionized gases when switching high currents, especially short circuit currents.

Installing, commissioning, maintaining, changing or refitting these appliances must be carried out only by qualified and suitably trained specialist personnel and under strict observation of national and international safety regulations.

During their operation, circuit breakers must be equipped with appropriately fitted covers, e.g. in suitable enclosures or panelboards. Safety distances must be observed. Certain work must only be carried out by suitably trained service personnel.

Non-compliance with these warnings can result in death, severe physical damage and extensive damage to equipment.

Prior to carrying out maintenance, inspection or checks, the circuit breaker must be open, the both terminals must be grounded, the circuit breaker must be switched off and the control plug removed.

During operation, i.e. when the circuit breaker is closed, manual activation is not permissible. Manual activation is only used for maintenance purposes.

The circuit breaker is equipped with quickly moving parts. There is a high risk of injury. Do not touch the circuit breaker during switching ON or OFF.

The control circuits are partly equipped with capacitors which may be charged with dangerous voltages. Work on this section must be carried out carefully.

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1.2 Technical Data

Table 1 Technical data for Gerapid 2607 - 8007 with arc chute 1X2.

1.3 Short Description Gerapid high-speed DC circuit breakers are single-pole circuit breakers designed for use in railway propulsion-power distribution systems with operating currents up to 6000 A and operating voltages up to 800V dc. They have a very high interruption capacity combined with a current limiting characteristic.

Closing of the circuit breaker is performed through a high-power activation magnet. During inspections, opening and closing may be carried out by means of a hand lever, which can be mounted onto the armature of the activation magnet. Overload tripping is achieved directly via a short circuit trip or, depending on the rate of current rise, by an external current-rise release with an internal capacitor trip (ed - trip available as an accessory). Indirect remote tripping can be achieved by means of a shunt trip or an undervoltage release. The arc chute works on the basis of a highly sophisticated, asbestos-free, arc splitting principle. A wide variety of accessories and spares parts is available for maintenance, repair, or possible extension.

1.4 Structure and Components Type Gerapid high speed DC circuit breakers have a compact and enclosed construction. They are IP 00 protected. All parts are mounted on thick-walled, non-breakable and fireproof insulation panels, whose large covers protect the breaker’s mechanism from damage. Transparent plastic side covers are available as an optional accessory to protect metal connecting elements on the panel.

Type Gerapid 2607 4207 6007 8007

Arc chute type 1X2 1X2 1X2 1X2

Rated voltage ( V DC )

acc.EN 50123-2/IEC 947-2

800 800 800 800

Rated continuous current Iu (A) acc. IEEE C37.14

2600 4150 5000 6000

Rated current Ith ( A ) acc.EN 50123-2/IEC 947-2

2600 4200 6000 8000

Rated impulse withstand voltage U imp (kV DC ) 12 12 12 12

Rated short circuit current at max. voltage

200kA at 800V DC 135kA at 1200V DC

Rated short circuit breaking capacity INSS/ ISS (kA) acc.EN 50123-2/IEC 947-2 Rated time constant t (ms)

50/70

31,5

50/70

31,5

50/70

31,5

50/70

31,5

Switching transient ( kV DC ) 2 2 2 2

Instantaneous overcurrent trip Setting ranges ( kA )

1...2.5 1.5...5 3...7 5...10 7...12

1,5...5 3...7 5...10 7...12

10...18

3...7 5...10 7...12 10...18 15...24

3...7 5...10 7...12 10...18 15...25

Mechan. operations (ops.)

Swtching frequency(ops./h)

20.000

60

20.000

60

20.000

40

20.000

40

AC 48V...230V DC 48V...220V approx. 300 ms

0.8 – 1.1 Us

without capacity unit approx. 8 sec. with capacity unit approx. 14 sec.

100 ms

Activation magnet Rated operating voltage Us Total make time Operating range

Min. interval between two ON – operations Min. command

Power consumption ( W ) 1750 2000 2800 Internal Power Supply Input - Voltage DC AC Input - Inrush current Output - Voltage Output - Current

38V...75V 60V...150V 130V...350V 120V...250V A A A 22V – 25V 5A ( short time ) 3A ( constant )

Control circuits Electrical connector

1x 12-pin AC 400V 20A 3x 15-pin AC 250V 8A

Total weight ( kg ) 100 100 105 130

Shunt trip module

24 VRated voltage Operating range 21.6V - 26.4V Power consumption approx.100W No voltage release

24 VRated voltage Operating range ON 19,2V - 26,4V Operating range OFF < 3V Power consumption approx.11W ed- trip

Capacity 2000 µF Charging voltage (optional, to be activated by an external signal:5...24V DC, 1mA)

300V

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Gerapid breakers are equipped with a two-stage contact system. The main contacts are coated with a silver composite material; the arcing contacts are made from copper and can be easily replaced. The flexible contact is linked to the connection by means of very tight braids.

An attachment set is used to mount the various arc splitting systems for different operating voltages to the breakers. The arc chutes consist of a highly durable, arc-proof material, into which the arc plates have been integrated. The arc plates of 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 absorb a large amount of the arc’s energy.

The overload trip design uses a release magnet with twin magnets, optimizing the twin magnetic field principle. This technology ensures equally fast tripping in both current directions. The magnetic system does not require an auxiliary voltage. The system consists of the holding circuit, the flexible armature and the tripping circuit. The holding magnet and the tripping magnet are both excited by the main current. Until the static overload release’s response threshold has been reached, the flexible armature is held in position by the holding circuit’s magnetic field and the counter spring. If the main current exceeds the set static response threshold, the tripping circuit’s power takes over and pulls the flexible armature down suddenly. During this operation, the armature trips the release lever. The main latch and contacts are opened immediately. The response threshold can be easily adjusted by turning the adjustment nut with a SW6 hexagon wrench. In combination with the transparent side cover accessory, a fixed-mounted insulated knob is available (accessory).

To detect high short circuit currents early and to record leakage currents in long peripheral sections (for railway equipment), whose final values are lower than the highest operating currents, protective relays for monitoring a current increase should be installed. If a fault occurs, a release signal can be passed on to the capacitor release, which causes the breaker to open rapidly (opening delay

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