INSTRUCTIONS AND RECOMMENDED PARTS GEK-41902 C FOR MAINTENANCE ‘Supersedes GEK-41902 B MAGNE-BLAST CIRCUIT BREAKER Type: AM-4.16- 250-9 1200 & 2000 Amperes With ML-13 Mechanism CONTENTS INTRODUCTION oo. ces eee ence eee 3 RECEIVING HANDLING And STORAGE INSTALLATION . . DESCRIPTION OF OF ADJUSTMENTS .. 6. + GENERAL MAINTENANCE RENEWAL PARTS... GENERAL @@ ELECTRICMAGNE-BLAST CIRCUIT BREAKER AM-4.16-250-9 (A) &X Letter Designation B, C, H, K, R and N, used immediately following the model number indicates basic design features. INTRODUCTION ‘The Magne-blast breaker is the removable and interchangeable interrupting element used.in metal- clad switchgear to provide reliable control andpro- tection of electrical apparatus and power systems. ‘The AM-4.16-250 Magne-blast breaker is available with continuous current ratings of 1200 amperes and 2000 amperes in accordance with applicable industry standards. Refer tothe breaker nameplate for complete rating information of any particular breaker. The nameplate also describes the control power requirements for that breaker. The application of a breaker must be such that its voltage, current, voltage, current, and interrupting ratings arenever exceeded, Since this book is written to include all ratings of the breaker as well as several design variations, the instructions will be of a general character ‘and all illustrations will be typical unless otherwise specified. PROPER INSTALLATION AND MAINTENANCE, ARE NECESSARY TO INSURE CONTINUED SAT- ISFACTORY OPERATION OF THE BREAKER. The following instructions will provide complete infor- mation for placing magne-blast breakers in service and for maintaining satisfactory operation. RECEIVING, HANDLING AND STORAGE Receiving and Handling Each breaker is carefully inspected and packed for shipment. Immediately upon receipt of the circuit breaker, an examination should be made for any damage’ sustained in transit. If injury or rough handling is evident, a damage claim should be filed immediately with’ the transportation com- pany and the nearest General Electric Sales Office should be notified, It is expected that due care will be exercised during the unpacking and installation of the breaker so that no damage will occur from careless or rough handling, or from exposure to moisture or dirt. Check all parts against the packing list to be ‘sure that no parts have been overlooked. Storag It is recommended that the breaker be put into service immediately in its permanent location. If this is not possible, the following precautions must be taken to insure the proper storage of the breaker: 1, The breaker should be carefully protected against condensation, preferable by stor- ing it in a warm dry room, since water absorption has an adverse effect on the insulation parts. Circuit breakers for outdoor metal-clad switchgear should be stored in the equipment only when power is. available and the heaters are in operation to prevent condensation, 2, The breaker should be stored in a clean location, free from corrosive gases or fumes; "particular care should be taken to protect the equipment from moisture and cement dust, as this combination has a very corrosive effect on many parts, 3, Unfinished surfaces of rollers, latches etc., of the operating mechanism should be Coated with grease to prevent rusting. If the breaker is stored for any lengthof time, it should be inspected periodically to see that rust- ing has not started and to insure good mechanical condition, Should the breaker be stored under unfavorable atmospheric conditions, it should be cleaned and dried out before being placed in service. (Cover Photo-8034472 These instructions do not purport to cover all details or variations in equipment nor to provide for ‘every possible contingency to be met in connection with installation, operation or mlintenance. Should further information be desired or should particular problens arise which are not covered sufficiently for the purchaser's purposes, the matter should be referred to the General Electric Company. To the extent requized the products described herein meet applicable ANSI, IEEE and NEMA standards; but no such assurance is given with respect to local codes and ordinances because they vary greatlyGEK~41902 Magne-blast Circuit Breaker INSTALLATION Each breaker has been tested and inspected before shipment from the factory; however, before placing the breaker in service the following items Should be checked to assure that no change has oc- curred during shipment and storage. 1. Remove the box barriers and mechanism cover and make a visual inspection to ascertain that the breaker and mechanism isin satisfactory condition. Check all bearing surfaces of the mechanism for lubrication. Refer to section on LUBRICATION page 16 and Figure 17, 2. Charge the breaker closing springs manually using a 5/8" ratchet wrench to turn the driving ec centric (6) Figurel. Turning the eccentric counter = clockwise will advance the ratchet wheel and com- ress the springs. When the springs have reached the fully charged position the indicator (1) will read "CHARGED", and the driving pawl will be raised from the ratchet wheel teeth. Additional turning of the eccentric will not advance the ratchet wheel. Insert the spring blocking device(10)and manually discharge the springs against the pins by pushing the manual release button (4). The springs are now blocked and slow closing of the breaker contacts can beaccomplished by again turning the driving eccen- tric with a 5/8" ratchet wrench. During the slow closing operation check to insure that the mechanism does not stick or bind during the entire stroke, that it latches securely in the closed position, and that it trips freely when the manual trip lever is operated, At this time, also check the following adjustments: a, Arcing contact wipe (Refer to page 10) b. Primary contact wipe (Refer to page 11) ¢. Primary contact gap (Refer to page 11) DO NOT WORK ON EITHER THE BREAKER OR ‘MECHANISM UNLESS THE CLOSING SPRINGS ARE BLOCKED AND THE OPENING SPRINGS HAVE BEEN TRIPPED OPEN OR MECHANICALLY BLOCKED. THIS PRECAUTION IS REQUIRED TO PREVENT ACCIDENTAL CLOSING OR TRIPPING The closing springs should now be unblocked. Ro- tate the driving eccentric until the indicator reads "CHARGED" and the ratchet wheel does not advance. The spring blocking device can now be removed. 3. To assure that the electrical connections have remained tight, they should be checked during installation as well as during each maintenance in- spection. This check of electrical connections is particularly necessary on breakers used in nuclear generating stations and other critical applications. The bolted braid connections on the stationary arcing contacts shouldbe checked for tightness by removing the arc chutes as described on page 15. 4. Connect the test coupler to the circuit breaker and operate it electrically several times. Check the control voltage as described under "CONTROL POWER CHECK" (Page 14). 5. Disconnect the test coupler and before replacing the box barrier, the primary bushings and other insulation should be wiped clean. 6. Ifthebreaker has been stored for a long period of time, it is recommended that the insulation be checked witha standard 60 hertz high potential test. Refer to Insulation Test (Page 16). NOTE: If the breaker secondary wiring is to be given a hi-potential test at 1500 volts, remove both the motor leads from the terminal connection. Failure to disconnect the motor from the circuit may cause damage to the winding insulation, 7. Lubticate the silver portion of the ball contact at the top of the breaker bushing and the rear por- tion of the ground shoe, by applying a thin jilm of contact lubricant DS0H47. 8. Refer to metal-clad instruction book GEH-1802 for instructions on inserting the breaker into the metal-clad unit. DESCRIPTION OF OPERATION ‘The Magne-blast Breaker has twoprincipal com- ponents; the breaker element and the operating mechanism: ‘The breaker element is three similar pole units, each of which includes the current carrying parts, main and arcing contacts, interrupter, and an enclosing barrier system that provides insulation between poles, or phases and to ground. The pri- mary connections to the associated metal-clad 4 * Indicates revision switchgear are made through the ball contacts at the top of the breaker bushings. The operating mechanism type ML~13 is of the stored energy type designed to give high speed closing and opening. The mechanism will operate on acc or d-c voltage as indicated on the breaker nameplate, Closing and opening operations are controlled’ either electrically from the metal-clad unit and remote location, or mechanically by themanual close and trip levers on the breake Magne-blast Circuit Breaker GEK-41902 All A spring release interlock, Fig 3, is provided Secondary connectionsfrom the breaker tothe metal to discharge both the closing and opening springs clad unit are made through the coupler (1) Fig; 2, when the breaker is withdrawn from or inserted Figure 1, (8034475) spring Blocking Device 1 2. 3. 4 5. 6 7 8 9 10. Figure 3, (8088805) Spring Discharge Linkage into the Metal Clad unit. Charge-Discharge Indicator Support Bolts Driving Pawl Manual Close Lever Motor Eccentric Closing Spring Manual Charging Wrench Fuse Spring Blocking Device Figure 2. (8034473) Left Side View ML~13 Operating Mechanism Ankh ON Secondary Coupler Interlock Switches Auxiliary Switch Latch Checking Switch ‘Switch Cam Charge-Discharge Indicator Closing Latch Roller Link Power Switches Adjusting Bolt ‘Trip Lateh Crank Closing Latch Discharge Crank Closing Springs Adjusting Clevis 11; Motor Spring Release Crank 12, FusesGEK-41902 Magne-blast Circuit Breaker A positive interlock (3) Figure 4 and interlock switch (2) Figure 2, are provided between the breaker and metal-clad unit to prevent raising or lowering of the breaker in the unit while in a closed position and to prevent a closing operation when the breaker is not in either the fully raised or lowered position, To insure that this interlock will function during manual, as well as during electrical operation of the equipment, both mechan- ical and electrical blocking is provided. If for any reason the closing springs should be dis- charged against the positive interlock the mechan- ism ‘will be jammed and be inoperable, The mechanism can be released and returned to the reset position by pushing in on the trip lever (8) Figure 5. It may require more than normal force to release the interlock, A plunger interlock, Figure 14 can be provided when required to operate a stationary auxiliary ‘switch and/or a rod interlock mounted in the metal- clad unit. =BP2 Wauran 5 Figure 4. (8034463) Right Side View-ML-13 Operating Mechanism Upper Spring Pin ; Latehing Pawis Bositive lterlock Roller ening Spring Cam Shaft Ratchet Wheel Bearing Block Driving Pawl Lower Spring Pin 10. Driving Pawl Lever 11. Eecentrie 12. Closing Spring Rogpone 6 + Indicates revision When the breaker is used interchangeably with type MS-13 solenoid operated breakers in M-26 lad units, fuses (12) Figure 2, are mounted on the breaker for protection of the motor and closing circuit. These breakers are identified by a"C" or "K" suffix in the breaker nomenclature. «In cases where breakers with type ML-13 mechanisms must match and line up with breakers having type ML~11 mechanisms the spring chargi circuit for both mechanisms should be fused wit Buss Company Fusetrons as follows: Cont. Volt. | Fuse Size | Cat. No. 48y dee 304 | FRN $0 110v dee FRN 4 125v dee FRN 4 115v a-e FRN 4 220v dee FRN 2.5 250v de FRN 2°5 230v ac FRN 2.5 spring Charging ‘The mechanism has a high speed gear motor (10) Figure 5, that compresses a set of closing springs through the action of an eccentric, ratchet, and pawl assembly. ‘The rotary actionof the motor 1s converted to a Straight stroke through the eccen- tric (11) Figure 4, and alever that carries a spring loaded driving pawl (3) Figure 1. Figure 5. (8034471) Front View ML~13 Operating Mechanism }, Auniliary Switeh 2. Open = Close Indicator 3. Trip Coil 4. Prop Spring 5. Operation Counter 6. Trip Latch 1. Charge-Discharge Indicator 8. Manual Trip Lever 9. Manual Close Lever 10. Motor ~~ am‘The pawl advances the ratchet wheel (6) Figure 4 a few degrees each stroke where it is held in pos- ition by the latching pawls (2). When the ratchet wheel has been rotated approximately 180 degrees the closing springs (12) will be fully compressed, ‘As the ratchet wheel continues to rotate, the spring load will shift over center and attempt to discharge. ‘After a few degrees of rotation, the closing roller (7) Figure 2, will engage the closing latch (9) and the compressed springs will be held by the latch until a closing operation is required. During the last few degrees of the ratchet wheel rotation the power switches (8) are opened ard the driving pawl is raised from the ratchet wheel surface. This allows the motor and driving mechanism to coast to a natural stop expending all residual energy. During the time the springs are being com- pressed a relay (17) Figure 6, is energized to hold the closing circuit open. 'The relay remains energized until the springs are fully charged and the control switch contacts are re-set. ‘The closing springs may be charged manually if control voltage is lost. A 5/8" ratchet wrench can be used to rotate the eccentric in a counter clockwise direction until the indicator reads"Charg- Magne-blast Circuit Breaker GEK~41902 ed and the driving pawl is raised from the fatehet wheel. The use of the ratchet wrench provides for maximum safety in the event that Control power is suddenly restored without warning. In this ‘event, the motor drive will override the ratchet wrench and continues to charge the springs. Closing Operation ‘The breaker can be closed electrically by energizing the spring release solenoid (15) Figure 6, or manually by pushing the close button (9) Figure 5. In either method the closing latch is rotated from under the closing roller, to release ihe closing springs (10) Figure 2. The enerey fn the springs 1s used to rotate a cam (16) Figure T and close the breaker through the operating mechanism linkage. During the closing operation the mechanism is trip-free at al times. The break- fer is held closed by the closing prop (14) moving fhto position under the prop pin 3}, During the closing operation the opening springs (4) Figure 4, fare compressed and held ready for an opening operation with the trip latch (8) Figure 7 bearing against the trip lateh roller (9). When the closing operation of the breaker is completed and the closing latch is fully reset, Figure 6. (8034467) Control Mechanism 1. Latch Checking Switch 7. Power Switches 13. Latch Monitoring Switch 2) Switch Cam 8, Closing Latch 14, Switch Mounting Bracket 3, Switch Striker 9, Closing Latch Shaft 15, Spring Release Solenoid 4, Switch Support Bolts 10, Latch Adjusting Screw 16. Release Coil Support 5, Switch Support 11, Release Coil Bolts 17. Control Relay 6. Closing Latch Roller 12. Closing Latch SpringGEK-41902 Magne-blast Circuit Breaker the contacts of the latch monitoring switch closes to permit the spring charging motor to be energiz~ ed and recharge the closing springs. ‘Qpening Operation The breaker can be opened either electrically by energizing the trip coil (3) Figure 5, or man= ually by pushing the trip lever (8). In each method the trip latch is rotated off the trip latch roller, permitting the operating mechanism linkage {0 collapse. ‘The energy stored in the opening springs is released to provide the required opening speed for successful interruption of the circuit. As the breaker opens to interrupt a current, the are finst starts af the arcing contacts (6 27) Figure 6, transfers to the are runner (4 & 10) and energizes the blow-out coils (3'& 11). This action introduces a magnetic field between the pole pieces (5 & 9) of the interrupter that forces the are deeper into the are chute (6). At the time the arcing contacts part a discharge of alr is expelled through the ‘booster tube (28), across the arc. This air flow assists the are transfer and interruption by blowing the arc away from the contacts and into the "are chute. The magnetic field forces the arc deeper into the interrupter along the diverging arc runners. Fig. 7 (0114C5320) Sectional Side View of Mechanism 1. Handle 10. Trip Latch Roller Support Stop Plate 2. Trip Coll Support 11. Crank Shaft Spring Rod 3. Trip Coil 12. Cranks Spring 4. Trip Armature 18. Prop Pin Spring 5. Prop Reset Spring 14. Prop Spring Guide 8. Cam Follower Roller 15. Drive Shaft Stop Bin 7. Trip Shaft 16. Cam Main Shaft Bearing 8. Trip Latch 17. Cheek Nut Cam Shaft Bearing 9° Trip Latch Roller‘Magne-blast Circuit Breaker GEK-41902 ' 2 = 3——_+—— 4 + 5 6 7 8 9 ——+f 10. A u AG 12 [ez 13 = Figure 8. (0152C5973) Cross Section of Breaker Pole Unit Box Barrier Support Lower Blow-out Coil 21. Operating Rod Upper Blow-out Core Lower Blow-out Core 22, Stationary Primary Contacts Upper Blow-out Coll Box Barrier Guide 23. Movable Primary Contacts ipper Are Runner Front Bushing 24. Cup Bearing Upper Pole Piece Rear Bushing 25. Yoke Stationary Arcing Contact Frame 26. Movable Contact Arm Assembly Box Barrier Main Operating Crank 27. Movable Arcing Contact Are Chute Side Primary Contact Springs 28. Booster Tube and Piston Lower Pole Piece Spring Retainer 29. Connection Bar Lower Arc Runner 20. Lower Horizontal Barrier 30. Booster CylinderGEK-41902 Magne-blast Circuit Breaker The arc chute has a series of interleaving cer- amic fins, Figure 19, As the arcis forced into the interrupter it is lengthened in the gradually deep- serpentine path between the fins so that the ctrical resistance of the arc is rapidly increased and its heat is absorbed by the ceramic material. ‘The increased resistance reduces the magnitude and phase angle of the current and at an early current zero the arc cannot re-establish itself and interruption occurs. ‘Trip Free Operation It the trip coil circuit is energized while the breaker is closing, the trip armature will force the trip latch (8) ’Figure 7 away from the trip roller (0) causing the mechanism ligkags to collapas and the breaker to re-open. The closing cam (16) Will complete its closing stroke and the springs will re-charge as in a normal closing operation, ADJUSTMENTS All adjustments should be checked during per- jodie inspections and whenever it becomes nec- essary to repair or replace parts that have become worn or defective while in service. The following adjustments are listed in the order in which they are to be checked after removing the box barriers and front cover from the breaker, DO NOT WORK ON EITHER THE BREAKEROR Nuon Primary Contact Wipe MECHANISM UNLESS THE CLOSING SPRINGS ARE BLOCKED AND THE OPENING SPRINGS HAVE BEEN TRIPPED OPEN OR MECHANICALLY BLOCKED. THIS MEASURE IS REQUIRED TO PREVENT ACCIDENTAL CLOSING OR TRIPPING, Arcing Contact Wipe Refer to Figure 9, Close the breaker until Arcing Contact Wipe Figure 9, "-9" Contact Structure (0132C2709) Figure 9 Contact Adjustments 1, Stationary Primary Contacts 5. 2, Movable Primary Contacts 3. Buffer Block 4. Stationary Arcing Contacts 10 Movable Arcing Contacts 6, Contact Arm 7. Throat Baffle ~,the arcing contacts just touch. This can be determined with the use of a circuit continuity fester such as a light indicator or bell set. In this position, the gap between the stationary prima contgets ()’and ihe movable primary. contact () Should be 8/16" or greater. This setting bas been made in the factory and no adjustment is provided. A wipe of 1ess than 5/16” is an indication that the acing contacts need fo be replaced. “When making ihis check, see that the movable arcing contact (3) passes between the probes on the upper are runner Without touching, "On. the "'=9" ‘design, check for clearance between the arcing contact’ (6) and the ‘slot inthe throat baffle (i) during ‘entire Stroke of the moving contact assembly. Primary Contact Wipe Refer to Figure 9, when the breaker is closed the stationary primary contacts. (1) should rise from 1/4" to 5/16". Before checking this dimen- sion be sure the mechanism is re-set so that the prop pin (13) Figure 7 is resting on the prop. To ‘obtain the proper contact adjustment, open the breaker and, referring to Figure 10, loosen the check nut (4) and turn the adjusting nut (3). Screw- ing up on the adjusting nut will decrease the primary contact wipe, down will increase it. Tighten the ‘check nut, close the breaker and recheck the wipe. With the primary contact wipe correctly adjusted, the clearance between the contact arm (6) Fig- ure 9 and the buffer block (3) should be 1/16” or greater when the breaker is fully closed. Figure 10. (8039619) Adjustable Coupling For Making Primary Contact Wipe Adjustments 1, Operating Rod 2. Operating Rod Pin 3. Adjusting Nut 4. Check Nut 5. Stationary Primary Contacts i 7 Contact Arm 8. Movable Primary Contacts * Indicates revision Magne-blast Circuit Breaker GEK-41902 Primary Contact Gay Refer to Figure 10, With the breaker closed, press the manual trip'button allowing the breaker fo trip open normally. Do not force the contacts open wider by hand, ‘The gap between the stationary primary contacts (5) and the movable primary con- fact (8) measured between the closest points, should be 3.5/8" to 315/16". To change this gap, loosen the check nut (17) Figure 7, and turn the adjusting nut (18) on stud (19). Screwing the adjusting nut down will decrease the primary contact gap. Tighten the check nut and re-measure the contact gap (close and trip the breaker before checking the measurement). Whenever the primary contact gap is changed, the primary contact wipe should be rechecked and, if necessary, readjusted. WHEN WORKING ON THE MECHANISM INTHE CLOSED POSITION, KEEP FINGERS CLEAR OF THE LINKAGE, AS ACCIDENTAL TRIPPING CAN CAUSE SEVERE INJURY. Trip Latch Wipe Refer to Figure 7. The wipe of the trip latch (8) on the trip roller (9) should be from'3/16” to 1/4", ‘This can be measured by putting a film vf grease on the latch (8), closing the breaker part way, and tripping. The mechanism has the proper trip latch wipe when the latch rests against the stop pin (23). No adjustment is provided and a visual inspection is usually all that is required, If this setting is not correct, look for insufficient travel of the trip shaft (7). Joly Armature Travel Refer to Figure 7. The trip armature (4) shoul: have 1/16" to 3/6" travel before the trip inten (O) starts to move plus 1/32" minimum overtravel after tripping. ‘This can be adjusted by moving the trip coil support (2) and/or by adjusting the trip armature screw (12) Figure 11, "A locking screw located behind the trip armature screw must first be loosened, Retighten locking screw after making adjustment. Release Latch Wipe Refer to Figure 6. ‘The wipe between the release latch (8) and roller (6) should be 3/16” to 1/4". If re-setting is required, loosen, set, and re- tighten adjustment nut and screw (10). Release Latch Monitoring Switch Refer to Figure 6, The release latch must be fully re-set and the latch monitoring switch (13) operated before the motor will start, When the latch is fully reset the clearance between the switch striker arm and the switch mounting bracket (14) is 1/32" or less, this can be adjusted by bending the striker arm, Motor and Relay Switches Refer to Figure 6, With the closing springs blocked rotate the switch cam (2) until the switch uGEK-41902 Magne-blast Circuit Breaker Figure 11, (8039585) Auxiliary Switch and Trip Coil 1. Open - Close Indicator 2) Auxiliary Switch 3. Prop Spring 4. Trip Latch Spring 5. Spring Discharge Crank 6. Cotter Pin 1. Trip Coil Support 8. Trip Coil 9. Mounting Bolts 10. Latch Set Screw 11. Trip Latch 12) Trip Arm Screw 13. Manual Trip Lever striker (3) has traveled the maximum amouct (about 180 degrees rotation of cam). At this point the clearance between the striker and the switch support (5) should be 1/32" or less. This can be adjusted by loosening the switch support mounting bolts (4) and rotating the support. Interlock Switch Wipe Refer to Figure 12. With the positive interlock in the reset, or normal position the clearance between the interlock switch arm (2) andthe switch mounting plate (3) should be 1/32" or less. This can be adjusted by bending the switch arm, Driving Pawl Adjustment Refer to Figure 4. The driving pawl (8) must advance the ratchet wheel (6) sufficiently on each stroke to allow the latching pawls (2) to fall into the ratchet teeth, This should be checked with the closing spring load against the driving members. With the ‘mechanism unblocked, hand charge the closing springs with the manual charging wrench until they are slightly more than half charged, Slowly rotate the charging wrench until the driving pawl has traveled through its return stroke and check the maximum clearance between the pawl and the ratchet tooth. Rotate the charging wrench until the driving pawl has advanced the ratchet tooth 12 * Indicates revision Figure 12. (8034474) Positive Interlock switch 1. Positive Interlock Shaft 2. Switch Arm ‘Switch Support Interlock Switch Auxiliary Switch Switch Suppo Latch Checking Switch Switch Arm Trip Shaft to its maximum travel. Now check the clearance between the ratchet tooth and the latching pawl, The clearance should be approximately equal for both the driving und latching pawls and not less than 015" in either case. If adjustment is required for either pawl the springs must first be fully charged and blocked, Loosen seven motor support bolts (2) Figure 1 and move entire motor assembly to the rear if the clearance is under the minimum at the latching pawls, and to the front if the clearance is under the minimum at the driving pawl, Move the motor assembly approximately twice the dimensional in- crease required at the pawl. Be certain the motor assembly is moved straight forward or rearward and tighten the one bolt on the right side of the mounting frame first to assure proper alignment, After tightening the remaining bolts the springs should be released and the clearance again checked as described above. Crank Shaft End Play ‘The outboard cranks (12)Figure 7 on the crank shaft shouldbe adjusted so the end play side to side——\, is less than 0.015 inch. After this adjustment is made, the clearance of the prop pin(13)Figure 7 to the frame is a minimum of 0.025 inch.AUXILIARY DEVICES Latch Checking Switch Refer to Figure 13. Charge the closing springs sufficiently to reset the mechanism linkage. Rotate the trip latch (4) by pressing the manual trip lever Figure 13, (0114C5320) Latch Checking Switch 1, Switch Support 5, Reset Pin Stop 2. Latch Checking Switch 6. Latch Roller 3. Switch Arm Latch Roller Link 4. Trip Latch ; Latch Roller Pin to open the latch checking switch (2), Allow the trip latch to reset slowly and determine the point at which the contacts are made by using a circuit Continuity tester Gught indicator, bell set, etc), ‘The contacts of the latch checking switch should just make when the gap between the trip latch {8)‘and the stop, pin (9) located on the latch roller Tine (i) is 1/16") "There should be a minimum of 1/64" between the switch arm (3) and the switeh Support (1). To obtain adjustment of the latch check- fagvewiteh, bend the latch checking switch arm Plunger Interlock Refer to Figure 14, With the breaker in the closed position, the vertical distance "A" from the top of the plunger bolt (1) to the bottom of the breaker lifting rail (3) should be 16-19/32" to 16-23/32", To change this adjustment, add or remove washers (2). Auxiliary Fuses Refer to Figure 15. Onbreakers witha "C" or “"K" suffix, a set of protecting fuses (10)are mounted ‘on the front of the breaker, These fuses are the primary protective devices for the closing control Gireuit on those breakers that are used in metal lad units designed for solenoid operated breakers. * Indicates revision Magne-blast Circuit Breaker GEK-41902 Figure 14, (8034464) Plunger Interlock 1, Plunger Bolt 2. Washer 3. Breaker Lifting Rail Figure 15. (8034471) Driving Elements 1, Mounting Bolts 2: Manual Close Button Retaining Rel Ring 5. Hex Charging Stud 6. Driving Link 7. Motor Support 8. Retaining Ring 9. Motor 10. Fuse Inspection and Test 1 For ease in reviewing the adjustments, the following are recapitulated: a, Primary contact wipe: 1/4" to 6/16". b. Arcing contact wipe: 5/16" or greater gap at primary contact: c. Primary contact gap: 3-5/8" to3-15/16". 4, Trip latch wipe: 3/16" to 1/4" with trip lateh resting against stop pin. e. Trip armature travel 1/16"t0 3/16" plus 1/32" minimum overtravel. {, Release latch wipe: 3/16" to 1/4". g. Release latch monitoring switch: Max- imum clearance 1/32", 13GEK-41902 Magne-blast Circuit Breaker h. Motor and relay switch: clearance 1/32". 1. Interlock switeh: maximum clearance i, Driving and Latching Pawl: minimum clearance to ratchet teeth .015", Kk, Latch checking switch contacts make when the gap between the trip latch and the stop pin is 1/16". 1, Plunger interlock: ‘16-19/32" to 16- 23/32", Check all nuts, washers, bolts, cotter pins, and terminal’ connections for tightness. maximum 3. Inspect all wiring to make sure that no damage has resulted during installation, and test for possible grounds or short circuits. 4, See that all bearing surfaces of the mech- anism have been lubricated. Refer to the section on LUBRICATION. (Page 16 and Figure 17). 5. Operate the breaker slowly with the manual charging wrench and note that there is no excessive binding or friction and that the breaker can be movedto the fully opened and fully closed positions, See that any place where the surface of the paint has been damaged is repainted immed- iately. 7. Check, the trip coll plunger and the release coil plunger to see that they move freely, Opening and Closing Speeds The closing speed of the arcing contact of the breaker should be a minimum of 11feetper second, This represents the average speed of the movable arcing contact from a point 3” before the tip is tangent to the lower surface of the probes on the upper arc runner to the tangent position, ‘The opening speed of the arcing contact should be a minimum of 12 feet per second, This repre- sents the average speed over 3" from the point when the tip on the movable arcing contact is tangent to the lower surface of the probes on the upper runner. Proper servicing and lubrication of the breaker and its operating mechanism should maintain these speeds and no adjustment is provided, Control Power Check After the breaker has been operated several times with the manual charging wrench and the mechanism adjustments are checked as described, the operating voltages should be checked at the release coil, trip coil, and motor terminals. Control Power for electrical operation of the breaker may be from either an alternating or direct current source. The operating ranges for the closing and tripping voltages as given on the breaker nameplate, are as follows: Nominal Voltage Closing ‘Tripping Range Range - 4 Sovdee | 28 ll5vd-c | 60 13ov d-e | 70 230v d-e | 120 260v d-e | 140 125v a-c | 95 250va-c | 190 2avd-e | - 4avd-c | 34 Lov dee | 80 125v dec | 90 220v dec | 160 250v d-e | 180 115v a-c | 95 230v a-c | 190 30v de Gov dec 125v dec 140v de 250v d-c 280v de 125v a-c 250v a-c If the closed circuit voltage at the terminals of the coil or motor does not fall in the specified range, check the voltage at the source of power and line drop between the power source and breaker. When two or more breakers operating from the same control power source are required to close simultaneously, the closed circuit voltage at the closing coil or motor of each breaker must fall within the specified limits. Electrical closing or opening is accomplished by energizing the closing or trip coil circuit. Control Switches are provided for this purpose on the metal-clad unit. It is also possible to trip or close the breaker manually by pressing the manual trip lever (8) Figure 5 or the manual close button (9). GENERAL MAINTENANCE General Safe and dependable service from electrical ap- paratus and power systems is contingent upon re- liable performance of power circuit breakers. To obtain maximum reliability the breaker should be inspected and maintained on a regular schedule, The breakers are designed in accordance with ap- plicable standards which require that they be capable of performing up to 5000 operations for 1200 ampere breakers and 3000 operations for 2000 ampere breakers switching rated continuous cur- rent before any replacement of parts should be necessary. This requirement is based on the breakers being serviced, or maintained, at least 14 every 2000 operations, or onceper year, whichever comes first. If the breaker is also required to interrupt fault currents during this period of time additional maintenance and replacement of parts may be necessary, BEFORE ANY MAINTENANCE WORK IS PER- FORMED, MAKE CERTAIN THAT ALL CONTROL CIRCUITS ARE DE-ENERGIZED AND THAT THE BREAKER 1S REMOVED FROMTHE METAL-CLAD ——\ UNIT. DO NOT WORK ON THE BREAKER OR MECHANISM WHILE IN THE CLOSED POSITION UNLESS THE PROP AND TRIP LATCH HAVE BEEN SECURELY WIRED OR BLOCKED TO PRE-VENT ACCIDENTAL TRIPPING. DO NOT WORK ON THE BREAKER OR MECHANISM WHILE THE SPRINGS ARE CHARGED UNLESS THEY ARE SECURED IN THAT POSITION BY THE MAIN- ‘TENANCE SPRING BLOCKING DEVICE. Periodic Inspection ‘The frequency of the inspection and maintenance operations required should be determined by each ‘operating company and will depend on the applica~ tion of the breakers and the operating conditions. Factors which should be considered are: Import- ance to overall plant or system operation; number of operations and magnitude of currents switched by Breaker; frequency of fault interruptions; and the atmospheric conditions in which the breaker nor- mally operates, Extreme conditions of dust, moisture, corrosive gases etc., can indicate that inapection and maintenance will be required more frequently than every 2000 operations. Very clean dry operating conditions with low current switching duty can justify a longer period of time between inspections, Any time a breaker is known to have interrupted a fault at or near its rating it is recommended that the breaker be inspected and necessary maintenance be performed as soon after the interruption as is practical. The following instructions give the items that should be included in an inspection and general recommendations on the maintenance of breakers. Interrupters Since there are no moving parts, the interrupters of a magne-blast breaker will normally require a TT i Magne-blast Circuit Breaker GEK-41902 little or no inspection unless there is evidence of damage to the arc chutes sides or contamination in the throat area. If either of these conditions are present the interrupters should be removed from the breaker and the following points noted: 1, The throat area of the interrupter should be cleaned with sandpaper (Do Not use emery cloth or other metallic abrasives). All flat areas on either side of the movable ‘arcing contact travel should be sanded. Do not sand or otherwise attempt to clean the ceramic fins of the arc chute sides. Heavily contaminated parts should be re- placed, Cracks which have formed in the fins of the are chute are to be expected in ceramic materials of this type when subjected to the severe heat of an arc, These cracks do not interfere with the operation of the device in any way and shouldbe disregarded. 3, If the are chute has suffered any mechanical injury due to dropping or accidental striking, resulting in the actual breaking off of fins, replacement will be necessary. Sm: broken corners on the exhaust end of the are chute sides will not interfere with its performance and can be disregarded, 4, The plastisol flexible covering for the pole pieces (3 & 6) Figure 18 shouldbe inspected for breaks in the insulation. If there are holes or breaks in the insulation they should be repaired or the part replaced. + Electrical Connections To assure that the electrical connections have remained tight, they should be checked during installation as well as during each maintenance in spection. This check of electrical connections is particularly necessary on breakers used in nuclear generating stations and other critical applications. ‘The bolted braid connections on the stationary arcing contacts should be checked for tightness by removing the are chutes as described on page 15. . Rear Bushing Supporting Bolt Upper Interrupter Support Stationary Arcing Contacts Movable Arcing Contact Mounting Bolts’ ‘Are Chute Brace ‘Support Bracket Lower Supporting Bolt Lower Interrupter Support interrupter Figure 16, (8917442A) Interrupter Removed Showing Accessibility of Arcing Contacts * Indicates revision 15GEK-41902 Magne-blast Circuit Breaker Interrupter Removal and Replacement Refer to Figure 16. To remove the interrupter loosen the two upper supporting bolts (2) and the one lower support bolt (9)using a standard 3/4" wrench, Raise the assembly approximately 3/8" and slide it toward the rear of the breaker. To reassemble the interrupter to the breaker, rest the lower interrupter support (10) on thé Support bracket (8). Slide the arc chute forward Lifting it slightly to engage the supporting bolts (2) in the slots of the upper interrupter support (3). Check to assure that the upper insulation is prop erly positioned within the barrier suspended from the stationary contact support (9) Figure 23. Tighten the supporting bolts (2 and 9) Figure 16, These bolts serve as both the electrical and mechanical connections between the bushings and the are runners within the interrupter. Check that the movable arcing contact (5) passes between the probes on the upper are runner (5) Figure 19 without touching, Breaker Contacts By removing the box barrier the movable and stationary primary contacts andthe movable arcing contacts ‘can be inspected, The stationary arcing contacts can be inspected only after removing the interrupter. If the contacts are burned or pitted, they can be made smooth with a fine file, After completing inspection of the contacts, check the contact adjustments as specified under ADJUSTMENTS. ‘Mechanism A careful inspection should be made to check for loose nuts or bolts and broken retaining rings: All ‘cam, ‘roller, and latch surfaces should be inspected for any evidence of damage or excessive Wear. Lubricate the mechanism as outlined below, then, using the manual charging wrench, open and close the breaker several times to make certain that the mechanism operates freely throughout its entire stroke. Check the mechanism adjustments: as Specified ‘under ADJUSTMENTS. Check the control wiring for tightness of connections and damaged insulation, Bushings and Insulation The surface of the bushings should be kept clean and unmarred to prevent moisture absorption. If the insulation surface should become damaged, it should be sanded and cleaned, and should be refinished with either clear varnish or clear resin, Allow to dry smooth and hard, All other insulation parts on the breaker should be kept clean and dry. Smoke or dust collected 16 * Indicates revision between inspection periods should be wiped off, and if dampness is apparent, heaters should installed in the metal clad switchgear to insure dryness, Insulation Test When insulation has been repaired or replaced, or when breaker has been operating in adversé moisture conditions, it is recommended that the insulation be checked before the breaker is placed back in service. A standard 60 hertz high poten- tial test at 14,000 volts RMS for one minute will normally indi¢ate whether the breaker is satis- factory for service. With the breaker contacts in the fully opened position, apply the test potential to each terminal of the breaker individually with all other terminals and the breaker frame grounded, After high potential tests are made on organic ine sulating materials, these materials should be inspected for visible leakage current paths, and necessary action must be takento repair or replace insulation that may have been affected by moisture absorption, If the breaker secondary wiring is to be given a high-potential test at 1500 volts, remove both of the motor leads from the terminal board. Failure to disconnect the motor from the circuit may cause damage to the winding insulation. Lubrication In order to maintain reliable operation, it is important that all circuit breakers be properly lu- bricated at all times. Some of the bearings and rolling surfaces utilize a new type of dry lubrica- tion that will require no maintenance and will last the life of the equipment. The remaining bearings and surfaces require lubrication as listed in the lubrication chart, Figure 17. These have been Properly lubricated during assembly at the factory, using the finest grades of lubricants available. However, even the finest oils and greases have a tendency to oxidize with age, as evidenced by hard- ening and darkening in color. Elimination of the hardened lubricant is essential for the proper op- eration of circuit breakers. Also frequent opera- tion of thebreaker causes the lubricant to be forced out from between the bearing surfaces. A simple lubrication will often clear up minor disturbances which might be mistaken for more serious trouble. A definite lubrication schedule should be set up taking into consideration the frequency of operation of the breaker and local conditions. It is recommended that lubrication of the breaker and its operating mechanism be a part of the per iodic inspection and maintenance program, with not more than a two year period between lubrications. It is also recommended that all circuit breakers be operated at regular intervals, at least once ayear, to insure the lubrication is in good condition and the breaker is operable,‘The lubrication chart, Figure 17, is divided into ‘two methods of lubricat{on. ‘The first method out lines the maintenance fubrication which should be performed at the time of periodic maintenance, and requires no disassembly. The second method out- lines a lubrication procedure similar to that per- ‘Magne-blast Circuit Breaker GEK-41902 formed on the breaker at the factory, and should be used when a general overhaul of the breaker is necessary, General Electric Lubricants D50H15 and D50H47 are available in 1/4lb collapsible tubes. It is so packaged to insure cleanliness and to prevent oxidation, PARTS LUBRICATION AT MAINTENANCE PERIOD ALTERNATE LUBRICATION (REQUIRES DISASSEMBLY) Prop & Trip Shaft Bearings (Teflon coated bearings) No lubrication required No lubrication required Sleeve Bearings - main crank shaft, mechanism pawls, spring charging and operating linkages, etc. (Bronze) Light application of machine oil SAE 20 or SAE 30. Remove bearings or links, clean per instructions and apply DS0H15 lubricant liberally. Contact Arm Hinge Assembly Cup Bearing Loose rings between bushing and contact arm No lubrication required Wipe clean and apply D50H47. Roller and Needle Bearings Light application of machine oil SAE 20 or SAE 30. Clean per instructions and re- pack with D50H15 lubricant. Ground surfaces such as cams, ratchet teeth, ete, (Surfaces coated with MoS) No lubrication required. No lubrication required. Ground surfaces such as latches, rollers, prop, etc. Wipe clean and apply DS0H15 lubricant Wipe clean and apply DS0H15 lubricant. Silver plated contacts and primary disconnect studs Wipe cleanad apply DS0H47 lubricant Wipe clean and apply DS50H47 lubricant. Booster Cylinder Do not lubricate Do not lubricate Arcing Contacts Do not lubricate Do not lubricate Figure 17, Lubrication Chart METHOD OF CLEANING ‘BEARINGS Whenever cleaning of bearings is required, as indicated in the lubrication chart, the following pro- cedures are recommended. * Indicates revision Sleeve Bearings The sleeve bearings used in the prop (14) Fig- ure‘ and the bearings for the trip shaft (7) utilize Teflon surfaces and do not require lubrication. After a number of operations, the surface will ac- 17GEK-41902 Magne-blast Circuit Breaker quire a thin black film. Do not remove this film unless there is evidence of outside contaminants, such as dry or hardened grease. If contaminants are present they should be removed by immersing thepropandbearing in clean petroleum solvent, or similar cleaner, and using a stiff brush, Do not remove the bearings from the prop or frame. DO NOT USE CARBON TETRACHLORIDE, The remaining sleeve bearings located in the driving element and the mechanism linkage and frame shouldbe cleaned and relubricated with G-E DSOH15 lubricant at general overhaul periods. This includes the bearings in the driving link (6) Figure 15, driving pawl lever (10) Figure 4, driving paw! (6), latching pawls (2), trip lateh roller support (10) Figure 7, cranks (3), and the bearings in the mechanism frameand interconnecting links. Bear- ings that are pressed into the frame or other mech- anism members should not be removed. The cup bearing (24) Figure 8 of the primary contact arm should be disassembled, cleaned, and lubricated with G-E D50H47 lubricant at gen- eral overhaul periods. ‘The main shaft bearings (24) Figure 7 should be removed, cleaned, and lubricated with G-E D50HI6 lubricant at general overhaul periods. Roller and Needle Bearings Refer to Figure 7, The cam follower bearings 6), lateh roller bearing (9), and cam shaft bearings (25) should be removed from the mechanism and the inner race disassembled, They should then be placed in a container of clean petroleum solvent or similar cleaner. DO NOT USE CARBON TETRACHLORIDE. ‘If the grease in the bearings has become badly oxidized, it may be necessary to use alcohol (type used for thinning shellac) to remove it. Ordinarily, by agitating the bearings in the cleaning solution, and using a stiff brush to remove the solid particles, the bearings can be satisfactorily cleaned. Do not handle the bearings with bare hands as deposits from the skin onto the bearings are inductive to corrosion, If the bear- ings are touched, the contamination can be removed by washing in alcohol, After the bearings have been thoroughly cleaned, spin them in clean new light machine oil until the cleaner or solvent is entirely removed, Allow this oil to drainoff and then repack them immediately with G-E lubricant D50H15 being sure all metal parts are greased. Theinner races should then be assembled, NOTE: If it becomes necessary to clean the bearings in alcohol (shellac thinner), be sure the alcohol is perfectly clean, and do not allow the bearings to remain in the alcohol more than a few hours. If it is desirable to leave the bearings in the alcohol for a longer time, an inhibited alcohol such as is used for anti-freeze should be used. Even then the bearings should be removedfrom the alcohol within twenty-four hours. Precautions against the toxic effects of the alcohol must be exercised by wearing rubber gloves and by using 18. * Indicates revision the alcohol in a well ventilated room; excessive exposure to the fumes is sometimes’ unpleasant, to” personnel, oil, draining ‘and repacking with lubricant DS0H15 should follow immediately. Bearings that are pressed into the frame or other members ‘such as the motor support (7) Figure 15, should not be removed. After removing the shaft and inner race the bearing can be cleaned satis- factorily with petroleum solvent or a similar cleaner and a stiff brush. Follow the procedure outlined above using a light machine oll and G-E lubricant D50H15 before reassembling the inner race and shaft, Rolling Surfaces A number of rolling and rubbing surfaces in the mechanism have been lubricated with a baked-on ary, molybdenum disulfide coating. This lubri- cation, which can be recognized by its dark, almost black ‘color (e.g. Face of switch cam (5) Figure 2) requires no maintenance and should last the life of the breaker. Other rolling or rubbing surfaces that are not lubricated with molybdenum disulfide should have the dried, dirty grease removed and a thin film of fresh lubricant D50H15 applied. MAINTENANCE, Magne-blast breakers used for switching arc furnaces or capacitors will require more frequent and more detailed inspection and maintenance because of the repetitive nature of the applications, The following schedule is recommended for such breaker: A. Every 500 Operations, or Every Six Months- Whichever Comes First: 1, Remove the box barriers. 2, Wipe all insulating parts clean of smoke deposit and dust with a clean dry cloth, including the bushings, and the inside of the box barriers, 3, All flat parts in the throat area of the interrupters shouldbe thoroughly clean- ed by using sandpaper. This cleaning should be performed any time the inter- rupter is removed. The fins onthe are chute sides should not be cleaned. Whenever the interrupter is removed, loose dust and dirt should be blown out before replacing arc chutes. Throat insulation which is heavily contaminated should be replaced. B, Every 2000 Operations, or Every Six Months Whichever Comes Firs 1, In addition to the servicing done each 500 operations, the following inspection should be made and work done when required, ‘Washing the bearings in the ligh™\ ~1 Primary Contacts (3 and 10 Figure 23). Inspect the condition of the stationary contact fingers and movable contact Blocks. Badly pittedor burned contacts should’ be replaced. (Note: Burned primary contacts indicate the probable need for arcing contact replacements) If the contact surfaces are only rough- ened or galled, they shouldbe smoothed with crocus cloth or draw filed. After contact dressing the primary contacts should be greased lightly with D50H47. Arcing Contacts (6 and 27 Figure 8). ‘When the arcing contact wipe is less than the minimum specified under AD- JUSTMENTS, the contacts should be replaced. "The contacts should be inspected for uneven wear and/or dam- age using a mirror to inspect the Stationary confacts. Normally it will not be necessary to remove the inter- rupters for this 2000 operation ser- vicing unless inadequate wipe or con- tact condition indicate a need for re- placement. If the interrupters are re~ moved, the contact braids, and other parts subject to arcing shouldbe check- ed for possible cleaning or replacement, Do not grease the arcing contacts under Par er aeestanes ecomactsn ‘circumstances. Check the breaker and mechanism ad- fustments as summarized under IN- SPECTION AND TEST. Thenecessary Teadjustments should be made as de~ scribed under ADJUSTMENTS. ‘The breaker and operating mechanism should be carefully inspected for loose nuts, bolts, retaining rings, etc., all ‘cam, latch’and roller surfaces should be inspected for damage or excessive wear. The buffer blocks and their retainers on the bottom of the stationary contact support should be inspectedfor possible need of replacement. ‘The contacts of the control relay (17) Figure 6, should be inspected for wear and cleaned if necessary. Lubricate the breaker operating mech- anism in accordance with instructions Under LUBRICATION, page 16 and the lubrication chart Figure 17. Inspect all wiring for tightness of con- nections and possible damage of in- sulation, After the breaker has been serviced, it should be operated manually to be sure there is no binding or friction and that the breaker contacts can move to the fully opened and fully closed ‘Magne-blast Circuit Breaker GEK-41902 positions. Its electrical operation should then be checked using either the test cabinet or the test couplers. C, After Every 10,000 Operations: 5. 6 In addition to the servicing done each 2000 operations, the interrupters should be removed from the breaker and dis- assembled to permit a detailed inspec- tion of insulation, blow-out coils, arc runners and assemblies which’ can become contaminated by arc products. The blow-out coils should be carefully examined and if the insulation hasbeen cracked, shrunk or eroded from are action and heat so that the turns of the coils are not fully insulated from each other, the coils should be replaced, All connections should be checked for tightness. The are runners should be inspected and replaced when any part of their area has been reduced to 25% of the original metal thickness as a result of are erosion. Check the stationary are contacts to assure that the arcing contacts are in good condition and that their connections are tight. Insulating material that is carbonized and cannot be satisfactorily cleaned should be replaced. Any parts damaged or severely burned and/or eroded from are action should be replaced. NOTE: Fine cracks may develop in the fins of the arc chute sides. This is to be expected with ceramic materials when subjected to the high heat of an are and may be disregarded unless they are long and present a possibility of fin sections breaking completely off. Small broken corners on the exhaust fend of the are chute will not interfere with its performance and can also be disregarded. ‘The cup bearing and the contact ring at the hinge point of the contact blade Should be disassembled, inspected, cleaned, and relubricated with G-E contact lubricant D50H47. The contact Ting should be inspected for wear and replaced when reduced in thickness to Jess than 1/32", When reassembling the cup bearing, be sure the cotter pin is properly assembled in the castle hut on the hinge pin (7) Figure 23. This assures proper contact pressure at the hinge. 19GEK-41902 Magne-blast Circuit Breaker D. Every 20,000 operations or Approximately Every Five Years - Whichever comes first: The breaker should be given a general inspection and overhaul as required, All excessively worn parts in both th mechanism and breaker should be re- placed. Such wear will usually be indicated when the breaker cannot be adjusted to indicated tolerances. This overhaul and inspection is more detail~ ed and will require disassembly of mech- anism and breaker operating parts, 2, All roller and needle bearings in the operating mechanism should be dis- assembled, cleaned, and repacked with G. E. lubricant DS0H15 as described under LUBRICATION, 3, The stationary primary contact fingers (3) Figure 23, should be disassembled and the silver-plated pivot area of the contact and contact support cleaned and lubricated with G-E lubricant D5cHa7. ‘The breaker and operating mechaniem should be serviced as described for every 2,000 operations and properly adjusted’ before being put back into service, REPAIR AND REPLACEMENT This section covers the proper method of removing and replacing those parts of the breaker subject to damage and wear that may require repair or replacement at the installation. IMPORTANT: UPON COMPLETION OF ANY REPAIR WORK, ALL. BREAKER AND MECHANISM ADJUSTMENTS MUST BE CHECKED. Refer to the section on IN- STALLATION, paying particular attention to AD- SUSTMENTS and FINAL INSPECTION. ARC CHUTE (To inspect or replace blow-out coils and are runners): With the breaker open and the closing springs in the blocked position, remove the box barriers (7) Figure 8. The interrupter can now be re- moved as described under INTERRUPTER RE- MOVAL AND REPLACEMENT page 16. To disassemble the interrupter after ithas been removed from the breaker, proceed as: follows: NOTE: When disassembling the arc chute and its components some small washers, spacers, etc., will be found that cannot be identified in these instructions. Care should be taken to collect and identify these items so they can be reassembled correctly. 1, Remove the assembly bolts (7, 9, 11, &13) Figure 18, 20 2. Romare the side brace (5), and pole pieces —N 3, To remove the upper are runner assem- bly (4) igure 20, remove assembly bolt G3 Figure 4, Remove the assembly bolts (15) Figure 18 to remove the lower brace (8). | Remove the lower interrupter support (13) by removing the assembly bolts C4) ana the connection nut (8) Figure 20, 6. At this point, the throat shields (5) Figure 20, ‘the lower arc runner assembly (6) cah be‘removed. 7, Further disassembly of both the upper and lower arc runner assemblies can be done by removing the various screws andassem- 'y bolts (not illustrated) as shown in Figure 19. The are chute sides (6) Figure 19, can also be separated for, ingpsction after removing assembly bolts (2 & 4) Figure 18, Reassemble the interrupter in the reverse order. ‘The following items should be noted during re- assembly: 1, The fins of the are chute sides should be equally spaced and aligned before bolt together. ‘The front edge (along the runner} of the two are chute sides shouldbe parallel and in line, 2. The gap between the fina atthe rear of the are chute sides measuredat east i" infrom the back end of the arc chute (See Figure 21) should be 1/64" to 3/32", 3. Check to insure that electrical connections to the blowout coils are tight. 4. When reassembling the arc runner as- smblies, check that the spacers are cor- ctly installed, Before bolting the upper supports in place, make certain that the upper are runner assembly is tight against the arc chute side so that the gap between the throat insulation (7) Figure 19, and the arc chute sides (6) is a minimum, 6. Make certain that the electrical connections (2&8) Figure 20 are tight. Reassemble the are chute on the breaker as described under INTERRUPTER REMOVAL AND REPLACEMENT, page 16, on,‘Magne-blast Circuit Breaker GEK-41902 Assembly Bolts and Bushing ‘Assembly Bolts Upper Pole Piece Assembly Bolt Side Brace Lower Pole Piece Assembly Bolt Lower Brace ‘Assembly Bolt Upper Interrupter Support ‘Throat Shield Assembly Bolt Lower Interrupter Support Assembly Bolts Assembly Bolts Upper Arc Runner Spacer Upper Arc Runner Assembly Blowout Core Blowout Coil Upper Are Runner ‘Are Chute Side Throat Insulation Lower Shield Lower Arc Runner Blowout Coil Blowout Core Lower Insulation Lower Are Runner Assembly Lower Coil Connection ‘Lower Arc Runner Spacers Figure 19, (8917442D) Interrupter Assembly with Side Removed 2GEK-41902 Magne-blast Circuit Breaker 22 Figure 20. (8917442C) interrupter Assembly 1. Upper Mounting Support 2. Connection Bolt 3. Insulation Plate 4. Upper Arc Runner Assembly 5. Throat Shield 8. Lower Arc Runner Assembly 7. Lower Coil Connection 8. Connection Nut 9. Lower Mounting Support Figure 21. (8029373) Are Chute Fin Spacing CONTACTS, Open the breaker and remove the box barrier and interrupters as previously described. To remove the contacts, proceed as follows: AL Stationary Arcing Contacts (10) Figure 22. 1, Disconnect the contact braids (7) from the contact fingers by removing two bolts and locking plates (8). 2, Grasp the lower end of the contact fingers with pliers and pull contact assembly downward to remove from stud assembly. 3. To disassemble braids from stud plate remove one bolt (5). 4, To disassemble stud plate from contact ‘Support, remove two bolts (6). 5, Reassemble in the reverse order, make sure locking plates are properly re- assembled with bolts (8). Movable Arcing Contact (14) Figure 23. 1, Remove the assembly bolts (12) making note of quantity and location of shims and spacers used between contacts and contact arms, 2, Reassemble in reverse order, re-using the shims and spacers. 3. Close the breaker slowly to check that the movable arcing contact is approximately centered on the station- ary arcing contact and that it does not rub on either side of the throat barrier (9). NOTE: Whenever it is found necessary to replace arcing contacts on any pole of a breaker it is recommended that both the stationary and movable con- tacts on that pole be replaced at the same time, Stationary Primary Contacts (9) Figure 24, 1, Compress the contact spring (6) by use of the spring compressor. 2, Remove spring and spring guide (1). 3, Raise the contact finger to clear the primary contact stop plate (8) and lift the finger out of contact support (7). Remove one contact finger at a time. To replace the Stationary Primary Contacts: 1, Apply a thin coating of D50H47 grease on the hinged edge of the finger (9) then place it on the contact support (7) so —~.4 ‘Magne -blast Circuit Breaker GEK-41902 1, Rear Bushing 2. Guide and Support for Interrupter 3. Bolts for Contact Support 4. Contact Support 5. Bolt for Flexible Braid 6. Mounting Bolt 7. Flexible Braid 8. Connection Bolt 9. Stud for Mounting Arcing Fingers 10. Stationary Arcing Contact Assembly 11. Throat Baffle Figure 22, (89174428) Rear Bushing Assembly that it is retained by stop plate (8). Open spring compressor (3) and as~ semble spr: ide, spring and spring compressor (Figure 24A), ‘Turn nut (2) in clockwise direction to compress contact spring (Figure 245). Hold spring firmly in yoke on spring ‘compressor to prevent spring from ‘slipping out of the compressor, st spring, place top of ple into top of spring, place hile in apring Tetainer (4) and the found end of spring guide in cutout in primary finger (Figure 24C). Hold spring assembly firmly in place and remove spring compressor. D. Movable Primary Contacts (10) Figure 23. tacts on a 12 To replace the movable primary con- ampere breaker proceed a5 follows: 1 Disassemble nuts from assembly bolts (11) and remove the movable primary contacts (10). Reassemble in reverse order. To replace the movable primary con- tacts on a 2000 ampere breaker it is first necessary to disassemble the movable arc- ing contacts, 1, then proceed as follows: Disassemble operating rod pin (4),first noting quantity and location of washers in the assemble. 23GEK-41902 Magne-blast Circuit breaker Figure 23. (8039588) Contact Assembly 24 Front Bushing Contact Springs Stationary Primary Contacts Operating Rod Pin Buffer Cup Bearing Hinge Pin Contact Arm ‘Throat Barrier Movable Primary Contacts Assembly Bolts, Assembly Bolts Piston Assembly Movable Arcing Contact Connection Bar Pry contact arms (8) apart enough to disengage pivot pins of piston assembly (13) allowing piston to drop down into its booster cylinder. Rotate the two parts of the contact arm assembly away from each other so as~ sembly bolts (11) are accessible and movable primary contacts (10) can be removed, Reassemble in reverse order. E, Contact Arm Assembly (8, 10, 12, 14, Figure 23). 1, Remove connection bar (15). 2, Disassemble hinge pin(7), cup bearing (6), and operating ‘rod pin (4) noting quantity and location of any washers and spacers used in assemblies. 3. The contact arm assembly including the piston assembly (13) can now be re- moved, 4. When reassembling, first insert piston tube agsembly (13) into the booster cylinder and reassemble the cup bear~ ing, making sure the silvered contact washers between the bushing and con- tact arms (both sides) are in place, Reassemble operating rod pin (4) and connection bar (15). F, After disassembly and reassembly of any contacts, check all contact adjustments as described under ADJUSTMENTS. BUSHINGS IMPORTANT: DO NOT REMOVE ALL Six BUSHINGS AT ONCE. The bushings have been carefully aligned with’ the breaker frame, during assembly at the factory, and it is important that this alignment be maintainedto insure interchange- ability of the breakers in the metal-clad units, It is, therefore, recommended that the bushings be removed and reassembled one at a time. Also, before removing any one bushing, measure the dis- tance from that particular bushing to adjacent bushings in both directions, so that It may be reinstalled in the same location, However, it is possible to remove and re- assemble three bushings at one time. If this is preferred, alignment of the bushings may be accomplished by placing the breaker in a de- energized spare metal~clad unit before tightening the bushing mounting bolts. This must be done before the interrupters are reinstalled, To replace the bushing, proceed as follows: Rear Bushing 1, Open the breaker and remove the box barrier and interrupters as already de- scribed, 2, Remove the upper and lower horizontal barriers (18 and 20) Figure 8, 3, Remove the four bolts at the mounting flange of the rear bushing being removed and lower the bushing assembly, NOTE: Shims may be found between the breaker mounting plate and the bushing‘Magne-blast Circuit Breaker GEK-41902 th pn =, # Figure 24A (8034466) Figure 248 (6034465) Figure 24C (8034469) ‘Figure 24D (8034468) Figure 24. Method of Installing Primary Contact Springs Using a Spring Compressor 1, Spring Guide 6. Spring 2. Compressor Nut ‘ontact Support 3. Spring Compressor 8. Stop Plate 4. Spring Retainer . Stationary Primary 5. Assembly Bolts Finger 25GEK-41902 Magne-blast Circuit Breaker mounting flange on some, or all bolts, These shims are for squaring up the bushing and may be required when new bushings are assembled, Referring to Figure 24, disassemble the primary contact springs’ (6) as previously described, Disassemble the spring retainer (4) by removing mounting bolts (5). Referring to Figure 22, disassemble the contact support (4) and interrupter mounting bracket (2) removing two bolts (3). Reassemble in the reverse order. The interrupter mounting bracket (2) ‘is not symmetrical and must be assembled cor- rectly to orient the interrupter properly on the breaker. The longest projection of the bracket should be toward the lower end of the bushing. Front Bushing 1 4 5 Open the breaker and remove the box barrier and interrupters as already de- seribed. Remove the upper and lower horizontal barriers (18 and 20) Figure 8, Remove the connection bar (15) Figure 23, cup bearing (6) and hinge pin (7). Remove the four bolts at the mounting flange of the front bushing being removed, and lower the bushing, (See note under rear bushings concerning use of shims.) When reassembling, first mount the bushing and assemble the cup bearing(6), contact arm (8), and replace pin (7) being sure the silvered contact washers between the bush- ing and contact arms are in place. The contact surfaces at the hinge point of the contact blade and bushing should have a'thin coating of D50H47 grease, Check all contact adjustments as outlined under ADJUSTMENTS, INTERLOCK SWITCH To remove the interlock switch (4) Figure 12, remove the two mounting screws and disconnect the lead wires, Reassemble in the reverse order and check the’ switch adjustments as explained under ADJUSTMENTS. LATCH CHECKING SWITCH To remove the latch checking switch (7) Figure 12, (when furnished), remove the two mounting screws and disconnect the lead wires. Reassemble in the reverse order and check the switch adjust= ments as explained under ADJUSTMENTS. 26 in tandem as required MOTOR, RELAY AND LIGHT SWITCHES Two or three switches (7) Figure 6, are mounted the application, 1, Remove the opening spring per instructions below. 2, Remove (2) mounting bolts (4) from switch bracket (5). 3, Remove the (2) mounting screws of the lower switch, 4. Remove the (2) mounting screws of the center switch, 5. Remove the (2) mounting screws of the upper switch, 6. Disconnect the lead wires of switch to be replaced, 7, Reassemble in the reverse order and check switch adjustment as explained under AD- JUSTMENTS. TRIP SHAFT AND LATCH (See Figure 11) 1. Remove spring discharge crank (5), manual trip lever (13) and if furnished, the latch checking switch operating arm (6) Figure 12 from the trip shaft. 2, Disengage trip latch spring (4) Figure 11. 3, Remove three (3) cotter pins from trip shaft. 4, Remove trip arm screw (12) and trip latch set screw (10). 5. Place a block between the trip latch (11) and the left side of the mechanism frame, Drive the trip shaft to the left until the latch is free of the key, then remove the key. Check for and remove any burrs raised around the keyway on the shaft to avoid damaging the trip shaft bearings, 7, Shaft, latch, etc, may now be removed by driving it to the left. Note quantity and location of washers used as spacers in the assembly, 8 Reassemble parts in reverse order. Be sure trip latch is aligned in center of trip latch roller and that the latch spring is properly installed. Check latch adjustment as de- scribed under ADJUSTMENTS. TRIP LATCH ROLLER BEARING 1, Remove (2) cotter pins at ends of trip latch roller shaft (8) Figure 13, Partially remove shaft out right side of frame until latch roller (6) is free.3 Reassemble in reverse order with proper Spacing of washers, Be sure latch roller rotates freely. CLOSING LATCH 1 5. Remove cotter pins at both ends of closing latch shaft (9) Figure 6, Remove spring and paddle (12). Remove set screws from latch (8). Move shaft (9) to left (away from frame) by tapping lightly on the inside end of shaft. Rotate shaft and continue tapping until shaft is free. Shaft will push outside needle bear- ing from housing. Reassemble in reverse order putting bearing into frame last. Use asmall piece of tubing or pipe when inserting bearing to assure proper alignment. Check closing latch adjustments as de- scribed under ADJUSTMENTS, MOTOR SUPPORT a To remove motor support (7) Figure 15, first remove the closing latch spring (12! Figure 6. Remove the retaining ring (4) Figure 15, and driving link (6). Remove motor leads from the terminal board. Remove six 3/8" bolts (1) Figure 15, on bottom and one 3/8” bolt on the right side (not shown). Remove four mounting bolts from motor (not shown). Remove the retaining ring (8) from the eccentric (3). ve) Reassemble all parts of the motor support in the reverse order and re-align itproperly as described under DRIVING PAWL AD- SJUSTMENTS, Remove 2 set screws from ratchet wheel (O, Figure 4 and remove wheel trom main st . Remove 2 set screws from switch cam (5) Figure 2 and remove cam from the main shaft. Remove prop reset spring (4) Fig. 5. Remove 2 set screws from cam (16) Figure 7, and move cam to the right on the shaft 5. 6 ‘Magne-blast Circuit Breaker GEK-41902 as far as it will go. Slide the shaft to the left until key is fully ‘exposed. Remove key and check shaft for burrs. Remove shaft out left side of frame, Reassemble in reverse order using the correct number of washers and spacers to properly locate the parts. Rotate the mechanism through a closing eration using the manual charging wrench. jeck the location of the cam follower (6) Figure 7, on the cam (16). if necessary, move thé cam to correct the alignment. Complete the closing operation and check the location of the prop pin (13) on the prop (14). It should be approximately centered. ‘TRIP COIL ‘To replace the potential trip coil (8) Figure 11, proceed as follows : 1 2 3 5. With the breaker in the open position, remove the two mounting bolts Qe” Remove trip coil support (7) and spacers. Cut wires at the butt connectors and remove coil, When replacing the coil be sure to assemble the correct fiber spacers at the ends before bolting support (7). Adjust coil location to allow approximately ae " of armature travel before latch starts move. Butt connect wires and check operation of solenoid electrically and mechanically. SPRING RELEASE COIL To remove the spring release coil (15) Figure 6, proceed as follows: 1 3 4, Block the closing springs as described in INSTALLATION, Remove the left hand closing spring as described in CLOSING SPRINGS below. Remove two mounting bolts (11), coil support (16), and spacers, Cut wires at the butt connectors and remove Replace the coil and the correct number of fiber spacers before bolting support. Butt connect wires and check that the arm- ature is not binding. Check coil for electrical operation. 27GEK-41902 Magne-blast Circuit Breaker CLOSING SPRINGS The closing springs (12) Figure 4, can be removed as follows: L 2, 5. It is recommended that sufficient renewal Charge the springs with the manual charg- ing wrench and apply the spring blocking device as described in INSTALLATION, Discharge springs by pushing manual close button (8) Figure 5. Rotate cam shaft (5) Figure 4, by using the manual charging wrench until the gap be- ‘tween the spring (12) and the bearing block (1) is 2 inches or more, Lift both springs until they clear the lower supports, then pull forward and down until the top supports are free, Either discharge the opening springs by —, pushing the manual trip lever or block the opening springs with a suitable blocking” device. OPENING SPRINGS To remove the opening springs (4) Figure 4, proceed as follows: 1, Charge and block the closing springs as described under INSTALLATION, Push manual trip lever (8) Figure 5, to be sure the opening springs are fully dis- charged. Remove upper pin (1) Figure 4, and lower pin (9). After reassembling springs check the open Bap at the primary contacts as described under PRIMARY CONTACT GAP. RENEWAL PARTS ORDERING INSTRUCTIONS arts be carried in stock to enable the prompt replace- ment of any worn, broken, or damaged parts. A stock of such parts minimize service interruptions caused by breakdowns, and saves time and expense. When continuous operation is a primary consider- ation, more renewal parts should be carried, the amount depending upon the severity of the service and the time required to secure replacements. Renewal parts which are furnished may not be identical to the original parts since improvements are made from time to time. The parts which are furnished, however, will be interchangeable. NOTE: The listed terms "Right" and "Left" apply when facing the mechanism endof the breaker, 28 1 Always specify the complete nameplate data of both the breaker and the mechanism, Specify the quantity, catalog number (it listed), reference number (if listed), and description of each part ordered, and this bulletin number. Standard hardware, such as screws, bolts, nuts, washers, etc., are not listed and should be purchased locally. For prices, refer to the nearest office of the General Electric Company. PARTS RECOMMENDED FOR NORMAL MAINTENANCE In the following tabulations are listed those parts of the breaker and operating mechanism which are usually recommendedfor stock for normal maintenance, Other} ‘parts canbe obtained by contacting the nearest office of the General Electric Company.‘Magne-blast Circuit Breaker GEK-41902 RECOMMENDED RENEWAL PARTS FOR TYPE ML-13 STORED ENERGY MECHANISM USED FOR AM-4.16-250-9 (*) 1200 & 2000 AMPERE (*) SUFFIX LETTERS - H, C, K, N, R Description Catalog No. Spring Charging Motor ~ ** 48 V-Di 0105C9393P001 110 & 126 V-DC & 115 V-AC, 60 Hz | 0105C9393P002 220 & 250 V-DC & 230 V-AC, 60Hz | 0105C9393P003 Relay - **, # 48 V-DC 0137A7575P004 110 & 125 V-DC 0137A7575P001 220 & 250 V-DC 0108B5565G004 115V-AC, 60 Hz 0137A7575P005 230V-AC, 60 Hz 0137A7575P002 Potential Trip Coil ~ 110 & 125 V-DC 006174582G001 220 V-DC 006174582G015, 250 V-DC 006174582G002 115 V-AG, 60 Hz 006174582G013 230 V-AC, 60 Hz 006174582G032 24 V-DC 006275070G001 48 V-DC 006174582G034 Closing Coil - ** 110 & 125 V-DC 006174582G001 220 V-DC 006174582G015 250 V-DC 006174582G002, 115 V-AC, 60 Hz 006174582G010 230 V-AC, 60 Hz 006174582G014 48 V-AC (006174582G034 Switch, Normally Open 045640866005 Switch, Normally Closed 0456A0866P006 Auxiliary Switch 0137A9192G011 Closing Latch Spring 0161A4231P001 Prop Spring 0137A9252P001 Driving Pawl Spring 0161A4241P001 Latching Pawl Spring - 9 0161A5909P001 ** Refer to breaker nameplate or summary for proper voltage rating. # Quantity two (2) relays required on special control circuits. Check breaker and connection diagram. § Furnish 0161A4241P001 for breakers without closing spring discharge mechanism. 29GEK-41902 Magne-blast Circuit Breaker RECOMMENDED RENEWAL PARTS FOR _, MAGNE-BLAST BREAKERS TYPE AM-4.16-250-9\ 1200 & 2000 AMPERES (A\SUFFIX LETTERS 4, C, N, K, B, & R) frig. No] Reto. [AmRete] Type | catalog No. [pS Deseription 8 a1 all * + |o281B0708G002 | 3 Operating Rod Assembly au B_ | 0281B0708G008| 3 ++ |_| 22 7 Au Aut | o286co7s1Go01| 3 Flexible Conn. Right 22 7 au An | o286co7s1G004| 3 Flexible Conn. Left 22 rte an Atl | 0195A7388Go02| 3 ‘Throat Barrier Assembly 22 10 an An | 0236Co790G009] 3 Areing Contact Assembly 23 2 Au ++ | o1z1aseesPoo1 | 18 Primary Contact Finger Spring Al B_ | o1z1asg64poo1 | 24 23 3 Al ++ | o11acsse2Po02 | 18 Primary Contact Finger al B_ | 0114¢5382P002 | 24 ~ 23 10 All ++ | o14csse2poos| 6 Movable Primary Contact aul B_ | o137asi64P003 au B | o137asi64Po04| 6 23 14 Au Aut | o1osBss4aGoo1] 3 Movable Arcing Contact 23 13 2000 | an | o21sxosaaco01| 3 ‘Tube & Piston Assembly 1200 ++ | o213x0s43co00| 3 1200 B | 0213x0343G091| 3 19 7 ALL All | 0152C5960G001] 3 ‘Throat Insulation (Right) All All | 0152c5960G002| 3 ‘Throat Insulation (Left) + 19 8 All Au | o227as367Po01] 6 ‘Lower Runner Shield 19 2 All ant | o1s2css61P003| 6 Lower Insulation Barrier ** Al Except Breakers with "B" in Suffix 30Magne-blast Circuit Breaker GEK-41902 TYPICAL ELEMENTARY WIRING FOR MAGNE-BLAST BREAKERS ttttt ‘SPARE CONTACTS on SZ Ox. sw YeREQUIRED FoR 2208 250V- OPERATION ONLY. Q.coNTACTS FURNISHED as"neauineD. (016557908) a DESCRIPTION a zee 2 3 [AUXILIARY SWITCH Erreee 18 CLOSING COM, (SPRG. REL. sOL’D) ay ° "7 CONTROL RELAY | 2 & 5 3 ‘TRIP con. leer T = 2 2 INTERLOCK SWITCHES a was ‘ 8 CLOSING LATCH MONITORING Swen 2 waits ‘ 1 POWER SWITCHES 2 & * 1 LATCH CHECKING SWITCH no wits 2 Hn SPRING CHARGING MOTOR 311-81 3-74 GENERAL ELECTRIC COMPANY SWITCHGEAR BUSINESS DEPARTMENT PHILADELPHIA, PA 19142 GENERAL @® ELECTRIC