Schneider TeSys GV5/GV6 Motor Circuit Breaker Operation and Protection Guide

Schneider TeSys GV5/GV6 Motor Circuit Breaker Operation and Protection Guide

In modern industrial automation systems, reliable protection of motor circuits is the core link to ensure production continuity and equipment safety. Schneider Electric's TeSys Giga series GV5 and GV6 motor circuit breakers (IEC standard) and manual motor protectors (UL/CSA standard) provide a complete overload, short circuit, and phase loss protection solution for high-power motors ranging from 150A to 500A. This article is based on the technical documentation of this series of devices, and writes a professional technical guide for on-site engineers from four dimensions: actual operation, protection function settings, common fault reset, and auxiliary accessory application. Whether you are debugging equipment for the first time or need to quickly troubleshoot, this article can provide clear step-by-step references.

Equipment Overview and Model Identification

1.1 Framework and Current Range

The TeSys Giga series is divided into two frameworks:

GV5 framework: rated current 150A, 220A

GV6 framework: rated current 320A, 500A

Both are suitable for AC power systems up to 690Vac and offer three trip levels of 5, 10, and 20 to meet the needs of motors with different starting characteristics.

1.2 Interpretation of Model Code

The commercial reference number of each device contains key information. Taking GV5P 220H as an example:

GV5 → Framework is GV5

P → Provide overload and short circuit protection

220 → Rated current 220A

H → Breaking capacity (70kA at 415Vac)

Different suffixes (F/H) correspond to different breaking capacities, for example, at 400/415Vac, GV5P150F is 36kA, while GV5P150H is 70kA. When selecting, it is necessary to match correctly according to the system short-circuit current level.

1.3 Compliance with standards

This series of products complies with IEC/EN 60947-2 (circuit breakers) and IEC/EN 60947-4-1 (motor protection circuit breakers) standards, as well as UL 60947-4-1 and CSA C22.2 No.60947-4-1, and can be used in industrial environments worldwide.

Daily operation and switch reset

2.1 Local operation of directly rotating the handle

Standard equipment is equipped with a direct rotating handle:

Close (ON): Rotate the handle clockwise to position I

Turn on (OFF): Rotate counterclockwise to the O position

The handle color is divided into black (standard application) and red on the yellow panel (machine control application), the latter being used for safety scenarios such as emergency shutdown.

2.2 Reset process after electrical failure

When the device trips due to overload, short circuit, or phase loss, the handle will move to the Trip position (between O and I). The correct reset steps are as follows:

Isolation power supply: Before inspecting downstream equipment, it is necessary to cut off the power supply from the upper level.

Find the cause of the fault: Check whether there is a short circuit, overload, or insulation damage in the motor, cable, contactor, etc.

Repair downstream equipment: replace damaged parts if necessary and conduct insulation testing.

Reset device: Turn the handle counterclockwise from Trip to the O (OFF) position.

Close again: Rotate the handle clockwise to the I (ON) position.

Key reminder: Simply resetting cannot eliminate the root cause of the fault. If the downstream issue is not fixed, closing it again may result in equipment damage or personal injury.

2.3 Push to Trip testing

Regular testing of the trip mechanism can verify whether the protection function is normal. Operation steps:

Close the device (position I).

Press the Push to trip button on the front panel. The equipment should trip immediately and the handle should be moved to the Trip position.

Rotate counterclockwise to position O, then clockwise back to position I to complete the reset.

Caution: This test will actually cut off the load, which may cause unnecessary alarms or backup power switching. Therefore, it should only be performed by qualified personnel during the maintenance window period.

2.4 Operation of Extending the Rotating Handle

When the equipment is installed deep in the switchgear, an extended rotating handle is required. At this point, the Push to trip button is located on the device body rather than the cabinet door. During testing, it is necessary to:

Place the device in position O and open the cabinet door.

Use specialized tools (open-end wrench or LV426937 operator) to rotate the extension shaft to position I.

Press the Push to trip button on the device.

Use a tool to turn the shaft counterclockwise back to the O position and close the cabinet door.

Locking and secure isolation

3.1 Direct handle padlock

Standard lock: Up to three padlocks (lock beam diameter 5-8mm) can only be used in the O (OFF) position.

Optional dual position locking: After modifying the handle, it can be locked in both I (ON) and O (OFF) positions. Attention: When locked in position I, the protection function is still effective; If an electrical failure occurs, the equipment will still trip, and the handle will display the Trip position after unlocking.

3.2 Door Interlocking (MCC Function)

The MCC adapter board with a direct handle can achieve interlocking between the cabinet door and the handle: when the handle is in the I (ON) position, the cabinet door cannot be opened to prevent electric opening. Only qualified personnel can temporarily disable this interlock, for example, to perform measurements in the closed state. To disable the operation, the handle needs to be modified. Please refer to the dedicated manual GHD16295AA for details.