GE Industrial Solutions EntelliGuard R AKD-5 User Manual
GE Energy
®
EntelliGuard
R
Circuit Breaker Retrofill
AKD-5 Installation Manual
General Electric AKD-5 Low Voltage Switchgear is a free-standing assembly of
metal-enclosed units of power circuit breakers and other auxiliary power circuit
protective devices. It may also be a part of a single-ended or double-ended load
center unit substation. It’s a draw-out breaker.
imagination at work
1 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Table of Contents
Preface .................................................................................................................................................................... 3
Hazards .................................................................................................................................................................................................. 3
Danger...............................................................................................................................................................................................3
Warning.............................................................................................................................................................................................4
Caution .............................................................................................................................................................................................. 4
Notice or Note................................................................................................................................................................................ 5
Warranty................................................................................................................................................................................................ 5
Trademarks and Patents................................................................................................................................................................ 5
Standards.............................................................................................................................................................................................. 5
Document Conventions.................................................................................................................................................................. 5
Related Publications......................................................................................................................................................................... 6
Service and Support......................................................................................................................................................................... 6
Estimated Time to Complete Tasks........................................................................................................................................... 6
Description............................................................................................................................................................. 6
Product Specs...................................................................................................................................................................................... 6
Weight (lbs)...................................................................................................................................................................................... 7
Views ..................................................................................................................................................................................................7
History and Types ................................................................................................................................................. 9
AKD........................................................................................................................................................................................................... 9
AKD-5—AK25/AK50........................................................................................................................................................................... 9
Unpack Retrofill Circuit Breaker......................................................................................................................... 9
Quality...................................................................................................................................................................................................11
Information Label ............................................................................................................................................................................11
Product and Catalog Serial Numbers ....................................................................................................................................11
Remove Circuit Breaker from Container ........................................................................................................ 11
Inspect ..................................................................................................................................................................................................11
Use Lifting Truck...............................................................................................................................................................................11
Store Circuit Breaker.......................................................................................................................................... 13
Check Before Installing ...................................................................................................................................... 14
Clean and Grease Breaker................................................................................................................................. 14
Customize Retrofill Secondary Wiring ............................................................................................................ 15
Modify AKD-5 Switchgear Compartment ....................................................................................................... 15
2 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Cut Power............................................................................................................................................................................................16
Rack Out Legacy Breaker.............................................................................................................................................................16
Empty Compartment—Legacy Breaker Removed ...........................................................................................................16
Check, Clean, Grease Compartment ......................................................................................................................................16
Install Position Switch Actuator—AK25 Breaker ........................................................................................... 17
Install Position Switch Actuator—AK50 Breaker ........................................................................................... 18
Racking-Lock Bracket—Initial Tasks................................................................................................................ 19
Install Cassette (Landed Wires)........................................................................................................................ 21
Install Lock Bracket ............................................................................................................................................ 23
Install AKD-5 Retrofill Breaker.......................................................................................................................... 25
Secondary Disconnects, Bullets................................................................................................................................................32
Wiring Diagram and Block Info (AK25)...................................................................................................................................33
AK25 Wiring Harness, B-Block (AK25/50) .............................................................................................................................35
Programmer Secondary Disconnect (Breaker Side—N/A) ............................................................................................37
AK25..................................................................................................................................................................................................37
Install Door Interlock System (Breaker Side).................................................................................................. 38
Neutral Disconnect Assembly (Breaker Side)................................................................................................. 38
Install AKD-5—Neutral Rogowski Current Transformer (CT)........................................................................................38
Remove Existing Iron Core Neutral CT Assembly .............................................................................................................39
Neutral CT assembly in Cable/Bus Compartment: ..........................................................................................................39
AKD-5—Neutral Sensor Packaging.................................................................................................................. 41
AKD-5—Multi-Source Ground Fault ................................................................................................................. 42
Remove and Replace AKD-5—Existing Door .................................................................................................. 43
Wiring Diagram for the AK/AKR Retrofill........................................................................................................ 44
Notes ..................................................................................................................................................................... 45
3 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Preface
Hazards
The following important highlighted information appears throughout this document to warn of potential
hazards or to call attention to information that clarifies a procedure. Carefully read all instructions and
become familiar with the devices before trying to install, operate, service, or maintain this equipment.
Danger
This indicates a hazardous situation which, if not avoided, results in death or serious injury. A variety
of electrical hazards warnings are displayed here and are applied to installation manuals. These are
standard or generic alerts and labels that must be taken quite seriously when installing Retrofill
circuit breakers in AKD switchgear and when working with potentially dangerous electrical equipment
(Table 1). There are also dangers, pertaining to product safety, that need to be custom-written for
particular or specific circumstances (Table 2).
Table 1. Generic Danger Alerts and Labels Used for Documentation and
Dangerous Equipment
Table 2. Custom Danger
Alerts and Labels Used for
Documentation and
Dangerous Equipment
4 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Warning
This indicates a hazardous situation, which, if not avoided, would result in death or serious injury. A
variety of electrical hazards warnings are displayed here and are applied to installation manuals. These
are standard or generic alerts and labels that must be taken quite seriously when installing Retrofill
circuit breakers in AKD switchgear and when working equipment that can cause injury, but may not be
necessarily fatal (Table 3). There are also warnings, pertaining to product safety, that need to be
custom-written for particular or specific circumstances (Table 4).
Table 3. Generic Warning
Alerts and Labels Used for
Documentation and Dangerous
Equipment
Table 4. Custom Warning Alerts and Labels Used for Documentation
and Dangerous Equipment
Caution
This pertains to a hazard that has a low level of risk, which means that if not avoided, it could result
in minor or moderate injury. It also indicates that failure to comply with instructions may result in
product damage. The label here requires a specific message that targets a special product or procedure
(Table 5).
Table 5. Custom Caution Alerts and Labels Used for
Documentation and Operating Equipment
5 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Notice or Note
This indicates important information in that it aids in job performance, that is, a notice or note is used to
notify practices not related to personal injury (Table 6).
Table 6. Custom Notice Alerts and Labels Used for
Documentation and Operating Equipment
Warranty
This document is based on information available at the time of its publication. While efforts have been
made to ensure accuracy, the information contained herein does not cover all details or variations in
hardware and software, not does it provide for every possible contingency in connection with
installation, operation, and maintenance.
Features may be described herein that are not present in all hardware and software systems. GE Energy
assumes no obligation of notice to holders of this document with respect to changes subsequently
made. GE Energy makes no representation or warranty, expressed, implied, or statutory, with respect to,
and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the
information contained here it. Not warrantees of merchantability or fitness for purpose shall apply.
Contact your local sales office if further information is required concerning any aspect of EntelliGuard R
Circuit breaker operation or maintenance.
Trademarks and Patents
EntelliGuard® R
EntelliGuard
®
TU
EntelliGuard
®
Trip Unit
EntelliGuard
®
G
Standards
Agency Certification
Standard Number
Title
ANSI C37.13,16,17,20,50,59
Low-Voltage AC Power Circuit Breakers
UL 1066
Low-Voltage AC and DC Power Circuit Breakers Used in Enclosures
Document Conventions
Topics and text are divided into primary, secondary, and tertiary paragraph headings.
6 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Related Publications
Publication
Publication Number
Brochure
DEA-532
Snapshot
DEE-543
Installation Manual AKD8
DEH-41549
Installation Manual AKD6
DEH-41548
Installation Manual AKD5
DEH-41547
Accessory: Door Interlock (Door Interlock Kit)
DEH-41529
Accessory Retrofill Doors Assembly
DEH-41563
Accessory: Position Switch Plate & Position Switch Assembly & Wiring (Position Switch Kit)
DEH-41530
Accessory: Neutral Rogowski CT Disconnect (Neutral Assemblies)
DEH-41531
Accessory: Programmer Disconnects
DEH-41532
Accessory: Finger Clusters (Cluster Assemblies)
DEH-41533
Accessory: Secondary Disconnects
DEH-41534
FAQ
DEQ-171
Application Guide
DET-753
Guideform Spec
DET-754
Spare/Renewal Parts Guide
DET-755
Service and Support
In addition to the local field sales office and service teams, GE also has a dedicated Aftermarket team to
assist customers with legacy information, selection, ordering, and upgrading.
Estimated Time to Complete Tasks
It takes about 20 minutes to install a feature-for-feature LSI assembly. This includes racking out the old
breaker, racking in the new breaker, and replacing the door. If new options are desired, or if it’s a 4-wire
LSIG circuit or modifications are needed to the cubicle, then additional time is required. Time also does
not include wiring the secondary disconnect on the retrofill.
Description
Product Specs
General Electric AKD-5 Low Voltage Switchgear is a free-standing assembly of metal-enclosed units
of power circuit breakers and other auxiliary power circuit protective devices. It may also be a part of
a single-ended or double-ended load center unit substation. It’s a draw-out breaker. Figure 1 shows
the retrofill circuit breaker projected out of its cassette. Figure 2 shows the AK25 retrofill breaker in
the cassette.
7 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Weight (lbs)
Retrofill Breaker
Weight
Box Weight 10101653P1
Pallet 10101650P1 Wt
Accessories
Wt
Total
Weight
AK25
197
16
33
2
248
Retrofill Breaker
Weight
Pb2 Large Frame Box Wt
10101653P1
Pallet 10101513P1 Wt
Accessories
Wt
Total
Weight
AK25
200
11
24
2
237
AK50
289
11
24
2
326
Retrofill Breaker
Weight
Box Weight 10101655P1
Pallet 10101650P1 Wt
Accessories
Wt
Total
Weight
AK50
289
18
33
2
342
Views
Figure 1. EntelliGuard R Retrofill (Circuit Breaker
Projected from Cassette)
Figure 2. EntelliGuard R AK25 Retrofill
(Front View)
A rear view of the AK25 is featured in Figure 3. Figure 4 shows the AK25 without its cassette.
8 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Figure 3. EntelliGuard R AKD-5—AK25 Retrofill
(Rear View)
Figure 4. AKD-5—AK25 Retrofill Breaker without
Cassette (Front View)
Figure 5 shows a rear view of the AKD-5—AK25 retrofill cassette, or substructure, without the breaker;
Figure 6 shows a front view of the cassette.
Figure 5. AKD-5—AK25 Retrofill Breaker Cassette
Assembly (Rear View)
Figure 6. AKD-5—AK25 Retrofill Breaker Cassette
Assembly (Front View)
The EntelliGuard R Circuit Breaker is suitable for application on power systems up to 600 VAC 50/60 Hz
systems and up to 600 Vdc as a main/source breaker, feeder breaker, bus coupler, or tie breaker.
9 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
History and Types
AKD
AK—Power Circuit Breaker Equipment
D—Drawout circuit breaker construction
Manufactured from 1951 to 1975 were these: all bolted, copper bus design, all drawout breakers—AK-1,
—2, —3,—15 / 25 / 50 / 75 / 100; the 4000A-max bus rating, 4 levels of bus, ring-bus used in all feeder
sections, and the main bus with provisions for future extension; sections in outdoor construction, which
did not line up in the front; and indoor construction, with extended frames allowing the section fronts to
line up. Moreover, there were indoor depths: 49" (225 / 600A breakers), 59" (1600A breakers), and 63"
(3200 / 4000A breakers).
Back then, breakers had a ratcheting drawout mechanism, with an open-door drawout. Breakers were
painted ANSI 61, light gray, manufactured in Philadelphia from 1951 to the mid-60s and in Burlington
from the mid-60s to 1975.
The breaker compartment was a welded assembly, and the equipment frame was bolted. Breaker
boxes were stacked to make a vertical section with equipment frame around the breaker boxes. There
were no bus compartment barriers, just an open bus design. Ring silver-plating was applied to bolted
connections.
AKD-5—AK25/AK50
Manufactured from 1960 until 1977, the aluminum bus had copper that was “flash-butt welded” to the
aluminum at bolted connections. During that time, AK-2A, 3A -25 / 50 / T50 / 75 / 100 (“A” signifies AKD5 drawout) were produced. Pull-lanyard drawout mechanism on early design was replaced by a single
jackscrew mechanism and then later replaced by a double jack-screw mechanism. Featured is a closeddoor, drawout with inner house breaker compartment. There is a 60"-deep frame with the 18"-extension
option. Outdoor protected aisle uses 60"-deep indoor frame. Two bus levels are available with a ring bus
used at 4000A. Particulars include: welded/riveted frame, bus compartment barriers, line/load
separation barriers on mains and ties, isolation barriers on transformer transitions, copper runbacks on
feeder breakers, ring silver-plating on copper, and aluminum bus un-plated (welded connections). The
switchgear is painted sand-gray (beige), with some instrument doors painted blue. AKR-30/50 in 22"wide sections were introduced in AKD-5 construction, early 70s. AK25s and AK50s were also available
as substructure kits for OEMs to build around customer gear.
Unpack Retrofill Circuit Breaker
By following the procedures below, you should be able to install the breaker with minimum effort
and time.
10 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Turn off all power to switchgear. Tagout and
lockout main source, up-stream or main
breaker.
Failure to comply with these instructions will
result in death or serious injury from severe
burns caused by arc flashing that has
exceedingly high temperatures.
Always wear personal protection equipment
according to OSHA standards and appropriate
to the severity of potential burns.
• Ensure only qualified personnel install, operate, service, and maintain all electrical
equipment.
Falling Object
• Do not walk or remain under any heavy assembly while
hoisted above head as the chains securing the
assembly may give way
• Ensure lifting equipment has capability for device being lifted.
• Wear hard hat, gloves, and safety shoes.
• Failure to comply with these instructions could result in serious injury.
PRODUCT DAMAGE
• Ensure circuit breaker and its accessories
are always used within their designated
ratings.
• Do not allow the circuit breaker to hit a
hard surface while handling.
• Do not drag or slide the circuit breaker
across a hard or rough surface
• A factory-installed rejection feature prevents mismatching circuit breakers and
cassettes/substructure, preventing the insertion of a circuit breaker with a lower rating into a
higher rated cassette/substructure, or the insertion of a higher rated circuit breaker into a lower
rated cassette/substructure.
11 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Quality
All EntelliGuard R circuit breakers have been designed and manufactured to ANSI standards. The design
was based on the original requirements from the Legacy Switchgear and Breaker. The product is
manufactured in the same factory as the AK and AKR; and is inspected using the same master gauges
used on the legacy AK, AKR breakers to confirm electrical and mechanical performance, including
rejections-features.
Information Label
On the side wall of each circuit breaker there is a detailed factory-assembled, side label that details all
features included on both the circuit breaker and on the trip unit.
Product and Catalog Serial Numbers
Product and catalog serial numbers should be kept handy when communicating about the circuit
breaker. Each circuit breaker has a unique serial number located on the left side (viewed from front) of
the front fascia.
Remove Circuit Breaker from Container
Inspect
1. Inspect the shipping container for obvious signs of rough handling and/or external damage incurred
during transportation.
2. Record any observed damage for reporting to the carrier. Ensure all recorded reports and claims
include the order number and name plate information.
3. Remove the banding straps and lift off the top cover.
4. Remove all packaging material.
5. Remove all product documentation and store properly.
6. Unscrew the mounting screws that fasten the circuit breaker to the bottom of the shipping palette
and remove the circuit breaker.
Use Lifting Truck
1. Use a lifting truck to lift and mount the assembly so that you can avoid personal injury or damaging
the breaker.
2. Contact the nearest sales office for availability of a hoisting device.
3. Avoid using hooks and chains since hooks can damage the fascia of the circuit breaker. Lifting bars
are available from GE.
• AK breakers use the EntelliGuard G lifting device.
• AKR breakers use the legacy lifting bar.
4. Pull out the ears of the AKD—5 so that the bar can be inserted through the ears for hoisting breaker
(Figure 7).
12 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Figure 7. AKD-5—Breaker Lifting Holes
5. Avoid using hooks and chains since hooks can damage or bend the “ears” as well damage the
fascia. Below are two examples of how not to handle the breaker (Figure 8 and Figure 9).
Figure 8. Crane Lifting Hooks Can Damage Lifting Holes
and Ears
Figure 9. Chains Can Damage Fascia
13 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Store Circuit Breaker
If you decide not to install the retrofill breaker until a later time, then you can store it away for
installing later.
PRODUCT DAMAGE
environments above LC1 (sea salt mist)
and G1 as per ANSI/ISA-S71.04-1985.
• Ensure circuit breakers and cassettes are
stored in a clean, dry location, in their
original packaging.
• Failure to comply with these instructions
may result in product damage.
1. Store the circuit breakers in a clean, dry location in an upright position.
2. Make sure that the breakers are properly supported to prevent bending of the studs or damaging
any of the breaker parts. Do not remove any protective grease until the breaker is ready to be
installed. A covering of draft or other non-absorbent paper prevents dust from settling on the
breakers.
3. If breakers are not to be placed in service immediately, remove them from their shipping cartons
and thoroughly inspect them.
4. If everything is in satisfactory condition, replace the breakers in their shipping cartons for storage.
Do not move the shipping members at this time.
If it is necessary to store the equipment for any length of time, follow these precautions to prevent
corrosion or deterioration.
5. Uncrate the equipment and check thoroughly for damage.
6. Store in a clean, dry, rodent-free location with moderate temperature and provide protective
coverings to prevent dirt, water, or other foreign substances from entering the breaker.
7. If dampness or condensation is encountered in the storage location, heaters for circuit breakers in a
closed environment can be used to prevent moisture damage.
14 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12
Check Before Installing
• It must be ensured that the supply power to
the compartment is turned off/ compartment
is de-energized for all the incoming and
outgoing circuits of the LVS prior to any work
being conducted on it.
• During the installation and related work on
the equipment, it must be ensured that the
operator is using the prescribed PPE for the
specified tasks.
• Ensure only qualified personnel install, operate, service, and maintain all electrical
equipment.
These breakers are supported on a rollout track in the same manner as the AKR breakers. However,
since the rack-out mechanism is mounted on the breaker, there are no jack-screws in the enclosure.
Racking arms on both sides of the breaker frame engage the drawout mechanism pins that are
fastened to both sides of the compartment.
1. Check to see that the breaker or breakers match their respective compartments. Each breaker is
assigned a part or mark number.
2. Read the breaker sheets summaries, the front view drawings, breaker nameplate, and the
identification card on the breaker shipping carton.
3. To match the breaker to its proper compartment, refer to the breaker location list on the front view
drawing. Find the proper breaker by the identification card on the breaker carton, or the mark
number on the breaker nameplate. All identical breakers have the same mark numbers.
4. For retrofills replacing AK25 breakers, if applicable, the neutral disconnect assembly block and
bracket within the compartment must be removed. Removing this item should be done only after
the breaker, having been removed from the compartment, has been de-energized.
Clean and Grease Breaker
1. Before installing or operating a breaker, refer to the EntelliGuard G Breaker DEH-41304 instruction
manual for pre-operation inspecting and testing.
2. Check thoroughly for any damaged or loose parts and for any dirt or foreign matter which may be in
the breaker.
3. Clean those areas if necessary with a clean, lint-free rag and isopropyl alcohol or acetone.
4. Be sure to apply a thin film of electrical grease (red, D50H47) to the contact areas for better
electrical connections on the breaker.
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