GE Industrial Solutions EntelliGuard R AKD-5 User Manual

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GE Energy

EntelliGuard

Circuit Breaker Retrofill

AKD-5 Installation Manual

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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

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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

EntelliGuard

Trip Unit

EntelliGuard

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.

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Weight (lbs)

Retrofill Breaker

Weight

Box Weight 10101653P1

Pallet 10101650P1 Wt

Accessories

Total

Weight

AK25

197

248

Retrofill Breaker

Weight

Pb2 Large Frame Box Wt

10101653P1

Pallet 10101513P1 Wt

Accessories

Total

Weight

AK25

200

237

AK50

289

326

Retrofill Breaker

Weight

Box Weight 10101655P1

Pallet 10101650P1 Wt

Accessories

Total

Weight

AK50

289

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.

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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.

15 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Customize Retrofill Secondary Wiring

WIRING

• Before installing the breaker, the secondary disconnects must be wired to the EntelliGuard Breaker.

• Wires with wire markers are provided on the retrofill. Make sure that the switchgear wiring connection points match up with the original wiring of the cubicle. This ensures that all wiring connections are properly made.

• Wrong connections will cause the breaker

to malfunction.

Modify AKD-5 Switchgear Compartment

• 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.

16 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Cut Power

1. Before modifying the switchgear compartment, de-energize/switch off the breaker. If the circuit

breaker is ON and the springs are charged, to turn it off, press the OPEN button on the circuit breaker fascia; and ensure that the circuit breaker contacts are open.

Rack Out Legacy Breaker

1. To rack-out legacy (old or original) breaker from the compartment, refer to your legacy-breaker’s

manual on how to remove the existing breaker.

Empty Compartment—Legacy Breaker Removed

The following examples show a legacy breaker removed from the enclosure or compartment (Figure 10).

Figure 10. AKD-5—Empty Cubicle

Check, Clean, Grease Compartment

1. Inspect the compartment for damage, rework.

2. Check cabinet for suitability of retrofill.

3. Check each breaker compartment for bolted joints in the primary disconnect bars. Where such

joints exist, check the bolts for tightness.

17 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

4. Inside the compartment, check the contact areas on each primary disconnect bar or cluster of fingers for foreign matter that may have accumulated. Clean those areas if necessary with a clean, lint-free rag and isopropyl alcohol or acetone.

5. Be sure to apply a thin film of electrical grease (red, D50H47) to the contact areas for better electrical connections inside the compartment.

After removing the existing breaker from the compartment, you now need to install the AKD-5 cassette in the AKD-5 compartment or enclosure.

Install Position Switch Actuator—AK25 Breaker

Installing the position switch actuator needs to be done before the cassette is racked into the compartment. Steps of installation of the position switch actuator are as follows.

1. Place the retrofit EntelliGuard ACB cassette assembly for AK25 on an elevated surface, such as a table, mounting the position switch actuator assembly on to the base plate.

Sufficient space should be available at the bottom of the cassette and the mounting table so as to provide easy access for inserting the 3-pin bracket from the bottom.

2. Unpack the position switch actuator assembly and mount it as shown in the exploded view (Figure 11).

Figure 11. Position Switch Actuator Assembly

3. Insert the 3-pin bracket from the bottom of the base of the cassette assembly such that the 2 pins

are within the longer slot and the single pin goes inside the smaller slot of the plate.

4. Place the L-bracket from the top of the cassette assembly such that the pins from the bottom 3 pin plate get inserted into the top plate.

5. Secure the connecting by fastening the nuts provided in the actuator kit along with the washers.

18 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

6. Mount the extension springs between the groove of the pin on this actuator assembly and the fixed pin provided on the cassette base plate.

Note that the position switch actuator on the cassette is now installed and ready for use once the breaker is being racked into the compartment.

7. Mount the cassette assembly on the rails of the AK25 cabinet in the AKD-5 and rack the cassette into the compartment of the AKD-5 LVS.

Note: During racking of the EntelliGuard ACB breaker into the cassette during racking in of the breaker, the position indicator window reads “connected.” This is the position that corresponds to the point when the retrofit system has activated the existing position switch in the LVS.

Install Position Switch Actuator—AK50 Breaker

Figure 12. AKD-5—AK50, Actuator for Position Switch Assembly (Exploded View)

The position switch actuator assembly for the AK50 should be mounted on the bottom right side of the cassette assembly of the AK50 retrofill. The actuator assembly consists of a linkage system that interfaces with the racking shaft assembly at one end and the position switch actuator arm on the other. Completing the racking in of the EntelliGuard breaker into the cassette corresponds to the end of stroke of the position switch system in the compartment for AK50 in AKD-5 LVS.

Figure 12 shows the AK50 position switch actuator assembly in an exploded view. The position switch actuator of the AK50 is a field-fit type of assembly and is assembled on the retrofill cassette before insertion of the cassette into the compartment of the AKD-5.

8. Make sure that the cassette is in the disconnected state.

This can be verified by checking the racking position status on the window located at the right side window on the frame of the AK50 Retrofill cassette, placed at the front. The position switch actuator kit of the AKD5—AK50 retrofits must be installed on the rear side, right-side sheet of the AK50 retrofit cassette.

19 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

9. Place the cassette on a work table.

The cassette should be positioned such that there is enough overhang of its side so that you can insert the position switch actuator assembly in the bottom of the cassette. Alternately, the installation can also be done by placing the cassette assembly on the retrofit AK50 while it is on the telescopic rails of the AKD5 compartment, being retrofitted.

10. As soon as the position switch actuator is installed, slide the assembly up from the bottom of the cassette. When inserted, flip the position switch.

11. Line up the holes on the cassette side sheet with the holes provided on the actuator assembly.

12. Fasten the 3 M6 bolts and 6mm washers provided with the actuator assembly to the three holes

on the cassette side sheet. Two holes are placed on the side and one hole on the rear of the cassette assembly.

The position switch actuator on the cassette is now installed and ready to be activated as soon as the breaker is racked into the compartment.

13. Mount the cassette assembly on the rails of the AK25 cabinet in the AKD-5 and rack the cassette into the compartment of the AKD-5 LVS.

Note: As the EntelliGuard ACB breaker is racked in the cassette, the position indicator window reads “connected”. This indicates that the retrofit system has activated the position switch in the LVS.

Racking-Lock Bracket—Initial Tasks

• 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.

1. Remove existing indicator assembly system from AKD-5 cabinet rails (Figure 13).

2. Clean the area of the moving frame assembly of any dirt or debris.

3. Unpack the racking lock kit for the AKD-5.

4. Use this bracket as a template for drilling the holes in the frame (Figure 14).

20 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Figure 13. Legacy Indicator Assembly

Figure 14. Bracket Template for Drilling Holes

5. Slide the bracket (Figure 14) up to its fixing location as shown in the illustration (Figure 15).

6. Line up the guiding holes (Figure 16).

Figure 15. Slide Bracket Up

Figure 16. Line Up Holes

7. Mark the bottom two holes using the bracket as a template.

8. Take the bracket out and drill 0.18-in diameter pilot holes in the frame.

21 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Install Cassette (Landed Wires)

• 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.

The photo in View 1 of Figure 17 shows the rear view of the wires landed on the AKD-5 cassette; View 2 shows the front view of the AKD-5 cassette, ready for installation.

Figure 17. AKD-5—Cassette, View 1

AKD-5—Cassette, View 2

1. Install the pre-wired cassette in the enclosure as demonstrated in the photos, below.

2. Place the cassette on the rails for racking into the switchgear cabinet (Figure 18).

3. Slide the retrofit cassette into the compartment till dead-stop.

4. Lock the rails of the legacy compartment to ensure inner and outer rail movement.

5. Use legacy (old or original) AKR racking handle for inserting the retrofit cassette.

6. Fix legacy (old or original) racker-lock on the compartment side frame to block slide back of sleeve.

The following photos show how the cassette is racked in and secured (Figure 19), rails extended (Figure 20), left side view; and (Figure 21), racking in.

22 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Figure 18. AKD-5—Cassette To Be Racked In, View 1

AKD-5—Cassette To Be Racked In, View 2

Figure 19. AKD-5—Cassette or Substructure, Rails Extended

Figure 20. AKD-5—Cassette or Substructure, Left Side Details

Figure 21. AKD-5—Cassette or Substructure, Racking and Removing Tool, View 1

The next two figures (Figure 22 and Figure 23) display the complete racking in of the pre-wired cassette.

23 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Figure 22. AKD-5—Cassette or Substructure, Racking and Removing Tool

Figure 23. AKD-5—Cassette or Substructure, Now Racked In

Install Lock Bracket

• 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.

1. Check that the retrofitted EntelliGuard cassette has been completely racked into the cabinet.

2. Slide the bracket back into position as shown in the image below (Figure 24) and line up the holes

previously drilled with the holes on the locking bracket (Figure 25).

24 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Figure 24. Position Bracket

Figure 25. Line Up Bracket

3. Secure the bracket to the side frame by using the two self-tapping screws provided with the kit

(Figure 26 and Figure 27).

Tools required: Spanner, 0.2-inch drill bit, hand drill

Figure 26. Installed Bracket (View 1)

Figure 27. Installed Bracket (View 2)

25 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Install AKD-5 Retrofill Breaker

• 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.

1. Before inserting the retrofit breaker into the cabinet, make sure that the breaker is switched off. If

the spring indicator shows that it is charged, the assembly needs to be discharged, by first switching on the breaker and then switching it off.

2. After you racked in the cassette, get ready to install the AKD-5 breaker assembly by pulling the lifting hooks up (lifting handles, eyes, or ears) from their slots. Use a tool or screwdriver to keep them up, if necessary (Figure 28).

Figure 28. AKD-5—Breaker Lifting Holes

3. Get a hand-crane and wheel it over to the breaker.

4. Lower the boom of the lifting device so that you have enough slack to insert its two hooks in the

breaker lifting holes (Figure 28). Or attach a lifting bar between the two holes eyes of the circuit breaker, instead of hooks.

5. Make sure that the crane lifting hooks are secured and locked in placed on the breaker.

6. Using the hydraulic lift, raise the breaker slowly so that it clears the breaker platform. Suspend the

hoisted breaker a yard off the ground or floor. Carefully wheel the crane with the hoisted breaker over to the switchgear for installation (Figure 29).

7. Put the breaker in front of the unit where it is to be installed, leaving enough clearance to swing the compartment door open to access the enclosure.

26 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

8. When the breaker is lined up with the compartment, raise the breaker only slightly higher than the compartment floor, keeping it at slight angle.

9. Open the compartment door, if not already opened, to install the breaker in the cassette, (Figure 30).

Figure 29. Cabinet with Compartment Door Closed

Figure 30. Cabinet with Compartment Door Open

10. After you open the compartment door, check that the cassette is free from obstruction. Figure 30

displays the racking assembly, supporting the new retrofill breaker.

11. Remove any padlocks and keep the key in place for key locks if applied from the racking panel of the cassette.

12. Verify that the cassette position indicator shows DISCONNECTED and the racking handle is disengaged.

13. Ensure that the cassette racking cams on both side walls of the cassette are in the completely racked-out position as shown in Figure 31.

14. Pull out the two racking arms (or loading/cassette rails) to their full extent, horizontal to the ground (Figure 31).

27 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Figure 31. Racking Arms / Loading Rails, Extended

15. Lower the circuit gradually, at an angle, so that the rollers drop over the rails. Make sure that the

grooves in all rollers straddle the rails as shown in Figure 32.

This might need a two-man effort: one to carefully and slowly lower the boom with the suspended breaker and the other to guide the breaker into the cassette enclosure. See Figure 32. You might have to jockey the circuit breaker into position to align wheels with the rails.

Figure 32. Inserting Breaker into Cassette, Wheels Lined Up with Roller Arms

16. Keep the breaker steady. Continue to guide the breaker, while checking both sides and underneath

the assembly, so that both sets of wheels can be lowered easily on the cassette rails (Figure 33). Check that the grooves in all rollers straddle the rails.

28 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Figure 33. Keeping Breaker Steady

17. Peer underneath the breaker, as you maneuver it in, to make sure that the dual blades clear the

bottom of cassette. See Figure 34.

Figure 34. View of Underside of Breaker

18. As soon as the breaker is resting on the rails Figure 35, unhook the lift from the ears of the circuit

breaker and move the hoisting apparatus out of the way.

29 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Figure 35. Breaker Positioned on Rails

19. Using the hand grips on either side, move or push the circuit breaker into the cassette until it

reaches a positive stop (the rollers on circuit breaker are engaged with the racking cams of the cassette on both sides). Or, from the front, shove the breaker in as far as it can go.

The circuit breaker is now in the DISCONNECTED position (Figure 36).

20. Push back both the extended rails of the cassette to the stowed position.

21. If the circuit breaker is ON and the springs are charged, to turn the breaker off, press the OPEN

button on the circuit breaker fascia and ensure the circuit breaker contacts are open.

Figure 36. Breaker Ready for Complete Installation

30 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

22. Remove the racking tool (Figure 37) from the storage location on the cassette front panel by grabbing the handle.

23. Pull out the torque bar from inside the handle and extend the device.

Figure 37. Racking Tool

24. Figure 38 shows the racking assembly without breaker inserted.

Figure 38. Racking Assembly Inside Switchgear Compartment (w/no breaker)

25. Take a screwdriver, insert it in the slot or rack-out lock, and turn it clockwise 45° so that the racking

handle shutter, inside and behind the racking hole, moves to the right. (It resembles a vehicle ignition lock. See Figure 39.)

31 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Figure 39. Shutter

26. After turning an eight of a turn and the shutter slides to the, remove the screwdriver, and insert the

racking tool in the hole (handle insertion hole). It’s located to the left of the racket lock (Figure 39).

27. Insert the tool so it that grabs or engages the racking mechanism inside the hole.

28. Line up the racking tool or crank with the handle straight up so that you can get some good

leverage or torque (Figure 40). Then, crank clockwise so that the cassette or substructure starts to move in, slowly sliding forward.

Rotating clockwise racks the circuit breaker all the way into the cassette or substructure.

Figure 40. Crank or Racking Handle Inserted

29. As the breaker approaches the TEST position, check the alignment of the fixed and moving parts

of the secondary circuit isolating contacts.

32 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

30. Continue rotating the racking handle clockwise until the position indicator first shows TEST, then CONNECTED.

When approaching the CONNECTED position, effort to turn the racking handle increases as the clusters engage with the cassette-mounted contacts. If a motor-spring charge or under-voltage-torelease is installed, the device may operate when approaching the TEST position.

31. Keep cranking as required, that is, when any further torqueing can’t be done.

At this point, the fingers at the back of the circuit breaker have completely grabbed onto the contacts at the back of the cassette.

32. Remove and store the racking handle in it storage location.

It is a good idea to keep the racking handle always in the same place for future use.

33. Note that the circuit breaker is now ready for normal operation.

Secondary Disconnects, Bullets

The circuit breaker secondary disconnects are already located on, or wired to, the breaker’s cassette. The landing of the wiring on the EntelliGuard R breaker cassette is done in the field. Up to 78 points are available so that all breaker accessories can be wired to dedicated

disconnect-points in the cubicle.

Each breaker wire is identified with a unique label. The wireframes in Figure 41 and Figure 42 depict the secondary disconnect assemblies for the AKD-5 AK25/AK50. Figure 43 shows the exploded view of four blocks of secondary disconnects. The cassette is a separate assembly from the retrofill breaker; first, the cassette is to be wired and then installed in the switchgear, the followed by the breaker being racked into the cassette.

Figure 41. AK25 Retrofill Breaker Cassette Assembly (Rear View)

Figure 42. AK25 Retrofill Breaker Cassette Assembly (Front View)

Figure 43. AK25 Retrofill Breaker Cassette Assembly (Exploded View)

P/N 386A110G2

Retrofill Sec Disc Assy AKR

AKD5

33 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

The wiring harness for the secondary disconnects, located on the AKD-5 retrofill cassette, has 21 wire connections (grouped in three blocks (A, B, C)) for AK50 or 28 wire connections (grouped in 4 blocks (A, B, C, D)) for AK25, with seven wire connections for each block). Each wire is clearly labeled, or identified, with wire markers or tags. Each wire on the 21-wire harness is connected to a bullet. Each bullet, when the cassette is racked in, engages with its respective points in the switchgear. The wires for Block A are identified as A1, A2,…A7. Block B wiring is likewise labeled as B1, B2, B3,….B7. Block C contains C1, C2,….C7. The end, opposite of the bullets, maps or connects to the retrofill EntelliGuard R Cassette 78-point, secondary-disconnect. For example, if bullets A1 and A4 are reserved for the motor, they connect to points A1 and A2 on the cassette’s 78-point, secondary-disconnect for a motor. Each breaker needs to be landed in the field based on the specifics breakers wiring diagram and modifications made in the field.

Figure 44 is a photo of the AKD-5—AK25 harness and Figure 45 is an AKD-5—AK25 C-block photo.

Figure 44. AK25 Harness, Top View

Figure 45. AK25 C-Block Harness

Wiring Diagram and Block Info (AK25)

Additional wire markers, cable ties, spade terminals, and sticky pads are provided. Refer to the AK wiring scheme (Figure 46) and land the wires on EG-fixed secondary-disconnects. Wires are cut to size and crimped with the terminal lugs, and provided with wire markers. Harness by cable ties is completed and overhanging wires are checked. Similar to the AKD-5 AK25, the AKD-5 AK50 breaker roll-in replacement uses a similar wire harness and is mounted on the cassette. For further information on blocks and secondary-disconnects see Wiring Diagram for the AK/AKR Retrofill on Page44.

1. Get these tools needed for the task: Philips head screw driver, wire strippers, wire crimps, tie-wraps.

2. Identify each bullet using the legacy wiring diagram and any changes that were made to the legacy

compartment. Four-wire ground fault CTs are wired through a dedicated neutral disconnect vs. the secondary bullets.

34 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

3. With each bullet identified, land the non-bullet side to the corresponding feature on the EntelliGuard R’s 78-point secondary disconnects. (See Wiring Diagram for the AK/AKR Retrofill on

Page 44.)

If a wire is too long, cut the wire, crimp a new connector, and install the provided wire markers on the bullets. Refer to Wiring Diagram for the AK/AKR Retrofill, Page 44.

Figure 46. Example Wiring Diagram for AK25 Secondary Disconnects and Photo Example

Below are tables (Table 7 and Table 8) featuring the two 39-blocks (A and B). They make up the 78-point secondary-disconnects.

35 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Table 7. EntelliGuard G 39-Point Secondary A-Block.

Table 8. EntelliGuard G 39-Point Secondary B-Block.

AK25 Wiring Harness, B-Block (AK25/50)

Photo in Figure 47 shows you the B-block harness and Figure 48 is a close-up photo of the harness. Figure 49 shows you the secondary bullets.

36 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Figure 47. AK25 B-Block Harness

Figure 48. AK25 Wiring Harness, Close Up

Figure 49. Wires from Secondary Bullets

37 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Programmer Secondary Disconnect (Breaker Side—N/A)

Programmer secondary disconnects are not provided on AKD5 legacy LVS breakers. If the customer chooses to use the advanced features of the EntelliGuard ACB, the control wiring needs to be routed from the LVS directly to the secondary disconnect landing points on the cassette assembly of the EntelliGuard ACB cassette. Refer to the tables (Table 7 and Table 8) featuring the two 39-blocks (A and B) that make up the 78-point secondary-disconnects. Ordering info given here:

Install Position Switch Actuator (Breaker Side)

Legacy Breaker

Kit Number

AK50

10106296G1

AK25

10106269G1

AK25

The position-switch actuator assembly for the AK25 should be mounted on the bottom plate of the cassette assembly of the AK25 retrofill. The actual actuator assembly consists of two plates, one on the top (top plate) and one on the bottom of the baseplate. The top plate of the actuator interfaces with the breaker when it is racked in and the motion of the same is transferred to the bottom plate which interfaces with the position switch lever on the legacy compartment.

Completing the racking in of the EntelliGuard breaker into the cassette corresponds to the end of stroke of the position switch system in the compartment for AK25 in AKD-5 LVS. Figure 50 shows the exploded view of the AK25 retrofill position-switch actuator (actually a bracket assembly); Figure 51 displays the assembly from the bottom.

Figure 50. AKD-5—AK25 Retrofill Breaker, Actuator for Position Switch Assembly (Exploded View)

Figure 51. AKD-5—AK25 Retrofill Breaker, Actuator for Position Switch Assembly (Bottom View)

38 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Install Door Interlock System (Breaker Side)

Figure 52 shows the components that make up the AKD-5 retrofill door interlocking assembly:

Figure 52. AKD-5—Door Interlocking Components

For the retrofit, instructions for installing the interlocking system on the AKD-5 switchgear are the same as those for EntelliGuard G Circuit Breaker. Refer to the Installation, Operation, and Maintenance Manual

for the EntelliGuard G Circuit Breaker, DEH-41304, 02 Apr 09.

Neutral Disconnect Assembly (Breaker Side)

When a legacy AK breaker is replaced with a retrofitted EntelliGuard ACB, the incoming wires from the neutral CTs need to be routed to the cassette secondary-disconnects directly.

Install AKD-5—Neutral Rogowski Current Transformer (CT)

The AKD-5 EntelliGuard R Circuit Breaker uses an open-core Rogowski Current sensor to measure current level vs. an iron core style used in the legacy AK, AKR breakers. For the retrofill to calculate the current levels on a 4-wire circuit, the neutral iron core CT in the cable compartment must be replaced with a Rogowski style CT.

The current transformer comes with the CT-mounted on copper bars matching the same hole-pattern as the existing neutral bar.

The external neutral Rogowski mounting kit comes with three mounting brackets, two fixing screws, two cable ties, one 2-m long twisted pair extension lead and one neutral Rogowski coil.

39 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Remove Existing Iron Core Neutral CT Assembly

• 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.

Figure 53 shows a photo of an existing iron core neutral current transformer.

Figure 53. Iron Core Neutral CT

Neutral CT assembly in Cable/Bus Compartment:

1. Verify that the LVS has been de-energized and the breaker in the compartment being retrofitted

are switched off and removed from the LVS.

2. Open the door on the rear of the compartment to gain access the cable/bus compartment of the LVS.

The existing neutral CT assemblies are usually mounted vertically on two copper bus bars placed horizontally.

40 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

3. Make a note of the neutral disconnect assembly orientation and the wire connections polarity.

This needs to be done to ensure that the assembly is maintained when the new CT assembly is installed.

4. Disconnect the wires attached to the existing CT assemblies and place them in a way that they do not interfere with the replacement of the CT assemblies.

5. Replace the neutral disconnect wiring with the new pared-wire which should be routed directly to the secondary disconnects of the cassette assembly.

6. Unfasten and remove the bolts that hold the neutral disconnects assemblies to the horizontal bus bars. Keep the hardware in a secure location for reassembly.

7. Care should be taken while handling the CT assemblies such that they do not fall down or damage other components within the LVS.

8. Replace the old CT assembly with the Rogowski assembly (Figure 54 and Figure 55 or Figure 56 and Figure 57) on the horizontal bus bars; and fasten the Rogowski using the hardware previously removed. Orientation of the new CT assembly should match that of the legacy which was referenced in Step 3.

9. Connect the wires back to the Rogowski CT assembly leads. Maintain the same polarity as that of the legacy CT connections which were noted during Step 3.

10. Check for continuity from the CT leads to the secondary disconnects on the retrofit EntelliGuard ACB.

11. The new Rogowski assemblies are installed and ready for use.

Tools required: Wrenches, Wire stripper, wire cutter, continuity tester

Figure 54. AKD-5—AK25 Neutral Bus Rogowski ASM 10108212

Figure 55. Neutral Bus Rogowski ASM 10108212 Photo

41 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Figure 56. AKD-5—AK50 Neutral Bus Rogowski ASM 10108216

Figure 57. Neutral Bus Rogowski ASM 10108216 Photo

AKD-5—Neutral Sensor Packaging

• 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.

• The Neutral Sensor is constructed using a phase sensor encapsulated appropriately to meet insulation and durability requirements.

• Lead wires are UL-recognized type 18AWG or larger, rated at 600V.

• Lead wires are 6 feet in length, minimum.

• Lead wires are colored white and black.

• The white wire is connected to the “positive” polarity termination.

• The black wire is connected to the “negative” polarity termination.

42 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

• Sensor window cross section conforms to criteria as found in the table below (Table 9):

Table 9. Frame Ratings and Sensor Areas

Frame & Rating

Sensor Window minimum area (in2)

Frame 1 / 2000A

2.0

Frame 2 / 3200A

3.2

Frame 3 / 6400A

6.4

The Frame 3 neutral sensor is implemented as two separate sensors, similarly to the phase sensors in the circuit breaker. Frame 3 neutral bus assemblies provide two independent parallel conductors in the neutral bus such that the neutral current is divided between the two sensors.

A special neutral bus section is provided within the switchgear to accommodate the specific form factor of each Rogowski—this is not the design responsibility of the Rogowski vendor.

• Encapsulation materials are UL recognized and suitable for operation at 130C.

• Neutral sensors of a given rating match all characteristics of the phase sensors.

AKD-5—Multi-Source Ground Fault

Retrofills can be used in the following ground fault applications:

• Single source feeder breakers, 3-wire or 4-wire

• Main circuit breakers, 3-wire or 4-wire

When multi-sources are present with the ground fault detection on the trip unit desired, then an external GF summing CT scheme must be implemented. This applies to Main—Tie—Main systems or systems with a main source and then a back-fed generator source.

43 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Remove and Replace AKD-5—Existing Door

• 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.

1. To remove existing compartment door(s), refer to your manual on how to remove the legacy doors.

2. To install new door, refer to the Retrofill Door Assemblies, DEH-41563.

44 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Wiring Diagram for the AK/AKR Retrofill

Neutral disconnect and programmer disconnect plugs are not used for AKD5. Points provided as reference for wiring purposes only.

45 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547 02/12

Notes

GE Energy

41 Woodford Avenue Plainville, CT 06062 www.geindustrial.com

imagination at work

DEH-41547 02/12

GE Industrial Solutions EntelliGuard R AKD-5 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual