GE Industrial Solutions EntelliGuard R AKD-6 User Manual

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EntelliGuard® R Circuit Breaker Retrofill

AKD-6 Installation Manual

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1 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Table of Content

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)..............................................................................................................................................................................................................6

Views..........................................................................................................................................................................................................................7

History and Types ....................................................................................................................................................................8

AKD ..................................................................................................................................................................................................................................8

AKD-6—AKR30H/AKR30L/AKR50H....................................................................................................................................................................8

Mechanical Drawings .............................................................................................................................................................................................9

AKD-6—Compartment...........................................................................................................................................................10

Interior.........................................................................................................................................................................................................................10

Unpack Retrofill Circuit Breaker..........................................................................................................................................13

Quality ......................................................................................................................................................................................................................... 14

Information Label...................................................................................................................................................................................................14

Product and Catalog Serial Numbers...........................................................................................................................................................14

Remove Circuit Breaker from Container..................................................................................................................................................... 15

Inspect.................................................................................................................................................................................................................... 15

Use Lifting Truck................................................................................................................................................................................................15

2 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Store Circuit Breaker .............................................................................................................................................................16

Check Before Installing .........................................................................................................................................................17

Clean and Grease Breaker....................................................................................................................................................17

Rack Out Legacy or Existing CB...........................................................................................................................................18

Install Secondary Disconnect Bullets (Breaker)................................................................................................................18

Wire Secondary Disconnect Assembly—AKR30/30H/50/50H ..........................................................................................................20

Install Position Switch Actuator (Breaker) .........................................................................................................................21

Install Door Interlock System (Breaker) .............................................................................................................................23

Install Neutral Rogowski Current Transformer (Breaker)...............................................................................................25

19-Pin Programmer Secondary Disconnect (Breaker).....................................................................................................25

Install or Insert AKD-6 Retrofill............................................................................................................................................27

Remove and Replace Existing Door....................................................................................................................................32

Prepare Switchgear Compartment.....................................................................................................................................32

Install Neutral Disconnect Assembly (Bus Compartment) .............................................................................................34

Multi-Source Ground Fault...................................................................................................................................................35

Install 19-Pin Programmer Secondary Disconnect (Compartment) .............................................................................36

Wiring Diagram for the AK/AKR Retrofill ...........................................................................................................................38

Notes ........................................................................................................................................................................................39

3 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 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-6 Installation Manual DEH-41548 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-6 Installation Manual DEH-41548 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-6 Installation Manual DEH-41548 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

Weight (lbs)

Retrofill Breaker

Weight

Box Weight 10101653P1

Pallet 10101650P1 Wt

Accessories

Total

Weight

AKD6

213

264

Retrofill Breaker

Weight

PB2 Large Frame Box Wt

10101653P1

Pallet 10101513P1 Wt

Accessories

Total

Weight

AKD6

213

250

7 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Views

General Electric AKD-6 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. One particular feature of the AKD-6 is that the breaker is built into the cassette. Figure 1 shows the AKD-6 EntelliGuard R Retrofill breaker permanently encased in its cassette (front view). Figure 2 shows also the AKD-6 EntelliGuard R Retrofill in the cassette (rear view).

Figure 3 presents the AKR50H (AKD-6) with four-fingered clusters.

Figure 1. AKD-6—AKR30H\50H Breaker in Cassette (Front View)

Figure 2. AKD-6—AKR30H Breaker in Cassette (Rear View)

Figure 3. AKD-6—AKR50H Breaker in Cassette (Rear 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.

8 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 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 / 4000-A 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-6—AKR30H/AKR30L/AKR50H

The AKD-6 was manufactured in Salisbury, NC from 1977 to 1981. Some AKD-5s, which were built in Salisbury from 1975 until 1977, got name-plated as AKD-6. There is no “flash-butt” welded aluminum to copper. Aluminum bus is tin-plated and bolted at shipping splits (but welded everywhere else). Copper bus design has ring silver plating at bolted joints. AKR-75 / 100s were introduced during this time. Stab-and-finger connections on 3200A and 4000A breakers were improvements, versus the round the primary disconnects located on the AKD-5s. The AKD-6 uses inner-house drawout breaker compartments and tuning fork primary disconnects (extrusions) on the 800—2000A breaker compartments. They have copper feeder breaker runbacks and 60"-deep frames with 18"optional rear extensions. They are painted ANSI 61 light gray and breakers have ECS or SST trip units.

9 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Mechanical Drawings

Below is an AKD-6 mechanical drawing that dimensions the breaker (DWG 1 and DWG 2)

DWG 1. AKD-6—Retrofill for AKR30/30H

DWG 2. AKD-6—Retrofill for AKR50/50H

10 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

AKD-6—Compartment

Interior

Figure 4 displays an empty compartment of the AKD-6 switchgear. Figure 5 shows features of the AKD-6 interior.

Figure 4. AKD-6 Switchgear, Empty Compartment

11 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Figure 5. AKD-6 Compartment Distinctions

Figure 6 is an example of a compartment in the AKD-6 switchgear that is empty; that is, the upper compartment is

ready for a retrofill breaker where the legacy, or original breaker, had been racked out and new wire connections made. The lower compartment has a retrofill breaker, already installed. In this figure, there is also a photo showing a mechanically-operated status indicator (connect/disconnect) that worked with the original breaker. This device, if left in the compartment as is, won’t interfere with the retrofill breaker; it can, however, be disassembled by removing its hardware. Figure 7 displays the bus inside the gear.

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Figure 6. AKD6 Breaker Compartment (Upper and Lower Compartments)

13 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Figure 7. Bus, Interior View

Unpack Retrofill Circuit Breaker

By following the procedures below, you should be able to install the breaker with minimum effort and time.

• 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.

14 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

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.

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.

15 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

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 crate cover.

4. Remove all packaging material.

5. Remove all product documentation and store properly.

6. Unscrew the 4 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 and 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.

16 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 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 it later.

PRODUCT DAMAGE

• Do not store circuit breaker in corrosive 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 they be properly supported to prevent bending of the studs or damage to any of the breaker

parts. Do not remove any protective grease until they are 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 at once, 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, do the following precautions to prevent corrosion or deterioration:

• Uncrate the equipment and check thoroughly for damage.

• 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.

• 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.

17 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 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 AK breakers. However, since the rackout mechanism is mounted on the breaker, there are no jackshafts in the enclosure. Racking arms on both sides of the breaker frame engage the drawout mechanism pins 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. Look on the breaker sheets summaries, the front view drawings, breaker nameplate, and on the identification card on the breaker shipping carton.

3. To locate the breaker for 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 number.

Clean and Grease Breaker

1. Before installing or operating a breaker, refer to the breaker instruction manual for pre-operation inspection

and test.

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 (fingers) for better electrical

connections on the breaker.

18 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Rack Out Legacy or Existing CB

• 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 rack-out legacy (old or original) breaker from compartment, refer to your legacy-breaker’s manual on how

to remove the existing breaker.

Install Secondary Disconnect Bullets (Breaker)

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.

This section deals with the installing and wiring the legacy secondary disconnect assemblies on to the Retrofill EntelliGuard ACB. Installing the secondary-disconnect assembly consists of the following tasks:

• Installation of the secondary disconnect assembly

• Wiring of the secondary disconnect assembly

The Retrofill EntelliGuard ACB has available either of these two options:

• All secondary disconnects installed

• No secondary disconnects installed

19 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

If the application requires installing all three secondary disconnect blocks, you would select the first option above. As the secondary disconnects are already pre-installed on the breaker, wiring the secondary disconnects can begin.

If the application does not require any secondary disconnect assemblies, you would select the second option above. This would mean that no further wiring is needed.

If the application requires less than three secondary disconnect blocks, the customer decides on the second option and orders the secondary disconnect blocks (bullets) as needed (Figure 8). Then the secondaries can be installed and wiring the Retrofill EntelliGuard ACB can be done. Steps for installing and wiring the secondary disconnect bullets are covered next.

Figure 8. EntelliGuard ACB Secondary Disconnect Bullets

1. Unpack the secondary disconnect block from the box. Each kit of secondary disconnect has four fixing

nuts, plain washers, and spring washers. These can be arranged on a work station to prepare for installing the assemblies.

2. Check that the bullets, on top of the secondary disconnects, are not damaged and that they slide in to the blocks freely. The bullets (Figure 9) are spring-loaded and retract to their initial positions when they are released from being pressed down.

3. Check for electrical continuity between the bullets on one and the wire terminations on the other. Blocks containing faulty bullets should be replaced.

4. Place the secondary disconnect block on top of the horizontal plate at the rear of the Retrofill EntelliGuard ACB, which runs across the width of the Retrofill EntelliGuard ACB.

5. Align the four studs at the base of the supplied block to the four holes on the plate. The plate is provided with three sets of four holes, one set for each block (A, B, and C blocks).

6. Slide the secondary blocks down into the plate such that the base of the secondary disconnect rests on top of the plate.

7. Secure the studs on to the fixing plates using the hardware provided as mentioned above. The nuts must be tightened hand-tight.

20 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

8. Verify that the wire markers are clearly visible and not damaged so that they are wired easily and efficiently.

9. Be careful that that the wires are not pinched or damaged while installing the secondary disconnect blocks.

Figure 9. AKD-6—Secondary Disconnects, Bullets

Wire Secondary Disconnect Assembly—AKR30/30H/50/50H

Tools required: wire stripper, wire cutter, and a Philips-head screw driver, M6 wrench

As mentioned above, the secondary disconnect blocks are available with all blocks installed. In this case, the wires on the blocks are routed through one side of the breaker and then on to the front. The wires on the front are left loose for tease of landing them to the EntelliGuard ACB breaker secondary disconnects.

When the secondary disconnect blocks are installed at the customer’s site, the wires would not have been already routed. The wires should not be routed from the outside of the metal structure as it might interfere with the motion of the kit during the racking into the compartment. Also, it should be kept in mind that the wires are securely fixed on the inside metal frame of the Retrofill kit with sticky pads and tie-wraps.

Check that wire routing does not exert pressure on the bullets because this can bend the connection points and effects biasing and contact pressure. By using tie-wraps and sticky-pads, wire routing can eliminate sagging of the wire harness and undue pressure on secondary bullets.

Once the above mentioned steps are completed, landing the wires to the points on the EntelliGuard ACB secondaries can begin.

21 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Typical wiring diagrams for the AKD-6 are given below (Figure 10).

Figure 10. Typical AKD-6—Wiring Diagrams for the Secondary Disconnect Bullets Example: Retrofill EntelliGuardACB (AKR30/30H/50/50H/30L)

Example: Retrofill EntelliGuard ACB (AKR30S)

Install Position Switch Actuator (Breaker)

Position switch actuator bracket can be installed on all versions of Retrofill EntelliGuard ACB for AKD6 LVS (Figure 11). The steps of installation are as follows:

Retrofills use the legacy position switch already mounted in the cubicle. If a new position switch has to be installed, refer to the legacy position switch installation manual.

1. Unpack the position switch bracket. Each bracket is provided with a pair of M6x16mm Allen-type bolts and washers.

2. Place the bracket on the bottom right side of the AKD6 base. Two locating holes are provided for mounting of the position switch bracket.

3. Fasten the two bolts to the locating holes after placing the washers to securely mount the bracket.

4. The bracket is ready for use.

22 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Figure 11. AKD-6—Position Switch Actuator (Breaker Side) and Parts

Level

Item or Part

Number

Description

Quantity

10105289P1

Position Switch

Brkt, AKD-6

10100950P4

Washer M6

10100380P1

Serrated Belleville

Washer M6

10100545P1

Cap Head

Screw M6x16

Note: Individual hardware for the position switch actuator cannot be ordered separately. The item numbers given below are for reference only. The assembly comes as a unit or a kit. Order the actuator assembly by part number.

23 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Install Door Interlock System (Breaker)

P/N 10108779G1 Door Interlock Kit

Tools required: Flat screw driver, E-clip mounting tool

The door interlock system prevents opening of the breaker compartment door when the breaker is in the racked-in position and connected state. Figure 12 shows the components that make up the AKD-6 retrofill door interlocking assembly.

Figure 12. AKD-6—Door Interlocking Components

The sequence of assembly steps of the door interlock is as follows:

1. Unpack the door interlock kit. Each kit consists of a torsion spring, two E-clips and a breaker side-door interlock bracket.

2. Place the torsion spring on the pin as shown in the exploded view below and anchor it by placing one end of the pin into the hole provided inside the side-sheet of the retrofil.

3. Mount the door interlock bracket on the same pin via the hole provided on the bracket. Also, it must be ensured that the slot of the door interlock bracket is mounted on the second pin, placed on the front as shown in Figure 13.

4. Mount the free end of the torsion spring on the bracket as shown Figure 14.

24 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

5. Insert the E-clips mentioned in Step 1 to complete the assembly.

Figure 13. Mounting the Door Interlock Bracket

Figure 14. Torsion Spring for Door Interlock Bracket

The completed assembly of the door interlock will be as shown below (Figure 15).

Figure 15. AKD-6 AKR30H/50H Door Interlock Assembly (exploded view)

P/N 10108779G1

Door Interlock Kit

AKD6

25 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Install Neutral Rogowski Current Transformer (Breaker)

Figure 16 shows an exploded view of the breaker side neutral disconnect assembly for the AKD-6

AKR30/30H/50/50H retrofils. These will be available preinstalled and wired from the factory.

Figure 16. Neutral Disconnect Assembly for the AKD-6 AKR30H\50H Retrofill

AKR AKD6

BREAKER SIDE:

P/N 10105292G1

COMPARTMENT:

P/N 10108266G1

19-Pin Programmer Secondary Disconnect (Breaker)

The 19-pin programmer disconnects can now be included with the AKD-6 series retrofills to accommodate the extended features of the EntelliGuard Trip Unit. The 19-pin programmer-disconnect assemblies already come preinstalled and wired from the factory and do not require any installation in the field.

The compartment side is installed and wired in the field by a qualified electrician or installation service company.

Figure 17 shows the 19-pin programmer-disconnect on the AKR30/50, bottom side of the breaker, already

installed. Figure 18 displays the wiring diagram for the programmer-disconnect (12-pin and 19-pin combined in one diagram, although the AKD-6 does not use the 12-pin). Figure 19 features an exploded view of the 19-pin programmer disconnect. An installed view of the 19-pin programmer disconnect appears in Figure 20. For the compartment side, the 19-pin is ordered separately and comes in a box. Below are the part numbers for the breaker and compartment 19-pin programmer-disconnect assemblies.

BREAKER SIDE

P/N 10107108G1

19-PIN PROGRAMMER DISC ASSY

AKD6

COMPARTMENT SIDE

P/N 10106652G1

19-PIN PROGRAMMER DISC ASSY

AKD6

26 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Figure 17. 19-Pin Programmer Disconnect on the AKR30/50 Breaker

Figure 18. Wiring for Programmer Disconnect (12- and 19-Pin)

Figure 19. 19-Pin Programmer Disconnect for the AKD-6 AKR30H\50H Retrofill, Exploded View

Figure 20. 19-Pin Programmer Disconnect AKD-6 AKR30H\50H Retrofill, Installed

27 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Install or Insert AKD-6 Retrofill

• 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.

After the existing breaker is removed, the pre-wired retrofill breaker can now be installed in the AKD-6 switchgear.

1. Verify that the breaker is in the disconnected, switched-off position before mounting it on rails.

2. Pull out the cubicle rails, horizontal to the ground.

3. While rotating the lever (away from the cubicle) at the end of each rail, which unlocks the inner rail, pull the rail

assemblies outwards to their fully extended positions. The rails can now support and secure the retrofill breaker in the switchgear (Figure 21).

28 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Figure 21. AKD-6 Rails or Arms for Mounting Retrofill Cassette/CB

4. Get a hand-crane and wheel it over to the breaker. 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 switchgear enclosure.

5. Lower the boom of the lifting device so that you have enough slack to insert its two hooks in the breaker’s lifting holes. Or attach a lifting bar between the two holes eyes of the circuit breaker, instead of hooks.

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

7. 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 crane, with hoisted breaker, over to the switchgear for installation.

8. Line up the breaker in front of the unit in where it is to be installed, leaving enough clearance to maneuver the retrofill.

9. Check that the retrofill is free from obstruction inside the compartment.

10. When the breaker is lined up with the compartment, raise the breaker only slightly higher than the

compartment floor, keeping it at slight angle.

11. Keep the breaker steady. Continue to guide the breaker, while checking both sides and underneath, so that both sets of pins can be lowered and lined up easily with the rails slots.

12. Place retrofit EntelliGuard R Retrofill breaker on the rails (Figure 22) to the disconnect position of the legacy breaker. (Note that the pins must line up with the slots on the rails.)

29 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

13. As soon as the breaker is resting on the rails, unhook the lift hooks from the ears or holes of the circuit breaker. Move the hoisting apparatus out of the way.

Figure 22. Retrofill Hoisted and Secured on Rails

14. Push the breaker into the compartment until it can’t be pushed any further in, that is, slide the retrofit cassette

into the compartment until dead-stop.

15. Pull the shutter pad lock lever to defeat the latch on the rail (Figure 23).

16. Put the rod of 3/8" in the hole of the shutter padlock lever (Figure 24).

17. Push the retrofill breaker to “test” position of the legacy breaker. This will be the disconnect position for the

retrofill breaker.

18. Latch the inner rail with outer rail.

19. Remove the rod from the shutter padlock lever and allow the lever to go back.

20. Now the new retrofill breaker can be racked in, using the racking mechanism provided in the breaker.

30 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Figure 23. Latching Inner Rail with Outer Rail

Figure 24. Inserting Rod

21. Remove the racking tool from the storage location on the retrofill front panel and grab the handle.

22. Pull out the torque bar from inside the handle and extend.

23. Take a blade-type screwdriver, insert it in the slot or rack-out lock of the breaker (Figure 25), and turn it

clockwise 45°to the right so that the racking handle shutter, inside and behind the racking hole, also moves to the right. (The insertion slot resembles a vehicle ignition lock.)

Figure 25. Racking in AKD6—Retrofill

24. After turning the screwdriver to the right with the shutter sliding to the right, remove the screwdriver and insert

the racking tool in the handle-insertion hole. It’s located on the left side.

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

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

torque. Then, crank clockwise so that the retrofill starts to move in, slowly sliding forward into the compartment.

27. Rotating clockwise racks the circuit breaker all the way into the enclosure.

31 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

28. As the breaker approaches the TEST position, check the alignment of the fixed and moving parts of the secondary circuit isolating contacts (Figure 26).

Figure 26. Stationay Secondary Contacts

29. Continue to rack in the breaker using the EntelliGuard racking handle while the screwdriver is inserted in the

shutter slot (Figure 25).

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

31. When approaching the CONNECTED position, more torque for turning the racking handle is needed as the clusters engage with the cassette-mounted contacts. If a motor spring-charge or under-voltage-to-release is installed, these devices might activate when approaching the TEST position.

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

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

back of the cassette (Figure 26).

34. 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.

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

32 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Remove and Replace 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.

Prepare Switchgear Compartment

• Ensure the circuit breaker has been tripped,

indicating OFF, and the main springs are fully discharged.

• Do not touch the circuit breaker’s isolating

contacts during lifting

• Failure to comply with these instructions could

result in death or serious injury.

• Ensure only qualified personnel install, operate, service, and maintain all electrical equipment.

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.

2. Inspect the compartment for damage, rework (Figure 27).

33 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Figure 27. Prepare AKD-6—Compartment

3. Check cabinet for suitability of retrofill.

4. Check each breaker compartment for bolted joints in the primary disconnect bars. Where such joints exist,

check the bolts for tightness.

5. 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.

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

34 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Install Neutral Disconnect Assembly (Bus 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.

The AKD-6 EntelliGuard R Circuit Breaker uses an air-core Rogowski Current sensor to measure current level vs. an iron core CTs 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 needs to be replaced with a Rogowski style CT (Figure 28). Consult the table for the appropriate Rogowski assembly for the switchgear (Table 7).

The Rogowski CT comes 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 2m (78.75 inches) long twisted pair extension lead and one neutral Rogowski coil.

Table 7. AKD-8—Rogowski Assemblies (Neutral Bus Part Numbers)

Figure 28. Neutral Bus Rogowski ASM 10108266

Breaker/Switchgear

Rogowski Assembly or

Neutral Bus Bar

Part Numbers

AKD6 400A

10108266G1

AKD6 600A

10108266G2

AKD6 800A

10108266G3

AKD6 1000A

10108266G4

AKD6 1200A

10108266G5

AKD6 1600A

10108266G6

1. Be sure that the LVS has been de-energized and the breaker in the compartment being retrofit 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.

35 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

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

4. Disconnect the wires that are attached to the existing CT assemblies and place them so that they do not

interfere with the replacement of the CT assemblies.

5. Unfasten and remove the bolts holding the neutral disconnect assemblies to the horizontal bus bars. Keep the hardware in a secure location for reassembly.

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

7. Replace the old CT assembly by the new Rogowski assembly on the horizontal bus bars and fasten it using the hardware previously removed.

8. Connect the wires back to the Rogowski CT assembly leads. In case of damaged wires, the same must be replaced with new ones as already mentioned.

9. Check for continuity from the CT leads to the plungers on the neutral-disconnect assemblies within the LVS compartment.

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

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

Multi-Source Ground Fault

Retrofils 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.

36 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Install 19-Pin Programmer Secondary Disconnect (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.

• Installing the programmer disconnect should not be carried out when the compartment is live.

• The compartment should be de-energized before the installing the programmer disconnect assembly.

NOTE: 12-Pin Programmer disconnect configuration is not provided with the AKD6 version of the Retrofils of the EntelliGuard ACB.

To install the programmer disconnect in the AKD-6 switchgear, do the following:

1. Turn off power to the switchgear, if not done already.

2. Have these tools ready for doing the task: hand-drill, cleaning solution, antirust, and wrench for metric M6

bolt/nut.

3. Clean the base of the compartment of any dirt or foreign particles, if not done already.

4. Slide the inner frame assembly to its maximum inserted condition (Figure 29).

5. This position corresponds to the frame position when the breaker would be in, fully connected.

6. Use the slot, inner semicircle as a datum reference and mark the mounting-hole locations using the template

shown in (Figure 29). Dimensions shown are in inches.

7. Drill ¼-inch diameter holes at 4 locations as marked.

37 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Figure 29. AKD-6—Slide the Inner Frame (Dimensioning)

8. Place the programmer disconnect assembly on the mounting holes (Figure 30) and secure it to the base of the

programmer using hardware (Bolt—M6 X 35, Nut—M6 (metric)) provided along with the programmer disconnect assembly kit.

9. Check the movement of programmer disconnect on slides for biasing.

10. Tighten the hardware hand-tight (Figure 31).

11. From the disconnect plug, route the wire to suitable incoming cables from the compartment.

Figure 30. AKD-6—Holes Drilled for Mounting Programmer Disconnect

Figure 31. AKD-6—Programmer Disconnect Assembly Secured in Place

38 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Wiring Diagram for the AK/AKR Retrofill

39 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 02/12

Notes

GE Energy

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

imagination at work

DEH-41548 02/12

GE Industrial Solutions EntelliGuard R AKD-6 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual