GE Industrial Solutions EntelliGuard R AKD-6 User Manual

GE Energy

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

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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

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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.

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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.

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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

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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

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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)

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GE Industrial Solutions EntelliGuard R AKD-6 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual