GE Industrial Solutions EntelliGuard R AKD-8 User Manual

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GE Energy

EntelliGuard® R Circuit Breaker Retrofill

AKD-8 Installation Manual

General Electric AKD-8 Low Voltage Switchgear is a free-standing assembly of metal-enclosed units of power circuit breakers and other auxiliary power circuit protective devices.

imagination at work

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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......................................................................................................................................................................................6

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.....................................................................................................................................................................................................7

AKD ..............................................................................................................................................................................................................................7

AKD-8—AKR30H, AKR30L, AKR50H, AKR30S ............................................................................................................................................8

AKD-8—Retrofill Breaker....................................................................................................................................................................................... 8

AKD-8—Mechanical Drawings ........................................................................................................................................................................8

AKD-8 Compartment ..............................................................................................................................................................................................9

Interior View.............................................................................................................................................................................................................9

Interior Components......................................................................................................................................................................................... 10

Unpack CB.................................................................................................................................................................................................................. 11

Quality Assured................................................................................................................................................................................................... 12

Information Check Sheet................................................................................................................................................................................ 12

Product and Catalog Serial Numbers .......................................................................................................................................................12

Environmental Conditions.............................................................................................................................................................................. 12

Remove Circuit Breaker from Container ................................................................................................................................................. 13

Inspect..................................................................................................................................................................................................................... 13

Use Lifting Truck..................................................................................................................................................................................................... 13

Store Circuit Breaker ........................................................................................................................................................................................... 14

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Check Before Installing....................................................................................................................................................................................... 15

Clean and Grease Breaker................................................................................................................................................................................ 15

Modify Retrofill........................................................................................................................................................................................................ 17

Modify AKD-8—AKR30S Switchgear Compartment, Only................................................................................................................ 17

AKD-8—Remove Glastic Sheet..................................................................................................................................................................... 18

AKD-8—Modify Bracket................................................................................................................................................................................... 18

Install AKD-8—Retrofill ....................................................................................................................................................................................... 19

AKD-8—Racked-In.............................................................................................................................................................................................. 22

AKD-8—Install Accessories............................................................................................................................................................................... 23

AKD-8—Secondary Disconnects, Bullets................................................................................................................................................. 23

Procedures ....................................................................................................................................................................................................... 24

Wire Secondary Disconnect Assembly—AKR30/30H/50/50H/30L/30S.............................................................................. 26

AKD-8—Programmer Disconnects............................................................................................................................................................. 27

Wiring and Completion...............................................................................................................................................................................30

AKD-8—Primary Disconnects (Contacts) or “Fingers”....................................................................................................................... 30

Remove and Replace................................................................................................................................................................................... 31

Mechanical Views ......................................................................................................................................................................................... 33

AKD-8—Position Switch Actuator ............................................................................................................................................................... 34

AKD-8—Shutter Actuation.............................................................................................................................................................................. 35

Install Door Interlock System.......................................................................................................................................................................... 35

AKD-8—Key Interlock........................................................................................................................................................................................ 36

Modify AKD-8—Switchgear Compartment............................................................................................................................................. 37

Cut Power to AKD-8—Switchgear.......................................................................................................................................................... 37

Rack Out AKD-8—Legacy/Existing CB ................................................................................................................................................. 37

Check, Clean, Grease AKD-8—Compartment .................................................................................................................................. 37

Install New Door ................................................................................................................................................................................................. 37

Install AKD-8—Neutral Rogowski Current Transformer (CT)......................................................................................................... 38

AKD-8—Neutral Disconnect Assembly..................................................................................................................................................... 38

AKD-8—Neutral Disconnect Assembly, Bus Compartment............................................................................................................ 38

AKD-8—Rogowski Assembly Part Numbers........................................................................................................................................... 39

AKD-8—Rogowski Assemblies, Mechanical Views.............................................................................................................................. 39

AKD-8—Multi-Source Ground Fault ...........................................................................................................................................................41

Wiring Diagram for the AK/AKR Retrofill.................................................................................................................................................. 42

Notes.............................................................................................................................................................................................................................

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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 Retrofil 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

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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

EntelliGuard

TripUnit

EntelliGuard

Standards

Agency Certification

Standard Number

Title

ANSI C37,13,16,17,20,50

Low-Voltage AC Power Circuit Breakers

NEMA SG 3,5

Low-Voltage Power Circuit Breakers

NEMA AB1

UL 1066

Low-Voltage AC and DC Power Circuit Breakers Used in Enclosures

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Document Conventions

Topics and text are divided into primary, secondary, and tertiary paragraph headings.

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

Service and support always available from GE Energy.

Estimated Time to Complete Tasks

It takes about 20 minutes to install the assembly, but the time for replacing neutral CT in the switchgear does not include the 20-minute timing claimed for the roll-in replacement.

Description

Product Specs

Weight (lbs)

Retrofill Breaker

Weight

Box Weight 10101653P1

Pallet 10101650P1 Wt

Accessories

Total

Weight

AKR30S

184

235

Retrofill Breaker

Weight

Pb2 Large Frame Box Wt

10101653P1

Pallet 10101513P1 Wt

Accessories

Total

Weight

AKD8

277

330

Retrofill Breaker

Weight

Box Weight 10101655P1

Pallet 10101650P1 Wt

Accessories Wt

Total

Weight

AKR30S

184

221

AKD8

277

314

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Views

General Electric AKD-8 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 defined as a draw-out breaker. Figure 1 (front and back views with finger clusters) presents an AKD-8 EntelliGuard R Retrofill breaker, permanently encased in a cassette-like structure.

Figure 1. AKD-8—AKR30H\50H Breaker in Cassette (Front View)

The EntelliGuard R Circuit Breaker is suitable for application on power systems up to 635 VAC 50/60 Hz systems and up to 1000 Vdc as a main/source breaker, feeder breaker, bus coupler, or tie breaker.

History and Types

AKD

AK — Power Circuit Breaker Equipment D — Drawout circuit breaker construction

Manufactured from 1951 to 1975, the breakers had these characteristics:

• All bolted

• Copper bus design

• All drawout-breakers—AK-1, —2, —3,—15 / 25 / 50 / 75 / 100

• 4000A-max bus rating

• 4 levels of bus

• Ring-bus used in all feeder sections

• Main bus with provisions for future extension

• Sections in outdoor construction, which did not line up in the front

• Indoor construction, with extended frames, allowing the section fronts to line up

• Indoor depths of 49" (225 / 600A breakers)

• Indoor depths of 59" (1600A breakers)

• Indoor depths of 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.

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AKD-8—AKR30H, AKR30L, AKR50H, AKR30S

The AKD-8 was produced from 1981 to 1999. Models 1 and 2 have extruded vertical buses. Model 2 was introduced in 1983 to accommodate automated wiring programs and harness routing. Model 3 was introduced in 1991, using a flat bar, vertical bus. AKR breakers use MicroVersaTrip 9, RMS9, EPIC, MVT Plus, MVT PM trip-units. The aluminum bus was removed from design in 1996 in favor of the standard tin-plated, copper bus (silver plating optional). Field convertible space compartment design was added to allow empty compartments to be modified for functioning breaker compartments without modifying the vertical bus.

AKD-8—Retrofilll Breaker

AKD-8—Mechanical Drawings

The following engineering or assembly drawings describe the layout and dimensions of the AKD-8 Retrofilll breaker (DWG 1, DWG 2, and DWG 3).

DWG 1. AKD-8—AKR30/30H—Retrofill Breaker, Dimensioning

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DWG 2. AKD-8—AKR30S—Retrofill Breaker, Dimensioning

DWG 3. AKD-8—AKR50/50H/30L—Retrofill Breaker, Dimensioning

AKD-8 Compartment

Interior View

The figures (Figure 2) and (Figure 3) below present a new AKD-8 compartment, with one photo showing the rails extended.

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Figure 2. AKD-8—(new) Empty Lower Compartment, View 1

Figure 3. AKD-8—(new) Empty Lower Compartment, View 2, Racks/Rails Extended

Figure 4 is a photo of the interior of the AKD-8. The photos point out the shutter assembly and telescopic rails

in the AKD-8.

Figure 4. AKD-8—Compartment Assemblies

Interior Components

Figure 5 points out the major components of an AKD-8 compartment.

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Figure 5. AKD-8—Circuit Breaker Compartment (22-Inch) for AKR-30/50/T50 Breakers

Unpack CB

• 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.

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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.

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

Quality Assured

All EntelliGuard R circuit breakers have been designed and manufactured to the highest technical standards. Strict procedures ensure first class product quality.

Information Check Sheet

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 Catalogue Serial Numbers

Product and catalogue 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.

Environmental Conditions

This indicates failure to comply with these instructions may result in product damage.

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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 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 and damaging the

breaker (Figure 6).

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.

Figure 6. AKD-8—On Lifting Truck or Fork Lift (with Some CB Assemblies Identified)—AKR30S (left) and AKR30H (right)

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Store Circuit Breaker

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.

If you decide not to install the Retrofilll breaker until a later time, then you can store it away for installing it later.

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 damage to

any of the breaker parts. Do not remove any protective grease until the assemblies 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.

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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 rack-out 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 (Figure 7).

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Figure 7. AKD-8—Primary Contacts or “Fingers” (Apply Grease)

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Modify Retrofill

WIRING

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

• Wires with wire markers are provided on the retrofil. 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-8—AKR30S Switchgear Compartment, Only

• 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.

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AKD-8—Remove Glastic Sheet

Figure 8. Remove Glastic Sheet

The AKD-8 AKR30S switchgear compartments (22" by 30" by 38") need this particular attention. The glastic sheet has to be removed (Figure 8).

In some cases, however, it is possible that this sheet is not secured to the top of the cabinet properly, and was found to sag around the middle of the cabinet. This could lead to the sheet interfering with secondary disconnects. Removing the glastic sheet does not require any tools, but you need to exercise the caution while removing the glastic sheet to avoid contact with compartment mounted secondary disconnects. After removing the glastic sheet, discard it.

AKD-8—Modify 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.

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Figure 9. Modify Bracket

Steps for removing the bracket pin:

1. Remove the left bracket assembly (75C149309G061) from compartment (Figure 9). The assembly is bolted to the side sheet. Four fixing bolts assembled can be removed by the service technician. For this task, a socket head wrench or a normal wrench, used for fastening hex bolts, is required.

2. Remove the pin from the bracket (75A106208P204). The pin is riveted from the inside and has to be drilled from the same side. Removing the bracket is necessary.

3. Note that assembly must be done by a trained service technician only.

4. Apply corrosion resistance treatment to the exposed metal after removing the pin.

5. Reassemble the bracket assembly and scrap or discard the pin.

Install AKD-8—Retrofilll

• 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 and the compartment modified, the pre-wired Retrofilll breaker can now be installed in the AKD-8 switchgear.

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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 Retrofilll breaker in the switchgear.

4. Get a hand-crane and wheel it over to the breaker (or use a forklift, Figure 10 and Figure 11). 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.

Figure 10. AKD-8—Using a Forklift, AKD-8 CB, Front View

Figure 11. AKD-8—Using a Forklift, AKD-8 CB, Top View

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 eye bolt provided with the circuit breaker, instead of hooks.

6. Make sure that the crane lifting hooks are secured and locked in place on the breaker if the fork lift is not being used.

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 Retrofilll 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 a 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 to the disconnect position of the legacy breaker. (Note that the pins must line up with the slots on the rails.)

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.

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14. Lock the rails of the legacy compartment to ensure inner and outer rail movement. This will help secure the Retrofill EntelliGuard into the compartment.

15. Remove the racking tool (Figure 12) from the storage location on the Retrofilll front panel and grab the handle.

Figure 12. AKD-8—Racking Tool

16. Take a blade-type screwdriver, insert it in the slot or rack-out lock of the breaker (Figure 13), 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.

Figure 13. AKD-8—Racking Tool and Screwdriver Inserted

Inserting the racking handle:

• First, insert a blade screwdriver in the righthand slot and rotate it 45° to the right.

• Then, while holding the screwdriver torqued to the right, insert the racking tool in the left slot until it engages with the machanism inside.

• After the racking tool engages,

remove the screwdriver.

17. After turning the screwdriver to the right with the shutter sliding to the right, remove the screwdriver and insert the racking tool (Figure 13) in the handle-insertion hole. It’s located on the left side. Insert this tool so it that grabs or engages the racking mechanism inside the hole. Once the racking tool has been properly engaged, the screwdriver can be disengaged.

18. 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 Retrofilll starts to move in, slowly sliding forward into the compartment. Rotating clockwise racks the circuit breaker all the way into the enclosure.

19. As the breaker approaches the TEST position, check the alignment of the fixed and moving parts of the secondary circuit isolating contacts.

20. Continue to rack in the breaker using the Entelliguard racking handle. Continue rotating the racking handle clockwise until the position indicator first shows TEST, then CONNECTED.

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

22. 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.

23. 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.

AKD-8—Racked-In

The photo below show only one example of a racked-in AKD-8 Retrofill (Figure 14).

Figure 14. AKD-8—AKD-8 Racked-In CB

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AKD-8—Install Accessories

WIRING

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

• Wrong connections will cause the

breaker to malfunction.

AKD-8—Secondary Disconnects, Bullets

This section deals with installing and wiring the legacy secondary disconnect assemblies onto the Retrofill EntelliGuard ACB. Installing the secondary disconnect assembly consists of doing these tasks:

• Installing the secondary disconnect assembly (bullets, shown in Figure 15, below)

• Wiring the secondary disconnect assembly (bullets, shown in Figure 15, below)

The Retrofill EntelliGuard ACB has these two options:

• All secondary disconnects installed

• No secondary disconnects installed

In case the application requires installing all 3 secondary disconnect blocks (actually, three sets of bullets), you would select the first option. As secondary disconnects can be pre-installed on the breaker, wiring the secondary disconnects can be done.

In case the application does not

require any secondary disconnect assemblies, take the second option. Thus,

no further wiring is needed.

If the application requires less than 3 secondary disconnect blocks, the customer can choose the second option, order the secondary disconnect blocks as needed, and then install the secondaries, completing the wiring for the Retrofill EntelliGuard ACB. These options are discussed in the next sections.

Secondary Disconnect Assemblies

P/N 10105366G1

Retrofill Sec Disc Assy AKR

AKD8

P/N 10099265G2

FIXED SD ASSEMBLY

AKD8

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24 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

Figure 15. AKD-8—Seven Bullets to a Block, Three Blocks

Entelliguard ACB secondary disconnect system:

Procedures

Figure 16. AKD-8—Seven Bullets to a Block, Three Blocks (Exploded View)

Along with this the secondary disconnect block assemblies (Figure 16, above) for the AKD8 version of the EntelliGuard Retrofill ACB can be purchased and installed. Here’s how to install:

1. Unpack the secondary disconnect block from the box. The kit comes in just one box. Each kit of secondary disconnect has 4 fixing nuts, plain washers, and spring washers. These can be arranged on a work station for preparing to install the secondary disconnect blocks.

2. Check that the bullets, on top of the secondary disconnects, are not damaged and that they are freely sliding in and out of their individual cylindrical cells, block-by-block. The bullets are spring-loaded and retracts to their initial positions if they are released from their pressed conditions. It is recommended that all 21 bullets be tested. Normally, just a visual check is enough for checking non-functioning bullets.

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25 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

3. Check for electrical continuity between the bullets on one end and the wire terminations on the other. In other words, a wire provides the electric connection between the secondary disconnects of the legacy bullets and the secondary disconnects on the EntelliGuard ACB. A multimeter may be used.

4. Replace bullet blocks that are found with faulty bullets. Even with only one non-working bullet, replace the whole

block of bullets.

5. 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.

6. Allign the 4 studs at the base of the supplied block to the 4 holes on the said plate. The plate is provided with 3 sets 4 of holes, one each for A, B, and C blocks respectively.

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

8. Secure the studs on to the fixing plates using the hardware provided as mentioned above. The nuts must be tightened handtight.

9. Check that the wire markers are clearly visible and not damaged so that wiring connections are done correctly and easily (Figure 17 and Figure 18).

WIRING

• Do not pinch/damage the wires while installing the secondary disconnect blocks.

Figure 17. AKD-8—Seven Bullets to a Block, Three Blocks to a Retrofill (Photo View)

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26 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

Figure 18. AKD-8—Landed Wiring (Photo View)

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

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

If the secondary disconnect blocks are installed at the customer site, the wires will not have been 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 ensured that the wires are securely fixed on the inside metal frame of the Retrofilll kit using sticky pads and tie-wraps.

Verify that the the wire routing is not exerting pressure on bullets because this can bend the connection points and effect biasing and contact pressure. By using tie-wraps and stickpads, wire routing can eliminate sagging of the wire harness and pressure on secondary bullets.

Once the above mentioned steps are completed, landing of the wires to the points on the EntelliGuard ACB secondaries can begin, based on the typical wiring diagrams found in Figure 19 and Figure 20.

Figure 19. AKD-8—Secondary Disconnects Wiring Diagram (Example for AKR30/30H/50/50H/30L)

Figure 20. AKD-8—Secondary Disconnects Wiring Diagram (Example for AKR30S)

• Tools needed: Philips Head screw driver, M6 spanner, wire strippers, wire cutters.

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27 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

AKD-8—Programmer Disconnects

WIRING

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

• Wrong connections will cause the

breaker to malfunction.

The programmer disconnect consists of 2 assemblies, one mounted on the breaker side and the other mounted on the cabinet. The breaker side assembly consists of the mounting bracket and plug assembly. The compartment side assembly consists of the plug assembly mounted on a spring-loaded assembly that receives the breaker.

WIRING

• Note: Look for the wiring connection scheme on the existing or old terminal block and use the same references or wiring info while re-wiring the new terminal block..

Procedures

1. Identify the existing programmer disconnect assemblies in the compartment.

The existing programmer disconnect plugs used in AKD-8 generation of the AKR breakers are provided on the right side for the AKR30/30H/50/50H/30L and on the left side for the AKR30S retrofits.

Programmer disconnects are provided with legacy AKR breakers in AKD-8 LVS. The breakers were equipped with the following pin configurations, depending on the application:

• 9-pin configuration

• 12-pin configuration

• 24-pin configuration

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28 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

2. Identify the type of programmer disconnect assemblies to be installed with retrofit kit.

The programmer disconnect assembly to be assembled depends upon the type of breaker the retrofil is replacing. These are as follows:

• AKR30/30H/50/50H/30L—In these, the programmer disconnect is mounted on the left side wall of the retrofil.

• AKR30S—In these, the programmer disconnect is mounted on the right side wall of the retrofil.

Programmer disconnect assemblies are available in two configurations for the Retrofill EntelliGuard ACB, namely:

• 12-pin configuration—If the legacy LVS has a 12-pin programmer disconnect in use, the same can be used with the Retrofill EntelliGuard ACB. In this case, only the breaker side programmer disconnect assembly on the breaker needs to be installed. The numbers for the programmer disconnects are mentioned below.

12-Pin Programmer Disconnect Breaker Side

P/N 10105385G1

PROG.DIS.ASSY, AKD8

AKR30H/ 50H AKD8

P/N 10105651G1

PROG. DIS. ASSY

AKR30S

19-Pin Programmer Disconnect Breaker Side

P/N 10108733G1

PROG.DIS.ASSY, AKD8

AKR30H/ 50H AKD8

P/N 10108732G1

PROG.DIS.ASSY, AKR30S

AKR30S

• 19-pin configuration—If the legacy LVS doesn’t have a 12-pin programmer disconnect configuration, and the customer chooses to install a programmer disconnect, then the 19-pin programmer disconnect assembly needs to be installed in the compartment and the breaker.

19-Pin Programmer Disconnect Breaker Side

10108733G1

PROG.DIS.ASSY, AKD8

AKR30H/ 50H AKD8

10108732G1

PROG.DIS.ASSY, AKR30S

AKR30S

19-Pin Programmer Disconnect Compartment Side

10108801G1

PROGRAMMER DISC ASSY

AKR30H/ 50H AKD8

10109176G1

PROGRAMMER DISC ASSY

AKR30S

3. If applicable, remove the existing compartment side programmer disconnect assembly.

The programmer disconnect assembly must be removed, if:

• A 9-pin programmer disconnect assembly is installed in the cabinet.

• A 24-pin programmer disconnect assembly is installed in the cabinet.

• Customer chooses to replace a 12-pin configuration with a 19-pin configuration.

4. Before uninstalling the existing programmer disconnect assembly, verify that the wiring details are match the wiring numbers. Any changes or deviations need to be noted for use while installing the new programmer disconnect.

5. Check that the compartment is de-energized and is safe to work in; and that the original or legacy breaker has been removed form the cabinet.

6. Disconnect the wires connecting the terminal block to the compartment programmer disconnect assembly. See Figure 21.

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29 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

7. If the customer has chosen to install a 19-pin programmer disconnect assembly, replacing a 12-pin programmer disconnect assembly, the terminal block mounted on the compartment needs to be removed as well. This can be achieved by unfastening the two screws securing the terminal block with the side wall of the compartment.

8. Unfasten the four bolts included that the that hold the programmer disconnect assembly on the wall of the compartment to remove the compartment-side programmer disconnect assembly.

Figure 21. AKD-8—Loosen Hardware for the Programmer Disconnect Assembly

9. Install applicable programmer disconnect assembly on compartment and breaker.

• Wiring and completing task:

Install 19-pin programmer disconnect assembly on compartment and breaker:

1. Unpack the 19-pin programmer disconnect assembly from the box. Each box of the programmer disconnect assemblies has a 20-pin terminal block supplied.

2. Check that the secondary disconnect plug assembly is not damaged and the wiring is intact.

3. Check that the programmer disconnect block is moving freely within the assembly and retracts to its

original position by spring-loading when it is slid back to the fully activated condition.

4. Check for electrical continuity between the contact pins on one and and the wire termination on the other. Blocks containing faulty bullets should not be used for installation.

5. Install the new terminal block on the side wall of the the compartment and land the incoming wires from the compartment to the terminal block. Any additional wires from the compartment side which

are

required for the 19-pin programmer need to be landed on the terminal block and checked for electrical continuity.

6. Mount the programmer disconnect assembly on the side wall of the compartment where the original programmer disconnect assembly was mounted.

7. Land the wires from the programmer disconnect to the terminal block mounted earlier.

8. Using a multimeter, check for continuity between the terminal block contact points to the corresponding

pins on the programmer disconnect. This should match against the wiring scheme planned for the new 19-pin programmer disconnect assembly on the compartment.

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30 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

Wiring and Completion

1. Note he breaker side programmer disconnect assemblies come pre-installed and wired from the factory.

So, no action is needed to be done on the breaker.

2. Check that the compartment side programmer disconnect assembly wiring scheme matches that of the breaker side wiring scheme.

3. See the wiring diagram used for the programmer disconnect as shown here (Figure 22):

Figure 22. AKD-8—Typical Programmer Disconnect Wiring Scheme

Top row—Terminal numbering on programmer disconnect Bottom row—Terminal numbering for A & B secondary disconnects of the EntelliGuard breaker

• Tools required: wrenches, flat head screw driver, wire stripper, wire cutter, star-type screw driver

AKD-8—Primary Disconnects (Contacts) or “Fingers”

The Accessory Retrofill Doors Assembly manual DEH-41563 covers the primary disconnects or fingers.

The primary disconnects are flexible connections between the breaker line and load terminals and between the equipment line and load terminals. All primary disconnect fingers are factory-installed and are assembled on EntelliGuard R Retrofill circuit breakers. Use this instruction sheet if damaged fingers need to be replaced. It takes about 5 minutes to install a finger cluster, defined as a double pair of fingers on a breaker.

Figure 23 shows finger clusters or primary disconnects on a retrofill circuit breaker. Figure 24 details the

finger-cluster assembly.

Figure 23. Circuit Breaker Removed, Featuring Primary Disconnects “Fingers” (Contacts)

Figure 24. Circuit Breaker, Fingers (Some Details)

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31 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

Remove and Replace

The primary disconnect assembly is factory-adjusted with a gage to apply a 105-lb force to a 1/2-inch thick copper bar, inserted between the upper and lower fingers. Set this force range, in the field, by tightening the nuts to set the spring dimension shown in Figure 25. Note that this dimension is measured between the top of the retainer and the underside of the washer. Also note that no bar is inserted between the fingers when setting this dimension. Figure 26 calls out cluster components.

Figure 25. Adjustment

Figure 26. Components

1. Using proper safety procedures and wearing required Personal Protective Equipment (PPE), remove

breaker from compartment, and place it on a solid work surface in a well-lit location.

2. To uninstall the primary disconnects, remove the two nuts from one of the long bolts holding the primary disconnect assembly together.

3. Carefully slide out the bolt while removing the flat washer, spring, bushing, upper retainer, bow-tie spacers, lower retainer, and fingers from the bottom of the assembly.

4. Do the same for the other assembly bolt and components.

5. Slide off the retainer clips.

6. Take off the main retainer from the stud.

7. Slide the main retainer over the stud.

8. Install eccentric spacer and position spring clips on the stud.

9. Set a pair of bow-tie spacers into a pair of fingers, place a pressure plate retainer over the spacers to

hold them in position, and then turn the subassembly over. Hook them into the main retainer.

10. Slide a long bolt through the hole in the retainer, between the finger, and then through the clip and eccentric stud spacer.

11. Hold the bottom finger subassembly in place.

12. Place two fingers around the bolt from the top, hooking the fingers into the main retainer. Then place a

bow-tie spacer in each finger and hold them in position with a pressure plate retainer.

13. Place a spring, bushing, and flat washer over the bolt, then secure with the two nuts.

14. Do Steps 7 through 13 for each set of fingers.

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32 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

15. Adjust the nut to get a spacing of 0.766—0.797 inch between the top of the upper retainer and the bottom of the flat washer.

16. Tighten the jam nut to lock in the adjustment.

17. Clean finger assemblies, if necessary, with a clean, lint-free rag and isopropyl alcohol or acetone.

18. Be sure to apply a thin film of Mobilgrease 28 (D50HD38) to the contact areas which slide onto the

switchgear stabs (See Figure 27, Step 2). This product is available in a 1-oz tube, GE Part #193A1751P1.

Figure 27 summarizes the steps for working with the primary contacts.

Figure 27. Steps in Exploded Views

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Mechanical Views

Figure 28 provides further details.

Figure 28. Fingers or Clusters, Mechanical View, and Notes

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AKD-8—Position Switch Actuator

Position switch actuator comes pre-installed on all versions of Retrofill EntelliGuard ACB. Hence, no installation is required. Retrofills provide the same electrical indication scheme as the legacy breakers (Figure

29).

Compartment Position Switch Assemblies

0343L0881

AKR30S

0343L690G1

AKR30/30H/30L/50/50H

• A customer can choose to install a position switch if it’s not already installed, although this is infrequent, or the existing assembly is damaged.

Figure 29. Breaker Surfaces Activate Position Switch.

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35 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

AKD-8—Shutter Actuation

AKD-8 LVS comes installed come with shutter assemblies for protection of the live bus bars. Retrofill EntelliGuard ACB comes pre-installed with shutter (Figure 30) actuators which operate the opening of the shutters. Hence, no installation is required. Retrofills provide the same mechanical indication scheme as legacy breakers.

Figure 30. AKD-8—Breaker Surfaces Activate Shutter

Install Door Interlock System

• 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.

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36 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

Figure 31 shows the components that make up the AKD-8 retrofill door interlocking assembly.

Figure 31. AKD-8—Door Interlocking Components

AKD-8—Key Interlock

After the switchgear equipment is first installed, all necessary interlock keys should be inserted into the appropriate locks and all spare keys should be placed in the hands of a responsible person. Refer to the key interlock schematic included in the summary furnished with the equipment. You can then determine the sequence of operation and correct number of operating keys required. This precaution is necessary since improper use of spare keys defeats the interlocking scheme. There are many other interlocking lockout and tag-out combinations. Some use two or more keys.

Door Interlock Assemblies

P/N 75C149377

Door Interlock Assembly

AKD8

P/N 75C149377

Door Interlock Assembly

AKR30s

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Modify AKD-8—Switchgear Compartment

Cut Power to AKD-8—Switchgear

• 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 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 AKD-8—Legacy/Existing CB

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.

Check, Clean, Grease AKD-8—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.

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.

Install New Door

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 Retrofilll Door Assemblies, DEH-41563.

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Install AKD-8—Neutral Rogowski Current Transformer (CT)

• 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.

AKD-8—Neutral Disconnect Assembly

SKUs

Breaker side

Compartment Side

Outline No

LCS Compt

Interface

AKR AKD8

P/N 10106054G1

10108266G1

139C5016

0343L0806G2

AKR30S

P/N 10107106G1

10108216G1

568B220

569B243-0020

Figure 32 shows an exploded view of the breaker side neutral disconnect assembly for the AKD-8

AKR30/30H/50/50H/30L and AKR30S Retrofillls. These are available pre-installed and wired from the factory.

Figure 32. AKD-8—Neutral Disconnect Assembly for the AKR30H\50H Retrofill

AKD-8—Neutral Disconnect Assembly, Bus Compartment

The AKD-8 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 Retrofilll 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.

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39 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

The Rogowski CT comes mounted on copper bars matching the same hole-pattern as the existing neutral bar. The existing wires and hardware can be reused if they are not damaged. Note, if existing wires need to be replaced, then a continuous wire runs from the CT to the Neutral Disconnect in the cubicle. If the threads on the hardware have got wornout, they need to be replaced with new ones before installation.

AKD-8—Rogowski Assembly Part Numbers

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

Breaker/Switchgear

Rogowski Assembly or

Neutral Bus Bar

Part Number

Figure References for Assembly Drawings

AKR30S

10108216G1

Figure 33. Neutral Bus Rogowski ASM 10108216

AKR AKD8

10108266G1

Figure 34. Neutral Bus Rogowski ASM 10108266

AKD8 600A

10108266G2

Figure 34. Neutral Bus Rogowski ASM 10108266

AKD8 800A

10108266G3

Figure 34. Neutral Bus Rogowski ASM 10108266

AKD8 1000A

10108266G4

Figure 34. Neutral Bus Rogowski ASM 10108266

AKD8 1200A

10108266G5

Figure 34. Neutral Bus Rogowski ASM 10108266

AKD8 1600A

10108266G6

Figure 34. Neutral Bus Rogowski ASM 10108266

AKD-8—Rogowski Assemblies, Mechanical Views

Figure 33 and Figure 34 show three Rogowski assemblies, each identified with a unique ASM

part number.

Figure 33. Neutral Bus Rogowski ASM 10108216

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40 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

Figure 34. Neutral Bus Rogowski ASM 10108266

Procedures

PRODUCT DAMAGE

• Write down the orientation of the existing Iron

core CT and the polarity of the connections. The orientation and polarity needs to be matched when the air core Rogowski is assembled in the cable compartment.Do not allow the circuit breaker to hit a hard surface while handling.

1. Ensure 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 access the Cable/ Bus compartment of the LVS

3. Note that he 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 such that they do not interfere with the replacement of the CT assemblies.

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

6. Be careful while handeling the CT assemblies such that they do not fall down or damage other components within the LVS.

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41 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

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 wire, 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.

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

• Tools required

: Wrenches, wire stripper, wire cutter, continuity tester.

AKD-8—Multi-Source Ground Fault

Retrofillls 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.

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42 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12

Wiring Diagram for the AK/AKR Retrofill Notes

Page 44

Page 45

GE Energy

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

imagination at work

DEH-41549 02/12