GE Industrial Solutions EntelliGuard R AKD-8 User Manual
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
1 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12
Table of Contents
Preface............................................................................................................................................................................................................................3
Hazards......................................................................................................................................................................................................................3
Danger...................................................................................................................................................................................................................3
Warning................................................................................................................................................................................................................4
Caution..................................................................................................................................................................................................................4
Notice or Note....................................................................................................................................................................................................5
Warranty...................................................................................................................................................................................................................5
Trademarks and Patents ...................................................................................................................................................................................5
Standards..................................................................................................................................................................................................................5
Document Conventions......................................................................................................................................................................................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
2 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12
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
Procedures ....................................................................................................................................................................................................... 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
Procedures ............................................................................................................................................................................................................ 40
AKD-8—Multi-Source Ground Fault ...........................................................................................................................................................41
Wiring Diagram for the AK/AKR Retrofill.................................................................................................................................................. 42
Notes.............................................................................................................................................................................................................................
43
3 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 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 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
4 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 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-8 Installation Manual DEH-41549 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
®
TripUnit
EntelliGuard
®
G
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
6 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12
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
Wt
Total
Weight
AKR30S
184
16
33
2
235
Retrofill Breaker
Weight
Pb2 Large Frame Box Wt
10101653P1
Pallet 10101513P1 Wt
Accessories
Wt
Total
Weight
AKD8
277
18
33
2
330
Retrofill Breaker
Weight
Box Weight 10101655P1
Pallet 10101650P1 Wt
Accessories Wt
Total
Weight
AKR30S
184
11
24
2
221
AKD8
277
11
24
2
314
7 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12
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.
8 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12
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
9 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12
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.
10 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12
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.
11 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 02/12
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.
12 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 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.
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.
13 EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual DEH-41549 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 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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