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GE EntelliGuard AKR-30-800, Installation Manual

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GE EntelliGuard AKR-30-800 Installation Manual Download Page 7

 

6  

EntelliGuard R Circuit Breaker Retrofill AKD-8 Installation Manual          DEH41549 R05

 

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-in. No warranties of merchantability or fitness for purpose shall apply. 

Contact your local sales office if further information is required concerning any aspect of EntelliGuard R 
Circuit Breaker operation or maintenance. 

Trademarks and Patents 

EntelliGuard* R 
EntelliGuard* TU 
EntelliGuard* Trip Unit 
EntelliGuard* G 

Standards 

Agency Certification 

Standard Number 

Title 

ANSI C37.13,16,17,20.1,50,51,59 

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 

Summary of Contents for EntelliGuard AKR-30-800

Page 1: ...y also be part of a single ended or double ended load center unit substation This manual applies to EntelliGuard R breakers to be used in AKD 8 Switchgear substructures found in OEM Equipment and GE Switchboards using legacy AKR circuit breakers of the following types 800 2000A AKR D 30 50 T50 circuit breakers in all Equipment types 3200 4000 5000A AKR D 75 100 125 for AKD 8 switchgear AKR B 75 10...

Page 2: ...Specs 7 Weight lbs 7 Views 8 History and Types 9 AKD 9 AKD 5 AK 25 AK 50 AKT 50 AK 75 AK 100 9 AKD 6 AKR 30 30H AKR 50 50H T50H AKR 75 75H AKR 100 9 AKD 8 AKR 30 30H 30L AKR 50 50H T50H AKR 75 75H AKR 100 AKR125 10 AKD 10 WPS 08 WPH 08 WPX 08 WPS 16 WPH 16 WPS 20 WPS 32 WPH 32 WPX 32 WPS 40 WPX 40 WPS 50 WPX 50 10 AKD 8 Retrofill Breaker 11 AKD 8 Breaker Models 11 AKD 8 Mechanical Drawings 13 AKD ...

Page 3: ...ts 31 Wire Secondary Disconnect Assembly AKR30 30H 50 50H 30L 30S T 50H 36 AKD 8 Programmer Disconnects 38 Procedures 38 Wiring and Completion 41 AKD 8 Primary Disconnects Contacts or Fingers 41 Remove and Replace 42 Mechanical Views 44 Remove and Replace AKR 75 100 125 45 Mechanical Views AKR 75 100 125 48 AKD 8 Position Switch Actuator 48 AKD 8 Shutter Actuation 51 Install Door Interlock System ...

Page 4: ...3 EntelliGuard R Circuit Breaker Retrofill AKD 8 Installation Manual DEH41549 R05 AKD 8 Neutral CT Adapter 400A 5000A 57 Procedures 58 AKD 8 Multi Source Ground Fault 59 ...

Page 5: ...avoided results in death or serious injury A variety of electrical hazards warnings are displayed here and are applied to installation manuals These are standard or generic alerts and labels that must be taken quite seriously when installing Retrofill circuit breakers in AKD switchgear and when working with potentially dangerous electrical equipment Table 1 There are also dangers pertaining to pro...

Page 6: ...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 a...

Page 7: ...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 in No warranties of mercha...

Page 8: ... 8 hrs depending on the complexity of the original breaker Once the retrofill breaker is fully prepared it should take about 20 minutes to swap out the old breaker and rack in the new EntelliGuard R retrofill circuit breaker if the proper lifting bar and hoist are available The EntelliGuard R retrofill when ordered with 4 wire ground fault will be equipped with a Neutral CT adapter The adapter wil...

Page 9: ...it breaker in a steel frame installing primary and secondary disconnects and driving drawout racking cams thru what looks like the EntelliGuard G Cassette s front dashboard Figure 1 AKD 8 AKR30H 50H Breaker in Cassette Front View Figure 1A AKD 8 AKR75 75H 100 125 Breaker in Cassette Front View The EntelliGuard R Circuit Breaker is suitable for application on power systems up to 635 VAC 50 60 Hz AK...

Page 10: ...kers ring silver plating on copper and aluminum bus un plated welded connections The switchgear is painted sand gray beige with some instrument doors painted blue AKR 30 50 in 22 wide sections were introduced in AKD 5 construction early 70s AK25s and AK50s were also available as substructure kits for OEMs to build around customer gear Note All legacy AK AKR breakers have a draw out letter code A E...

Page 11: ...ve a drawout letter code D OEM versions are drawout letter code B and GE Switchboard versions are drawout letter code F B F breakers only differed by appearance items All Primary disconnect stabs are vertically oriented The AKR 125 is a 5000A breaker that had cooling fan It was release in 1995 None of the retrofill breakers utilize fans EntelliGuard R breakers with a catalog number beginning with ...

Page 12: ...ers Feature Model 1 Retrofill Breaker 800 1600A Model 2 Retrofill Breaker 800 1600A 2000A except AKR 30S Secondary Disc Bullet mounting Secondary disconnect bullets mounted on spring loaded bracket assembly Secondary disconnect bullets mounted directly on metal bracket Kirklock Actuator Not provided Kirklock Mechanism to achieve kirklock feature through existing compartment installed kirklock leve...

Page 13: ... AKR125 Feature Retrofill Breaker 3200 5000A Secondary Disc Bullet mounting Secondary disconnect bullets mounted directly on metal bracket as on the legacy AKR breakers Kirk lock Actuator Compartment Release lever AKD 8 compartment Kirk lock can lockout all 3200 5000A EntelliGuard R types Compartment Release Lever Kirk lock Interface ...

Page 14: ... AKD 8 Mechanical Drawings The following engineering or assembly drawings describe the layout and dimensions of the AKD 8 Retrofill breaker Figure 2 Figure 3 Figure 4 Figure 5 Figure 2 AKD 8 AKR30 30H Retrofill Breaker Dimensioning Figure 3 AKD 8 AKR30S Retrofill Breaker Dimensioning ...

Page 15: ... Breaker Retrofill AKD 8 Installation Manual DEH41549 R05 Figure 4 AKD 8 AKR50 50H 30L Retrofill Breaker Dimensioning Model 1 R3 type Figure 5 AKD 8 AKR50 50H 30L AKRT 50H Retrofill Breaker Dimensioning Model 2 R3 type R6 type ...

Page 16: ...15 EntelliGuard R Circuit Breaker Retrofill AKD 8 Installation Manual DEH41549 R05 Figure 5A AKD 8 AKR75 75H AKR 100 Retrofill Breaker Dimensioning Figure 5B AKD 8 AKR 125 Retrofill Breaker Dimensioning ...

Page 17: ...sent a Typical AKR 30 50 T50 AKD 8 compartment Figure 6 AKD 8 new Empty Compartment View 1 Figure 7 AKD 8 new Empty Compartment View 2 Racks Rails Extended Figure 8 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 8 AKD 8 Compartment Assemblies Position Switch Neutral Disconnect ...

Page 18: ...nts of an AKD 8 compartment Figure 9 AKD 8 Circuit Breaker Compartment 22 Inch for AKR 30 50 T50 Breakers Interior View The figures Figure 6A 7A 8A 9A below present a Typical 30 AKR 75 100 AKD 8 compartment AKR 125 is similar but 38 wide Figure 6A AKD 8 Empty Compartment View 1 Figure 7A AKD 8 Empty Compartment View 2 Drawout Tray Extended ...

Page 19: ...e AKD 8 The photos point out the shutter assembly and Draw out tray assembly in the AKD 8 Figure 8A AKD 8 Compartment Assemblies Interior Components Figure 9A points out the major components of an AKD 8 compartment Figure 9A AKD 8 Circuit Breaker Compartment for AKR 75 75H 100 125 Breakers Draw out Tray Assembly Locating Pins ...

Page 20: ...curing 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 s...

Page 21: ...left side viewed from front of the front fascia Remove Circuit Breaker from Container Inspect 1 Inspect the shipping container for obvious signs of rough handling and or external damage incurred during transportation 2 Record any observed damage for reporting to the carrier Ensure all recorded reports and claims include the order number and name plate information 3 Remove the banding straps and li...

Page 22: ...from entering the breaker If dampness or condensation is encountered in the storage location heaters can be used to prevent moisture damage Use Lifting Truck 1 Use a lifting truck to lift and mount the assembly to avoid personal injury and damaging the breaker 2 Contact the nearest sales office for availability of a hoisting device Check Before Installing It must be ensured that the supply power t...

Page 23: ...ing 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 DH0HD38 Mobilgrease 28 to the primary...

Page 24: ... all wiring connections are properly made Wrong connections will cause the breaker to malfunction Modify AKD 8 AKR30S Switchgear Compartment Only 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 ...

Page 25: ...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 AKR 30S Modify Bracket It must be ensured that the supply power to the compartment is turned off compartment is de energized for all the incoming and ...

Page 26: ...ly 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 Torque 20 thread forming screws to 85 in lb Install AKD 8 800 2000A Retrofill Breaker It must be ensured that the supply power to the compartment is turned off compartment is de energized for all the i...

Page 27: ... breaker OR Use GE part number 0247B8961G002 lifting bar and suitable hoist to lift from above as shown in Figure 14 Figure 13 AKD 8 Location of Eyebolts Figure 14 AKD 8 Using GE Lifting bar and hoist 6 Make sure that the lifting bar is secured and locked in place on the breaker Check that the breaker is free from obstruction inside the compartment 7 When the breaker is lined up with the compartme...

Page 28: ... right with the shutter open insert the racking tool in the handle insertion hole so that it engages with the racking mechanism and remove the screwdriver Figure 16 14 With the racking tool inserted crank clockwise so that the Retrofill starts to move in slowly sliding forward into the compartment Rotating clockwise racks the circuit breaker all the way into the enclosure 15 Rotating clockwise 37 ...

Page 29: ...breaker is in its maximum travel position At this point the primary disconnect fingers have completely engaged with the primary bus stabs 20 Remove and store the racking handle in it storage location AKD 8 Racked In The photo below shows one example of a racked in AKD 8 Retrofill Figure 17 Figure 17 AKD 8 Racked In CB ...

Page 30: ... shown in Figure 18A This lifting bar has been tested to 200 of its 700 lb rating B Alternate method use a lifting chain and hooks rated at least 1400 lbs to lift the breaker from above as shown in Figure 18B chains must not be at an angle less than 45 degrees from the horizontal plane Installation in upper compartments may not be possible with limited overhead space or using the GE switchgear hoi...

Page 31: ...er Figure 16 and turn it clockwise to the right so that the racking handle shutter opens 15 While turning the screwdriver to the right with the shutter open insert the racking tool in the handle insertion hole so that it engages with the racking mechanism and remove the screwdriver Figure 16 16 Rotating clockwise 37 turns racks the circuit breaker all the way into the compartment 17 As the breaker...

Page 32: ... the secondary disconnect assembly bullets shown in Figure 20 below Wiring the secondary disconnect assembly bullets shown in Figure 20 below The EntelliGuard R Retrofill Breaker 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 th...

Page 33: ... secondary disconnect block from the box The kit comes in just one box Each kit of secondary disconnect has 4 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 slide in to the blocks freely The bullets are spring loaded and ...

Page 34: ...sily Figure 23 and Figure 24 For Model 2 AKD8 Retrofill Breakers Figure 22 AKD 8 Seven Bullets to a Block Three Blocks Exploded View Model 2 1 If the EntelliGuard R Retrofill breaker order included 3 7 point secondary disconnect blocks see step 2 otherwise skip past the wiring instructions 2 Check that bullets on top of the secondary disconnects are not damaged and that they slide in to the blocks...

Page 35: ...turn to their initial positions when they are released from being pressed down 3 Check for electrical continuity between the bullets on one end and the wire terminations on the other Blocks containing faulty bullets should be replaced 4 Place the secondary disconnect block on top of the horizontal L Bracket at the rear of the Retrofill EntelliGuard ACB which runs across the width of the Retrofill ...

Page 36: ...AKD 8 Installation Manual DEH41549 R05 WIRING Do not pinch damage the wires while installing the secondary disconnect blocks Figure 23 AKD 8 Seven Bullets to a Block Three Blocks to a Retrofill Photo View Figure 24 AKD 8 Landed Wiring Photo View ...

Page 37: ...outed The wires should not be routed from the outside of the metal structure as it might interfere with the motion of the kit when racking into the compartment Ensure that the wires are securely fixed on the inside metal frame of the cassette using sticky pads and tie wraps or holes available in side frames Verify that the wire routing is not exerting pressure on bullets because this can bend the ...

Page 38: ...For Shunt trip 125Vdc only Use 2 NO contacts in series with coil For S T 1 use 2nd NO contact at terminals B25 B26 Jumper A21 to B25 and B26 to A5 For S T 2 use 2nd NO contact at terminals B17 B18 Jumper B20 to B17 and B18 to A12 For Shunt trip 125Vdc only Use 2 NO contacts in series with coil For S T 1 use 2nd NO contact at terminals B25 B26 Jumper A21 to B25 and B26 to A5 For S T 2 use 2nd NO co...

Page 39: ...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 information while re wiring the new terminal block Procedures 1 Identify the existing programmer disconnect assemblies in the compartment The existing programmer disconnect ...

Page 40: ...S ASSY AKR75 100 125 AKR75 100 125 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 T50H AKD8 10108732G1 ...

Page 41: ...minal 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 end and the wire termination ...

Page 42: ...rs The Finger Clusters Accessory Manual DEH 41533 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 nee...

Page 43: ...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 spri...

Page 44: ...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 33 Step 2 This product is available in a 1 oz tube GE Part 193A1751P1 Figure 33 summarizes the steps for working with the primary contacts Fig...

Page 45: ...44 EntelliGuard R Circuit Breaker Retrofill AKD 8 Installation Manual DEH41549 R05 Mechanical Views Figure 34 provides further details Figure 34 Fingers or Clusters Mechanical View and Notes ...

Page 46: ...tting this dimension Figure 36A 36B shows the cluster components Figure 35A Adjustment 3200A only Double springs Figure 36A Components 3200A Figure 35B Adjustment 4000A 5000A Figure 36B Components 4000A 5000A 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 uninst...

Page 47: ...pacer in each finger and hold them in position with a pressure plate retainer 12 Place a spring bushing and flat washer over the bolt then secure with the Adjusting nut 13 Repeat Steps 7 through 13 for each set of fingers 14 Adjust the nut to get a spacing of 0 865 0 895 inch for AKR75 75H with Double springs and 0 766 0 797 inch for AKR100 125 between the top of the upper retainer and the bottom ...

Page 48: ...47 EntelliGuard R Circuit Breaker Retrofill AKD 8 Installation Manual DEH41549 R05 Figure 37 Steps in Exploded Views AKR 75 75H Figure 38 Steps in Exploded Views AKR 100 125 ...

Page 49: ...ator 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 40 and Figure 41 and 41 A Compartment Position Switch Assemblies 0343L0881 AKR30S 0343L690G1 AKR30 30H 30L 50 50H Consult Factory AKR 75 100 125 A customer can choose to install a position switch if it s not ...

Page 50: ...49 EntelliGuard R Circuit Breaker Retrofill AKD 8 Installation Manual DEH41549 R05 Figure 40 Breaker Surfaces Activate Position Switch ...

Page 51: ...ntelliGuard R Circuit Breaker Retrofill AKD 8 Installation Manual DEH41549 R05 Figure 41 Breaker Surfaces Activate Position Switch Model 2 Figure 41A Breaker Surfaces Activate Position Switch AKR75 100 125 ...

Page 52: ... R breaker comes pre installed with shutter Figure 42 Figure 43 and figure 43A actuators which operate the opening of the shutters Hence no installation is required Retrofills provide the same mechanical indication scheme as legacy breakers Figure 42 AKD 8 Breaker Surfaces Activate Shutter Model 1 Figure 43 AKD 8 Breaker Surfaces Activate Shutter Model 2 Figure 43A AKD 8 Breaker Surfaces Activate ...

Page 53: ...ate service and maintain all electrical equipment Details regarding installation of the door interlock system are shown below in Figure 44 45 and 46 Figure 44 AKD 8 Door Interlocking Components Model 1 Racking stroke of legacy 4 25 Racking stroke of Retrofills 2 75 Racking stroke of the Retrofills is equal to that of AKR30S Same mounting bracket used for all AKR breakers in AKD8 depending on SKU t...

Page 54: ...fill door interlocking assembly Please remove the existing Door Interlock Actuators from the compartment for AKR 30 30H 50 50H AKRT 50 50H The Retrofill breaker has a Door Interlock Actuator Bracket mounted on breaker Figure below shows the Door Interlock Actuator mounted on Retrofill Breaker for AKR 30 30H 50 50H AKRT 50 50H For AKR30S please use compartment Door Interlock Actuator Door Interlock...

Page 55: ... Figure 46 AKD 8 AKR75 100 125 Door Interlocking Components Figure below shows the components that make up the AKD 8 Retrofill door interlocking assembly Figure below shows the Door Interlock Actuator mounted on Retrofill Breaker for AKR 75 100 125 Door Interlock Actuator Screw Head ...

Page 56: ...position Modify AKD 8 Switchgear Compartment Cut Power to AKD 8 Switchgear 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 th...

Page 57: ...KD 6 AKD 8 AKD 10 DEH 41563 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 standar...

Page 58: ...Bus Rogowski ASM 10108266 AKD8 600A 10108266G2 Figure 40 Neutral Bus Rogowski ASM 10108266 AKD8 800A 10108266G3 Figure 40 Neutral Bus Rogowski ASM 10108266 AKD8 1000A 10108266G4 Figure 40 Neutral Bus Rogowski ASM 10108266 AKD8 1200A 10108266G5 Figure 40 Neutral Bus Rogowski ASM 10108266 AKD8 1600A 10108266G6 Figure 40 Neutral Bus Rogowski ASM 10108266 AKD8 2000A 10108266G7 Figure 40 Neutral Bus Ro...

Page 59: ...energized and the breaker in the compartment being retrofit is 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...

Page 60: ...sed in the following ground fault applications Single Source Feeder breakers 3 wire or 4 wire Main Circuit breakers 3 wire or 4 wire For 4 wire multi source Ground Fault systems the Retrofill should be ordered with a neutral CT adapter These neutral CT adapters are compatible with MVT style neutral sensors This will allow the new breaker to operate with the existing Neutral CT in most cases Exampl...

Page 61: ...Wiring Diagram for the AK AKR Retrofill 60 EntelliGuard R Circuit Breaker Retrofill AKD 8 Installation Manual DEH41549 R05 ...

Page 62: ...61 EntelliGuard R Circuit Breaker Retrofill AKD 8 Installation Manual DEH41549 R05 ...

Page 63: ...62 EntelliGuard R Circuit Breaker Retrofill AKD 8 Installation Manual DEH41549 R05 NOTES ...

Page 64: ...fill AKD 8 Installation Manual DEH41549 R05 GE Energy Connections 41 Woodford Avenue Plainville CT 06062 www geindustrial com 2016 General Electric Company Trademark of the General Electric Company and or its subsidiaries DEH41549 R05 12 16 ...

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