ABB Legace GE AK 4000A Installation And Maintenance Manual Download

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Installation and maintenance guide

Emax 2 Retrofill Circuit Breakers

Direct/CiC Replacement of Legacy GE
AK 600A - 4000A Circuit Breakers Used in
AKD-5 & Substructures



General Electric AKD-5 Low Voltage Switchgear is a free-standing assembly of metal-
enclosed ANSI power circuit breakers. It may be a part of a single-ended or double-
ended load center unit substation.

It uses AK/AKJ/AKJT/AKS/AKST Breaker.

This manual applies to both Emax 2 Retrofill breakers for AKD-5 switchgear and OEM
substructures

Emax

2 Retrofill C

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Summary of Contents for Legace GE AK 4000A

Page 1: ...KD 5 Low Voltage Switchgear is a free standing assembly of metal enclosed ANSI power circuit breakers It may be a part of a single ended or double ended load center unit substation It uses AK AKJ AKJT AKS AKST Breaker This manual applies to both Emax 2 Retrofill breakers for AKD 5 switchgear and OEM substructures Emax 2 Retrofill Circuit Breakers Installation and maintenance guide ...

Page 2: ...RETROFILL SECONDARY WIRING 26 INSTALL POSITION SWITCH ACTUATOR AKT BREAKER RETROFILL ONLY 27 RACKING LOCK BRACKET INSTALLATION AK 25 AK50 AKT50 CABINET ONLY 28 INSTALL CASSETTE LANDED WIRES 29 INSTALL CASSETTE RAIL LEVER LOCKOUT BRACKETS AK AKT50 COMPT S ONLY 32 INSTALL AKD5 RETROFILL BREAKER 33 21 AK AKT50 Kirkey Interlock 38 22 Secondary Disconnects Bullets 39 23 Wiring diagram and Block info AK...

Page 3: ...ed here are applied to installation manuals These are standard or generic alerts labels that must be taken quite seriously when installing Retrofill circuit breakers in AKD other OEM s switchgear and when working with potentially dangerous electrical equipment Table 1 Generic Danger Alerts Warning Table 2 This indicates a hazardous situation which if not avoided would result in death or serious in...

Page 4: ...to ensure accuracy the information contained herein does not cover all details or variations in hardware and software nor does it provide for every possible contingency in connection with installation operation and maintenance Features may be described herein that are not present in allhardware and software systems ABB Inc USA assumes no obligation of notice to holders of this document with respec...

Page 5: ...ct Replacement Cradle in Cradle Full Door Kits AKD 5 6 8 10 2TSA451007P0000 Accessory Retrofill Direct Replacement Ciradle in Cradle Door Adaptor Kits AKD 5 6 8 10 2TSA451008P0000 Accessory OEM Direct Replacement Adaptor kits AKD8 10 2TSE431967R1000 Accessory OEM Direct Replacement Door Adaptor kits AKD8 10 AKR 75 100 B F TYPE 2TSE431968R1000 Accessory OEM Direct Replacement Door Adaptor kits AKD8...

Page 6: ... AKT50 is a Backless Cradle in Cradle BCiC solution using EGR cassette Views Typical Emax 2 Retrofill circuit breakers for GE AKD 5 OEM switchgear are shown below All circuit breakers are drawout types Each Retrofill is constructed by permanently joining an Emax 2 circuit breaker in a steel frame installing primary and secondary disconnects and driving drawout racking cams thru what look the Emax ...

Page 7: ...5 1600A Breaker in Cassette Fig 3 Front View Fig 4 Rear View Figure 5 6 AKD 5 2000A Breaker in Cassette Fig 5 Front View Fig 6 Rear View Figure 7 8 AKD 5 3000A Breaker in Cassette Fig 7 Front View Fig 8 Rear View Figure 9 10 AKD 5 4000A Breaker in Cassette Fig 9 Front View Fig 10 Rear View ...

Page 8: ...de welded riveted frame bus compartment barriers line load separation barriers on mains and ties isolation barriers on transformer transitions copper runbacks on feeder breakers 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 construct...

Page 9: ...rame similar to the small frame breakers The positions DISC TEST CONN are shown on the side of the front escutcheon by position of the sliding picture frame The GE AKD 8 breakers have 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...

Page 10: ...owing figures depicts the AKD5 Retrofill breakers 600 4000A AKD5 AK25 Emax 1 2 600A CiC Cradle in Cradle Retrofill Kit Figure 11 12 Fig 11 Emax 1 2 Circuit Breaker Moving Portion Fig 12 Circuit Breaker Projected from Cassette Figure 13 Retrofill Kit Figure 14 15 Fig 14 Rear View of Retrofill Kit Fig 15 Front view inside SwitchGear ...

Page 11: ...1 AKD5 AK50 Emax 2 2 1600A CiC Cradle in Cradle Retrofill Kit Figure 16 17 Fig 16 Emax 2 2 Circuit Breaker Moving Portion Fig 17 Circuit Breaker Projected from Cassette Figure 18 Retrofill Kit Figure 19 20 Fig 19 Rear View of Retrofill Kit Fig 20 Front View of Retrofill Kit ...

Page 12: ...t Figure 21 22 Fig 21 Emax 2 2 Circuit Breaker Front view Fig 22 Emax 2 2 Circuit Breaker Rear view Figure 23 Circuit Breaker Projected from Cassette Figure 24 25 Fig 24 Rear View of Retrofill Kit Fig 25 Front View of Retrofill Kit The Emax 1 2 Emax 2 2 Circuit Breaker is suitable for application on power systems up to 600 VAC 50 60 Hz ...

Page 13: ...A 13 AK75 Emax 4 2 3000A Cradle in Cradle Retrofill Breaker Figure 26 27 Fig 26 Emax 4 2 Circuit Breaker Moving Portion Fig 27 Circuit Breaker Projected from Cassette Figure 28 Figure 29 30 Retrofill Kit Fig 29 Rear View of Retrofill Kit Fig 30 Front View of Retrofill Kit ...

Page 14: ...v B Figure 31 32 Figure 33 Figure 34 35 AK100 Emax 6 2 4000A Cradle in Cradle Retrofill Breaker Fig 31 Emax 6 2 Circuit Breaker Moving Portion Fig 32 Circuit Breaker Projected from Cassette Retrofill Kit Fig 34 Rear View of Retrofill Kit Fig 35 Front View of Retrofill Kit ...

Page 15: ...Breakers 600A 4000A 15 12 AKD5 Mechanical drawings The following engineering or assembly drawings describe the layout and dimensions of the AKD 5 Retrofill breaker Figure 36 AK25 Emax 1 2 600A Figure 37 AK50 Emax 2 2 1600A Figure 38 AKT50 Emax 2 2 2000A ...

Page 16: ...SA451011P0000 Rev B Figure 39 AK75 Emax 4 2 3000A Figure 40 AK100 Emax 6 2 4000A Forced cooling Fans for 3000A Rating only Fans Turn ON at 2500A and OFF at 2300A For other detail related to Trip unit config and wiring refer to Fan control section in manual ...

Page 17: ...rsonnel install operate service and maintain all electrical equipment 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 Discharge the closing spring before removing the breaker from the switchg...

Page 18: ...18 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 2TSA451011P0000 Rev B Figure 43 Figure 44 Figure 45 AKD5 600A AKD5 1600A 2000A AKD5 3000A 4000A ...

Page 19: ... necessary with a clean lint free rag and isopropyl alcohol or acetone 7 Be sure to apply a thin film of red Mobilgrease 28 to the primary disconnect contact areas for better electrical connections inside the compartment 8 After removing the original AK breaker from the compartment install the AKD 5 retrofill cassette Note If compartment has a position switch and a position switch actuator will be...

Page 20: ...pment Caution 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 Notice PRODUCT DAMAGE Ensure circuit breaker and its accessories are always...

Page 21: ...r number and name plate information 3 Remove the banding straps and lift off the top cover 4 Remove all packaging material 5 Remove all product documentation and store properly Unscrew the mounting screws that fasten the circuit breaker to the bottom of the shipping pallet and remove the circuit breaker or cassette Use Lifting Device 1 Use a lifting device to lift and mount the cassettes and circu...

Page 22: ...rs 600A 4000A 2TSA451011P0000 Rev B Figure 46 Emax2 2 4 2 6 2 Moving Portion Lifting Plates Figure 47 Emax2 2 4 2 6 2 Loading Rails Figure 48 Loading Emax2 Breaker Into the Cradle Figure 49 Disengagement of Lifting Plates from Emax2 Breaker ...

Page 23: ...akers if they are not left in their original containers 3 If breakers are not to be placed in service immediately remove them from their shipping cartons and thoroughly inspect them 4 If everything is in satisfactory condition replace the breakers into their shipping cartons for storage If it is necessary to store the equipment for any length of time follow these precautions to prevent corrosion o...

Page 24: ...ement to rack in and out the breakers while AKT 50 has special EntelliGuard cassette equipped with AK style 7 point bullet connectors which interface with the original AKD 5 secondary disconnect blocks The cassette also has a new racking mechanism Two cams in this cassette engage pins on the new breaker to pull it into the cassette The new breaker has primary disconnect fingers which will directly...

Page 25: ...0002 for pre operation inspecting and testing Check thoroughly for any damaged or loose parts and for any dirt or foreign matter which may be on the breaker Clean those areas if necessary with a clean lint free rag and isopropyl alcohol or acetone Be sure to apply a thin film of Mobilgrease 28 to the primary disconnect fingers for better electrical connections on the breaker and lower racking forc...

Page 26: ...reaker the secondary disconnects must be wired to the Emax 2 Retrofill Breaker Wires with wire markers are provided on the Retrofill Make sure that the switchgear wiring connection points match up with the original wiring of the cubicle This ensures that all wiring connections are properly made Wrong connections will cause the breaker to malfunction ...

Page 27: ... 3 To install the position switch actuator slide the assembly up from the bottom of the cassette 4 Line up the holes on the cassette side sheet with the holes provided on the actuator assembly 5 Fasten the 3 M6 bolts and 6mm washers provided with the actuator assembly to the three holes on the cassette side sheet Two holes are placed on the side and one hole on the rear of the cassette assembly Th...

Page 28: ...escribed PPE for the specified tasks Ensure only qualified personnel install operate service and maintain all electrical equipment 1 Remove existing indicator assembly system from AKD 5 cabinet rails Figure 46 2 Clean the area of the moving frame assembly of any dirt or debris 3 Unpack the racking lock kit for the AKD 5 4 Use this bracket as a template for drilling the holes in the frame Figure 47...

Page 29: ...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 Fig 53 shows the front view of the AKD 5 cassette ready for installation Figure 52 53 AKD 5 AK50 Fig 52 Cassette Projected from Switchgear Fig ...

Page 30: ...he cassette on the rails for racking into the switchgear cabinet figure 55 56 3 Slide the retrofit cassette into the compartment till dead stop 4 Lock the rails of the legacy compartment to ensure inner and outer rail movement 5 Use legacy old or original AKR racking handle for inserting the retrofit cassette 6 Fix legacy old or original racker lock on the compartment side frame to block slide bac...

Page 31: ...rofill Circuit Breakers 600A 4000A 31 Figure 58 59 AKD 5 AK25 Cassette To Be Racked In Fig 58 Fig 59 Figure 60 61 AKD 5 AK 25 Cassette or Substructure Rails Extended Fig 60 Fig 61 Figure 62 AKD 5 AK25 Cassette or Substructure Now Racked In ...

Page 32: ...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 Check that the retrofitted Emax 2 cassette has been completely racked into the cabinet 2 Slide the bracket back into position as shown in the image below Figure 46 and line up the holes...

Page 33: ...E for the specified tasks Ensure only qualified personnel install operate service and maintain all electrical equipment 1 Before inserting the retrofit breaker into the cabinet make sure that the breaker is switched off If the spring indicator shows that it is charged the assembly needs to be discharged by first switching on the breaker and then switching it off After racking in the cassette get r...

Page 34: ... it is to be installed leaving enough clearance to swing the compartment door open to access the enclosure figure 66 5 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 6 Open the compartment door to install the breaker in the cassette figure 67 Figure 66 Cabinet with Compartment Door Closed Figure 67 Ca...

Page 35: ...e 69 Figure 69 Inserting Breaker into Cassette Wheels Lined Up with Roller Arms 11 Lower the circuit breaker gradually at an angle so that the rollers drop over the rails Make sure that the grooves in all rollers straddle the rails as shown in Figure 69 This might need a two man effort one to carefully and slowly lower the suspended breaker and the other to guide the breaker into the cassette encl...

Page 36: ...NNECTED position figure 72 15 Push back both the extended rails of the cassette to the stowed position 16 If the circuit breaker is ON and the springs are charged to turn the breaker off press the OPEN button on the circuit breaker fascia and ensure the circuit breaker contacts are open 17 Remove racking tool figure 73 from the storage location on the cassette right front panel Figure 72 AKT50 Ret...

Page 37: ...king tool It resembles a vehicle ignition lock See figure 76 Figure 75 Shutter 20 Insert the tool so it engages the racking mechanism inside the hole 21 Then crank clockwise so that the breaker starts to move in slowly sliding forward Rotating clockwise 37 turns racks the circuit breaker all the way into the cassette Figure 76 Crank or Racking Handle Inserted Shutter slides to the right in back of...

Page 38: ...tions of the switchgear bus stabs 26 Remove and store the racking handle in its storage location Note that the circuit breaker is now ready for normal operation 21 AK AKT50 Kirkey Interlock The Emax 2 2 Retrofill circuit breakers provided as replacements for AK AKR circuit breakers have a trip interlock feature which will function using the AKT 50 compartment mounted Key Interlock A label is provi...

Page 39: ... identified with wire markers or tags Each wire on the 21 wire harness is connected to a bullet Each bullet when the cassette is racked in engages with its respective points in the switchgear The wires for Block A are identified as A1 A2 A7 Block B wiring is likewise labeled as B1 B2 B3 B7 Block C contains C1 C2 C7 The end opposite of the bullets maps or connects to the Emax 2 Retrofill Cassette 7...

Page 40: ...r to the AKD 5 AK25 the AKD 5 AK50 breaker roll in replacement uses a similar wire harness and is mounted on the cassette Get these tools needed for task Philips head screw driver wire strippers crimps tiewraps 1 Identify each bullet using the legacy wiring diagram and any changes that were made to the legacy compartment Four wire ground fault CTs are wired through a dedicated neutral disconnect v...

Page 41: ...2TSA451011P0000 Rev B 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 41 Figure 82 Example wiring diagram for AK25 secondary disconnects ...

Page 42: ...42 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 2TSA451011P0000 Rev B Figure 83 Figure 84 Example of AK25 Secondary Disconnects Images ...

Page 43: ...00A 43 Below are tables Table 5 for for Emax 2 AKT50 Retrofill Table 6 7 featuring the two 39 blocks A and B They make up the 78 point secondary disconnects Table 5 6 Table 6 AKT50 Emax 2 Retrofill Point Secondary A Block Table 5 AKT50 Emax 2 Secondary Block connections ...

Page 44: ...44 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 2TSA451011P0000 Rev B Table 7 AKT50 Emax 2 Retrofill Point Secondary B Block ...

Page 45: ...k AK25 50 Photo in Figure 85 shows you the B block harness and Figure 86 is a close up photo of the harness Figure 87 shows you the secondary bullets Figure 85 AK25 B Block Harness Figure 86 AK25 Wiring Harness Close Up Figure 87 Figure 88 Wires from Secondary Bullets Wires from Secondary Bullets Close Up ...

Page 46: ...anual Number AKD5 AK25 Emax 1 2 2TSA451017P0000 AKD5 AK50 Emax 2 2 1SDH001000R0709 AKD5 AKT50 Emax 2 2 DEH 41304 Below representations are provided only to show the overview of the interlock assemblies Figure 89 Components that make up AKD 5 AK25 Retrofill Door interlock assembly Figure 90 Components that make up AKD 5 AK50 Retrofill Door interlock assembly Figure 91 Components that make up AKD 5 ...

Page 47: ...adaptor 1 Remove existing compartment door s and remove hinge block using 2 Phillips headed screw driver 2 To install new door follow the instructions below De energize switch off the LVS section that is to be retrofitted Open the compartment door that is to be retrofitted Rack out the existing legacy AKR breaker from the LVS Keep the door open for accessing the door mounting pads placed on the ri...

Page 48: ...door Adaptor kit assembly Modify the door cut out as per the new door cutout template Check the through door racking with the new door assembly Insert the new retrofitted Emax 2 Retrofill circuit breaker into the compartment and slide the breaker into the disconnected condition Close the door and secure it to the compartment Rack in the new retrofitted Emax 2 Retrofill Breaker For detail instructi...

Page 49: ...rent levels on a 4 wire circuit the Neutral Iron Core CT in the cable compartment needs to be replaced with a Rogowski style CT The Rogowski CT comes mounted on copper bars matching the same hole pattern as the existing neutral bar Neutral CT wires from the Rogowski coil to the AKD 5 grey terminal blocks must be run as a twisted pair 27 AKD 5 Neutral CT Adapter upto 5000A This is a miniature Rogow...

Page 50: ...ed 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 handling the CT assemblies such that they do not fall down or damage other components within the LVS 7...

Page 51: ...will allow the new breaker to operate with the existing Neutral CT in most cases Example Neutral sensor Cat numbers beginning with TSVG CT part s 139C4970G s Please note that these neutral CT adapters are not compatible with Power Sensor or SST style neutral sensors Replace an SST Neutral CT with a TSVG BK iron core sensor which will be compatible with the Neutral CT Adapter Note For 4 wire multi ...

Page 52: ...nnections between the 2k 1 signalling unit relay and fans Refer Relay diagram 1SDH001000R0524 to identify the terminal marking in circuit diagram Note U1 U2 Emax 2 motor operator 120 V terminal NOTE 1 In the absence of motor or if motor voltage rating is different than 120 V connect 120 V directly to T1 and T2 Refer 2TSE432074P1000 and 2TSE432048R1000 for the wire length and lug details Figure 96 ...

Page 53: ...2TSA451011P0000 Rev B 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 53 Figure 98 Wiring of WP 4000A Breaker with Fan Control Unit Routing wire to the fans ...

Page 54: ...rcuit Breakers 600A 4000A 2TSA451011P0000 Rev B Configuring Ekip Touch Hi Touch Trip unit 30 Connecting Ekip Touch Figure 99 Connet Ekip Touch or Hi Touch Trip unit using Ekip connect 3 0 357 9 or later software and Ekip T P unit ...

Page 55: ...tus and correct communication with Ekip Touch Off module off Fixed or flashing light synchronized on power LED of Ekip Touch module ON and communication with Trip unit present Flashing not synchronized with power LED of Ekip Touch two fast flashes per second module ON and communication with Trip unit absent If the Ekip Signalling 2K module is detected correctly by Ekip Touch the specific configura...

Page 56: ... programmable contacts of the Ekip Signalling modules Two pairs of programmable contacts are available Threshold 1 I1 and Threshold 2 I1 with control referred to I1 Threshold Iw1 and Threshold Iw2 with control referred to In For fan control configure Iw1 and Iw2 For AKD5 considering 3000A as a rated current In fans will activate when the current crosses 2500 amps will stop if the current drops bel...

Page 57: ...ll Circuit Breakers 600A 4000A 57 33 Programing 2K 1 signaling contacts output Figure 103 Figure 104 The output of 2K 1 module consists of 2 contacts K11 K12 and K13 K14 Configure these two output contacts as per following to control the fans ...

Page 58: ...l the fans Autotest command that activates the automatic sequence of output tests contacts and LEDs and input test LED and includes the following operations 1 Reset output contacts open and LEDs off 2 Turn on all the LEDs in sequence output and input 3 Closure and shutdown of the two output contacts in sequence switching on the relative LEDs 4 Restore initial conditions The Autotest command closes...

Page 59: ...2TSA451011P0000 Rev B 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 59 Revisions Overhaul ECN Description B ECN000122590 Second version ...

Page 60: ...ght to make technical changes or modify the Contents of this document without prior notice ABB does not accept any responsibility whatsoever for Potential errors or possible lack of information in This document We reserve all rights in this document and in the subject Matter and illustrations contained therein Any reproduction Disclosure to third parties or utilization of its contents in whole or ...

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