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DEH41549 R05 

 

 

 

 

 

 

EntelliGuard * R Retrofill 
Circuit Breakers 800-5000A 

 

Installation Manual for R3 & R6 Type Retrofill Circuit Breakers replacing 
Drawout Letter Code B, D & F Legacy AKR Circuit Breakers used in  
AKD-8 & Substructures.   
 
General Electric AKD-8 Low Voltage Switchgear is a free-standing 
assembly of metal-enclosed power circuit breakers.  It may 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-75/100/125 types in OEM equipment and AKR-#F-75/100/125 
types in GE switchboards.  
 

(# is shown in place of a number which designates the trip unit type.) 

 

 

 

 

 

Summary of Contents for EntelliGuard AKR30S-800A

Page 1: ...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 Sw...

Page 2: ...pecs 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...

Page 3: ...s 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...

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: ...voided 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...

Page 6: ...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 a...

Page 7: ...ot 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 war...

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 re...

Page 9: ...t 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 Br...

Page 10: ...ers 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 int...

Page 11: ...e 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 v...

Page 12: ...rs 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 ass...

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 R...

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...

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 Dimensionin...

Page 16: ...5 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 Dimensionin...

Page 17: ...ent 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 AK...

Page 18: ...ts 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 compar...

Page 19: ...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...

Page 20: ...uring 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...

Page 21: ...eft 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...

Page 22: ...rom 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...

Page 23: ...ng 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 b...

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 compart...

Page 25: ...isconnects 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 A...

Page 26: ...y 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 To...

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...

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 cr...

Page 29: ...reaker 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 A...

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 Fig...

Page 31: ...r 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 insert...

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...

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...

Page 34: ...ily 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...

Page 35: ...urn 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...

Page 36: ...KD 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 V...

Page 37: ...uted 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...

Page 38: ...or 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 Jump...

Page 39: ...ssembly 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...

Page 40: ...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...

Page 41: ...inal 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 re...

Page 42: ...s 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...

Page 43: ...ssembly 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 fo...

Page 44: ...ut 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 contac...

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: ...ting 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 4000...

Page 47: ...acer 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...

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: ...tor 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 Fi...

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

Page 51: ...telliGuard 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...

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 mechanic...

Page 53: ...te 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...

Page 54: ...ill 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 mo...

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...

Page 56: ...osition 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...

Page 57: ...D 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...

Page 58: ...us 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 R...

Page 59: ...nergized 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...

Page 60: ...ed 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...

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: ...ill 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...

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