GE EntelliGuard R7 Installation Manual
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GE EntelliGuard R7 Installation Manual

GE EntelliGuard R7 Installation Manual

Retrofill circuit breakers 800-5000a
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DEH41550 R06
EntelliGuard*R Retrofill Circuit
Breakers 800-5000A
Installation Manual for R7 & R8 Type Retrofill Circuit Breakers replacing
WavePro Legacy Circuit Breakers used in AKD-10 & Substructures.
General Electric AKD-10 Low Voltage Switchgear is a free-standing
assembly of metal-enclosed power circuit breakers. It may also be
a part of a single-ended or double-ended load center unit
substation. It uses WavePro type ANSI Low Voltage Power Circuit
Breakers. This manual applies to both EntelliGuard R breakers for
AKD-10 switchgear and OEM substructures.

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Summary of Contents for GE EntelliGuard R7

  • Page 1 DEH41550 R06 EntelliGuard*R Retrofill Circuit Breakers 800-5000A Installation Manual for R7 & R8 Type Retrofill Circuit Breakers replacing WavePro Legacy Circuit Breakers used in AKD-10 & Substructures. General Electric AKD-10 Low Voltage Switchgear is a free-standing assembly of metal-enclosed power circuit breakers. It may also be a part of a single-ended or double-ended load center unit substation.

  • Page 2: Table Of Contents

    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 ........................................
  • Page 3 Store Circuit Breaker .............................. 16 Check Before Installing............................17 Clean and Grease Breaker ............................. 18 Install AKD-10 Retrofill Breaker ..........................19 AKD-10—Racked-In ........................................23 Install AKD-8 & substructure type 3200, 4000 & 5000A Retrofill Breaker............ 24 AKD-10 Retrofill Breaker Racked-In ................................... 25 AKD-10—Install Accessories ..........................

  • Page 4: Preface

    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.

  • Page 5: Warning

    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).

  • Page 6: Notice Or Note

    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...

  • Page 7: Document Conventions

    The EntelliGuard R retrofill, when ordered with 4 wire ground fault, will be equipped with a Neutral CT adapter. The adapter will modify the GE MicroVersaTrip type Neutral CT output to a Rogowski sensor output compatible with the EntelliGuard R’s Trip Unit. With this device, it will not be necessary to change the neutral CT in the switchgear to a Rogowski sensor.

  • Page 8: Views

    Views General Electric AKD-10 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. The AKD-10 EntelliGuard R Retrofill breaker is defined as a draw-out breaker.

  • Page 9: History And Types

    History and Types AK—Power Circuit Breaker Equipment D—Drawout circuit breaker construction Manufactured from 1951 to 1975, all bolted, copper bus design, all drawout breakers—AK-1, —2, —3,—15 / 25 / 50 / 75 / 100; the 4000A-max bus rating. Breakers had a ratcheting drawout mechanism, with an open- door drawout.

  • Page 10: Akd-8-Akr30H/Akr30L/Akr50H/Akrt50H/Akr75/Akr75H/Akr100/Akr125

    “picture frame” 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”.

  • Page 11: Akd-10-Retrofill Breaker

    AKD-10—Retrofill Breaker AKD-10—Mechanical Drawings The following engineering or assembly drawings describe the layout and dimensions of the AKD-10 Retrofill breaker (Figure 2, Figure 3). Figure 2. AKD-10 800A Retrofill Breaker Dimensioning (WPS-08, WPH-08) Figure 3. AKD-10 800-2000A Retrofill Breaker Dimensioning (WPX-08, WPS-16, WPH-16, WPS-20) EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...
  • Page 12 Figure 2A. AKD-10 800A Retrofill Breaker Dimensioning (WPS-32, WPH-32 WPX-32, WPS-40, WPX-40) Figure 3A. AKD-10 800-2000A Retrofill Breaker Dimensioning (WPS-50, WPX-50) EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...

  • Page 13: Akd-10 Compartment

    AKD-10 Compartment Interior View The figures (Figure 4) and (Figure 5) below present a new AKD-10 compartment, with one photo showing the rails extended. Figure 5. AKD-10—Empty Compartment with Racks/Rails Figure 4. AKD-10—Empty Compartment with Shutters Extended Interior Components Figure 6 points out the major components of an AKD-10 compartment. Figure 6.

  • Page 14: Interior View

    Interior View The figures (Figure 4A) and (Figure 5A) below present a new AKD-10 compartment, with one photo showing the rails extended. Figure 5A. AKD-10—Empty Compartment with Racks/Rails Figure 4A. AKD-10—Empty Compartment Extended Interior Components Figure 6A points out the major components of an AKD-10 compartment. Figure 6A.

  • Page 15: Unpack Cb

    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.

  • Page 16: Quality

    Quality All EntelliGuard R circuit breakers have been designed and manufactured to ANSI standards. The design was based on the original requirements of the legacy switchgear and breaker. The product is manufactured in Burlington, Iowa; and is inspected using some of the same master gauges used on the legacy AK, AKR breakers to confirm electrical and mechanical performance, including rejections-features.

  • Page 17: Store Circuit Breaker

    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 are stored in a clean, dry location, in their original packaging. • Failure to comply with these instructions may result in product damage.

  • Page 18: Check Before Installing

    W2, check to be sure the breaker has equal sized racking cam slots on both sides. NOTE: GE Switchboard plants initially shipped “WS” style breakers and later shifted to “WE” style breakers to be consistent with GE Switchgear from Burlington, Iowa...

  • Page 19: Clean And Grease Breaker

    4. Be sure to apply a thin film of electrical grease DH0HD38 (Mobilgrease 28) to the primary disconnect fingers (Figure 7 and 7A). GE part #193A1751P1 is a 1 oz. tube of Mobilgrease 28. Figure 7. AKD-10—Primary Contacts or “Fingers” (Apply Figure 7A.

  • Page 20: Install Akd-10 Retrofill Breaker

    Figure 7. Use a chain and hook to lift the breaker from above. Use GE part number 0247B8961G002 lifting bar and suitable hoist to lift from above as shown in Figure 8.
  • Page 21 8A. This will ensure the breaker is better balanced when lifted. Figure 8A. AKD-10—Using GE Lifting bar and hoist 6. The Size of the slot at the top of the lifting bar is 0.7” wide and 1” high. Hook used in the hoist should be suitable to engage with this slot size.
  • Page 22 Figure 8D. AKD-10—Using eye bolts, chain and connector. 8. Check that the breaker is free from obstruction inside the compartment. 9. When the breaker is lined up with the compartment, raise the breaker only slightly higher than the compartment floor. 10.
  • Page 23 13. Remove the racking tool (Figure 9) from the storage location on the breaker front panel and extend the torque bar from inside the handle. Figure 9. AKD-10—Racking Tool 14. Use a blade-type screwdriver in the slot or rack out lock of the breaker (Figure 10), and turn it clockwise to the right so that the racking handle shutter opens Figure 10.

  • Page 24: Akd-10-Racked-In

    21. At the end of 37 rotations, the breaker is in its maximum travel position. At this point, the primary disconnect fingers have completely engaged with the primary bus stabs. 22. Remove and store the racking handle in it storage location. AKD-10—Racked-In The photo below shows one example of a racked-in AKD-10 Retrofill (Figure 11).

  • Page 25: Install Akd-8 & Substructure Type 3200, 4000 & 5000A Retrofill Breaker

    Verify that the new breaker is in the disconnected and OPEN position. 2. For WPS-32/WPH-32/WPX-32/WPS-40/WPX-40/WPS-50/WPX-50 Retrofill Breaker. A. It is best to use Lifting Bar GE Part number 0247B8961G001 for 3200-4000A and 0247B8961G003 for 5000A and a suitable hoist to lift from above as shown in Figure 12A. (These lifting bars have been tested to 200% of their 700 lb ratings.)

  • Page 26: Akd-10 Retrofill Breaker Racked-In

    9. When fully installed to the DISCONNECT position, the racking cams will stop on the racking pins in the compartment and the breaker will be ready to rack in. 10. Remove the racking tool. (Figure 9) from the storage location on the breaker front panel and extend the torque bar from inside the handle.

  • Page 27: Akd-10-Install Accessories

    AKD-10—Install Accessories WIRING • Before installing the breaker, the secondary disconnects must be wired to the EntelliGuard R Breaker. • Wires with wire markers are provided on the breaker . Make sure that the switchgear wiring connection points match up with the original wiring of the cubicle.
  • Page 28 Figure 16. AKD-10— Secondary Disconnects Exploded View Inputs and outputs to the circuit breaker are wired through secondary disconnects located on the top of the breaker. The plug-style secondary disconnects engage mating disconnects in the breaker cubicle when the breaker is in the TEST or CONNECT position. Up to 72 dedicated points are available so that all breaker accessories can be wired to dedicated disconnect points.
  • Page 29 Table 8. WavePro secondary disconnect terminals and standard connections. A Disconnect Block (left side from front) C Disconnect Block (right side from front) Aux Switch (NO contact) Aux Switch (N.O. contact) Aux Switch Aux Switch Aux Switch Aux Switch Aux Switch (NC contact) Aux Switch (NC contact) Aux Switch (NO contact) Aux Switch (NO contact)
  • Page 30 Table 9. AKD-10— Secondary Disconnects Example Wiring Diagram EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...
  • Page 31 Table 9A. WavePro to EntelliGuard R wiring. 4. Aux contacts B25/B26 and B17/18 are used for Shunt trip 1 and or 2 >125V dc only. EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...
  • Page 32 Table 9A. WavePro to EntelliGuard R wiring - Continued WAVEPRO ENTELLIGUARD R WAVEPRO ENTELLIGUARD R COMMAND SHUNT TRIP #1 @ COMMAND SHUNT TRIP #1 @ CLOSE COIL (ONLY FOR >120VDC) CLOSE COIL (ONLY FOR >120VDC) DASHES INDICATE COMM COMM EXTERNAL JUMPERS SECOND UV SECOND UV SHUNT TRIP #2 %...

  • Page 33: Akd-10-Primary Disconnects (Contacts) Or "Fingers

    WIRING • Do not pinch/damage the wires while installing the secondary disconnect blocks. AKD-10—Primary Disconnects (Contacts) or “Fingers” covers the primary disconnects or fingers. Finger Clusters Accessory Manual DEH-41533 The primary disconnects are flexible connections between the breaker line and load terminals and between the equipment line and load terminals.
  • Page 34 18. Be sure to apply a thin film of Mobilgrease 28 (D50HD38) to the contact areas which slide onto the switchgear stabs (See Figure 21, Step 2). This product is available in a 1-oz tube, GE Part #193A1751P1. EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual...
  • Page 35 Figure 21 summarizes the steps for working with the primary contacts. Figure 21. Steps in Exploded Views EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...

  • Page 36: Mechanical Views

    Mechanical Views Figure 22 provides further details. Figure 22. Fingers or Clusters, Mechanical View, and Notes EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...

  • Page 37: Remove And Replace- Wps-32/Wph-32/Wpx-32/Wps-40/ Wpx-40/Wps-50/Wpx-50

    Remove and Replace- WPS-32/WPH-32/WPX-32/WPS-40/ WPX-40/WPS-50/WPX-50 The primary disconnect assembly is factory-adjusted to apply a 95 ± 10 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 23A/23B.
  • Page 38 16. Be sure to apply a thin film of Mobilgrease 28 (D50HD38) to the contact areas which slide onto the switchgear stabs (See Figure 25/26, Step 2). This product is available in a 1-oz tube, GE Part #193A1751P1. 17. Figure 25 (WPS-32/WPH-32/WPX-32) and figure 26 (WPS-40/ WPX-40/WPS-50/WPX-50) summarizes the steps for working with the primary contacts.
  • Page 39 Figure 25. Steps in Exploded Views (WPS-32/WPH-32/WPX-32) Figure 26. Steps in Exploded Views (A WPS-40/ WPX-40/WPS-50/WPX-50 ) EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...

  • Page 40: Mechanical Views-Akr-75/100/125

    Mechanical Views-AKR-75/100/125 Figure 27provides further details. Figure 27. Fingers or Clusters, Mechanical View, and Notes WPS-32/WPH-32/WPX-32 WPS-40/ WPX-40/WPS-50/WPX-50 AKD-10—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 WavePro breaker. •...
  • Page 41 Figure 28. AKD-10 Breaker Surfaces Activate Position Switch. Surface activating the position switch for WPS- 08, WPH-08, WPX-08, WPS-16, WPH-16, WPS-20 EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...

  • Page 42: Akd-10-Shutter Actuation

    AKD-10—Shutter Actuation AKD-10 LVS may be equipped with optional shutter assemblies for protection of the live bus bars. EntelliGuard R breakers come with pre-installed shutter actuators which operate the opening of the shutters as shown in Figure 29. Figure 29. AKD-10—Breaker Surfaces Activate Shutter. Surfaces activating the shutters for WPS-08, WPH-08, WPX-08, WPS-16, WPH-16, WPS-20...

  • Page 43: Door Interlock System

    Door Interlock System • 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...

  • Page 44: Akd-10-Key Interlock

    AKD-10—Key Interlock The EntelliGuard R retrofill circuit breakers provided as replacements for WavePro 800-5000A frame circuit breakers have a trip interlock feature which will function using the AKD-10 compartment mounted Key Interlock. A label is provided with full instructions on how to operate the Legacy Key Interlock. It is suggested to apply the label on the inside of the compartment door.

  • Page 45: Install Secondary Disconnect Spacer Block (800-2000A Only)

    5. Be sure to apply a thin film of red Mobilgrease 28 to the primary disconnect contact areas for better electrical connections inside the compartment. This is available in 1 oz. tubes, GE part # 193A1751P1. Install Secondary Disconnect Spacer Block (800-2000A ONLY) Install the spacer block provided as shown in Figure 31, below.

  • Page 46: Install Akd-10-Neutral Rogowski Current Transformer (Ct)

    Install AKD-10—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.

  • Page 47: Neutral Ct Adapter 150A-5000A

    The Neutral CT Adapter supports iron core Neutral sensors compatible with MicroVersa Trip, MVT RMS-9, Power Plus, Pro Trip and EntelliGuard TU rated from 150 to 5000Amps as used in GE switchboards and switchgear. It is available in five variations (shown in below Table).

  • Page 48: Procedures

    Procedures NEUTRAL CT ORIENTATION • 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. 1.
  • Page 49 Wiring Diagram for the WavePro Retrofill EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...
  • Page 50 EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...
  • Page 51 NOTES: EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...
  • Page 52 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 DEH41550 R06 01/17 EntelliGuard R Circuit Breaker Retrofill AKD-10 Installation Manual DEH41550 R06...

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