ABB EntelliGuard AKD-5 Installation Manual
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ABB EntelliGuard AKD-5 Installation Manual

ABB EntelliGuard AKD-5 Installation Manual

600-2000a retrofill circuit breakers
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IN STA L LA TION MANUAL
EntelliGuard Retrofill Circuit Breakers
600-2000A AKD-5
AKD-5 Low Voltage Switchgear is a freestanding assembly of metal-
enclosed ANSI power circuit breakers. It may be a part of a single-
ended or double-ended load center unit substation. This applies to
EntelliGuard R breakers to replace AK-#A-25/50/T50 legacy circuit
breakers and AKJ/AKJT/AKS/AKST legacy replacement breakers . .

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  • Page 1 — IN STA L LA TION MANUAL EntelliGuard Retrofill Circuit Breakers 600-2000A AKD-5 AKD-5 Low Voltage Switchgear is a freestanding assembly of metal- enclosed ANSI power circuit breakers. It may be a part of a single- ended or double-ended load center unit substation. This applies to EntelliGuard R breakers to replace AK-#A-25/50/T50 legacy circuit breakers and AKJ/AKJT/AKS/AKST legacy replacement breakers .
  • Page 2 In 2018 ABB acquired GE Industrial Solutions. EntelliGuard circuit breaker is now serviced and maintained by ABB. If you need spare parts or your installed equipment has aged and requires modernization or replacement – ABB is your first point of contact (look for contact details on the last page).

  • Page 3: 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 ..................................5 Related Publications ................................... 6 Service and Support ...................................
  • Page 4 Cut Power ......................................16 Rack Out Legacy Breaker ................................17 Empty Compartment—Legacy Breaker Removed ......................17 Check, Clean, Grease Compartment ............................17 Install Position Switch Actuator—AK25 Breaker .................... 18 Install Position Switch Actuator—AK50 Breaker .................... 19 Racking-Lock Bracket—Initial Tasks ......................... 20 Install Cassette (Landed Wires) .........................

  • Page 5: 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 6: 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...

  • Page 7: Notice Or Note

    Features may be described herein that are not present in all hardware and software systems. ABB assumes no obligation of notice to holders of this document with respect to changes subsequently made.

  • Page 8: Related Publications

    Spare/Renewal Parts Guide DET-755 Service and Support In addition to the local field sales office and service teams, ABB also has a dedicated aftermarket team to assist customers with legacy information, selection, ordering, and upgrading. Estimated Time to Complete Tasks It takes about 20 minutes to install a feature-for-feature LSI assembly.

  • Page 9: Weight (Lbs)

    Weight (lbs) Accessories Total Retrofill Breaker Weight Box Weight 10101653P1 Pallet 10101650P1 Wt Weight AK25 Large Frame Box Wt Accessories Total Retrofill Breaker Weight Pallet 10101513P1 Wt 10101653P1 Weight AK25 AK50/T50 Accessories Total Retrofill Breaker Weight Box Weight 10101655P1 Pallet 10101650P1 Wt Weight AK50/T50 Views...
  • Page 10 Figure 3. EntelliGuard R AKD-5—AK25 Retrofill Figure 4. AKD-5—AK25 Retrofill Breaker without (Rear View) Cassette (Front View) Figure 5 shows a rear view of the AKD-5—AK25 retrofill cassette, or substructure, without the breaker; Figure 6 shows a front view of the cassette. Figure 5.

  • Page 11: 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 12 spring loaded sliding “picture frame”. These are draw out letter code “B” i.e. AKR-4B-30 which will be replaced by an EntelliGuard R with a catalog # beginning with R5. AKD-8—AKR30H/AKR30L/AKR50H/AKRT50H The AKD-8 was manufactured in Salisbury, NC from 1980 to 1984 and in Burlington, Iowa from 1984 to 1999.

  • Page 13: Unpack Retrofill Circuit Breaker

    Unpack Retrofill Circuit Breaker By following the procedures below, one should be able to install the breaker with minimum effort and time. 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 14: Quality

    rated cassette/substructure. Quality All EntelliGuard R circuit breakers have been designed and manufactured to ANSI standards. The design was based on the original requirements from the Legacy Switchgear and Breaker. The product is assembledd in the Burlington, Iowa factory; and is inspected using the same master gauges used on the legacy AK, AKR breakers to confirm electrical and mechanical performance, including rejections-features.
  • Page 15 Figure 7. AKD-5—Breaker Lifting Holes 5. Avoid using hooks and chains since hooks can damage or bend the “ears” as well damage the fascia. Below are two examples of how not to handle the breaker (Figure 8 Figure Figure 8. Crane Lifting Hooks Can Damage Lifting Holes Figure 9.

  • Page 16: Store Circuit Breaker

    Store Circuit Breaker If you decide not to install the retrofill breaker until a later time, then you can store it away for installing later. PRODUCT DAMAGE  Do not store circuit breaker in corrosive environments above LC1 (sea salt mist) and G1 as per ANSI/ISA-S71.04-1985.

  • Page 17: Check Before Installing

    Check Before Installing  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 the...

  • Page 18: Customize Retrofill Secondary Wiring

    Customize Retrofill Secondary Wiring WIRING  Before installing the breaker, the secondary disconnects must be wired to the EntelliGuard 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.

  • Page 19: Rack Out Legacy Breaker

    Turn OFF/ OPEN the Legacy Circuit Breaker 1. 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 switchgear.

  • Page 20: Install Position Switch Actuator-Ak25 Breaker

    Figure 10A / 10B. AK-50 & AKT-50 – Retrofill Kits Install Position Switch Actuator—AK25 Breaker Installing the position switch actuator needs to be done before the cassette is racked into the compartment. Steps of installation of the position switch actuator are as follows. 1.

  • Page 21: Install Position Switch Actuator-Ak50 Breaker

    4. Place the L-bracket from the top of the cassette assembly such that the pins from the bottom 3 pin plate get inserted into the top plate. 5. Secure the connecting by fastening the nuts provided in the actuator kit along with the washers. 6.

  • Page 22: Racking-Lock Bracket-Initial Tasks

    AK50 retrofits must be installed on the rear side, right-side sheet of the AK50 retrofill cassette. 9. Place the cassette on a work table. The cassette should be positioned such that there is enough overhang of its side to insert the position switch actuator assembly in the bottom of the cassette.
  • Page 23 Figure 13. Legacy Indicator Assembly Figure 14. Bracket Template for Drilling Holes 5. Slide the bracket (Figure 14) up to its fixing location as shown in the illustration (Figure 15). 6. Line up the guiding holes (Figure 16). Figure 15. Slide Bracket Up Figure 16.

  • Page 24: Install Cassette (Landed Wires)

    Install Cassette (Landed Wires)  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. ...
  • Page 25 Figure 18. AKD-5—Cassette To Be Racked In, View 1 AKD-5—Cassette To Be Racked In, View 2 Figure 21. AKD-5—Cassette or Figure 19. AKD-5—Cassette or Figure 20. AKD-5—Cassette or Substructure, Racking and Substructure, Rails Extended Substructure, Left Side Details Removing Tool, View 1 The next two figures (Figure 22 Figure...
  • Page 26 Figure 22. AKD-5—Cassette or Substructure, Racking and Figure 23. AKD-5—Cassette or Removing Tool – (AK-25 Cabinet Only) Substructure, Now Racked In Install Cassette Rail Lever Lockout Brackets- AK/AKT-50 Comp’t Only 24 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547...

  • Page 27: Install Lock Bracket

    Install Lock Bracket (AK-25 Cabinet 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. ...

  • Page 28: Install Akd-5 Retrofill Breaker

    Figure 26. Installed Bracket (View 1) Figure 27. Installed Bracket (View 2) Install AKD-5 Retrofill Breaker  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.
  • Page 29 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. 2.
  • Page 30 9. If the racking panel of the cassette is padlocked, it may need to be opened to access the racking mechanism. 10. Verify that the cassette position indicator shows DISCONNECTED and the racking handle is disengaged. 11. Ensure that the cassette racking cams on both side walls of the cassette are in the completely racked-out position.
  • Page 31 Figure 32. Inserting Breaker into Cassette, Wheels Lined Up with Roller Arms 14. Keep the breaker steady. Continue to guide the breaker, while checking both sides and underneath the assembly, so that both sets of wheels can be lowered easily on the cassette rails (Figure 33).
  • Page 32 Figure 34. View of Underside of Breaker 16. As soon as the breaker is resting on the rails Figure 35, unhook the lift from the ears of the circuit breaker and move the hoisting apparatus out of the way. Figure 35. Breaker Positioned on Rails 17.
  • Page 33 19. 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. Figure 36. Breaker Ready for Complete Installation 20.
  • Page 34 Figure 38. Racking Assembly Inside Switchgear Compartment (w/no breaker) 23. Insert a screwdriver in the slot or rack-out lock, and turn it clockwise 90° so that the racking handle shutter opens and insert the racking tool. (It resembles a vehicle ignition lock. See Figure 39.) Figure 39.
  • Page 35 Figure 40. Crank or Racking Handle Inserted 26. As the breaker approaches the TEST position, check the alignment of the fixed and moving parts of the secondary disconnect contacts. (If a motor-spring charge or under-voltage release is installed, the device may operate when approaching the TEST position) 27.

  • Page 36: Ak/Akt-50 - Key Interlock

    Secondary Disconnects, Bullets The circuit breaker secondary disconnects are already located on, or wired to, the breaker’s cassette. The landing of the wiring on the EntelliGuard R breaker cassette is done in the field. Up to 78 points are available so that all breaker accessories can be wired to dedicated disconnect-points in the cubicle. Each breaker wire is identified with a unique label.

  • Page 37: Wiring Diagram And Block Info (Ak25)

    The wiring harness for the secondary disconnects, located on the AKD-5 retrofill cassette, has 21 wire connections (grouped in three blocks (A, B, C)) for AK50 or 28 wire connections (grouped in 4 blocks (A, B, C, D)) for AK25, with seven wire connections for each block). Each wire is clearly labeled, or identified, with wire markers or tags.
  • Page 38 3. With each bullet identified, land the non-bullet side to the corresponding feature on the EntelliGuard R’s 78-point secondary disconnects. (See Error! Reference source not found. Page Error! Bookmark not defined..) If a wire is too long, cut the wire, crimp a new connector, and install the provided wire markers on the bullets.

  • Page 39: Ak25 Wiring Harness, B-Block (Ak25/50)

    Table 7. EntelliGuard G 39-Point Secondary A-Block. Table 8. EntelliGuard G 39-Point Secondary B-Block. AK25 Wiring Harness, B-Block (AK25/50) Photo in Figure 47 shows you the B-block harness and Figure 48 is a close-up photo of the harness. Figure 49 shows you the secondary bullets. 37 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547...
  • Page 40 Figure 47. AK25 B-Block Harness Figure 48. AK25 Wiring Harness, Close Up Figure 49. Wires from Secondary Bullets 38 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547...

  • Page 41: Programmer Secondary Disconnect (Breaker Side-N/A)

    Programmer Secondary Disconnect (Breaker Side—N/A) Programmer secondary disconnects are not provided on AKD5 legacy LVS breakers. If the customer chooses to use the advanced features of the EntelliGuard ACB, the control wiring needs to be routed from the LVS directly to the secondary disconnect landing points on the cassette assembly of the EntelliGuard ACB cassette.

  • Page 42: Install Door Interlock System (Breaker Side)

    Install Door Interlock System (Breaker Side) Figure 52 shows the components that make up the AKD-5 retrofill door interlocking assembly: Figure 52. AKD-5—Door Interlocking Components For the retrofit, instructions for installing the interlocking system on the AKD-5 switchgear are the same as those for EntelliGuard G Circuit Breaker.

  • Page 43: Remove Existing Iron Core Neutral Ct Assembly

    Remove Existing Iron Core Neutral CT Assembly  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. ...
  • Page 44 3. Make a note of the neutral disconnect assembly orientation and the wire connections polarity. This needs to be done to ensure that the assembly is maintained when the new CT assembly is installed. 4. Disconnect the wires attached to the existing CT assemblies and place them in a way that they do not interfere with the replacement of the CT assemblies.

  • Page 45: Akd-5-Neutral Sensor Packaging

    Figure 56. AKD-5—AKT50 2000A Neutral Bus Rogowski ASM 10108216G7 Figure 57. Neutral Bus Rogowski ASM 10108216G7 Photo AKD-5—Neutral Sensor Packaging  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.

  • Page 46: Akd-5-Multi-Source Ground Fault

     Sensor window cross section conforms to criteria as found in the table below (Table 9): Table 9. Frame Ratings and Sensor Areas Frame & Rating Sensor Window minimum area (in Frame 1 / 2000A Frame 2 / 3200A Frame 3 / 6400A The Frame 3 neutral sensor is implemented as two separate sensors, similarly to the phase sensors in the circuit breaker.

  • Page 47: Remove And Replace Akd-5-Existing Door

    Remove and Replace AKD-5—Existing Door  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. ...
  • Page 48 Neutral disconnect and programmer disconnect plugs are not used for AKD5. Points provided as reference for wiring purposes only. 46 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547...
  • Page 49 47 EntelliGuard R Circuit Breaker Retrofill AKD-5 Installation Manual DEH-41547...

  • Page 50: Wiring Diagram For The Ak/Akr Retrofill

    1-540-387-8617 (International) — The information contained in this document is for general information purposes only. While ABB strives to keep the information up to date and correct, it makes no representations or warranties of any kind, express or implied, about the completeness, accuracy, reliability,...

This manual is also suitable for:

Entelliguard ak25Entelliguard ak50Entelliguard akt50

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