GE EntelliGuard R7, Installation Manual

Page 1: ... 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 ...

Page 2: ... 7 History and Types 8 AKD 8 AKD 5 AK25 AK50 8 AKD 6 AKR30H AKR30L AKR50H AKRT50H 8 AKD 8 AKR30H AKR30L AKR50H AKRT50H AKR75 AKR75H AKR100 AKR125 9 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 9 AKD 10 Retrofill Breaker 10 AKD 10 Mechanical Drawings 10 AKD 10 Compartment 12 Interior View 12 Interior Components 12 Interior View 13 Interior Compon...

Page 3: ...5 Remove and Replace WPS 32 WPH 32 WPX 32 WPS 40 WPX 40 WPS 50 WPX 50 36 Mechanical Views AKR 75 100 125 39 AKD 10 Position Switch Actuator 39 AKD 10 Shutter Actuation 41 Door Interlock System 42 AKD 10 Key Interlock 43 Modify AKD 10 Switchgear Compartment 43 Cut Power to AKD 10 Switchgear 43 Rack Out AKD 10 Legacy Existing CB 43 Check Clean Grease AKD 10 Compartment 43 Install Secondary Disconnec...

Page 4: ... 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 pr...

Page 5: ... 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 ...

Page 6: ... 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 merch...

Page 7: ...eutral CT Adapters DEH0002400 Service and Support Service and support always available from GE Energy Estimated Time to Complete Tasks Verify the secondary disconnects and match the switchgear cublicle which may take up to 1Hr 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 ...

Page 8: ... Retrofill breaker is defined as a draw out breaker Figure 1 front and back views with finger clusters presents an AKD 10 EntelliGuard R Retrofill breaker permanently encased in a cassette like structure Figure 1 AKD 10 Breaker in Cassette Front and Back View Figure 1A AKD 10 Breaker in Cassette Front and Back View The EntelliGuard R Circuit Breaker is suitable for application on power systems up ...

Page 9: ...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 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 En...

Page 10: ...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 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 wit...

Page 11: ... 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 ...

Page 12: ...cuit Breaker Retrofill AKD 10 Installation Manual DEH41550 R06 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 ...

Page 13: ...e 5 below present a new AKD 10 compartment with one photo showing the rails extended Figure 4 AKD 10 Empty Compartment with Shutters Figure 5 AKD 10 Empty Compartment with Racks Rails Extended Interior Components Figure 6 points out the major components of an AKD 10 compartment Figure 6 AKD 10 Circuit Breaker Compartment for AKR 30 50 T50 Breakers ...

Page 14: ... Empty Compartment Figure 5A AKD 10 Empty Compartment with Racks Rails Extended Interior Components Figure 6A points out the major components of an AKD 10 compartment Figure 6A AKD 10 Circuit Breaker Compartment for WPS 32 WPH 32 WPX 32 WPS 40 WPX 40 WPS 50 WPX 50 Breakers Position switch Rejection Plate Drawout Rails Kirk key lock Secondary Disconnect Primary Disconnects Top Primary Disconnects B...

Page 15: ...ecuring 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 ...

Page 16: ... Circuit Breaker from Container Inspect and Prepare 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 lift the top cover 4 Remove all packaging ma...

Page 17: ...or damage to any of the breaker parts Do not remove any protective grease until the assemblies are ready to be installed Cover to prevent dust from settling on the breakers 3 If breakers are not to be placed in service at once remove them from their shipping cartons and thoroughly inspect them 4 If everything is in satisfactory condition replace the breakers in their shipping cartons for storage I...

Page 18: ...ok on the breaker summary sheet the front view drawings breaker nameplate and on the identification card on the breaker shipping carton 2 To locate the breaker for its proper compartment refer to the breaker location list on the front view drawing Find the proper breaker by the identification card on the breaker carton or the mark number on the breaker nameplate All identical legacy breakers have ...

Page 19: ...d 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 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 ...

Page 20: ... electrical equipment After the existing breaker is removed and the compartment modified the pre wired Retrofill breaker can now be installed in the AKD 10 switchgear 1 Verify that the breaker is in the disconnected and OPEN position before mounting it on rails 2 Pull out the cubicle rails horizontal to the ground 3 The rails can now support and secure the Retrofill breaker in the switchgear 4 For...

Page 21: ... Retrofill Breaker Examples of an eye bolt and connector are shown in fig s 8B and 8C Insert M10 eyebolts of rating minimum 250lbs in the eye bolt weld nuts as shown in Figures 7 8D Use four eye bolts chain and suitable S hooks or chain connectors to safely lift the breaker onto the rails S hooks with a locking feature as shown in Figure 8D are preferred to basic S hooks Each chain should be rated...

Page 22: ...tment raise the breaker only slightly higher than the compartment floor 10 Keep the breaker steady Continue to guide the breaker while checking both sides and underneath so that both sets of rollers are lined up with the rails 11 Once the breaker is resting on the rails unhook the lifting hooks from the circuit breaker Move the hoisting apparatus out of the way 12 Push the breaker in until the com...

Page 23: ...iver 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 10 16 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 17 Rotating cl...

Page 24: ...reaker 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 Figure 11 AKD 10 Racked In CB ...

Page 25: ...t 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 B Alternate method use a lifting chain and hooks rated at least 1400 lbs to lift the breaker from above as shown in Figure 12B chains must not be at an angle less than 45 degrees from the horizontal plane...

Page 26: ...emove the screwdriver Figure 10 13 Rotating clockwise 37 turns racks the circuit breaker all the way into the compartment 14 As the breaker approaches the TEST position a spring charging motor or undervoltage release if installed may operate 9 racking turns 15 Continue rotating the racking handle clockwise until the position indicator first shows TEST then CONNECTED 16 When approaching the CONNECT...

Page 27: ...to malfunction AKD 10 Secondary Disconnects This section deals with installing and wiring the legacy secondary disconnect assemblies onto the EntelliGuard R breaker Installing the secondary disconnect assembly consists of doing these tasks Installing the secondary disconnect assembly Figure 14 Figure 15 and Figure 16 Wiring the secondary disconnect assembly Table 8 shows the WavePro secondary disc...

Page 28: ...eaker 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 Refer to Table 7 for the secondary disconnect kit catalog numbers Table 7 AKD 10 Secondary Disconnect Kit Catalog Numbers WP 08 16 20 Breaker side WPSDSUBF1 Cell side WPSDSUBM1 Table 8 shows the WavePro secondary disco...

Page 29: ...2 Undervoltage or Electric Lockout 22 OFLO phase A 23 Undervoltage or Electric Lockout 23 OFLO phase A 24 Neutral Sensor tap 24 OFLO phase B 25 Neutral Sensor common 25 OFLO phase B 26 Modbus RX 26 OFLO phase C 27 Modbus TX 27 OFLO phase C 28 Zone Selective Interlock In 28 Output 2 29 Zone Selective Interlock In 29 NI NO 30 Zone Selective Interlock Out 30 NI COMM 31 Zone Selective Interlock Out 31...

Page 30: ...29 EntelliGuard R Circuit Breaker Retrofill AKD 10 Installation Manual DEH41550 R06 Table 9 AKD 10 Secondary Disconnects Example Wiring Diagram ...

Page 31: ...EntelliGuard R Circuit Breaker Retrofill AKD 10 Installation Manual DEH41550 R06 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 ...

Page 32: ... SECOND O P C32 C28 A30 A29 C36 C31 B3 B2 NET WORK INTERLOCK C19 C18 C21 C20 SET TRIP RESET COMM COMM NET WORK INTERLOCK A6 A5 A8 A7 SET TRIP RESET COMM COMM NI STATUS SWITCH C30 C29 WAVEPRO ENTELLIGUARD R SHUNT TRIP 1 ONLY FOR 120VDC A7 A5 A6 A14 A21 A20 A6 A5 B25 B26 SHUNT TRIP 1 ONLY FOR 120VDC C5 C14 SHUNT TRIP 2 ONLY FOR 120VDC B20 B19 A13 A12 B17 B18 SHUNT TRIP 2 ONLY FOR 120VDC A15 NI STATU...

Page 33: ...luster defined as a double pair of fingers on a breaker Figure 17 shows finger clusters or primary disconnects on a Retrofill circuit breaker Figure 18 details the finger cluster assembly Figure 17 Circuit Breaker Removed Featuring Primary Disconnects Fingers Contacts Figure 18 Circuit Breaker Finger Details Remove and Replace The primary disconnect assembly is factory adjusted with a gage to appl...

Page 34: ...ressure plate retainer over the spacers to hold them in position and then turn the subassembly over Hook them into the main retainer 10 Slide a long bolt through the hole in the retainer between the finger and then through the clip and eccentric stud spacer 11 Hold the bottom finger subassembly in place 12 Place two fingers around the bolt from the top hooking the fingers into the main retainer Th...

Page 35: ...34 EntelliGuard R Circuit Breaker Retrofill AKD 10 Installation Manual DEH41550 R06 Figure 21 summarizes the steps for working with the primary contacts Figure 21 Steps in Exploded Views ...

Page 36: ...35 EntelliGuard R Circuit Breaker Retrofill AKD 10 Installation Manual DEH41550 R06 Mechanical Views Figure 22 provides further details Figure 22 Fingers or Clusters Mechanical View and Notes ...

Page 37: ... the fingers when setting this dimension Figure 24B 24B shows the cluster components Figure 23A Adjustment 3200A Double Spring Figure 24A Components 3200A Figure 23B Adjustment 4000A 5000A Figure 24B 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 locati...

Page 38: ...em 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 WPS 32 WPH 32 WPX 32 with Double springs and 0 766 0 797 inch for WPS 40 WPX 40 WPS 50 WPX 50 between the top of the upper retainer and the bottom of t...

Page 39: ...38 EntelliGuard R Circuit Breaker Retrofill AKD 10 Installation Manual DEH41550 R06 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 ...

Page 40: ... 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 A customer can choose to install a position switch if it s not already installed although this is infrequent or the existing assembly is damaged Figure 28 shows the s...

Page 41: ...rd R Circuit Breaker Retrofill AKD 10 Installation Manual DEH41550 R06 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 ...

Page 42: ...pped 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: ...red that the operator is using the prescribed PPE for the specified tasks Ensure only qualified personnel install operate service and maintain all electrical equipment Details regarding installation of the door interlock system are shown below in Figure 30A and 30B Figure 30A AKD 10 Door Interlocking Components for WPS 08 WPH 08 WPX 08 WPS 16 WPH 16 WPS 20 Breaker Figure 30B AKD 10 Door Interlocki...

Page 44: ...Switchgear Compartment Cut Power to AKD 10 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 the specified tasks Ens...

Page 45: ...ovided as shown in Figure 31 below Remove the protective tape on the block and stick it on the secondary disconnect mounting plate as shown in Figure 31 Be sure the spring is moved to the front of the spacer block Optional The hole in the spacer block can be used to add a 10 32 screw Drill a 0 177 4 5mm hole in the steel plate above and install 10 32 taptite thread forming screw GE part N722P16012...

Page 46: ...evels on a 4 wire circuit the Neutral Iron Core CT in the cable compartment needs to be replaced with a Rogowski style CT or have iron core CT output modified by a neutral CT adapter See Neutral CT Adapter 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 10 gray terminal blocks must be run as ...

Page 47: ...s 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 Catalog Number Supported Neutral CT ratings A RNCTA1200 R 600 1200 RNCTA2000 R 150 200 400 800 1000 1600 2000 RNCTA3000 R 3000 RNCTA4...

Page 48: ...disconnect assemblies to the horizontal bus bars Keep the hardware in a secure location for reassembly 6 Be careful while handeling the CT assemblies such that they do not fall down or damage other components within the LVS 7 Replace the old CT assembly with the new Rogowski assembly on the horizontal bus bars and fasten it using the hardware previously removed 8 Connect a twisted pair of wires ba...

Page 49: ...Wiring Diagram for the WavePro Retrofill 48 EntelliGuard R Circuit Breaker Retrofill AKD 10 Installation Manual DEH41550 R06 ...

Page 50: ...49 EntelliGuard R Circuit Breaker Retrofill AKD 10 Installation Manual DEH41550 R06 ...

Page 51: ...50 EntelliGuard R Circuit Breaker Retrofill AKD 10 Installation Manual DEH41550 R06 NOTES ...

Page 52: ...fill AKD 10 Installation Manual DEH41550 R06 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 ...