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ABB AKD-5 Installation Manual

Entelliguard retrofill circuit breakers
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IN STALLATIO N M AN UAL
EntelliGuard Retrofill Circuit Breakers
AKD-5 & AKD-6 3000A-4000A
AKD-5, AKD-6 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. This applies to EntelliGuard R breakers to
replace AK-#A-75, AK-#A-100, AKR-#C-75, AKR-#C 100 legacy
circuit breakers .
# Denotes trip unit type and A and C are the legacy breaker drawout codes

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Summary of Contents for ABB AKD-5

  • Page 1 IN STALLATIO N M AN UAL EntelliGuard Retrofill Circuit Breakers AKD-5 & AKD-6 3000A-4000A AKD-5, AKD-6 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.
  • 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

    Store Circuit Breaker ............................. 14 Clean and Grease Breaker ..........................15 Customize Retrofill Secondary Wiring ......................15 Modify AKD-5 Switchgear Compartment ....................16 Turn OFF/ OPEN the Legacy Circuit Breaker ........................16 1 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 4 Install AKD-5 AKD-6 Retrofill Breaker......................22 Install Neutral Current Transformer Adapter (NCT Adapter) 150A-5000A ..........31 Install Door Interlock System (Cassette Side) ..................... 31 Remove and Replace AKD-5—Existing Door ....................32 2 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...

  • Page 5: Preface

    (Table 2). Table 1. Generic Danger Alerts and Labels Used for Documentation and Table 2. Custom Danger Alerts and Dangerous Equipment Labels Used for Documentation and Dangerous Equipment 3 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...

  • Page 6: Warning

    The label here requires a specific message that targets a special product or procedure (Table 5). Table 5. Custom Caution Alerts and Labels Used for Documentation and Operating Equipment 4 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...

  • 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. ABB 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 it.

  • Page 8: Related Publications

    DEH0002400 Service and Support In addition to the local field sales office and service teams, ABB has a dedicated Aftermarket team to assist customers with legacy information, selection, ordering, and upgrading. Find contact details on the last page. Estimated Time to Complete Tasks It takes about 60 minutes to install a feature-for-feature LSI assembly.

  • Page 9: Description

    (Rear View) Cassette (Front View) 5shows a rear view of the AKD-6 - retrofill cassette, or substructure, without the breaker; 6shows a Figure Figure front view of the cassette. 7 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...

  • Page 10: History And Types

    Manufactured from 1960 until 1977, the aluminum bus had copper that was “flash-butt welded” to the aluminum at bolted connections. During that time, AK-2A, 3A -25 / 50 / T50 / 75 / 100 (“A” signifies AKD-5 drawout) were produced.

  • Page 11: Akd-6-Akr-30/30H, Akr-50/50H/T50H, Akr-75/75H, Akr-100

    AKR-75 / 100s were introduced during this time. Stab-and-finger connections on 3200A and 4000A breakers were improvements, versus the round the primary disconnects on the AKD-5. The 4000A breaker was also narrowed to same width and phase-phase spacing as the 3200A.

  • Page 12: 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

    • 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. 10 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...

  • Page 13: Quality

    5. Remove all product documentation and store properly. 6. Unscrew the mounting screws that fasten the circuit breaker to the bottom of the shipping palette and remove the circuit breaker. 11 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...

  • Page 14: Use Lifting Truck

    6. Pull out the ears of the Retrofill breaker so that the lifting Rod can be inserted through the ears for hoisting breaker (Figure 7). Figure 7. AKD-5—Breaker Lifting Holes 12 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 15 7. Avoid using hooks and chains since hooks can damage or bend the “ears” or may damage the fascia see Figure 8 Figure Figure 8. Crane Lifting Hooks Can Damage lifting Ears and 0247B8961G007 Figure 9. Lifting using Kit Chains Can Damage or Scratch Fascia 13 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...

  • Page 16: Store Circuit Breaker

    PPE for the specified tasks. • Ensure only qualified personnel install, operate, service, and maintain all electrical equipment. 14 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...

  • Page 17: Clean And Grease Breaker

    The cassette also has a new racking mechanism. Two cams in the cassette engage pins on the new breaker to pull it into the cassette. The new breaker for AKD-5 has tubular primary disconnects and AKD-6 breakers have primary disconnect fingers which will directly connect to the primary disconnects in the AKD-5/6 switchgear.

  • Page 18: Modify Akd-5 Switchgear Compartment

    Inspect the Kirk key slide mechanism, grease with Mobilgrease 28 (D50HD38) if required. 9. Install parts to prevent use of the old/original legacy Draw out Mechanism. 16 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 19 Figure 10A / 10B. AK-75 & AK-100 – Retrofill Kits Figure 10A SUPPLIED WITH CASSETTE AS A RETROFILL KIT Figure 10B SUPPLIED WITH CASSETTE AS A RETROFILL KIT 17 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...

  • Page 20: Racking-Lock Bracket-Initial Tasks (Ak-75, Ak-100, Akr-75, Akr-100)

    Figures 10A, 10B &figure14). Racking-Lock Bracket—Initial Tasks (AK-75, AK-100, AKR-75, AKR-100) 1. Remove existing indicator assembly system from AKD-5/6 cabinet rails . 2. Clean any dirt and debris from rails and kirk interlock slide system. Install Position Switch Actuator / Neutral CT Adapter Bracket Assembly...
  • Page 21 AKD-5 4000A 10106054G6 Adapter & Neutral Disconnect Figure 13A BRACKET ASSEMBLY AKD-5 and AKD-6 3000A – 4000A RETROFILL - 10106054G2 Figure 13B BRACKET ASSEMBLY AKD-5 4000A RETROFILL - 10106054G3 19 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 22 NCT BRACKET ASSEMBLY AKD-5 3000A RETROFILL - 10106054G4 Figure 13D BRACKET ASSEMBLY AKD-6 3200A - 4000A RETROFILL - 10106054G5 Figure 13E BRACKET ASSEMBLY AKD-5 4000A RETROFILL - 10106054G6 20 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...

  • Page 23: Install Rail Toggle Lever Lockout Brackets- Ak-75, Ak-100, Akr-75, Akr-100

    Install Rail Toggle Lever Lockout Brackets- AK-75, AK-100, AKR-75, AKR-100 Figure 14 INSTALL BRACKETS SUPPLIED WITH CASSETTE AS A RETROFILL KIT IN PLACE AS SHOWN BOTH SIDES TORQUE (2) ¼-20 BOLTS TO 9.5Nm (85 in-LBF). 21 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...

  • Page 24: Install Akd-5 Akd-6 Retrofill Breaker

    (Figure 16 Figure 17 6. When the breaker is lined up with the compartment, raise the breaker only slightly higher than the compartment Rails. 22 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 25 (Figure 18). NOTE: Both loading rails should be fully extended and latched or they will not be able to support the breaker. Figure 18. Racking Arms / Loading Rails, Extended 23 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 26 14. If the circuit breaker is ON, to turn the breaker off, press the OPEN button on the circuit breaker fascia and ensure the circuit breaker contacts are open. Figure 20. Breaker Ready for Complete Installation 24 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 27 17. 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 23). 25 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 28 23. Using a light and mirror from below the breaker attempt to observe the primary disconnects are making good contact. 24. Remove and store the racking handle in its storage location. Note that the circuit breaker is now ready for normal operation. 26 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 29 The wiring harness for the secondary disconnects, located on the AKD-5/6 retrofill cassette, has 21 wire connections (grouped in three blocks (A, B, C)) for 75/100, with seven wire connections for each block). Each wire is clearly labeled, or identified, with wire markers or tags.
  • Page 30 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. (Jumper B20 to B17 and B18 to A12 28 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 31 Table 9. EntelliGuard G 39-Point Secondary A-Block. (Right Front) Table 10. EntelliGuard G 39-Point Secondary B-Block. (Left Front) 29 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 32 When a legacy AK or AKR breaker of this type is replaced with a retrofill EntelliGuard R circuit breaker with 4-wire GF in AKD-5 or AKD-6 switchgear, the incoming wires from the neutral CT typically connect to the Equipment Neutral disconnect on the floor of the switchgear compartment.

  • Page 33: Install Neutral Current Transformer Adapter (Nct Adapter) 150A-5000A

    Note: The RNCTA1200 is unique because the Rogowski sensors on the breaker are actually 630A & 1250A rated. Install Door Interlock System (Cassette Side) shows the components that make up the AKD-5 retrofill door interlocking assembly: Figure 27 Figure 27. AKD-5, AKD-6—Door Interlocking Components...

  • Page 34: Remove And Replace Akd-5-Existing Door

    For the retrofill, instructions for installing the interlocking system on the AKD-5 switchgear are the same as those for EntelliGuard G Circuit Breaker. Install the Door Interlock Lever and torsion spring with an E-ring on pins already found on the cassette side frame. Install the door bracket to holes already located in the retrofill door. For more detailed...
  • Page 35 Programmer disconnect plugs are not used for AKD5/6. Programmer input/output functions are wired directly to the 39 point disconnects on the cassette. Points provided as reference for wiring purposes only. 33 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 36 34 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH0005240 R01...
  • Page 37 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,...

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Akd-6

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