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ABB AKD6-800A Installation Manual

Entelliguard r retrofill circuit breakers
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IN STALLATIO N M AN UAL
EntelliGuard R Retrofill Circuit Breakers
800-2000A AKD-6
AKD-6 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. This manual applies to
EntelliGuard R breakers for OEM substructures using AKR-#B-30/50/T50
legacy breakers and AKD-6 switchgears using AKR-#A-30/50/T50 legacy
breakers.

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Summary of Contents for ABB AKD6-800A

  • Page 1 — IN STALLATIO N M AN UAL EntelliGuard R Retrofill Circuit Breakers 800-2000A AKD-6 AKD-6 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. This manual applies to EntelliGuard R breakers for OEM substructures using AKR-#B-30/50/T50 legacy breakers and AKD-6 switchgears using AKR-#A-30/50/T50 legacy breakers.
  • Page 2 In 2018 ABB acquired GE Industrial Solutions. EntelliGuard 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 Content 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 ................................... 6 Estimated Time to Complete Tasks .............................
  • Page 4 Inspect ............................................16 Use Lifting Truck ........................................16 Store Circuit Breaker ................................17 Check Before Installing................................17 Clean and Grease Breaker ..............................18 Rack Out Legacy or Existing CB ............................18 Install Secondary Disconnect Bullets (Breaker) ........................ 19 Wire Secondary Disconnect Assembly—AKR30/30H/50/50H..................21 Figure 10.

  • 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 3).

  • 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 in.

  • 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 Views AKD-6 Low Voltage Switchgear is a free-standing assembly of metal-enclosed of power circuit breakers. It may also be a part of a single-ended or double-ended load center unit substation. One particular feature of the AKD-6 is that the breaker is built into the cassette. Figure 1 shows the AKD-6 EntelliGuard R Retrofill breaker permanently encased in its cassette (front view).

  • Page 10: History And Types

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

  • Page 11: Akd-10-Wps-08, Wph-08, Wpx-08, Wps-16, Wph-16, Wps-20

    vertical bus. Model 2 was introduced in 1983 to accommodate revised wire harness routing. Model 3 was introduced in 1991, using a flat bar vertical bus. AKR breakers use MicroVersaTrip 9, MVT RMS9, EPIC, MVT Plus, MVT PM, or EntelliGuard TU trip units. Aluminum bus was removed from the design in 1996 in favor of the standard tin-plated copper bus (silver plated optional).

  • Page 12: Akd-6-Breaker Models

    AKD-6—Breaker Models Following table depicts the key differences between Model 1 & 2 AKD6 Retrofill breakers (800-1600A). Note: All features of Model 2 (800-1600A) Retrofill breakers are incorporated in all the 2000A breakers. Breaker Model Comparison Table Model 2 Retrofill Breaker Feature Model 1 Retrofill Breaker (800-1600A) (800-1600A &...

  • Page 13: Mechanical Drawings

    Mechanical Drawings Below is an AKD-6 mechanical drawing that dimensions the breaker DWG 1. AKD-6—Retrofill for AKR30/30H (Model -1 for 800A) DWG 2. AKD-6—Retrofill for AKR50/50H (Model-1 for 1600A ) EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 07/15...

  • Page 14: Akd-6-Compartment

    DWG 3. AKD-6—Retrofill for AKRT-50H –( Model 2 for 2000A & Model 2 for 800-1600A ) AKD-6—Compartment Interior Figure 4 displays an empty compartment of the AKD-6 switchgear. Figure 5 shows features of the AKD-6 interior. Figure 4. AKD-6 Switchgear, Empty Compartment EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 07/15...
  • Page 15 Figure 5. AKD-6 Compartment Distinctions Figure 6 is an example of a compartment in the AKD-6 switchgear that is empty; that is, the upper compartment is ready for a retrofill breaker where the legacy, or original breaker, had been racked out and new wire connections made.

  • Page 16: Unpack Retrofill Circuit Breaker

    Figure 7. Bus, Interior View Unpack Retrofill Circuit Breaker By following the procedures below, you 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.

  • Page 17: Quality

     Do not walk or remain under any heavy assembly while hoisted as the chains securing the assembly may give way Falling Object  Ensure lifting equipment has capability for device being lifted.  Wear hard hat, gloves, and safety shoes. ...

  • Page 18: Remove Circuit Breaker From Container

    Remove Circuit Breaker from Container Inspect 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.

  • Page 19: 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 it 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 20: Clean And Grease Breaker

    These breakers are supported on a rollout track in the same manner as the AK ,AKR breakers. However, since the Rack-out mechanism is mounted on the breaker, there are no jackshafts in the enclosure. Racking arms on both sides of the breaker frame engage the drawout mechanism pins fastened to both sides of the compartment. 1.

  • Page 21: Install Secondary Disconnect Bullets (Breaker)

    To rack-out legacy (old or original) breaker from compartment, refer to your legacy-breaker’s manual on how to remove the existing breaker. Install Secondary Disconnect Bullets (Breaker) WIRING Before installing the breaker, the secondary  disconnects must be wired to the EntelliGuard Breaker.
  • Page 22 Figure 8. EntelliGuard ACB Secondary Disconnect Bullets (Model 1 Breakers) For Model 1 (800-1600A) AKD6 retrofill breakers 1. Unpack the secondary disconnect block from the box. Each kit of secondary disconnect has four fixing nuts, plain washers, and spring washers. These can be arranged on a work station to prepare for installing the assemblies.

  • Page 23: Wire Secondary Disconnect Assembly-Akr30/30H/50/50H

    2. Check that the bullets, on top of the secondary disconnects, are not damaged and that they slide in to the blocks freely. The bullets are spring-loaded and return to their initial positions when they are released from being pressed down. 3.
  • Page 24 Check that wire routing does not exert pressure on the bullets because this can bend the connection points and effects biasing and contact pressure. By using tie-wraps, wire routing can eliminate sagging of the wire harness and undue pressure on secondary bullets. Once the above mentioned steps are completed, landing the wires to the points on the EntelliGuard ACB secondaries can begin.
  • Page 25 Figure 10. Typical AKD-6 Wiring Diagram EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 07/15...

  • Page 26: Installing Position Switch Actuator (Breaker)

    Installing Position Switch Actuator (Breaker) Note: Later models of breakers (Q3 2015) are shipped with position switch bracket pre-installed. Position switch actuator bracket can be installed on all versions of Retrofill EntelliGuard ACB for AKD6 LVS (Figure 10). The steps of installation are as follows:` Retrofills use the legacy position switch already mounted in the cubicle.

  • Page 27: Installing Door Interlock System (Breaker)

    Installing Door Interlock System (Breaker) P/N 10108779G1 Door Interlock Kit Tools required: Flat screw driver, E-clip mounting tool The door interlock system prevents opening of the breaker compartment door when the breaker is in the racked-in position and connected state. shows the components that make up the AKD-6 retrofill door Figure 11 interlocking assembly.
  • Page 28 Figure 12. Mounting the Door Figure 13. Torsion Spring for Door Interlock Bracket Interlock Bracket The completed assembly of the door interlock will be as shown below (Figure 14). Figure 14. AKD-6 AKR30H/50H Door Interlock Assembly (exploded view) P/N 10108779G1 Door Interlock Kit AKD6 EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual...

  • Page 29: Akd-6 Key Interlock

    AKD-6 Key Interlock The EntelliGuard R retrofill circuit breakers provided as replacements for AKR 800-2000A frame circuit breakers have a trip interlock feature which will function using the AKD-6 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 30: 19-Pin Programmer Secondary Disconnect (Breaker)

    19-Pin Programmer Secondary Disconnect (Breaker) The 19-pin programmer disconnects can now be included with the AKD-6 series retrofills to accommodate the extended features of the EntelliGuard Trip Unit. The 19-pin programmer-disconnect assemblies already come pre- installed and wired from the factory and do not require any installation in the field. The compartment side is installed and wired in the field by a qualified electrician or installation service company.
  • Page 31 Figure 18. 19-Pin Programmer Disconnect for Figure 19. 19-Pin Programmer Disconnect AKD-6 the AKD-6 AKR30H\50H Retrofill, Exploded View AKR30H\50H Retrofill, Installed EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 07/15...
  • Page 32 Figure 20. Wiring for Programmer Disconnect (19-Pin) EntelliGuard R Circuit Breaker Retrofill AKD-6 Installation Manual DEH-41548 07/15...
  • Page 33 Installing AKD-6 Retrofill Circuit 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 34: Install Or Insert Akd-6 Retrofill

    Note 1: In the model 2 design, two spring clips are given for installation in the compartment to permanently defeat the AKD-6compartment locking levers. Two tools are given to block motion of the inner housing and door assembly. See Figures 27 & 28. Note 2: The two tools are stored inboard on each steel side frame of the breaker, hung on a key slot arrangement.
  • Page 35 Figure 21. AKD-6 Rails or Arms for Mounting Retrofill Cassette/CB 3. Use a suitable lifting device and AKR lifting bar. This might require a two-man effort: one to carefully and slowly operate the lift and the other to guide the breaker into the switchgear rail slots. 4.
  • Page 36 Figure 22. Retrofill Hoisted and Secured on Rails (model 1) 10. Push the breaker into the compartment until it can’t be pushed in any further and toggle the rail levers to latch the inner rail with outer rail. 11. Pull the shutter pad lock lever to defeat the latch on the rail (fig. 24).( Model 1 only) 12.
  • Page 37 Figure 23. Latching Inner Rail with Outer Rail Figure 24. Inserting Rod Remove the racking tool from the storage location on the retrofill front panel and grab the handle and extend the torque bar from inside the handle. Use a blade-type screwdriver in the slot or rack-out lock of the breaker (fig. 25) and turn it clockwise 45°to the right so that the racking handle shutter.
  • Page 38 Figure 26. Stationay Secondary Contacts Continue rotating the racking handle clockwise until the position indicator first shows TEST, and then finally shows CONNECTED. When approaching the CONNECTED position, more torque for turning the racking handle is normal as the primary finger clusters engage with AKD6 primary bus stabs. Keep cranking as required, that is, when any further torqueing can’t be done.
  • Page 39 Figure 27. AKD-6 Stationary rail Tabs for Mounting Spring clips ( for Model 2 Breakers) LH side Stationary Rail RH side Stationary Rail Rail Latch RH TAB LH TAB INSTALLED LH SPRING INSTALLED RH SPRING CLIP CLIP SPRING CLIP INSTALLATION KIT PART # 2200053286A 3.
  • Page 40 4. Push the breaker into the compartment until it hits the first complete stop due to installed breaker installation tools (fig 28). 5. Push the breaker and sliding rails fully into the compartment. 6. Latch the inner rail with outer rail (fig. 29) by rotating the rail lever 7.

  • Page 41: Remove And Replace Existing Door

    Remove and Replace 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 42 Figure 30. Prepare AKD-6—Compartment 3. Check cabinet for suitability of retrofill. 4. Check each breaker compartment for bolted joints in the primary disconnect bars. Where such joints exist, check the bolts for tightness. 5. Inside the compartment, check the contact areas on each primary disconnect bar or cluster of fingers for foreign matter that may have accumulated.

  • Page 43: Install Neutral Ct Assembly (Bus Compartment)

    Install Neutral CT Assembly (Bus Compartment)  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 ...

  • Page 44: Multi-Source Ground Fault

    4. Disconnect the wires that are attached to the existing CT assemblies and place them so that they do not interfere with the replacement of the CT assemblies. 5. Unfasten and remove the bolts holding the neutral disconnect assemblies to the horizontal bus bars. Keep the hardware in a secure location for reassembly.

  • Page 45: Install 19-Pin Programmer Secondary Disconnect (Compartment)

    Install 19-Pin Programmer Secondary Disconnect (Compartment)  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 Figure 32. AKD-6—Slide the Inner Frame (Dimensioning) 8. Place the programmer disconnect assembly on the mounting holes (Figure 33) and secure it to the base of the programmer using hardware (Bolt—M6 X 35, Nut—M6 (metric)) provided along with the programmer disconnect assembly kit.
  • Page 47 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:

Akd6-1600aAkd6-2000a

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