ABB AKD-5 User manual

—
INSTALLATION MANUAL
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

—
ABB Electrification
Service
—
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).
ABB provides comprehensive maintenance, diagnostics, and repair services for
medium voltage and low voltage electrical apparatus.
The ABB Electrification Service offering is comprised of services that will help you to
take care of the equipment, modernize it, and recommend the most appropriate
business decisions toguarantee the availability, reliability and sustainability ofcritical
assets and meet your evolving needs.
Modernization
• Extensions, upgrades
and retrofits
• Replacement
• End-of-life services
Advisory
• Engineering and consulting
Care
• Installation and commissioning
• Spares and consumables
• Technical support and repairs
• Trainings
• Maintenance
• Advanced services
• Service agreements
Availability
Reliability
Sustainability
Predictability

1 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
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 ........................................................................................................................................................................... 6
Estimated Time to Complete Tasks ............................................................................................................................................ 6
Weight (LBS) ........................................................................................................................................................................................... 6
Description ....................................................................................................................................................... 7
Product Specs ....................................................................................................................................................................................... 7
History and Types ............................................................................................................................................
AKD ............................................................................................................................................................................................................. 8
AKD-5—AK-25, AK-50, AKT-50, AK-75, AK-100 ..................................................................................................................... 8
AKD-6—AKR-30/30H, AKR-50/50H/T50H, AKR-75/75H, AKR-100 ............................................................................... 9
AKD-8—AKR-30/30H/30L, AKR-50/50H/T50H, AKR-75/75H, AKR-100, 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 ........................................................................................................................................................... 10
Unpack Retrofill Circuit Breaker .................................................................................................................. 10
Quality .................................................................................................................................................................................................... 11
nformation Label ............................................................................................................................................................................. 11
Product and Catalog Serial Numbers ..................................................................................................................................... 11
Remove Circuit Breaker from Container ..................................................................................................... 11
nspect ................................................................................................................................................................................................... 11
Use Lifting Truck ............................................................................................................................................................................... 12
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

2 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
Rack Out Legacy Breaker ............................................................................................................................................................. 16
Empty Compartment—Legacy Breaker Removed ........................................................................................................... 16
Check, Clean, Grease Compartment ....................................................................................................................................... 16
Racking-Lock Bracket—Initial Tasks (AK-75, AK-100, AKR-75, AKR-100) ................................................. 1
Install Position Switch Actuator / Neutral CT Adapter Bracket Assembly .............................................. 1
AK-75, AK-100, AKR-75, AKR-100 Breaker ................................................................................................... 1
Install Rail Toggle Lever Lockout Brackets- AK-75, AK-100, AKR-75, AKR-100 ....................................... 21
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

3 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
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. 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 product safety, that need to be custom-written for particular or specific
circumstances (Table 2).
Table
1
.
Generic
Danger Alerts and Labels Used for Documentation and
Dangerous Equipment
Table
2
.
Custom
Danger Alerts and
Labels Used for Documentation and
Dangerous Equipment

4 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
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). 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 Us
ed for Documentation
and Dangerous Equipment
Caution
This pertains to a hazard that has a low level of risk, which means that if not avoided, it could result
in minor or moderate injury. t also indicates that failure to comply with instructions may result in product damage.
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

5 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
Notice or Note
This indicates important information in that it aids in job performance, that is, a notice or note is used to notify
practices not related to personal injury (Table 6).
Table
6
.
Custom
Notice
Alerts and Labels Used for Documentation
and Operating Equipment
Warranty
This document is based on information available at the time of its publication. While efforts have been made to
ensure accuracy, the information contained herein does not cover all details or variations in hardware and software,
not does it provide for every possible contingency in connection with installation, operation, and maintenance.
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. Not warrantees of
merchantability or fitness for purpose shall apply.
Contact your local sales office if further information is required concerning any aspect of EntelliGuard R Circuit
breaker operation or maintenance.
Trademarks and Patents
EntelliGuard
®
R
EntelliGuard
®
TU
EntelliGuard
®
Trip Unit
EntelliGuard
®
G
Standards
Agency Certification
Standard Number Title
ANS C37.13,16,17,20.1,50,51,59 Low-Voltage AC Power Circuit Breakers
UL 1066 Low-Voltage AC and DC Power Circuit Breakers Used in Enclosures
Document Conventions
Topics and text are divided into primary, secondary, and tertiary paragraph headings.

6 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
Related Publications
Publication
Publication Number
Brochure DEA-532
Snapshot DEE-543
nstallation Manual AKD-10 DEH-41550
nstallation Manual
AKD
-
8
DEH
41549
nstallation Manual AKD-6 (800A-2000A) DEH-41548
nstallation Manual AKD-5 (600A-2000A) DEH-41547
nstallation Manual AKD-5 and AKD-6 (3000A/3200A/4000A) DEH0005240
Accessory: Door nterlock (Door nterlock Kit) DEH-41529
Accessory Retrofill Doors Assembly DEH-41563
Accessory: Position Switch Plate & Position Switch Assembly & Wiring (Position Switch Kit) DEH-41530
Accessory: Neutral Rogowski CT Disconnect (Neutral
Assemblies)
DEH
-
41531
Accessory: Programmer Disconnects DEH-41532
Accessory: Finger Clusters (Cluster Assemblies) DEH-41533
Accessory: Secondary Disconnects DEH-41534
FAQ DEQ-171
Application Guide
DET
-
753
Guideform Spec DET-754
Spare/Renewal Parts Guide DET-755
Retrofill Neutral CT Adapter nstruction DEH0002400
Service and Support
n 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
t takes about 60 minutes to install a feature-for-feature LS assembly. This includes racking out the old breaker,
installing the (hollow–backed) drawout cassette and then racking in the new breaker, and replacing the door. f
new options are desired, or if it’s a 4-wire LS G circuit or modifications are needed to the cubicle, then additional
time is required. Time also does not include wiring the secondary disconnect on the Retrofill cassette.
Weight (LBS)
Table 7
Retrofill Breaker ~Weight ~Box Weight ~Pallet Weight ~Accessories Weight ~ Total Weight
AK-75 430 LBS 15 LBS 30 LBS 10 LBS 485 LBS
AK-100 460 LBS 15 LBS 30 LBS 10 LBS 515 LBS
AKR-75 460 LBS 15 LBS 30 LBS 10 LBS 515 LBS
AKR-100 490 LBS 15 LBS 30 LBS 10 LBS 545 LBS
Retrofill Cassette ~Weight ~Box Weight ~Pallet Weight ~Accessories Weight ~Total Weight
AK-75, AKR-75,
AKR-100, 150 LBS 15 LBS 30 LBS NA 195 LBS
AK-100 156 LBS 15 LBS 30 LBS NA 201 LBS

7 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
Description
Product Specs
AKD-6 Low Voltage Switchgear is a free-standing assembly of metal-enclosed ANS
power circuit breakers. t may also be a part of a single-ended or double-ended load center unit substation.
Figure 1shows the retrofill circuit breaker projected out of its cassette. Figure 2 shows the AKD-6 retrofill breaker in
the cassette. This is an R24051 4000A EntelliGuard R breaker & cassette to replace an AKR-#C-100 breaker.
Figure
1
.
EntelliGuard
R Retrofill (Circuit Breaker Projected
from Cassette)
Figure
2
. EntelliGuard
R AKD
-
6
Retrofill
(Drawout Code C)
(Front View)
A rear view of the AKD-6 is featured in Figure 3 and Figure 4shows the AKD-6 without its cassette.
Figure
3
. EntelliGuard
R AKD
-
6
-
Retrofill
Breaker
(Rear View)
Figure
4
. AKD
-
6
-
Retrofill Breaker without
Cassette (Front View)
Figure 5shows a rear view of the AKD-6 - retrofill cassette, or substructure, without the breaker; Figure 6shows a
front view of the cassette.

8 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
Figure
5
.
AKD
-
6
-
Retrofill Cassette Assembly (Rear
View)
Figure
6
.
AKD
-
6
-
Retrofill Cassette Assembly (Front
View)
The EntelliGuard R Circuit Breaker is suitable for application on power systems up to 635 VAC 50/60 Hz.
History and Types
AKD
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; with a 4000A-max bus rating. Breakers had a ratcheting drawout mechanism, with an open-door drawout.
Breakers were painted ANS 61, light gray, manufactured in Philadelphia from 1951 to the mid-60s and in Burlington,
owa from the mid-60s to 1975.
The breaker compartment was a welded assembly, and the equipment frame was bolted. Breaker boxes were
stacked to make a vertical section with equipment frame around the breaker boxes. There were no bus
compartment barriers, just an open bus design. Ring silver-plating was applied to bolted connections.
AKD-5—AK-25, AK-50, AKT-50, AK-75, AK-100
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.
Breakers up to 2000A had primary finger clusters. 3000 & 4000A breakers had a circular primary finger cluster
arrangement in the switchgear compartment. Pull-lanyard drawout mechanism in the switchgear on early designs
was replaced by a single jackscrew mechanism and then later replaced by a double jack-screw mechanism.
Featured is a closed-door, drawout with inner house breaker compartment, where door moves with the breaker as it
is racked in or out. Two bus levels are available with a ring bus used at 4000A. Particulars include: welded/riveted
frame, bus compartment barriers, line/load separation barriers on mains and ties, isolation barriers on transformer
transitions, copper runbacks on feeder breakers, 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”. EntelliGuard R Retrofill breakers for this gear will
have a catalog number beginning with R1 for AK replacements or R2 for AKR-30/50 replacements.
LOAD NG RA LS
LOCK NG LATCH
BOTH S DES

9 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
AKD-6—AKR-30/30H, AKR-50/50H/T50H, AKR-75/75H, AKR-100
AKD-6 was manufactured in Salisbury, NC from 1977 to 1981. Some AKD-5s, which were built in Salisbury from 1975
until 1977, got name-plated as AKD-6. There is no “flash-butt” welded aluminum to copper. Aluminum bus is tin-
plated and bolted at shipping splits (but welded everywhere else) . Copper bus design has ring silver plating at bolted
joints. 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.
The AKD-6 uses inner-house drawout breaker compartments on the 800—2000A breaker compartments. They are
painted ANS 61 light gray and breakers have ECS or SST trip units.
AKD-6 should mark a shift away from all AK breakers and to AKR breakers. The AKR-30/50/50H/T50 breakers used in
AKD6 have a shallow 1” steel front escutcheon are drawout letter code “A” i.e. AKR-4A-30 and will be replaced by an
EntelliGuard R with a catalog number beginning with R2. The AKR-30/50/50H/T50/75/100 breakers sold to OEMs for
their switchgear have a 5” deep plastic front escutcheon & 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 up to
2000A frame size and R6 for 3200 & 4000A frame sizes.
The AKR-75/100 breakers used in AKD-6 have a shallow 1” steel front escutcheon and vertical primary fingers. They
are drawout letter code”C” i.e. AKR-4C-75 and will be replaced by EntelliGuard R with catalog # beginning with R2.
AKD- —AKR-30/30H/30L, AKR-50/50H/T50H, AKR-75/75H, AKR-100, AKR125
AKD-8 was manufactured in Salisbury, NC from 1980 to 1984 and in Burlington, owa from 1984 to 1999. t was
mostly replaced by AKD-10 in 1999 to 2000 but was available thru 2015. Model 1 and 2 have extruded 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, EP C, 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) .
The AKR-30/50/50H/T50 breakers used in AKD8 have 5” deep plastic front escutcheon& spring loaded sliding
“picture frame”. They are drawout letter code “D” i.e. AKR-7D-30. n AKD-8, most 800-2000A breakers are “feeder”
breakers with vertical lower stud & primary disconnect fingers clusters, but 800-2000A breakers designated as
“Main” breakers, have horizontal lower finger clusters, which is the same as “D” letter code breakers sold to OEM’s. A
lower stud rejection bracket differentiates between lower stud orientations. EntelliGuard R breakers with a catalog
number beginning with R3 replace an AKR-30/50/50H/T50 breaker with vertical lower stud & fingers. EntelliGuard R
breakers with a catalog number beginning with R6 replace an AKR-30/50/50H/T50 breaker with horizontal lower
stud & fingers.
AKR-75/100/125 circuit breakers used in AKD-8 switchgear have a 5” deep plastic front escutcheon & spring loaded
sliding “picture frame” similar to the small frame breakers. The positions D SC/TEST/CONN are shown on the side of
the front escutcheon by position of the sliding “picture frame”. The AKD-8 breakers have a drawout letter code “D”.
OEM versions are drawout letter code “B” and 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. t was release in 1995. None of the retrofill breakers utilize fans.
EntelliGuard R breakers with a catalog number beginning with R3 replace and AKR-75/100/125 breakers in AKD-8
switchgear. EntelliGuard R breakers with a catalog number beginning with R6 replace and AKR-75/100/125
breakers in OEM switchgear or switchboards or Switchboard which all utilize an OEM substructure mounted on a
shelf. The R6 breakers will require a different door with a “bump inward” as the original compartment depth is 1.4”
greater than AKD-8.

1 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
AKD-10—WPS-0 , WPH-0 , WPX-0 , WPS-16, WPH-16, WPS-20, WPS-32, WPH-32 WPX-32, WPS-40,
WPX-40, WPS-50, WPX-50
AKD-10 was manufactured in Burlington, A from 1999 thru 2015. The switchgear compartment sizes and main &
vertical bus arrangements are the same as AKD-8 Model 3. The compartments have pull-out rails. AKD-10 uses
WavePro * drawout-only style breakers. All breakers have 4 rollers which align with the compartment rails. The
secondary control wiring for all functions is connected thru either one or two 36 point secondary disconnects with
gold plated contacts. Secondary control wiring terminates at fixed standard locations on the 36 point disconnects.
Each breaker has a pump style manual charging handle and manual push OPEN and Push CLOSE buttons. The front
escutcheon is 5” deep with a sliding picture frame, but is wide enough so the trip unit and new style bell alarm are
visible thru the front door of the switchgear. EntelliGuard R breakers with a catalog number beginning with R7 will
replace a WavePro breaker with a catalog number beginning with WE or W1. EntelliGuard R breaker with a catalog
number beginning with R will replace a WavePro breaker with a catalog number beginning with WS or W2. Note
Switchboard plants initially shipped “WS” style breakers and later shifted to “WE” style breakers to be consistent
with Switchgear from Burlington, owa. The 5000A breaker had cooling fans. None of the retrofill breakers utilize
fans.
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.
Always wear personal protection equipment
according to OSHA standards and appropriate
to the severity of potential burns.
•Ensure only qualified personnel install, operate, service, and maintain all electrical
equipment.
Falling Object
•Do not walk or remain under any heavy assembly while
hoisted above head as the chains securing 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.

11 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
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 slide the circuit breaker
across a hard or rough surface
•A factory-installed rejection feature prevents mismatching circuit breakers and
cassettes/substructure, preventing the insertion of a circuit breaker with a lower rating into a higher
rated cassette/substructure, or the insertion of a higher rated circuit breaker into a lower rated
cassette/substructure.
Quality
All EntelliGuard R circuit breakers have been designed and manufactured to ANS standards. The design was based
on the original requirements from the Legacy Switchgear and Breaker. The product is assembled in the Burlington,
owa factory; and is inspected using some of the same master gauges used on the legacy AK, AKR breakers to
confirm electrical and mechanical performance.
Information Label
On the side wall of each circuit breaker there is a factory-assembled, side label that details all features included on
both the circuit breaker and on the trip unit.
Product and Catalog Serial Numbers
Product and catalog serial numbers should be kept handy when communicating about the circuit breaker. Each
circuit breaker has a unique serial number located on the left side (viewed from front) of the front fascia.
Remove Circuit Breaker from Container
Inspect
1. nspect 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 off the top cover.
4. Remove all packaging material.
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.

12 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
Use Lifting Truck
1. Use a lifting truck for moving circuit breaker in order to avoid personal injury and damaging
the breaker.
2. Use a proper overhead lifting device to mount the breaker into the switchgear
3. Use lifting kit 0247B8961G007 for balanced 3 point lifting of these type breakers.
4. Contact the nearest sales office for availability of a hoisting device.
5. Avoid using hooks and chains since chains can damage the fascia of the circuit breaker.
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
LIFTING KIT – 0247B 961G007
EntelliGuard R AKD-5, AKD-6
3000A-4000A RETROFILL

13 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
7. Avoid using hooks and chains since hooks can damage or bend the “ears” or may damage the fascia see
Figure 8 and Figure 9.
Figure
. Crane Lifting Hooks
Can Damage lifting
Ears
and
Chains Can Damage or Scratch Fascia
Figure 9. Lifting using Kit
0247B 961G007

14 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
Store Circuit Breaker
f not installing the retrofill breaker until a later time, store it properly.
PRODUCT DAMAGE
Do not store circuit breaker in corrosive
environments above LC1 (sea salt mist)
and G1 as per ANSI/ISA-S71.04-19 5.
•Ensure circuit breakers and cassettes are
stored in a clean, dry location, in their
original packaging.
•Failure to comply with these instructions
may result in product damage.
1. Store the circuit breakers in a clean, dry location in an upright position.
2. Make sure that the breakers are properly supported to prevent bending of the studs or damaging any of the
breaker parts. Do not remove any protective grease until the breaker is ready to be installed. Cover to prevent
dust from settling on the breakers if they are not left in their original containers.
3. f breakers are not to be placed in service immediately, remove them from their shipping cartons and thoroughly
inspect them.
4. f everything is in satisfactory condition, replace the breakers into their shipping cartons for storage.
f it is necessary to store the equipment for any length of time, follow these precautions to prevent corrosion or
deterioration.
5. Store in a clean, dry, rodent-free location with moderate temperature and provide protective coverings to
prevent dirt, water, or other foreign substances from entering the breaker.
6. f dampness or condensation is encountered in the storage location, heaters can be used to prevent moisture
damage. Check Before nstalling
•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.
•
Ensure only qualified personnel install, operate, service, and maintain all electrical
equipment.

15 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
These retrofill breakers are designed to rack into a special Cassette with a hollow back. The special cassette is
equipped with AK style 7 point bullet connectors which interface with the original AKD-5/6 secondary disconnect
blocks. 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.
1. Check to see that the breaker or breakers match their respective compartments.
2. Read the breaker summary sheet, the front view drawings, breaker nameplate, and the identification card on the
breaker shipping carton.
3. To match the breaker to its proper compartment, refer to the breaker location list on the old original switchgear
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 breakers have the same mark numbers.
Clean and Grease Breaker
1. Before installing or operating a breaker, refer to the EntelliGuard G Breaker DEH-41304 instruction manual for
pre-operation inspecting and testing.
2. Check thoroughly for any damaged or loose parts and for any dirt or foreign matter which may be on 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 Mobilgrease 28 (D50HD38) to the primary disconnect fingers
for better electrical connections on the breaker. Part # 193A1751P1 is a 1 oz. tube of this grease.
Customize Retrofill Secondary Wiring
WIRING
•Before installing the breaker, the
secondary disconnect bullets on the rear
of the cassette must be wired to the
EntelliGuard secondary disconnects on
the front of the cassette.
•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. This ensures that all wiring
connections are properly made.
•Wrong connections will cause the breaker
to malfunction.

16 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
Modify AKD-5 Switchgear Compartment
Turn OFF/ OPEN the Legacy Circuit Breaker
1. Before modifying the switchgear compartment, de-energize/switch off the breaker. f 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.
Rack Out Legacy Breaker
1. To rack-out legacy (old or original) breaker from the compartment, refer to your legacy-breaker’s manual on how
to remove the existing breaker or contact a qualified Field Service Engineer.
Empty Compartment—Legacy Breaker Removed
Figure 10 Shows an empty AK75 compartment.
Check, Clean, Grease Compartment
1. nspect the compartment for damage.
2. Check compartment for suitability of retrofill.
3. Having fully de-energized primary and control power, check each
breaker compartment for bolted joints in the primary disconnect bars.
Where such joints exist, check the bolts for tightness.
4. nside the compartment, check the contact areas on each primary disconnect bar or cluster of fingers for foreign
matter that may have accumulated. Clean those areas if necessary with a clean, lint-free rag and isopropyl
alcohol or acetone.
5. Be sure to apply a thin film of electrical grease Mobilgrease 28 (D50HD38) to the contact areas for better
electrical connections inside the compartment.
6. f compartment has a position switch and a position switch actuator will be added to the cassette, see nstall
Position Switch Actuator section appropriate for the particular frame size breaker.
7. nstall the AKD-5 AKD-6 retrofill cassette.
. Locate and replace Kirk key slide return spring on left side of AK75 and AK100 compartments (supplied with the
cassette assembly as a kit). nspect the Kirk key slide mechanism, grease with Mobilgrease 28 (D50HD38) if
required.
9. nstall parts to prevent use of the old/original legacy Draw out Mechanism.
Figure
10
. AKD
-
5
—
Empty C
omp’t

17 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
Figure 10A / 10B. AK
-
75 & AK
-
100
–
Retrofill Kit
s
Figure 10A
SUPPL ED W TH
CASSETTE AS A
RETROF LL K T
Figure 10B
SUPPL ED W TH
CASSETTE AS A
RETROF LL K T

18 EntelliGuard R Circuit Breaker Retrofill AKD-5/6 Installation Manual DEH 524 R 1
Figure
11
. AKD
-
5
—
Cassette
1. Field wire the cassette from the 21 pt bullet sec disc’s to the EntelliGuard front Sec Disc’s Figure 11.
2. Remove Anti-tilt brackets and place the cassette side pins into the rails of the switchgear cabinet.
3. nstall Anti-tilt Brackets and NCT adapter/Position switch actuator bracket assembly (Figures 13A-F).
4. Slide the retrofill cassette into the compartment (defeat rail stops on both sides) until dead-stop.
5. Lock the rails of the legacy compartment using both rail locking levers.
6. Disable the legacy racking mechanism and install rail lever lockout brackets ( 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
AK-75, AK-100, AKR-75, AKR-100 Breaker
nstalling the position switch actuator needs to be done after the cassette is installed onto the legacy switchgear
rail system. This can be done before pushing the cassette fully into the compartment. Steps of installation for the
position switch actuator are as follows.
Figure 12A Figure 12B
Cassette shown
with Loading Rails
Extended.