ABB Emax 2 Retrofill AKR-100-A, Installation And Maintenance Manual

Page 1: ...structures found in GE Switchboards 800A 2000A AKR A 30 50 T50 3200A 4000A AKR C 75 100 OEM Substructures Equipment using legacy AKR circuit breakers of the following types AKR B 30 50 T50 75 100 is shown in place of a number which designates the trip unit type Installation and maintenance guide Emax 2 Retrofill Circuit Breakers Direct Replacement of Legacy GE AK 800A 4000A Circuit Breakers Used i...

Page 2: ...TROFILL 22 PREPARE SWITCHGEAR COMPARTMENT 24 INSTALLING AKD 6 RETROFILL CIRCUIT BREAKER 24 21 Breaker Installation Overview 25 22 For AKR 30 50 T50 AKD 6 Retrofill Breaker 26 INSTALL OR INSERT AKD 6 RETROFILL 29 INSTALLATION OF AKD 6 AKR 75 100 Retrofill Breaker AKD 6 INSTALL ACCESSORIES 30 30 23 AKD 6 Secondary Disconnects Bullets 36 24 19 pin Programmer Secondary Disconnect Breaker 39 25 Install...

Page 3: ... seriously when install ing Retrofill circuit breakers in AKD other OEM s switchgear and when working with pote ntially dangerous electrical equipment Table 1 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 instal lation manuals These are standard or generic alerts and l...

Page 4: ... also indicates that failure to comply with instructions may result in product damage Table 3 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 4 Custom Caution Alerts Custom Notice Alerts 4 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 2TSA451014P0000 Rev B ...

Page 5: ...e accuracy completeness sufficiency or usefulness of the information contained herein No warrantees of merchantability or fitness for purpose shall apply Contact Email Phone 888 385 1221 if further information is eppc support us abb com required concerning any aspect of Emax 2 Retrofill Circuit breaker operation or maintenance Emax 2 Retrofill Emax 2 Retrofill TU Ekip DIP Ekip Touch Ekip Hi Touch ...

Page 6: ...1014P0000 Rev B Installation Manual AKD 10 Installation Manual AKD 8 Installation Manual AKD 6 Installation Manual AKD 5 Accessory Door Interlock Door Interlock Kit Accessory Kirk Key Installation Manual Accessory Retrofill Direct Replacement CiC Full Door Kits AKD 5 6 8 10 Accessory Retrofill Direct Replacement CiC Adaptors Kits AKD 5 6 8 10 Accessory OEM Direct Replacement Adaptor kits AKD 8 10 ...

Page 7: ... RMS9C trip units Non Automatic 2 3 4 5 6 7 8 9 10 N Figures 2 3 Fig 2 AKD 6 AKR30 Breaker in Cassette Rear View Fig 3 AKD 6 AKR50 Breaker in Cassette Rear View 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 7 2TSA451014P0000 Rev B Retrofill Breaker which replaces AKR 30 800A AKR 50 1600A AKRT 50 2000A AKR75 3200A w o Fans AKR100 4000A w Fans Weight 184 230 270 552 572 11 11 11 15 15 BOX Weight...

Page 8: ...T 50 Breaker in Cassette Rear View Figure 5 Emax 2 Retrofill Circuit Breaker is suitable for application on power systems up to 635 VAC 50 60 Hz 8 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 2TSA451014P0000 Rev B Figure 5a Front View Figure 5b Rear View ...

Page 9: ...uminum 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 None of the Emax 2 Retrofill breakers utilize fans except for 3000A rating only Note All legacy AK AKR b...

Page 10: ... 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 2 cooling fans It was release in 1995 None of the Emax 2 Retrofill breakers utilize fans except for 4000A rating only AKD 10 was manufactured in Burlington IA from 19...

Page 11: ...0000 Rev B Feature AKR 30 50 AKRT50 Retrofill Breaker 800A 1600A 2000A AKR 75 100 Retrofill Breaker 3200A 4000A Rail latch defeat Breaker mounted mechanism is removed No levers on the breaker side panels Needs Spring clip installation in the compartment to achieve rail latch defeat Existing AKD6 Racking Mechanism will be reused Rail Latch Defeats are not requred or installed on the loading rails S...

Page 12: ...eaker Dimensions The following engineering or assembly drawings describe the layout and dimensions of the AKD 6 Retrofill breaker 12 AKD 6 Mechanical Drawings AKD 6 AKRT 50 Retrofill Breaker Dimensions 12 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 2TSA451014P0000 Rev B Figure 7 ...

Page 13: ...ns 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 13 2TSA451014P0000 Rev B Forced cooling Fans for 4000A Rating only Fans Turn ON at 3600A and OFF at 3400A For other detail related to Trip unit config and wiring refer to Fan control section in manual ...

Page 14: ... AKR 30 50 T50 and figure 12 represents typical AKR 75 100 AKD 6 compartment Figure 10 AKD 6 Switchgear Empty Compartment Figure 11 AKD 6 Compartment Distinctions 14 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 2TSA451014P0000 Rev B AKD 6 3200A 4000A Compartment Figure 12 ...

Page 15: ...n this figure there is also a photo showing a mechanically operated status indicator connect disconnect that worked with the original breaker This device if left in the compartment as is won t interfere with the retrofill breaker it can however be disassembled by removing its hardware Figure 14 displays the bus inside the gear Figure 14 Figure 13 AKD6 Breaker Compartment Upper and Lower Compartmen...

Page 16: ...emove the existing breaker 15 Rack Out AKD 6 Legacy Existing CB 16 Check Clean Grease AKD 6 Compartment 1 Inspect the compartment for damage or signs of overheating 2 Check the orientation of primary finger clusters match the switchgear stabs 3 Check racking pin diameters agree with breaker racking cam slots 4 Check the secondary disconnect integrity their mounting supports for any damage or crack...

Page 17: ...ves 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 slide the circuit breaker across a hard or rough surface A factory installed rejection feature prevents mismatching...

Page 18: ...igns 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 material 5 Remove all product documentation and store properly 6 Unscrew the mounting screws that fa...

Page 19: ...rrosion 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 If dampness or condensation is encountered in the storage location heaters can be used to prevent moisture damage 7 After prolonged storage Level 1 maintenance is needed under two years of stora...

Page 20: ...ork 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 Danger Check Before Installing 20 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 2TSA451014P0000 Rev B 1 Before installing or operating a breaker refer to the breaker instruction manual for pre...

Page 21: ...ovided 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 Notice Modify Retrofill 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 21 2TSA451014P0000 Rev B ...

Page 22: ...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 Clean those areas if necessary with a clean lint free rag and isopropyl alcohol or acetone Be sure to apply a thin film...

Page 23: ...ator is using the prescribed PPE for the specified tasks Ensure only qualified personnel install operate service and maintain all electrical equipment Danger Notice 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 r...

Page 24: ...Drive out the pins Remove both right and left side levers torsion springs and roll pins After loading the new breaker and sliding the rails fully inward the rail levers are toggled as usual the breaker inner housing can be pushed inward until the new breaker s racking cams engage the compartment racking pins Then the door can be closed and the breaker can be racked in normally The rail latch defea...

Page 25: ...he Loading Stop Tool back on the left side frame of the breaker 8 Now the new retrofill breaker can be racked in using the racking mechanism provided in the breaker 9 Follow the procedure steps from 15 to 25 as described for installing AKR 30 50 T50 retrofill breaker LH side Stationary Rail RH side Stationary Rail 1 After the legacy breaker is removed Check that everything in the compartment looks...

Page 26: ... rail slots 4 Make sure that the lifting bar is secured and locked in placed on the breaker 5 Check that the retrofill is free from obstruction inside the compartment 6 When the breaker is lined up with the compartment raise the breaker only slightly higher than the compartment floor keeping it at slight angle Figure 21 AKD 6 Rails or Arms for Mounting Retrofill Cassette CB 7 Keep the breaker stea...

Page 27: ...eaker 11 Note Now the new retrofill breaker can be racked in using the racking mechanism provided in the breaker Figure 23 Latching Inner Rail with Outer Rail 15 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 16 Use a blade type screwdriver in the slot or rack out lock of the breaker fig 24 and tur...

Page 28: ...TEST position The AKD 6 7 pt Secondary Disconnect Blocks will have full conductive copper Ag plated strips including the ramp that depresses the Secondary Bullets on the breaker In case Emax2 Retrofill breakers Secondary Bullets touch those in the DISConnect Position and if this must be isolated then the old Secondary Disconnect Blocks would need to be replaced with the new ones that have the fron...

Page 29: ... AKR75 100 Retrofill breaker from disconnect postion to connect position Follow the indications on the drum indicator on the legacy switch gear 4 The Installation sequence for AKD6 Emax2 AKR75 100 Retrofill Breaker into AKD 6 Co mpartment is explained through Figs 26a g Figure 26 INSTALLATION SEQUENCE FOR AKD 6 EMAX2 AKR75 100 RETROFILL BREAKER INTO AKD 6 COMPARTMENT a b c d f g e AKD6 AKR75 100 C...

Page 30: ...tion requires installing all 3 secondary disconnect blocks actually three sets of bullets you would select the first option As secondary disconnects can be pre installed on the breaker wiring the secondary disconnects can be done In case the application does not require any secondary disconnect assemblies take the second option Thus no further wiring is needed If the application requires less than...

Page 31: ...ds on to the fixing plates using the hardware provided as mentioned above The nuts must be tightened hand tight 8 Verify that the wire markers are clearly visible and not damaged so that they are wired easily and efficiently 9 Be careful that that the wires are not pinched or damaged while installing the secondary disconnect blocks For AKR 30 50 T50 75 100 AKD6 retrofill breakers 1 If the Emax 2 r...

Page 32: ...ucture as it might interfere with the motion of the kit during the racking into the compartment Also it should be kept in mind that the wires are securely fixed on the inside metal frame of the Retrofill kit with tie wraps 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 routi...

Page 33: ...Table 6 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 33 2TSA451014P0000 Rev B ...

Page 34: ... of 24V 2 This is a sample wiring diagram For exact connection points on the fixed side refer the wiring diagram supplied with original breaker Refer Emax catalogue for all other available connection schemes 34 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 2TSA451014P0000 Rev B Table 7 ...

Page 35: ...ne can be supplied 3 M indicates when the circuit breaker has two or three applications but only one can be supplied 4 A7 A8 A5 A6 A9 A10 A11 A12 A13 use wire length 150mm 5 Emax 2 standard offering ST1 UVR1 CC or CCC UV2 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 35 2TSA451014P0000 Rev B Table 8 ...

Page 36: ...he 19 pin programmer disconnect on the AKR30 50 bottom side of the breaker already installed Table 9 displays the wiring diagram for the programmer discon nect 12 pin and 19 pin combined in one diagram although the AKD 6 does not use the 12 pin features an exploded view of the 19 pin programmer disconnect An installed view of the 19 pin programmer disconnect appears in For the compartment side the...

Page 37: ...ploded view of the 19 pin programmer disconnect An installed view of the 19 pin programmer disconnect appears in Figure 31b For the compartment side the 19 pin programmer disconnect comes in a box Figure 31a 19 Pin Programmer Disconnect for the AKD 6 AKR75 100 Retrofill Exploded View Figure 31b 19 Pin Programmer Disconnect AKD 6 AKR75 100 Retrofill Installed 19 PIN PROGRAMMER DISCONNECT ASSEMBLY E...

Page 38: ... to its maximum inserted condition 5 This position corresponds to the frame position when the breaker would be in fully connected 6 Use the slot inner semicircle as a datum reference and mark the mounting hole locations using the template shown in figures 32 34 Dimensions shown are in inches 7 Drill inch diameter holes at 4 locations as marked in figures 32 34 It must be ensured that the supply po...

Page 39: ...dware hand tight 11 From the disconnect plug route the wire to suitable incoming cables from the compartment AKD 6 AKR75 100 Slide the Inner Frame Dimensioning 9 957 6 940 8 511 4 038 b AKD 6 AKR75 100 Holes Drilled for Mounting Programmer Disconnect c AKD 6 AKR75 100 Programmer Disconnect Assembly Secured in Place AKD 6 Programmer Disconnect Assembly Secured in Place AKD 6 Holes Drilled for Mount...

Page 40: ...Figure 35 Wiring Diagram for the AK AKR Retrofill 40 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 2TSA451014P0000 Rev B ...

Page 41: ... bracket on the bottom right side of the AKD6 base Two locating holes are provided for mounting of the position switch bracket 3 Fasten the two bolts to the locating holes after placing the washers to securely mount the bracket 4 The bracket is ready for use Figure 36 AKD 6 Position Switch Actuator Breaker Side and Parts Note Individual hardware for the position switch actuator cannot be ordered s...

Page 42: ...ctrical equipment Danger 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 Figure 37 shows the components that make up the AKD 6 AKR30H 50H retrofill door interlocking assembly Figure 37 AKD 6 AKR30H 50H Door Interlocking Components The sequence of assemb...

Page 43: ...in 4 Mount the free end of the torsion spring on the bracket as shown 5 Insert the E clips mentioned in Step 1 to complete the assembly Figure 38 Figure 39 AKD 6 AKR30H 50H Door Interlock Assembly exploded view The completed assembly of the door interlock will be as shown below DOOR INTERLOCK ASSEMBLY EXPLODED AKD6 AKR30H 50H RETROFILL 6 For AKD6 AKR75 100 Retrofill The Existing Door Interlock in ...

Page 44: ...be available prein stalled and wired from the factory Figure 40 Neutral Disconnect Assembly for the AKD 6 AKR30H 50H Retrofill Neutral Disconnect Assembly for the AKD 6 AKR75 100 Retrofill Emploded View Neutral Disconnect Assembly AKD 6 AKR75 100 Neutral Disconnect Connected Inside AKD 6 AKR75 100 Compartment 44 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 2TSA451014P0000 Rev B Figure 41 a a ...

Page 45: ...ram Note U1 U2 Emax 2 motor operator 120 V terminal NOTE 1 In the absence of motor or if motor voltage rating is different than 120 V connect 120 V directly to T1 and T2 Refer 2TSE432074P1000 and 2TSE432048R1000 for the wire length and lug details Wiring Diagram AKR 100 4000A Fan Control Unit Wiring Trip unit Programming instructions 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 45 2TSA451014P...

Page 46: ...Figure 44 Wiring of WP 4000A breaker with FAN control unit 46 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 2TSA451014P0000 Rev B ...

Page 47: ...ouch Trip unit Figure 45 27 Connecting Ekip Touch Connet Ekip Touch or Hi Touch Trip unit using Ekip connect 3 0 357 9 or later software and Ekip T P unit 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 47 2TSA451014P0000 Rev B ...

Page 48: ...tion with Trip unit absent If the Ekip Signalling 2K module is detected correctly by Ekip Touch the specific configuration area in the Modules Settings menu is activated For each Ekip Signalling 2K module detected by Ekip Touch a specific menu is available containing the submenus of all the available and configurable inputs and outputs Power LED reports ON status and correct communication with Eki...

Page 49: ... lines to be combined with the programmable contacts of the Ekip Signalling modules Two pairs of programmable contacts are available Threshold 1 I1 and Threshold 2 I1 with control referred to I1 Threshold Iw1 and Threshold Iw2 with control referred to In For Fan control configure Iw1 and Iw2 29 Configuring threshold currents 0 90 0 85 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 49 2TSA451014...

Page 50: ...tput Figure 49 Figure 50 The output of 2K 1 module consists of 2 contacts K11 K12 and K13 K14 Configure these two output contacts as per following to control the fans 50 2022 Emax 2 Retrofill Circuit Breakers 800A 4000A 2TSA451014P0000 Rev B ...

Page 51: ...ions The Autotest command closes the contacts regardless of the configuration set by the user Autotest command that activates the automatic sequence of output tests contacts and LEDs and input test LED and includes the following operations The output of 2K 1 module consists of 2 contacts K11 K12 and K13 K14 Configure these two output contacts as per following to control the fans 2022 Emax 2 Retrof...

Page 52: ...ibility whatsoever for potential errors or possible lack of information in this document We reserve all rights in this document and in the subject matter and illustrations contained therein Any reproduction disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB Copyright 2022 ABB All rights reserved ...