ABB Emax 2 Retrofill, Installation And Maintenance Manual

Page 1: ...ype ANSI Low Voltage Power Circuit Breakers This manual applies to both Emax 2 Retrofill breakers for AKD 10 switchgear and OEM substructures Installation and maintenance guide Emax 2 Retrofill Circuit Breakers Direct Replacement Replacing legacy GE WaveProTM 800A 5000A WavePro integrally fused 800A 1600A Circuit Breakers used in AKD 10 Substructures Emax 2 Retrofill Circuit Breakers Installation a...

Page 2: ...FUSED RETROFILL BREAKER 71 39 Fuse size and mounting 71 40 Special 2500A Fuse for WPF 16 72 OPEN FUSE LOCKOUT DEVICE 75 C ...

Page 3: ...ic alerts and labels that must be taken quite seriously when installing Retrofill circuit breakers in GE OEM switchgear and when working with potentially 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 installation manuals These are...

Page 4: ...esult in minor or moderate injury It 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 C ...

Page 5: ...ory with respect to and assumes no responsibility for the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply Contact your local sales office if further information is required concerning any aspect of Emax 2 Retrofill Circuit Breaker operation or maintenance Emax 2 Retrofill Emax 2 Retrofill TU Eki...

Page 6: ...lation 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 Door AdaptorsKits AKD 5 6 8 10 Accessory OEM Direct Replacement Adaptor kits AKD8 10 Accessory OEM Direct Replacement Adaptor kits AKD8 10 AKR 75 100 B F TYP...

Page 7: ...g switchgear Emax 2 Retrofill breakers are cost effective solution to upgrade the existing electrical system Direct Replacement is the solution where the legacy WavePro circuit breaker is removed and a new circuit breaker is provided which racks into the existing Switchgear Compartment The direct replacement retrofitting kit allows a reliable upgrade of the old GE legacy breakers to new Emax 2 Ret...

Page 8: ... 3 Figure 4 AKD 10 800A to 2000A WPX 08 WPS 16 WPH 16 WPS 20 Back View Primary Finger Clusters AKD 10 800A WPS 08 WPH 08 Front View Primary Finger Clusters AKD 10 3200A WPS 32 WPH 32 WPX 32 WPS 40 WPX 40 Front view C ...

Page 9: ...WPS 32 WPH 32 WPX32 Back view AKD 10 4000A WPS 40 WPX 40 Back View AKD 10 5000A WPS 50 WPX 50 Front View AKD 10 5000A WPS 50 WPX 50 Back View Emax 2 Retrofill Circuit Breaker is suitable for application on power systems up to 635 VAC 50 60 Hz C ...

Page 10: ...solation 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 cu...

Page 11: ...reakers have a drawout letter code D OEM versions are drawout letter code B and GE Switchboard versions are drawout letter code FP 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 ...

Page 12: ...2000A Retrofill Breaker Dimensions WPX 08 WPS 16 WPH 16 WPS 20 AKD 10 3200A Retrofill Breaker Dimensions WPS 32 WPH 32 WPX 32 The following engineering or assembly drawings describe the layout and dimensions of the AKD 10 Retrofill breaker AKD 10 Retrofill Breaker 11 AKD 10 Mechanical Drawings C ...

Page 13: ...n ON at 3600A and OFF at 3400A For other detail related to Trip unit config and wiring refer to Fan control section Breakers ordered with a 3600A Rating plug for max 90 load do not require fans AKD 10 5000A Retrofill Breaker Dimensions WPS 50 WPX 50 The legacy WavePro 5000A breaker was equipped with fans The Emax 2 5000A retrofill does NOT require fans C ...

Page 14: ...mpartment with Shutters NOTE Section width 22 800 2000A AKD 10 Empty Compartment with Racks Rails Extended 12 Interior View AKD 10 Compartment The figures below present a new AKD 10 compartment with one photo showing the rails extended C ...

Page 15: ...ll 800 1600 2000 compartments See Modify AKD 10 Switchgear Compartment Once spacer Blocks are a added behind Secondary disconnects the Legacy WavePro circuit breakers must not be installed AKD 10 Circuit Breaker Compartment for Wave Pro breakers Major components of an AKD 10 compartment AKD 10 Empty Compartment NOTE Section width 30 3200 4000A 38 5000A C ...

Page 16: ...partment with Racks Rails Extended Figure 18 Figure 19 15 Interior Components AKD 10 Circuit Breaker Compartment for WPS 32 WPH 32 WPX 32 WPS 40 WPX 40 WPS 50 WPX 50 Breakers Major components of an AKD 10 compartment C ...

Page 17: ...r s manual on how to remove the existing breaker 17 Rack Out AKD 10 Legacy Existing CB 18 Check Clean Grease AKD 10 Compartment Inspect the compartment for damage or signs of overheating Check the orientation of primary finger clusters match the switchgear stabs Check racking pin diameters agree with breaker racking cam slots AKD 10 has a large diameter pin and cam slot on right side Check the sec...

Page 18: ...auges used on the legacy WavePro breakers to confirm electrical and mechanical performance including rejection features Install the spacer block provided as shown in Figure 20 below Remove the protective tape on the block and stick it on the secondary disconnect mounting plate as shown in Figure 20 Be sure the spring is moved to the front of the spacer block Optional The hole in the spacer block c...

Page 19: ...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 pallet and remove the circuit breaker 7 Reverse the orientation of two shipping plates with flanges inward and reinstall on breaker 3200A 4000A 5000A only These flanges will keep the breaker from resting on the r...

Page 20: ...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 slide the circuit breaker across a hard or rough surface A factory installed r...

Page 21: ...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 Mobilgrease 28 to the primary disconnect fingers Figure 21 and 22 Primary Contacts or Fingers Apply Grease to sliding surfaces Figure 21 Figure 22 Primary Contacts or Fingers Apply Grease to sliding surfaces Clean and Grease Br...

Page 22: ...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 Danger These breakers are supported on two extendable rails each breaker has four rollers Racking arms on both sides of the breaker frame engage the drawout mechanism pin...

Page 23: ... coverings to prevent dirt water or other foreign substances from entering the breaker If dampness or condensation is encountered in the storage location heaters installed in the switchgear can be used to prevent moisture damage After prolonged storage Level 1 maintenance is needed under two years of storage While Level 2 maintenance is needed over two years of storage Refer to circuit breaker man...

Page 24: ...R1000 old GE 0247B8961G001 5000A Breakers ABB Lifting Bar 2TSE431932R1000 old GE 0247B8961G003 1 Verify that the breaker is in the DISCONNECTED and OPEN position before mounting it on the rails Refer to figure 23 Cassette Position Indicator Figure 23 2 Using the chosen lifting method raise the breaker to a height slightly above the rails 3 Pull out the two rails being cautious not to position anyo...

Page 25: ... the lifting bar is 0 7 wide and 1 high Hooks used in the hoist should be suitable to engage with this slot size After loading on rails of fully withdrawn position remove the eye bolts or lifting means Note 3 Use of Lifting bar or spreader bar allows to reach the top most switchgear Compartment easily so it is the recommended method Note 4 As an alternate to above lifting process eye bolts chain a...

Page 26: ...asic S hooks Each chain should be rated minimum 500lbs Mount a connector to join both chains in the center Connector should be rated minimum 1000lbs The connector is then attached to a hoist hook as shown in Fig 28 to lift the breaker Note Eye bolts chain connectors are not supplied If used remove before Installing breaker into the compartment Figure 26 Eye bolt Ex McMaster CARR Part 3107T43 Figur...

Page 27: ...the rejection features below the breaker 7 Check the secondary disconnects are aligning while pushing the breaker into the compartment from fully withdrawn to DISCONNECT position 8 Push the breaker in until the compartment racking pins engage with the breaker racking cams 9 Remove the racking tool from the storage location on the breaker front panel and extend the torque bar from inside the handle...

Page 28: ...ure 31 Cassette Position Indicator Figure 30 11 While turning the screwdriver 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 30 12 With the racking tool inserted crank clockwise so that the Retrofill starts to move in slowly sliding forward into the compartment 13 Rotating clock...

Page 29: ...Figure 32 Emax 2 Retrofill 800 1600 2000A Frames Emax 2 Retrofill AKD 10 Connect Position 24 AKD 10 Racked In C ...

Page 30: ...ave been tested to 200 of their 700 Ib ratings b Use of Lifting Spreader bar allows to reach the top most switchgear compartment easily so it is the recommended method c Alternate method use a lifting chain and hooks rated at least 1400 Ibs to lift the breaker from above as shown in Figure 33 chains must not be at an angle less than 45 degrees from the horizontal plane Installation in upper compar...

Page 31: ...lot or rack out lock of the breaker Figure 30 and turn it clockwise to the right so that the racking handle shutter opens While turning the screwdriver 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 30 Rotating clockwise 37 turns racks the circuit breaker all the way into the co...

Page 32: ...Figure 35 Emax 2 Retrofill AKD 10 CONNECT POSITION 25 AKD 10 Retrofill BreakerRacked In The photo below shows an example of a racked in AKD 10 Retrofill C ...

Page 33: ...rofill breaker Installing the secondary disconnect assembly consists of doing these tasks Figure 36 AKD 10 Secondary Disconnects View 1 26 AKD 10 Secondary Disconnects Installing the secondary disconnect assembly Figure 36 Figure 37 and Figure 38 Wiring the secondary disconnect assembly Table 6 shows the WavePro secondary disconnect terminals The Emax 2 Retrofill Breaker has these three options On...

Page 34: ...ries can be wired to dedicated disconnect points Refer to Table 5 for the secondary disconnect kit catalog numbers Figure 37 Figure 38 AKD 10 Secondary Disconnects View 2 AKD 10 Secondary Disconnects Exploded View 3 AKD 10 Secondary Disconnect Kit Catalog Numbers WP 08 16 20 WPSDSUBF1 WPSDSUBM1 Breaker side Cell side Table 5 Available from GEXPRO Table 6 shows the WavePro secondary disconnect term...

Page 35: ... Switch Aux Switch Aux Switch NC contact 6 15 8 17 Remote charge Indicator Remote charge Indicator WPS 50 Fan Motor 120Vac H WPS 50 Fan Motor 120Vac N 16 7 Remote Charge NC Remote Charge NC Spare Spare Spare 9 18 19 20 21 OFLO phase A OFLO phase A 22 23 24 25 26 27 OFLO phase B OFLO phase B OFLO phase C OFLO phase C 29 30 31 32 33 34 35 36 Spare Spare Spare Spare Output RELT GFA Output RELT GFA In...

Page 36: ...11 14 22 21 31 34 42 41 C2 C1 51 54 62 61 71 74 82 81 91 94 02 01 45 48 R1 R2 C ...

Page 37: ...place all legacy breakers connected with Emaxe retrofill 1SDCO007100G0205 Dialogue Module Emax2 offers multiple communication modules like Ekip Com Modbus TCP Ekip Com EtherNet IP Ekip Com Profinet Ekip Com IEC 61850 Ekip Com Modbus RTU Ekip Com Profibus DP Ekip Com DeviceNet integration with Emax2 integrated communication modules with different protocols requires the adaptation of existing superv...

Page 38: ...C ...

Page 39: ... are of 24V 3 This is a sample wiring diagram for exact connection points on the fixed side refer the wiring diagram supplied with original breaker refer emax 2 catalogue for all other available connection schemes Note To refer all the other different option connections refer Emax 2 manual 1SDH001000R0002 page no 48 50 C ...

Page 40: ...NOTES 1 WP WavePro fixed connection point 2 B refers to the mixed Auxilliary Contacts like Q5 Q6 Q7 are of 400 V while Q8 Q9 Q10 are of 24V C ...

Page 41: ...NOTES WP WavePro fixed connection point 51 EKIP COM MODBUS RS 485 52 EKIP COM MODBUS TCP 53 EKIP COM PROFIBUS C ...

Page 42: ...ne can be supplied 3 M indicates when the circuit breaker has two or three applications but only one can be supplied 4 Emax 2 standard offering ST1 UVR1 CC or CCC UV2 5 This is a sample wiring diagram For exact connection points on the fixed side refer the wiring diagram supplied with original breaker C ...

Page 43: ...NOTES 1 WP WavePro fixed connection point C ...

Page 44: ...NOTES 1 WP WavePro fixed connection point Notice WIRING Do not pinch damage the wires while installing the secondary disconnect blocks C ...

Page 45: ...38 shows finger clusters or primary disconnects on a Retrofill circuit breaker Figure 39 details the finger cluster assembly Figure 38 Circuit Breaker Removed Featuring Primary Disconnects Fingers Contacts Figure 39 Circuit Breaker Fingers Details The primary disconnect assembly is factory adjusted with a gage to apply a 95 10 Ib force t o a 1 2 inch thick copper bar inserted between the upper and...

Page 46: ...g upper retainer bow tie spacers lower retainer and fingers from the bottom of the assembly Do the same for the other assembly bolt and components Slide off the retainer clips Take off the main retainer from the stud Slide the main retainer over the stud Install eccentric spacer and position spring clips on the stud Set a pair of bow tie spacers into a pair of fingers place a pressure plate retain...

Page 47: ...through 13 for each set of fingers Adjust the nut to get a spacing of 0 766 0 797 inch between the top of the upper retainer and the bottom of the flat washer Tighten the jam nut to lock in the adjustment Clean finger assemblies if necessary with a clean lint free rag and isopropyl alcohol or acetone Be sure to apply a thin film of Mobilgrease 28 to the contact areas which slide onto the switchgea...

Page 48: ...Figure 43 Mechanical Views Below pictures provide further details Remove and Replace WPS 32 WPH 32 WPX 32 WPS 40 WPX 40 WPS 50 WPX 50 C ...

Page 49: ...ning the nuts to set the spring dimension shown in Figure 44 45 Note that this dimension is measured between the top of the retainer and the underside of the washer Also note that no bar is inserted between the fingers when setting this dimension Figure 46 47 shows the cluster components Adjustment 3200A Double Spring Cluster Components 3200A Figure 44 Figure 45 Figure 46 Adjustment 4000A 5000A C ...

Page 50: ... the retainer between the finger and then through the clip and stud spacer Hold the bottom finger subassembly in place Place two fingers around the bolt from the top hooking the fingers into the main retainer Then place a bow tie spacer in each finger and hold them in position with a pressure plate retainer Place a spring bushing and flat washer over the bolt then secure with the Adjusting nut Rep...

Page 51: ...ONLY for 3200A Figure 48 Steps in Exploded Views for 3200A WPS 32 WPH 32 WPX 32 C ...

Page 52: ...ONLY for 3200A Figure 49 Steps in Exploded Views for 4000A WPS 40 WPX 40 C ...

Page 53: ...Figure 50 Steps in Exploded Views for 5000A WPS 50 WPX 50 ONLY for 3200A C ...

Page 54: ...Figure 51 Mechanical Views AKR 75 100 125 Below pictures provide further details on Fingers or Clusters Mechanical views WPS 32 WPH 32 WPX 32 WPS 40 WPX 40 WPS 50 WPX 50 C ...

Page 55: ...Figure 53 Position switch actuator comes preinstalled on all versions of Emax 2 Retrofill ACB Hence no installation is required Retrofills provide same electrical indication scheme as WavePro breaker A customer can choose to install a position switch if it s not already installed or if the existing assembly is damaged Figure 52 53 shows the surface on the Retrofill which activates the position swi...

Page 56: ...tection of the live bus bars Emax 2 Retrofill circuit breakers come with pre installed shutter actuators which operate the opening of the shutters as shown in Figure 54 55 Figure 55 Surfaces activating the shutter for WPS 32 WPH 32 WPX 32 WPS 40 WPX 40 WPS 50 WPX 50 Surfaces activating the shutters for WPS 08 WPH 08 WPX 08 WPS 16 WPH 16 WPS 20 C ...

Page 57: ...nd Saad compartment is turned off compartment is denergized 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 Dange...

Page 58: ...the inside of the compartment door Following is a brief summary of how the Key Interlock system is operated To activate the key interlock 1 OPEN the breaker 2 Rotate the screw on the lower front panel of the breaker which normally allows access to the racking screw This will hold the breaker trip free 3 While the screw is held rotated Clockwise the Key Interlock slide in the switchgear is pushed i...

Page 59: ...ess for removing the old door from the LVS compartment Unpack the new door assembly and mount it on the compartment and secure via placing the hinges and tightening the screws Insert the new retrofitted Emax 2 Retrofill circuit breaker into the compartment and slide the breaker into the disconnected condition Close the new door and secure it to the compartment Rack in the new retrofitted Emax 2 Re...

Page 60: ...ut template Check the through door racking with the new door assembly Insert the new retrofitted Emax 2 Retrofill circuit breaker into the compartment and slide the breaker into the disconnected condition Close the door and secure it to the compartment Rack in the new retrofitted Emax 2 Retrofill Breaker For detail instructions refer document 2TSE431967R1000 2TSE431968R1000 2TSE431996R1000 C ...

Page 61: ...nts on the breaker between the breaker s Neutral Disconnect and the breaker trip unit It converts the signal from an iron Core Neutral sensor to a Rogowski voltage output which is wired to the Breaker s Trip Unit Neutral input connections The Neutral CT Adapter supports iron core Neutral sensors compatible with MicroVersa Trip MVT RMS 9 Power Plus Pro Trip Emax 2 TU rated from 250 to 5000 Amps as ...

Page 62: ... a secure location for reassembly Be careful while handling the CT assemblies such that they do not fall down or damage other components within the LVS Replace the old CT assembly with the new Rogowski assembly on the horizontal bus bars and fasten it using the hardware previously removed Connect a twisted pair of wires back to the Rogowski CT assembly leads Check for continuity from the CT leads ...

Page 63: ...gle Source Feeder breakers 3 wire or 4 wire Main Circuit breakers 3 wire or 4 wire Main or Tie breakers 3 or 4 wire multi source ground fault scheme using original iron core neutral CT and the neutral CT adapter on each Retrofill breaker Retrofills can be used in the following ground fault applications C ...

Page 64: ...lay diagram 1SDHOO1000R0524 to identify the terminal marking in circuit diagram 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 Tl and T2 Wiring Diagram WavePro 4000A Fan Control Unit Wiring Trip unit Programming instructions C ...

Page 65: ...Figure 64 Wiring of WP 4000A breaker with FAN control unit C ...

Page 66: ...Configuring Ekip Touch Hi Touch Trip unit for Fan control Figure 65 34 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 C ...

Page 67: ...s per second module ON and communication 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 statu...

Page 68: ...ow you to set controls on current 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 Iwi and Iw 36 Configuring threshould currents for Fan control C ...

Page 69: ...Programing 2K 1 signaling contacts output Figure 69 Figure 70 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 C ...

Page 70: ...relative LEDs Restore initial conditions 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...

Page 71: ...lly mounted fuses on the upper studs the WPF 08 and WPF 16 breakers are identical to the unfuse WP 08 and WP 16 models Overcurrent trip devices are the same for both types 39 Fuse size and mounting Figure 73 Table 6 lists the range of fuse sizes available for these breakers The Class L fuses are mounted as shown in Fig 51 Other than the 800A size which has a single mounting hole per tang each Clas...

Page 72: ...emoving the flat washer spring upper retainer bowtie spacers lower retainer and fingers from the bottom of the assembly 3 Do the same for the other assembly bolt and components 4 Slide off the retainer clips 5 Take off the main retainer from the stud 6 Slide the main retainer over the stud 7 Set a pair of bow tie spacers into a pair of fingers place a pressure plate retainer over the spacers to ho...

Page 73: ...ailable in a 1 0z tube ABB Part 193A1751P1 Refer manual 2TSA451015P0000 c Remove the upper barrier d Detach the inboard end of the fuse by removing the two 1 2 inch 13 bolts A ratchet and socket with a short extension will be requied e Remove the fuse f Install the new fuse by reversing the disassembly procedure Ensure that the mating faces of the fuse are clean Figure 74 300 THRU 600 AMP CLASS J ...

Page 74: ...Figure 75 Figure 76 WPF 16 with special 2500A Fuse WPF 16 2500A Fuse Tang Positions 74 C ...

Page 75: ... a ring terminal which is attached with a screw to the busbar 2 This accessory is meant to work with a pin wheel style Blown Fuse Detector equipped with 3 trigger fuses Wiring of the Retrofill Breakers with UL recognized high temperature control wire is provided with the kit 3 All these wirings are installed at factory Refer manual 2TSE432409P1000 2TSE432408P1000 2TSA1028P0000 4 For Fused breakers...

Page 76: ...Figure 78 Figure 79 Figure 80 AKD10 WPF 08 WITH 800A FUSES AKD10 WPF 16 WITH 1600A FUSES AKD10 WPF 16 WITH 2500A FUSES 76 C ...

Page 77: ...2TSA451010P0000 ECN000239455 Rev C ...