Download
Share
Print this page
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Circuit breakers
  5. Emax 2 Retrofill
  6. Installation and maintenance manual

ABB Emax 2 Retrofill Installation And Maintenance Manual

Hide thumbs

Advertisement

Quick Links

Download this manual
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
- General Electric AKD-10 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
substation.
- It uses WavePro type ANSI Low Voltage Power Circuit Breakers. This manual applies to both
Emax 2 Retrofill breakers for AKD-10 switchgear and OEM substructures.
load center unit

Advertisement

loading

Related Manuals for ABB Emax 2 Retrofill

Summary of Contents for ABB Emax 2 Retrofill

  • Page 1 It may also be a part of a single-ended or double-ended load center unit substation. - It uses WavePro type ANSI Low Voltage Power Circuit Breakers. This manual applies to both Emax 2 Retrofill breakers for AKD-10 switchgear and OEM substructures.
  • 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...
  • Page 3 Preface 1 - Hazards Overview 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.
  • Page 4 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. It also indicates that failure to comply with instructions may result in product damage. (Table 3). Table 3 Custom Caution Alerts Notice or Note...
  • Page 5 Emax 2 Retrofill Circuit Breaker operation or maintenance. 3 - Trademarks and Patents Details Emax 2 Retrofill Emax 2 Retrofill TU, Ekip DIP, Ekip Touch, Ekip Hi-Touch, Ekip G Touch, Ekip G Hi-Touch, Kip Measuring, Ekip Measuring Pro Emax 2 Retrofill Trip Unit Emax2...
  • Page 6 20 minutes to swap out the old breaker and rack in the new Emax 2 Retrofill circuit breaker if the proper lifting bar and hoist are available, it may take an additional 30 min to replace the door.
  • Page 7 Switchgear Compartment. The direct replacement retrofitting kit allows a reliable upgrade of the old GE legacy breakers to new Emax 2 Retrofill Breakers. Below figures (front and back views with finger clusters) present Emax 2 Retrofill breakers, Which can replace WavePro breakers.
  • Page 8 Figure 2 AKD-10 800A to 2000A WPX-08, WPS-16, WPH-16 & WPS-20 Back View Primary Finger Clusters Figure 3 AKD: 10 800A WPS- 08 & WPH-08 Front View Primary Finger Clusters Figure 4 AKD-10 3200A WPS-32, WPH 32 , WPX-32, , WPS-40 & WPX- 40 Front view...
  • Page 9 AKD-10 4000A WPS-40 & WPX-40 Back View Figure 7 AKD-10 5000A WPS-50 & WPX-50 Front View Figure 8 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.
  • Page 10 History and Types 10 - History of 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 / mechanism, with an 50 /75 / 100;...
  • Page 11 Note GE Switchboard plants initially shipped “WS” style breakers and later shifted to “WE” style breakers to be consistent with GE Switchgear from Burlington, lowa. The 5000A breaker had cooling fans. None of the Emax 2 Retrofill breakers utilize fans except the 4000A fully rated breaker.
  • Page 12 AKD-10: Retrofill Breaker 11 - AKD -10 :Mechanical Drawings The following engineering or assembly drawings describe the layout and dimensions of the AKD-10 Retrofill breaker. AKD-10, 800A Retrofill Breaker Dimensions (WPS-08, WPH-08) Figure 9 AKD-10, 800-2000A Retrofill Breaker Dimensions (WPX-08, WPS-16, WPH-16, WPS-20 Figure 10 AKD-10, 3200A Retrofill Breaker Dimensions (WPS-32, WPH-32, WPX-32 Figure 11...
  • Page 13 Figure 12 AKD-10, 4000A with forced cooling (w/fans) Retrofill Breaker Dimensions (WPS-40, WPX-40) Forced cooling (w/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 Breakers ordered with a 3600A Rating plug for max 90% load do not require fans.
  • Page 14 AKD-10 : Compartment 12 - Interior View The figures below present a new AKD-10 compartment, with one photo showing the rails extended. Figure 14 AKD-10: Empty Compartment with Shutters NOTE: Section width 22”-800-2000A Figure 15 AKD-10: Empty Compartment with Racks/Rails Extended...
  • Page 15 13 - Interior Components Major components of an AKD-10 compartment. AKD-10, Circuit Breaker Compartment for Wave Pro breakers Figure 16 All 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 14 - Interior View...
  • Page 16 Figure 18 AKD-10, Empty Compartment with Racks/Rails Extended 15 - Interior Components Figure 19 Major components of an AKD-10 compartment. AKD-10, Circuit Breaker Compartment for WPS-32/WPH-32/WPX-32/WPS-40/WPX-40/WPS-50/WPX-50 Breakers...
  • Page 17 Check the secondary disconnect integrity & their mounting supports for any damage or cracks . If switchgear parts show cracks or damage contact ABB post sales service 888-437- 3765. Check each breaker compartment for bolted joints in the primary disconnect bars.
  • Page 18 AKD-10, Secondary Disconnect Spacer Black (800-2000A ONLY) Figure 20 20 - Quality All Emax 2 Retrofill circuit breakers have been designed and manufactured to ANSI standards. The design was based on the original requirements of the legacy switchgear and breaker.
  • Page 19 22 - Product and Catalog Serial Numbers Product catalog and serial numbers should be kept handy when communicating about the circuit breaker. Each circuit breaker has a unique serial number (S/N) located on the front fascia. 23 - Remove Circuit Breaker from Container Inspect and 1.
  • Page 20 Unpack Circuit Breaker Danger 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.
  • Page 21 Clean and Grease Breaker 1. Before installing or operating a breaker, refer to the breaker instruction manual for pre-operation inspection and test. 2. Check thoroughly for any damaged or loose parts and for any dirt or foreign matter which may be in the breaker. 3.
  • Page 22 Check Before Installing Danger lt must be ensured that the supply power to the Shack and Saad compartment is turned off/ compartment is denergized for all the incoming and outgoingcircuits 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...
  • Page 23 Store Circuit Breaker Notice PRODUCT DAMAGE Do not store circuit breaker in corrosive environments above LC1 (sea salt mist) and G1 as per ANSI/ISA-S71.04-1985. Ensure circuit breakers are stored in a clean, location, in their original packaging. Failure to comply with these instructions may result in product damage.
  • Page 24 Retrofill breaker can now be installed in the AKD-10 switchgear, OEM switchgear or switchboard. Note : the preferred lifting method is always to use proper ABB lifting (spreader) bar. It will provide the best chance of installing breakers, especially into the upper compartments, without damaging the breakers.
  • Page 25 5. Remove the lifting bar, any lifting eye hooks and chains. Figure 24 AKD-10, Using ABB Lifting bar and hoist Note 1: Make sure the J hook of the lifting bar is secured in the front window on both Side sheets of the breaker as shown in fig 25. This will ensure the breaker is better balanced when lifted.
  • Page 26 eyebolts of rating minimum 250lbs in the eye bolt weld nuts as shown in Figure 28. Use four eye bolts, chain and suitable “S” hooks or chain connectors to safely lift the breaker onto the rails. “S” hooks with a locking feature as shown in Figure 28 are preferred to basic “S”...
  • Page 27 Figure 28 AKD-10: Using eye bolts, chain and connector 6. Check that the breaker is free from obstruction while pushing it inside the compartment, especially 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.
  • Page 28 10. Use a blade-type screwdriver in the slot or rack out lock of the breaker (Figure 30), and turn it clockwise to the right so that the racking handle shutter opens. Figure 30 Inserting the racking handle: First, insert a blade screwdriver in the right- hand slot and rotate it to the right.
  • Page 29 24 - AKD-10: Racked -In Figure 32 Emax 2 Retrofill 800, 1600 & 2000A Frames Emax 2 Retrofill , AKD-10,Connect Position...
  • Page 30 1. Verify that the new breaker is in the DISCONNECTED and OPEN position. 2. For WPS-32/WPH-32/WPX-32/WPS-40/WPX-40/WPS-50/WPX-50 Retrofill Breaker. a. It is best to use ABB Lifting Bar Part number 2TSE431931R1000 for 3200-4000A and 2TSE431932R1000 for 5000A and a suitable hoist to lift from above as shown in Figure 34.
  • Page 31 Figure 34 AKD-10 Using ABB Lifting bar and hoist Make sure that the lifting bar “J” hooks or generic chain-hooks are secured and locked in place. Dropping a breaker can result in injury or death. Line up the breaker in front of the compartment where it will be installed; then raise it slightly above the height of the drawout Rail assembly.
  • Page 32 25 - AKD-10: Retrofill BreakerRacked -In The photo below shows an example of a racked-in AKD-10 Retrofill Figure 35 Emax 2 Retrofill ,AKD-10, CONNECT POSITION...
  • Page 33 26 - AKD-10: Secondary Disconnects This section deals with installing and wiring the legacy secondary disconnect assemblies onto the Emax 2 Retrofill breaker. Installing the secondary disconnect assembly consists of doing these tasks: Installing the secondary disconnect assembly (Figure 36, Figure 37, and Figure 38).
  • Page 34 WP -08/ 16 /20 Table 5 Breaker side WPSDSUBF1 Cell side WPSDSUBM1 Available from GEXPRO connections. Table 6 shows the WavePro secondary disconnect terminals and standard Refer to Table 7 for an example showing wiring from AKD-10 to the Emax 2 Retrofill breaker...
  • Page 35 Legacy Wave-Pro secondary disconnect terminals and standard connections. Table 6 A-Disc Block (left side from front) C-Disc Block (right side from front) Aux Switch (NO contact) Aux Switch (NO contact) Aux Switch Aux Switch Aux Switch Aux Switch Aux Switch (NC contact) Aux Switch (NC contact) Aux Switch (NO contact) Aux Switch (NO contact)
  • Page 37 Table 8 RELT: It requires a dedicated RELT-Signaling 2K-3 module + Relt blu switch “GTUTRSK” 1SDHO01000R0524 IGF: will require NCT adapter 1SDHO01000R0530 Zone selectivity: Reuse of external existing wiring by rewiring the internal ZSi, “Legacy zone selectivity is not compatible with Emax2. In case the functions is used, it is necessary to replace all legacy breakers connected with Emaxe retrofill”...
  • Page 39 NOTES: 1, WP -WavePro fixed connection point 2. "*B" refers to the mixed Auxilliary Contacts, like Q1 & Q2 are of 400 V while Q3 & Q4 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.
  • 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.
  • Page 41 NOTES: WP - WavePro fixed connection point 51. EKIP COM MODBUS RS-485 52. EKIP COM MODBUS TCP 53. EKIP COM PROFIBUS...
  • Page 42 NOTES: 1. 77(YC)-78(YC,EKIP COM ACTUATOR) as an alternative to each other 2. 73A(YU2 or YO2) out of 2 only one can be supplied 3. "M*" indicates when the circuit breaker has two or three applications but only one can be supplied. 4.
  • Page 43 NOTES: 1. WP - WavePro fixed connection point...
  • Page 44 NOTES: 1. WP -WavePro fixed connection point Notice WIRING Do not pinch/damage the wires while installing the secondary disconnect blocks.
  • Page 45 The primary disconnects are flexible connections between the breaker line and load terminals and between the equipment line and load terminals. All primary disconnect fingers are factory-installed and are assembled on Emax 2 Retrofill circuit breakers. Use this instruction sheet if damaged fingers need to be replaced. It takes about 5 minutes to install a finger cluster, defined as a double pair of fingers on a breaker.
  • Page 46 Adjustment Figure 40 Figure 41 Cluster Components Using proper safety procedures and wearing required Personal Protective Equipment (PPE), remove breaker from compartment, and place it on a solid work surface in a well-lit location. To uninstall the primary disconnects, remove the two nuts from one of the long bolts holding the primary disconnect assembly together.
  • Page 47 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 two nuts.
  • Page 48 Mechanical Views Below pictures provide further details Figure 43 Remove and Replace - WPS-32/WPH-32/WPX-32/WPS-40/ WPX-40/WPS-50/WPX-50...
  • Page 49 The primary disconnect assembly is factory-adjusted to apply a 95 + 10 lb. force to a 1/2-inch thick copper bar, inserted between the upper and lower fingers. Set this force range, in the field, by tightening the nuts to set the spring dimension shown in Figure 44/45.
  • Page 50 Be sure to apply a thin film of Mobilgrease 28 (DS50HD38) to the contact areas which slide onto the switchgear stabs (See Figure 48/49, Step 2). This product is available in a 1-0z tube, ABB Part #193A1751P1. Figure 48 (WPS-32/WPH-32/WPX-32), Figure 49(WPS-40/ WPX-40) and figure 50 (WPS-...
  • Page 51 Figure 48 Steps in Exploded Views for 3200A (WPS-32/WPH-32/WPX-32) ONLY for 3200A...
  • Page 52 Steps in Exploded Views for 4000A (WPS-40/WPX-40) Figure 49 ONLY for 3200A...
  • Page 53 Figure 50 Steps in Exploded Views for 5000A (WPS-50/WPX-50) ONLY for 3200A...
  • Page 54 Mechanical Views Below pictures provide further details on (Fingers or Clusters, Mechanical views) AKR 75/100/125 WPS-32/WPH-32/WPX-32 WPS-40/WPX-40/WPS-50/WPX-50 Figure 51...
  • Page 55 28 - AKD-10: Position Switch Actuator Position switch actuator comes preinstalled on all versions of Emax 2 Retrofill ACB. Hence, as WavePro no installation is required. Retrofills provide same electrical indication scheme breaker. A customer can choose to install a position switch if it’s not already installed or if the existing assembly is damaged.
  • Page 56 AKD-10 LVS may be equipped with optional shutter assemblies for protection 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.
  • Page 57 Door Interlock System Danger lt must be ensured that the supply power to the Shack and 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...
  • Page 58 30 - AKD-10: Key Interlock 5000A The Emax 2 Retrofill circuit breakers provided as replacements for WavePro 800- frame circuit breakers have a trip interlock feature which will function using instructions on AKD-10 compartment mounted Key Interlock. A label is provided with full how to operate the Legacy Key Interlock.
  • Page 59 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.
  • Page 60 Modify the door cut out as per the new door cutout 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.
  • Page 61 Install AKD-10 , Neutral Sensing for 4 Wire Ground Fault Danger 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.
  • Page 62 Wiring Diagram Figure 60 For Detail Instructions on NCT Adaptor refer installation manual No 2TSA451018P0000 32 - Procedures NEUTRAL CT ORIENTATION Notice Write down the orientation of the existing Iron core CT and the polarity of the connections. The orientation and polarity NOTICE needs to be matched when the air core Rogowski is assembled in the cable compartment.
  • Page 63 33 - AKD-10: Multi-Source Ground Fault Retrofills can be used in the following ground fault applications: Single 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.
  • Page 64 WavePro 4000A, Fan Control Unit Wiring & Trip unit Programming instructions Wiring Diagram Follow the below circuit diagram to make the connections between the 2k-1 signalling unit, relay and fans. Refer Relay diagram & 1SDHOO1000R0524 to identify the terminal marking in circuit diagram.
  • Page 65 Figure 64 Wiring of WP 4000A breaker with FAN control unit...
  • Page 66 Configuring Ekip Touch, Hi Touch Trip unit for Fan control 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. Figure 65...
  • Page 67 35 - Synchronizing 2K-1 signalling module with the trip unit The activation of local bus — essential to start the communication between the module and the Trip unit Figure 66 Once the local bus is activated 2k modue should synchronize with the Ekip touch trip unit.
  • Page 68 36 - Configuring threshould currents for Fan control The current thresholds allow 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.
  • Page 69 37 - Programing 2K-1 signaling contacts output 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. Figure 69 Figure 70...
  • Page 70 38 - Contact readiness Auto Test 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. Figure 71 Figure 72 Autotest command that activates the automatic sequence of output tests (contacts and LEDs) and input test (LED), and includes the following operations: Reset output contacts (= open) and LEDs (= off).

  • Page 71: Fused Retrofill Breaker

    Fused Retrofill Breaker Danger lt must be ensured that the supply power to the 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...

  • Page 72: Special 2500A Fuse For Wpf-16

    Table 9 Fuses For WPF Breakers 40 - Special 2500A Fuse for WPF-16 This fuse provides a melting time-current characteristic that coordinates with 1600A trip devices. Compared physically with a 2500A NEMA Class L fuse, the special fuse is more compact (shorter);...
  • Page 73 15. Be sure to apply a thin film of Mobilgrease 28 (DS50HD38) to the contact areas which slide on to the switchgear stabs . This product is available in a 1-0z tube, ABB Part #193A1751P1. Refer manual 2TSA451015P0000 c) Remove the upper barrier.
  • Page 74 Figure 75 WPF-16 with special 2500A Fuse WPF-16-2500A Fuse Tang Positions Figure 76...

  • Page 75: Open Fuse Lockout Device

    Open Fuse Lockout Device This device automatically trips the fuse breaker if one of the fuses opens. When this happens, the breaker is locked open until the reset button of the phase involved is pushed. The breaker should not be reclosed, of course, until the opened fuse is replaced. 1.
  • Page 76 Figure 78 AKD10 WPF-08 WITH 800A FUSES Figure 79 AKD10 WPF-16 WITH 1600A FUSES Figure 80 AKD10 WPF-16 WITH 2500A FUSES...

This manual is also suitable for:

Akd-5Akd-6Akd-8Akd-10