ABB Emax 2 Installation And Maintenance Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Circuit breakers
  5. SACE Emax 2
  6. Installation and maintenance manual

ABB Emax 2 Installation And Maintenance Manual

Direct/cic replacement of legacy ge ak 600a - 4000a circuit breakers used in akd-5 & substructures
Hide thumbs Also See for Emax 2:
Table of Contents

Advertisement

Quick Links

Download this manual
Installation and maintenance guide
Emax 2 Retrofill Circuit Breakers
Direct/CiC Replacement of Legacy GE
AK 600A - 4000A Circuit Breakers Used in
AKD-5 & Substructures
-
General Electric AKD-5 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.
-
It uses AK/AKJ/AKJT/AKS/AKST Breaker.
-
This manual applies to both Emax 2 Retrofill breakers for AKD-5 switchgear and OEM
substructures

Advertisement

Table of Contents
loading

Related Manuals for ABB Emax 2

Summary of Contents for ABB Emax 2

  • Page 1 ANSI power circuit breakers. It may be a part of a single-ended or double- ended load center unit substation. It uses AK/AKJ/AKJT/AKS/AKST Breaker. This manual applies to both Emax 2 Retrofill breakers for AKD-5 switchgear and OEM substructures ...

  • Page 2: Table Of Contents

    AK 75 - 3000A, FAN CONTROL UNIT WIRING & TRIP UNIT PROGRAMMING INSTRUCTIONS ............ 52 CONFIGURING EKIP TOUCH, HI TOUCH TRIP UNIT ..... 54 30 - Connecting Ekip Touch..............54 2TSA451011P0000 Rev-B 2| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 3: Preface

    Retrofill circuit breakers in AKD & other OEMs switchgear and when working equipment that can cause injury, but may not be necessarily fatal (Table 2) Table 2 Generic Warning Alerts 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 3...

  • Page 4: Warranty

    Features may be described herein that are not present in all hardware and software systems. ABB Inc USA assumes no obligation of notice to holders of this document with respect to changes subsequently made. ABB Inc USA 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 herein.

  • Page 5: Trademarks And Patents

    E2.2, 4.2, 6.2 Breakers Installation, Operation & Maintenance Manual 1SDH001000R0002 E1.2 Breakers Installation, Operation & Maintenance Manual 1SDH000999R0002 Instructions for using Ekip touch protection releases & accesories 1SDH001316R0002 Emax 2 Family Trip units Engineering manual 1SDH001330R0002 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 5...

  • Page 6: Service And Support

    The direct replacement retrofitting kit allows a reliable upgrade of the old GE legacy breakers to new Emax 2 Retrofill Breakers Range.
  • Page 7 Figure 7 & 8 Fig 7. Front View Fig 8. Rear View AKD-5 4000A Breaker in Cassette Figure 9 & 10 Fig 9. Front View Fig 10. Rear View 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 7...

  • Page 8: History And Types

    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 breakers have a draw out letter code “A”.
  • Page 9 Note GE Switchboard plants initially shipped “WS” style breakers and later shifted to “WE” style breakers to be consistent with GE Switchgear from Burlington, Iowa. The 5000A breaker had cooling fans. None of the Emax 2 Retrofill breakers utilize fans except the 4000A fully rated breaker.

  • Page 10: Akd - 5, Retrofill Breaker

    Fig 11. Emax 1.2 Circuit Breaker (Moving Portion) Fig 12. Circuit Breaker Projected from Cassette Figure 13 Retrofill Kit Figure 14 & 15 Fig 14. Rear View of Retrofill Kit Fig 15. Front view inside SwitchGear 2TSA451011P0000 Rev-B 10| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...
  • Page 11 AKD5 AK50, Emax 2.2 1600A CiC (Cradle in Cradle ) Retrofill Kit Figure 16 & 17 Fig 16. Emax 2.2 Circuit Breaker (Moving Portion) Fig 17. Circuit Breaker Projected from Cassette Figure 18 Retrofill Kit Fig 19. Rear View of Retrofill Kit Fig 20.
  • Page 12 Figure 24 & 25 Fig 24. Rear View of Retrofill Kit Fig 25. Front View of Retrofill Kit The Emax 1.2 & Emax 2.2 Circuit Breaker is suitable for application on power systems up to 600 VAC 50/60 Hz. 2TSA451011P0000 Rev-B...
  • Page 13 Fig 27. Circuit Breaker Projected from Cassette Figure 28 Retrofill Kit Fig 29. Rear View of Retrofill Kit Fig 30. Front View of Retrofill Kit Figure 29 & 30 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 13...
  • Page 14 Fig 32. Circuit Breaker Projected from Cassette Retrofill Kit Figure 33 Fig 34. Rear View of Retrofill Kit Fig 35. Front View of Retrofill Kit Figure 34 & 35 2TSA451011P0000 Rev-B 14| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 15: Akd5 Mechanical Drawings

    The following engineering or assembly drawings describe the layout and dimensions of the AKD-5 Retrofill breaker. AK25 , Emax 1.2 600A Figure 36 AK50 , Emax 2.2 1600A Figure 37 AKT50 , Emax 2.2 2000A Figure 38 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 15...
  • Page 16 Fans Turn ON at 2500A and OFF at 2300A For other detail related to Trip unit config and wiring refer to Fan control section in manual. AK100 , Emax 6.2 4000A Figure 40 2TSA451011P0000 Rev-B 16| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 17: Modify Akd-5, Switchgear Compartment

    15 - Empty compartment legacy breaker removed The following figures (Figure 41, 42 & 43) show a legacy breaker removed from enclosure or compartment. Fig 41 Fig 42 Figure 41 & 42 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 17...
  • Page 18 AKD5 – 600A Figure 43 AKD5 – 1600A / 2000A Figure 44 AKD5 – 3000A / 4000A Figure 45 2TSA451011P0000 Rev-B 18| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 19: Check, Clean And Grease Compartment

    3. Check the secondary disconnect integrity & mounting supports for any damage or cracks . 4. If switchgear parts show cracks or damage contact ABB post sales service 888-437-3765. 5. Check each breaker compartment for bolted joints in the primary disconnect bars.

  • Page 20: Unpack Retrofill Circuit Breaker

    2TSA451011P0000 Rev-B 20| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 21: Quality

    Use a lifting device to lift and mount the cassettes and circuit breakers to avoid personal injury or damaging the devices. NOTE: Emax 2 frame 1.2 has no lifting bar. Lift with 2 people to install into cassette. Contact the nearest sales office for availability of a hoisting device or contact ABB post sales service 888-437-3765.
  • Page 22 Figure 46 Emax2.2/4.2/6.2 Moving Portion Lifting Plates Emax2.2/4.2/6.2 Loading Rails Figure 47 Figure 48 Loading Emax2 Breaker Into the Cradle Disengagement of Lifting Plates from Emax2 Breaker Figure 49 2TSA451011P0000 Rev-B 22| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 23: Store Circuit Breaker

    While Level 2 maintenance is needed over two years of storage. Refer to circuit breaker manual in maintenance L1-L2 descriptions. Refer Emax2 1SDH001000R0002 manual for maintainance section on page 68-72. 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 23...

  • Page 24: Check Before Installing

    These Emax 2 Retrofill breakers are of two types. AK 25 & 50 circuit breakers are replaced by standard Emax 2 drawout breaker for a Cradle in Cradle (CiC) solution & AKT 50 has a hollow back EntelliGuard R Cradle and uses a customized Emax 2 circuit breaker. The AK 25 &...

  • Page 25: Clean And Grease Breaker

    Clean and Grease Breaker  Before installing or operating a breaker, refer to the Emax 2 Breaker installation manual 1SDH001330R0002 for pre-operation inspecting and testing.  Check thoroughly for any damaged or loose parts and for any dirt or foreign matter which may be on the breaker.

  • Page 26: Customize Retrofill Secondary Wiring

    Customize retrofill secondary wiring Notice WIRING  Before installing the breaker, the secondary disconnects must be wired to the Emax 2 Retrofill Breaker.  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.

  • Page 27: Install Position Switch Actuator, Akt Breaker Retrofill Only

    6. Mount the cassette assembly on the rails of the AKD-5 LVS and rack the cassette into the compartment using the legacy racking system. Note: As the Emax 2 Retrofill breaker is racked into the cassette, and the position indicator window reads “connected” the retrofill Position Switch actuator should activate the compartment mounted position switch in the AKD-5 LVS.

  • Page 28: Racking-Lock Bracket Installation

    6. Line up the guiding holes (Figure 49). 7. Mark the bottom two holes using the bracket as a template. 8. Take the bracket out and drill 0.18-in diameter pilot holes in the frame. 2TSA451011P0000 Rev-B 28| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 29: Install Cassette (Landed Wires)

    Fig 53 shows the front view of the AKD-5 cassette, ready for installation Figure 52 & 53 AKD-5, AK50 Fig 52. Cassette Projected from Switchgear Fig 53. Cassette racking on Switchgear rails Figure 54 Switchgear and Cassette assembly (Front View) 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 29...
  • Page 30 Fix legacy (old or original) racker-lock on the compartment side frame to block slide back of sleeve. The following photos show how the cassette is racked in and secured figure 60, rails extended figure 58, racking in (figure 59) 2TSA451011P0000 Rev-B 30| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...
  • Page 31 Fig 59 Figure 60 & 61 AKD-5, AK 25 Cassette or Substructure, Rails Extended Fig 60 Fig 61 Figure 62 AKD-5, AK25 Cassette or Substructure, Now Racked In 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 31...

  • Page 32: Install Cassette Rail Lever Lockout Brackets Ak/Akt50 Compt's Only

    Ensure only qualified personnel install, operate, service and maintain all electrical equipment. Check that the retrofitted Emax 2 cassette has been completely racked into the cabinet. Slide the bracket back into position as shown in the image below (Figure 46) and line up the holes previously drilled with the holes on the locking bracket (figure 47).

  • Page 33: Install Akd5 Retrofill Breaker

    Use a tool or screwdriver to keep them up, if necessary (figure 64). Figure 64 Loading Emax2 Breaker Into the Cradle Figure 65 Loading Emax2 Breaker Into the Cradle 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 33...
  • Page 34 Open the compartment door, to install the breaker in the cassette (figure 67). Figure 66 Cabinet with Compartment, Door Closed Figure 67 Cabinet with Compartment, Door Open Figure 68 Racking Arms / Loading Rails, Extended 2TSA451011P0000 Rev-B 34| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...
  • Page 35 Peer underneath the breaker, as you maneuver it in, to make sure that the dual blades clear the bottom of cassette (Figure 71). Refer Emax 2 installation manual (1SDH001000R0002) for installing Emax 1.2, 2.2, 4.2 & 6.2 MP (Moving Portion) into the AKD5 compartment.
  • Page 36 AKT50 Retrofit Breaker Before installing the breaker, press OPEN to turn breaker OFF. Figure 73 AKD-5, Racking Tool & storage location for AKT 50 Racking handle tool storage location for AKT50 2TSA451011P0000 Rev-B 36| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...
  • Page 37 Then, crank clockwise so that the breaker starts to move in, slowly sliding forward. Rotating clockwise ~ 37 turns racks the circuit breaker all the way into the cassette. Figure 76 Crank or Racking Handle Inserted 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 37...

  • Page 38: Ak/Akt50 Kirkey Interlock

    Note that the circuit breaker is now ready for normal operation 21 - AK/AKT50 Kirkey Interlock The Emax 2.2 Retrofill circuit breakers provided as replacements for AK/AKR circuit breakers have a trip interlock feature which will function using the AKT-50 compartment mounted Key Interlock.

  • Page 39: Secondary Disconnects, Bullets

    (mounted on the breaker). Figure 78 & 79 shows the AKR disconnects installed on the AK 25 Emax 2 Retrofill cassette. Max up to 4 blocks of secondary disconnects can be installed on AK 25 Emax 2 retrofill cassette (28 points)

  • Page 40: Wiring Diagram And Block Info (Ak25)

    2. With each bullet identified, land the non-bullet side to the corresponding feature on the Emax 2 secondary disconnects If a wire is too long, cut the wire, crimp a new connector, and install the provided wire markers on the bullets. 2TSA451011P0000 Rev-B 40| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...
  • Page 41 Figure 82 Example wiring diagram for AK25 secondary disconnects 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 41...
  • Page 42 Figure 83 Example of AK25 Secondary Disconnects (Images) Figure 84 2TSA451011P0000 Rev-B 42| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...
  • Page 43 Table 5 for for Emax 2 AKT50 Retrofill  Table 6 & 7 featuring the two 39-blocks (A and B). They make up the 78-point secondary- disconnects. Table 5 & 6 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 43...
  • Page 44 Table 7 AKT50, Emax 2 Retrofill, Point Secondary B-Block 2TSA451011P0000 Rev-B 44| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 45: Ak25 Wiring Harness, B Block Ak25/50

    Figure 87 shows you the secondary bullets. Figure 85 AK25 B-Block Harness Figure 86 AK25 Wiring Harness, Close Up Figure 87 Wires from Secondary Bullets Figure 88 Wires from Secondary Bullets Close Up 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 45...

  • Page 46: Install Door Interlock Accessory

    Components that make up AKD-5, AK25 Retrofill Door interlock assembly Figure 90 Components that make up AKD-5, AK50 Retrofill Door interlock assembly Figure 91 Components that make up AKD-5, AK50T Retrofill Door interlock assembly 2TSA451011P0000 Rev-B 46| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 47: New Door Installation

    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 48  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.

  • Page 49: Install Akd-5, Neutral Sensing For 4 Wire Ground Fault

    The Neutral CT Adapter supports iron core Neutral sensors compatible with MicroVersa Trip, MVT RMS-9, MVT Plus & PM, Power Plus, Pro Trip & Emax 2 TU rated from 250 to 5000 Amps as used in GE switchboards and switchgear from 1979-2015. It is available in seven variations (shown in Table below).

  • Page 50: Procedures

    LVS compartment. Be sure to orient the CT and wires for proper polarity.  The new Rogowski assemblies are installed and ready for use.  Tools required: Wrenches, wire stripper, wire cutter, continuity tester. 2TSA451011P0000 Rev-B 50| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 51: Akd-5, Multi-Source Ground Fault

    GF summing CT scheme must be implemented. This applies to Main—Tie—Main systems or systems with a Main source and then a back-fed generator source. 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 51...

  • Page 52: Ak 75 - 3000A, Fan Control Unit Wiring & Trip Unit Programming Instructions

    Refer Relay diagram & 1SDH001000R0524 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 T1 and T2 ...
  • Page 53 Figure 98 Wiring of WP 4000A Breaker with Fan Control Unit Routing wire to the fans 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 53...

  • Page 54: Configuring Ekip Touch, Hi Touch Trip Unit

    Configuring Ekip Touch, Hi Touch Trip unit 30 - 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 99 2TSA451011P0000 Rev-B 54| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 55: Synchronizing 2K-1 Signalling Modul With The Trip Unit

    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. Figure 101 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 55...

  • Page 56: Configuring Threshould Currents

    Figure 102 For AKD5, considering 3000A as a rated current (In), fans will activate when the current crosses 2500 amps & will stop if the current drops below 2300 amps. 2TSA451011P0000 Rev-B 56| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

  • Page 57: 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 103 Figure 104 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 57...

  • Page 58: Contact Readiness Auto Test

    3. Closure and shutdown of the two output contacts in sequence, switching on the relative LEDs. 4. Restore initial conditions The Autotest command closes the contacts regardless of the configuration set by the user 2TSA451011P0000 Rev-B 58| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...
  • Page 59 Revisions Overhaul Description ECN000122590 Second version 2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 59...
  • Page 60 Disclosure to third parties or utilization of its contents - in whole or in parts - is forbidden without prior written Consent of ABB. Copyright 2021 ABB - All rights reserved. © 2TSA451011P0000 Rev-B 60| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A...

This manual is also suitable for:

Legacy ge ak 600aLegace ge ak 4000a

Table of Contents