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ABB Emax 2 Retrofill AKR-30-800A Installation And Maintenance Manual

Direct replacement of legacy ge ak 800a - 4000a circuit breakers used in akd-6 & substructures
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Installation and maintenance guide
Emax 2 Retrofill Circuit Breakers
Direct Replacement of Legacy GE AK 800A - 4000A
Circuit Breakers Used in AKD-6 & Substructures
General Electric AKD-6 Low Voltage Switchgear is a free-standing assembly of metal-enclosed
power circuit breakers. It may also be part of a single-ended or double-ended load center unit
substation. This manual applies to Emax 2 Retrofill circuit breakers to be used in AKD-6
Switchgear & substructures 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.)

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Summary of Contents for ABB Emax 2 Retrofill AKR-30-800A

  • Page 1 Installation and maintenance guide Emax 2 Retrofill Circuit Breakers Direct Replacement of Legacy GE AK 800A - 4000A Circuit Breakers Used in AKD-6 & Substructures General Electric AKD-6 Low Voltage Switchgear is a free-standing assembly of metal-enclosed power circuit breakers. It may also be part of a single-ended or double-ended load center unit substation.

  • Page 2: Table Of Contents

    PREFACE................................3 1- Hazards ..................................3 2- Warranty ...................................5 3- Trademarks and patents ............................5 4- Standards ................................5 5- Document Conventions ............................5 6- Related Publications .............................6 7- Service and Support .............................6 8- Estimated Time to Complete Tasks ........................6 9- Product Specs ................................7 HISTORY AND TYPES ............................9 10- History of AKD ..............................9...

  • Page 3: Preface

    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: 2- 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 6: 6- Related Publications

    Instructions for using Ekip touch protection releases & accesories 1SDH001330R0002 Emax 2 Family Trip units Engineering manual 7 - Service and Support Service and support are available from ABB Inc USA. Email: eppc.support@us.abb.com Phone: 888-385-1221 8 - Estimated Time to Complete Tasks Wiring the secondary disconnects and verifying they match the switchgear cublicle may take 1 to 8 hrs depending on the complexity of the original breaker.

  • Page 7: 9- Product Specs

    9 - Product Specs Trip Unit Versions Code (#) Trip Unit Type EC – AC/DC Power Sensor – AC Only ECS – AC Only SST – AC Only Micro Versa Trip Micro Versa Trip RMS-9 Micro Versa Trip EPIC Power Leader MVT+, MVT PM Power Leader MVT+, MVT PM with RMS9C trip units Non-Automatic Retrofill Breaker...
  • Page 8 Figure 4 AKD-6 - AKRT-50 Breaker in Cassette (Rear View) Figure 5 AKD-6, AKR75\75H\100 Breaker in Cassette Figure 5a Front View Figure 5b Rear View Emax 2 Retrofill Circuit Breaker is suitable for application on power systems up to 635 VAC 50/60 Hz.

  • Page 9: History And Types

    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 / 50 / 75 / 100; the 4000A-max bus rating. Breakers had a ratcheting drawout mechanism, with an open-door drawout.
  • Page 10 AKD - 8 The AKD-8 was manufactured in Salisbury, NC from 1980 to 1984 and in Burlington, Iowa from 1984 to 1999. It 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.

  • Page 11: Akd-6, Retrofill Breaker

    AKD-6: Retrofill Breaker 11 - AKD-6, Breaker Models Following table depicts the key features of AKR 30/50/AKRT50/AKR75/100 AKD6 Retrofill breakers. Note: All features of the Legacy AKR 30/50/T50/75/100 breakers are offered with the corresponding Emax2 Retrofill breakers. Breaker Model Comparison Table Table 5 AKR 30/50, AKRT50 Retrofill AKR 75/100 Retrofill Breaker...

  • Page 12: 12- Akd-6, Mechanical Drawings

    12 - AKD-6, Mechanical Drawings The following engineering or assembly drawings describe the layout and dimensions of the AKD-6 Retrofill breaker. AKD-6: AKR30, Retrofill Breaker Dimensions Figure 6 AKD-6, AKR50 , Retrofill Breaker Dimensions Figure 7 AKD-6, AKRT-50, Retrofill Breaker Dimensions Figure 8 2TSA451014P0000 Rev-B 12 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A...
  • Page 13 Figure 9 AKD-6, AKR75/100, Retrofill Breaker Dimensions 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. ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 13 2TSA451014P0000 Rev-B...

  • Page 14: Akd-6 Compartment

    AKD-6 Compartment 13 - Interior View The figures 10&11 below represent typical AKR-30/50/T50 and figure 12 represents typical AKR-75/100 AKD-6 compartment. AKD-6 Switchgear, Empty Compartment Figure 10 AKD-6 Compartment Distinctions Figure 11 AKD-6 3200A/4000A Compartment Figure 12 2TSA451014P0000 Rev-B 14 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A...
  • Page 15 Figure 13 is an example of a compartment in the AKD-6 switchgear that is empty; that is, the upper compartment is ready for a retrofill breaker where the legacy, or original breaker, had been racked out and new wire connections made. The lower compartment has a retrofill breaker, already installed.

  • Page 16: Modify Akd-6 , Switchgear Compartment

    4. Check the secondary disconnect integrity & their mounting supports for any damage or cracks. 5. If switchgear parts show cracks or damage contact ABB post sales service 888-437-3765. 6. Check each breaker compartment for bolted joints in the primary disconnect bars. Where such joints exist, check the bolts for tightness.

  • Page 17: Unpack Circuit Breaker

    Unpack Circuit Breaker By following the procedures below, one should be able to install the breaker with minimum effort and time. 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 18: 17- Quality

    The design was based on the original requirements of the legacy switchgear and breakers. The product is manufactured in ABB Inc USA, Senotobia, Missisipi (MS) and is inspected using some of the same master gauges used on the legacy AK, AKR breakers to confirm electrical and mechanical performance, including rejections-features.

  • Page 19: Store Circuit Breaker

    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 and cassettes are stored in a clean, dry location, in their original packaging. Failure to comply with these instructions may result in product damage.

  • Page 20: Check Before Installing

    Check Before Installing Danger 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.

  • Page 21: Modify Retrofill

    Modify Retrofill 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 22: Prepare Switchgear Compartment

    Prepare Switchgear Compartment 1. Before modifying the switchgear compartment, de-energize/switch off the breaker. If 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. 2.
  • Page 23 Figure 18 Latching Inner Rail with Outer Rail Danger 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.

  • Page 24: Installing Akd-6 Retrofill Circuit Breaker

    Installing AKD-6 Retrofill Circuit Breaker Danger 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...

  • Page 25: 22- For Akr 30/50/T50 Akd-6 Retrofill Breaker

    22 - For AKR 30/50/T50 AKD-6 Retrofill Breaker 1. After the legacy breaker is removed. Check that everything in the compartment looks good, clean, aligned, not bent, not overheating. 2. Remove the thin sheet metal locking levers on both sides of the compartment as shown in Figures 19.

  • Page 26: Install Or Insert Akd6 Retrofill

    Install or Insert AKD6 Retrofill After the existing breaker is removed and the retrofill breaker is wired to match the compartment, it can be installed in the AKD-6 switchgear. Verify that the breaker is in the disconnected, switched-off position before mounting it on the rails.
  • Page 27 Figure 22 AKR30/50 Retrofill Breaker Hoisted and Secured on Rails 10. Push the breaker into the compartment until it can't be pushed in any further and tog- -gle the rail levers to latch the inner rail with outer rail. Push the retrofill breaker to “test”...
  • Page 28 Figure 24 Racking in AKD6 AKR 30/50—Retrofill Figure 25 Stationary Secondary Contacts Fig. 25b Fig. 25a Fig. 25c 17. While turning the screwdriver to the right with the racking tool shutter open, insert the racking tool in the handle-insertion hole, so that it engages the racking mechanism inside the hole.

  • Page 29: Installation Of Akd-6 Akr 75/100 Retrofill Breaker

    Installation for AKD6 AKR75/100 Installation process for AKD6 AKR75/100 remains same as detailed in Pages 26,27 and 28. However Below are the main differences: 1. Removal of rail latch levers is not applicable for AKD6 AKR75/100 compartment. 2. Breaker “disconnect” position of the legacy breaker will be same as corresponding disconnect position for the retrofill breaker.

  • Page 30: Akd-6 - Install Accessories

    AKD-6 - Install Accessories 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 31 Figure 27 Secondary Disconnect Bullets for AKR 30/50 retrofill Breaker For AKR 30/50/75/100 AKD6 retrofill breakers 1. Unpack the secondary disconnect block from the box. Each kit of secondary disconnect has four fixing nuts, plain washers, and spring washers. These can be arranged on a work station to prepare for installing the assemblies.
  • Page 32 Notice WIRING Do not pinch/damage the wires while installing the secondary disconnect blocks. Figure 28 AKD-6 - Secondary Disconnects, Bullets Wire Secondary Disconnect Assembly-AKR30/30H/50/50H/75/100 Tools required: wire stripper, wire cutter, and a Philips-head screw driver, M6 wrench As mentioned above, the secondary disconnect blocks are available with all blocks installed. In this case, the wires on the blocks are routed through one side of the breaker and then on to the front.
  • Page 33 Table 6 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 33 2TSA451014P0000 Rev-B...
  • Page 34 Table 7 NOTES: 1. "*B" refers to the mixed auxilliary contacts, like Q1 & Q2 are of 400 v while Q3 & Q4 are 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.
  • Page 35 Table 8 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 36: Pin Programmer Secondary Disconnect (Breaker)

    24 - 19 pin Programmer Secondary Disconnect (Breaker) The 19-pin programmer disconnects can now be included with the AKD-6 series retrofills to accommodate the extended features of the Emax 2 T rip Unit. The 19-pin programmer- disconnect assemblies already come pre-installed and wired from the factory and do not require any installation in the field.
  • Page 37 Figure 30 19-Pin Programmer Disconnect for the AKD-6 AKR30H\50H Retrofill, Exploded View Installed Exploded View Figure 31 shows the 19-pin programmer-disconnect on the AKR75/100, rear left side of the breaker, already installed. Figure 31a features an exploded view of the 19-pin programmer disconnect.

  • Page 38: 25- Install 19 Pin Programmer Secondary Disconnect (Compartment)

    25 - Install 19 Pin Programmer Secondary Disconnect (Compartment) Danger 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.
  • Page 39 8. Place the programmer disconnect assembly on the mounting holes and secure it to the base of the programmer using hardware (Bolt—M6 X 35/55, Nut—M6 (metric)) provided along with the programmer disconnect assembly kit as represented in figs. 33 & 34. 9.
  • Page 40 Figure 35 Wiring Diagram for the AK/AKR Retrofill 2TSA451014P0000 Rev-B 40 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A...

  • Page 41: 26- Akd-6: Position Switch Actuator

    26 - AKD-6: Position Switch Actuator Note: Later models of breakers (Q3 2015) are shipped with position switch bracket pre- installed. Position switch actuator bracket can be installed on AKR30H/50H versions of Emax 2 ACB for AKD6 LVS. There are no additional parts to be instaled for AKR75/100 retrofill variants. The steps of installation are as follows: Retrofills use the legacy position switch already mounted in the cubicle.

  • Page 42: Door Interlock System

    Door Interlock System Danger 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...
  • Page 43 2. Place the torsion spring on the pin as shown in the exploded view below and anchor it by placing one end of the pin into the hole provided inside the side-sheet of the retrofill. 3. Mount the door interlock bracket on the same pin via the hole provided on the bracket. Also, it must be ensured that the slot of the door interlock bracket is mounted on the second pin, placed on the front as shown in 4.

  • Page 44: Installing Neutral Disconnect Assembly(Breaker Side)

    Installing Neutral Disconnect Assembly (Breaker) Figures 40 & 41 show the exploded/assembled view/s of the breaker side neutral disconnect assembly for the AKD-6 AKR30/30H/50/50H/75/100 retrofills. These will be available prein- -stalled and wired from the factory. Figure 40 Neutral Disconnect Assembly for the AKD-6 AKR30H\50H Retrofill Figure 41 Neutral Disconnect Assembly for the AKD-6 AKR75\100 Retrofill Neutral Disconnect Connected Inside...

  • Page 45: Akr 100 - 4000A , Fan Control Unit Wiring & Trip Unit Programming Instructions

    AKR 100 - 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 & 1SDH001000R0524 to identify the terminal marking in circuit diagram.
  • Page 46 Figure 44 Wiring of WP 4000A breaker with FAN control unit 2TSA451014P0000 Rev-B 46 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A...

  • Page 47: Configuring Ekip Touch, Hi Touch Trip Unit

    Configuring Ekip Touch, Hi Touch Trip unit 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. Figure 45 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 47 2TSA451014P0000 Rev-B...

  • Page 48: 28- Synchronizing 2K-1 Signalling Module With The Trip Unit

    28 - 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 46 Once the local bus is activated 2k modue should synchronize with the Ekip touch trip unit.

  • Page 49: 29- Configuring Threshould Currents

    29 - Configuring threshold currents 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 Iw1 and Iw2.

  • Page 50: 30- Programing 2K-1 Signaling Contacts Output

    30 - 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 49 Figure 50 2TSA451014P0000 Rev-B 50 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A...

  • Page 51: 31- Contact Readiness Auto Test

    31 - 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 51 Figure 52 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 52 We reserve the right to make technical changes or modify the contents of this document without prior notice. ABB does not accept any responsibility 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.

This manual is also suitable for:

Emax 2 retrofill akr-50-1600aEmax 2 retrofill akrt-50-2000aEmax 2 retrofill akr-75-aEmax 2 retrofill akr-3200-aEmax 2 retrofill akr-100-aEmax 2 retrofill akr-4000-a

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