ABB AKR30S-800A Installation And Maintenance Manual Download

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Summary of Contents for AKR30S-800A

Page 1: ...This manual applies to Emax 2 Retrofill circuit breakers to be used in AKD 8 Switchgear substructures found in GE Switchboards OEM Substructures Equipment using legacy AKR circuit breakers of the foll...

Page 2: ...KD 8 AKR 30S Remove Glastic Sheet of compartment 28 25 AKD 8 AKR 30S Modify Bracket INSTALL AKD 8 800 2000A RETROFILL BREAKER 30 26 AKD 8 RACKO IN o sessessessssssossosentessessensorsossnsensesnesnses...

Page 3: ...ctrical equipment Table 1 Generic Danger Alerts Shock and arc flash explosion hazards Are flash and Folion ALL roqurements hazard eS orcuces a er com ADANGER 2 Ny 4 PELIGRO HAZARDOUS i VOLTAGE a j Dis...

Page 4: ...t in product damage Table 3 Table 3 Custom Caution Alerts Word message Symbol Panel Notice or Note This indicates important information in that it aids in job performance that is a notice or note is u...

Page 5: ...ciency 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 concerni...

Page 6: ...onnects Installation Instructions 2TSA451016P0000 E2 2 4 2 6 2 Breakers Installation Operation Maintenance Manual 1SDHOO1000RO0002 Instructions for using Ekip touch protection releases accesories 1SDH...

Page 7: ...driving drawout racking cams thru what look the Emax 2 Cassette s front dashboard With least modifications to be made to existing switchgear Emax 2 Retrofill breakers are cost effective solution to up...

Page 8: ...Figure 2 BREAKER IN CASSETTE AKD8 AKR30H RETROFILL Primary Finger Clusters Ki Figure 3 Figure 4 8 2020 Emax 2 Retrofill Circuit Breakers 800 S000A 2TSA451009P0000 Rev B...

Page 9: ...reaker in Cassette Front View Back View Figure 7 Figure 8 Emax 2 Retrofill Circuit Breaker is suitable for application on power systems up to 635 VAC 50 60 Hz 2TSA451009P0000 Rev B 2020 Emax 2 Retrofi...

Page 10: ...r 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 painte...

Page 11: ...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 AK...

Page 12: ...e following figures depicts the AKD8 Retrofill breakers 800 5000A Figure 9 Retrofill Breaker 800 2000A Figure 10 Kirk lock Actuator LinkAKD 8 Compartment Kirk lock upto 2000A 12 2020 Emax 2 Retrofill...

Page 13: ...3200A 5000A Figure 12 AKD 8 Compartment Kirk lock 3200A 4000A Kirk lock Actuator Compartment Release lever Kirk lock Interface Compartment Release Lever 2TSA451009P0000 Rev B 2020 Emax 2 Retrofill Ci...

Page 14: ...30H Retrofill Breaker Dimensions 13 99 16 69 att _l 3 89 16 26 15 50 6 82 10 38 8 63 ___ 1 43 Figure 14 AKD 8 AKR30S Retrofill Breaker Dimensions ol om F I AL 14 67 i oe 12 89 e eee i P iol ei e 6 50...

Page 15: ...ns for q i 40004 Rating Only el sft Io Fans Turn ON at 3600A and OFF Fee at 3400A 26 94 10 77 eR e f For other detail related to Trip ripe 7 unit config and wiring refer to ai Fan control section in m...

Page 16: ...The figures below represent a Typical AKR 30 50 T50 AKD 8 compartment AKD 8 New Empty Compartment View 1 Figure 19 NOTE Setion width 22 AKR 30 50 T50 Figure 20 16 2020 Emax 2 Retrofill Circuit Breake...

Page 17: ...The photos point out the shutter assembly and telescopic rails in the AKD 8 Figure 21 AKD 8 Compartment Assemblies Shutter oon Neutral Assembly wite Disconnect Telescopic rails 2TSA451009P0000 Rev B 2...

Page 18: ...ARRIER BARRIER PRIMARY i DISCONNECTS 3 LINE ez a i hi 5 i s POSITION SWITCH os 4 r F DISCONNECTS LOAD BOTTOM BARRIER eae A 1 be DRAWOUT RAILS I Ca Zoi 15 Interior View The figures below present a Typi...

Page 19: ...Figure 25 is a photo of the interior of the AKD 8 The photos point out the shutter assembly and Draw out tray assembly in the AKD 8 AKD 8 Compartment Assemblies Figure 25 a Shutter Assembly 2TSA451009...

Page 20: ...onents Figure 27 points out the major components of an AKD 8 compartment AKD 8 Circuit Breaker Compartment for AKR 75 75H 100 125 Breakers Figure 27 Racking Pins Side Barrier Disconnects Load 4 A Ki e...

Page 21: ...rtment refer to your legacybreaker s manual on how to remove the existing breaker 19 Check Clean Grease AKD 8 Compartment Inspect the compartment for damage or signs of overheating Check the orientati...

Page 22: ...quipment has capability for device being lifted Wear hard hat gloves and safety shoes e Failure to comply with these instructions could result in serious injury Notice PRODUCT DAMAGE e Ensure circuit...

Page 23: ...fascia 23 Remove Circuit Breaker from Container Inspectand 1 Prepare 2 am hw Inspect the shipping container for obvious signs of rough handling and or external damage incurred during transportation R...

Page 24: ...are not to be placed in service at once remove them from their shipping cartons and thoroughly inspect them for damage If everything is in satisfactory condition replace the breakers in their shipping...

Page 25: ...scribed PPE for the specified tasks e Ensure only qualified personnel install operate service and maintain all electrical equipment These breakers are supported on a rollout track in the same manner a...

Page 26: ...an 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 28 2...

Page 27: ...with wire markers are provided on the NOTICE Retrofill Make sure that the switchgear wiring connection points match up with the original wiring of the cubicle This ensures that all wiring connections...

Page 28: ...operate service and maintain all electrical equipment 24 AKD 8 AKR 30S Remove Glastic Sheet of compartment Remove Glastic Sheet for AKR 30S only Figure 30 Remove glastic sheet The AKD 8 AKR30S switchg...

Page 29: ...intain all electrical equipment Modify Bracket Remove this pin Steps for removing the bracket pin 1 S Remove the left bracket assembly 75C149309G061 from the compartment Figure 31 The assembly is bolt...

Page 30: ...BB lifting spreader bar It will provide the best chance of installing breakers especially into the upper compartments without damaging the breakers The WavePro small frame lifting bar had a 3rd liftin...

Page 31: ...the lifting bar any lifting eye hooks and chains 6 For AKR 30S Retrofill Breaker Insert eyebolts in the 10 mm eye bolt weld nuts as shown in Figure 33 Use a chain and hook to lift the breaker from ab...

Page 32: ...chain attached to eye bolts through S hook and connector can be used to lift the AKR Retrofill Breaker Examples of an eye bolt and connector are shown in fig s 36 and 37 Insert M10 eyebolts of rating...

Page 33: ...shing the breaker into the compartment from fully withdrawn to DISCONNECT position 10 Push the breaker in until the compartment racking pins engage with the breaker racking cams 11 Remove the racking...

Page 34: ...ing the screwdriver Blade type Screw Driver torqued to the right insert the racking tool in the left slot until it engages with the mechanism inside e After the racking tool engages remove the screwdr...

Page 35: ...CTED position more torque for turning the racking handle is normal as the primary finger clusters engage with the AKD 8 or OEM substructure primary bus stabs NOTE At the end of 37 rotations the breake...

Page 36: ...correct breaker is being used Compare the rejection plate arrangement on the new breaker to those on the old breaker After the old breaker is removed and the compartment updated with any added featur...

Page 37: ...AKD 8 Using Lifting bar hoist preferred method Figure 45 J Hook Figure 46 2TSA451009P0000 Rev B 2020 Emax 2 Retrofill Circuit Breakers 800 5000A 37...

Page 38: ...secondary disconnects and opening of the optional shutter A compartment interlock rod in the right front will ride over a cam and drop into position in the Disconnect position When fully installed to...

Page 39: ...AKD 8 Racked In The photo below shows one example of a racked in AKD 8 Retrofill Emax 2 Retrofill AKD 8 CONNECT POSITION Figure 47 2TSA451009P0000 Rev B 2020 Emax 2 Retrofill Circuit Breakers 800 5000...

Page 40: ...l 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 do...

Page 41: ...ontaining faulty bullets should be replaced Place the secondary disconnect block on top of the horizontal plate at the rear of the Emax2 Retrofill ACB which runs across the width of breaker Align the...

Page 42: ...this can bend the connection points and effect biasing and contact pressure By using tie wraps and stickpads wire routing can eliminate sagging of the wire harness and pressure on secondary bullets O...

Page 43: ...pa my rh Py aj mh ey hh ry tant al TT ae Ore Ora ra av eit eI fT ec v a xr yell pel al yl AKR wl mtd wl Mi 44d 1 B refers to the mixed auxilliary contacts like Q1 Q2 are of 400 v while Q3 Q4 are of 24...

Page 44: ...ll cl 4 ARR i xu fH ti CT x pasa s S iW de ae aD BST KAA ray Al TRE pe 3 8582 Bal rae al WIt Ou Lew te Cle tC xBeur x i boi ace ARR Tie Eas a a 1 5 126 126 Ke eas LIL _ oA ARR das 44 NOTES 1 77 YC 78...

Page 45: ...isting programmer disconnect assemblies in the compartment The existing programmer disconnect plugs used in AKD 8 generation of the AKR breakers are provided on the left side for the AKR30 30H 50 50H...

Page 46: ...in programmer disconnect assembly is installed in the cabinet original MicroVersaTrip 1979 1984 e Customer chooses to replace a 12 pin configuration with a 19 pin configuration to Add RELT 4 Before un...

Page 47: ...ing wires from the compartment to the terminal block Any additional wires from the compartment side which are required for the 19 pin programmer need to be landed on the terminal block and checked for...

Page 48: ...euse of external existing wiring by rewiring the internal ZSi Legacy zone selectivity is not compatible with Emaxz In case the functions is used it is necessary to replace all legacy breakers connecte...

Page 49: ...eo xv Sz zo Gz Gzo a 3 3 8 Al SZi SZo Gzi GZo Lest DFI DFo DBI DBo EKIP o N a xv LE x Use A4 A K51 Szc os Sz0 Szi Gzo Gzl e K51 Sze Q2 6 sai 2 t 2 Zi Gz0 zi 8 K51 Sze ey Szo Szi Gzo Gzi ESEMPIO DI SCH...

Page 50: ...28 225 288 32 L W2 LOCAL BUS IN A B Aa Uaux Q 110 240VAC DG 24 48VDC cr Hh L Kt k2 wa w4 g gg S it 38 bs K51 x3 SUPPLY te Re IU i PD 2 3 x Kd k2 wa wa xv eK eK ws ws zt X 2 s Al K51 EXP 1 Auxiliary su...

Page 51: ...wer 1K 2 a3 pe g 8 K51 i K51 j Ks1 i COM COM 5 cOM _ i x Tw Uwe wo ws we PD u 12 12 1 Je C HI clip C th AA S R U A data data B A date datat B BUS 1 BUS 1 BUS 1 Tools required wrenches flat head screw...

Page 52: ...disconnects on a Retrofill circuit breaker Figure 54 details the finger cluster assembly Figure 53 Circuit Breaker Removed Featuring Primary Disconnects Fingers Contacts Figure 54 Circuit Breaker Fing...

Page 53: ...ng clips on the stud Set a pair of bow tie spacers into a pair of fingers place a pressure plate retainer over the spacers to hold them in position and then turn the subassembly over Hook them into th...

Page 54: ...steps for working with the primary contacts Figure of Steps for working with the primary contacts for 800A 1600A and 2000A 5 For 1600A 2000A 6 For 800A 54 2020 Emax 2 Retrofill Circuit Breakers 800 50...

Page 55: ...ures provide further details Figure 58 2TSA451009P0000 Rev B ASSEMBLE ITEM 6 WITH NARROW SECT AWAY FROM BREAKER he eccentric stud spacer ie roo QQ M EE I Ed __ i I k al Sl aT 2020 Emax 2 Retrofill Cir...

Page 56: ...et the spring dimension shown in Figure 59 60 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...

Page 57: ...hem into the main retainer Slide a long bolt through the hole in the retainer between the finger and then through the clip and stud spacer Hold the bottom finger subassembly in place Place two fingers...

Page 58: ...Steps in Exploded Views for 3200A WPS 32 WPH 32 WPX 32 Figure 63 2TSA451009P0000 Rev B 58 2020 Emax 2 Retrofill Circuit Breakers 800 5000A...

Page 59: ...Steps in Exploded Views for 4000A WPS 40 WPX 40 Figure 64 2020 Emax 2 Retrofill Circuit Breakers 800 5000A 59 2TSA451009P0000 Rev B...

Page 60: ...Steps in Exploded Views for 5000A WPS 50 WPX 50 Figure 65 2TSA451009P0000 Rev B 60 2020 Emax 2 Retrofill Circuit Breakers 800 5000A...

Page 61: ...al Views AKR 75 100 125 Figure 66 Below pictures provide further details on Fingers or Clusters Mechanical views AKR75 75H AKR100 125 2TSA451009P0000 Rev B 2020 Emax 2 Retrofill Circuit Breakers 800 5...

Page 62: ...all a position switch if it s not already installed or if the existing assembly is damaged Compartment Position Switch Assemblies 0343L0881 AKR30S 0343L690G1 AKR30 30H 30L 50 50H Consult Factory AKR 7...

Page 63: ...l 2 Figure 69 Surface activating the position switch for AKR30 30H 30L 50 50H AKRT 50H Model 2 Figure 70 position switch for AKR75 75H 100 125 v J D Cc 5 5 uu Y 9g o c 3 an 2020 Emax 2 Retrofill Circu...

Page 64: ...73 and 74 which operate the opening of the shutters Hence no installation is required Retrofills provide the same mechanical indication scheme as legacy breakers Figure 71 AKD 8 Breaker Surfaces Activ...

Page 65: ...odel 2 Surfaces activating the shutters for AKR30 30H 30L 50 50H AKRT 50H Figure 74 AKD 8 Breaker Surfaces Activate Shutter Surfaces activating the shutter for AKR75 75H 100 125 2TSA451009P0000 Rev B...

Page 66: ...t state for Connected state for AKR30 30H AKR305 AKR30 30H AKR50 50H AKRS50 S0H Retrofil GACB Benes Retrofil GACB DOOR INTERLOCK ACTIVE Racking stroke of legacy 4 25inches while for retrofils 2 75inch...

Page 67: ...AKR30S Please remove the existing Door Interlock Actuators from the compartment for AKR 30 30H 50 50H AKRT 50 50H The Retrofill breaker has a Door Interlock Actuator Bracket mounted on breaker Figure...

Page 68: ...provided with full instructions on how to operate the Legacy Key Interlock It is suggested to apply the label on the inside of the compartment door Following is a brief summary of how the Key Interlo...

Page 69: ...rovide access 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...

Page 70: ...he door and secure it to the compartment Rack in the new retrofitted Emax 2 Retrofill Breaker For detail instructions refer document 2TSE431967R1000 2TSE431968R1000 2TSE431996R1000 OEM Adaptor Show as...

Page 71: ...e and maintain all electrical equipment 34 AKD 8 Neutral Disconnect Assembly Figure 81 shows an exploded view of the breaker side neutral disconnect assembly for the AKD 8 AKR30 30H 50 50H 30L and AKR...

Page 72: ...om 250 to 5000 Amps as used in GE switchboards and switchgear from 1979 2015 It is available in seven variations shown in table below Kit Number Supported Neutral CT ratings Supported T U ENCTA0250 25...

Page 73: ...plungers on the neutral disconnect assemblies within the LVS compartment Be sure to orient the CT and wires for proper polarity e The new Rogowski assemblies are installed and ready for use e Tools r...

Page 74: ...e U1 U2 Emax 2 motor operator 120 V terminal e 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 Figure 83 11 T3 T3 T...

Page 75: ...Figure 85 2TSA451009P0000 Rev B Wiring of AKR 100 4000A breaker with FAN control unit Routing wire to the fans 7 2020 Emax 2 Retrofill Circuit Breakers 800 5000A 75...

Page 76: ...nit using Ekip connect 3 0 357 9 or later software and Ekip T P unit Figure 86 FOUND DEVICES Bluetooth Configure Ethernet SCAN Confare ABB Ability Electrica Distribution Control System ctivate ABB Abi...

Page 77: ...ith Ekip Touch e Off module off e Fixed or flashing light synchronized on power LED of Ekip Touch module ON and communication with Trip unit present e Flashing not synchronized with power LED of Ekip...

Page 78: ...et drops below 3400 amps Enable Activate protection and availability of protection threshold on menu OFF Direction enables you to choose to have the signal when the current is ee higher Up or lower Do...

Page 79: ...output contacts as per following to control the fans Figure 90 Classic View Nee os 4 Q saugatacas inabb com a Or t ie xx x tease J s g Ea vo v A Ba Figure 91 Classic View RR saugata caszin avb co Trig...

Page 80: ...el On v Qo 4 Or v Qe y 7 Autotest command that activates the automatic sequence of output tests contacts and LEDs and input test LED and includes the following operations 1 Reset output contacts open...

Page 81: ...y 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 th...

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ABB AKR30S-800A, Installation And Maintenance Manual

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