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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

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Содержание SACE Emax 2

Страница 1: ...D 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...

Страница 2: ...ETROFILL SECONDARY WIRING 26 INSTALL POSITION SWITCH ACTUATOR AKT BREAKER RETROFILL ONLY 27 RACKING LOCK BRACKET INSTALLATION AK 25 AK50 AKT50 CABINET ONLY 28 INSTALL CASSETTE LANDED WIRES 29 INSTALL...

Страница 3: ...d here are applied to installation manuals These are standard or generic alerts labels that must be taken quite seriously when installing Retrofill circuit breakers in AKD other OEM s switchgear and w...

Страница 4: ...o ensure accuracy the information contained herein does not cover all details or variations in hardware and software nor does it provide for every possible contingency in connection with installation...

Страница 5: ...t Replacement Cradle in Cradle Full Door Kits AKD 5 6 8 10 2TSA451007P0000 Accessory Retrofill Direct Replacement Ciradle in Cradle Door Adaptor Kits AKD 5 6 8 10 2TSA451008P0000 Accessory OEM Direct...

Страница 6: ...AKT50 is a Backless Cradle in Cradle BCiC solution using EGR cassette Views Typical Emax 2 Retrofill circuit breakers for GE AKD 5 OEM switchgear are shown below All circuit breakers are drawout types...

Страница 7: ...1600A Breaker in Cassette Fig 3 Front View Fig 4 Rear View Figure 5 6 AKD 5 2000A Breaker in Cassette Fig 5 Front View Fig 6 Rear View Figure 7 8 AKD 5 3000A Breaker in Cassette Fig 7 Front View Fig...

Страница 8: ...e welded riveted frame bus compartment barriers line load separation barriers on mains and ties isolation barriers on transformer transitions copper runbacks on feeder breakers ring silver plating on...

Страница 9: ...ame similar to the small frame breakers The positions DISC TEST CONN are shown on the side of the front escutcheon by position of the sliding picture frame The GE AKD 8 breakers have a drawout letter...

Страница 10: ...wing figures depicts the AKD5 Retrofill breakers 600 4000A AKD5 AK25 Emax 1 2 600A CiC Cradle in Cradle Retrofill Kit Figure 11 12 Fig 11 Emax 1 2 Circuit Breaker Moving Portion Fig 12 Circuit Breaker...

Страница 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 Figure 1...

Страница 12: ...Figure 21 22 Fig 21 Emax 2 2 Circuit Breaker Front view Fig 22 Emax 2 2 Circuit Breaker Rear view Figure 23 Circuit Breaker Projected from Cassette Figure 24 25 Fig 24 Rear View of Retrofill Kit Fig...

Страница 13: ...13 AK75 Emax 4 2 3000A Cradle in Cradle Retrofill Breaker Figure 26 27 Fig 26 Emax 4 2 Circuit Breaker Moving Portion Fig 27 Circuit Breaker Projected from Cassette Figure 28 Figure 29 30 Retrofill K...

Страница 14: ...B Figure 31 32 Figure 33 Figure 34 35 AK100 Emax 6 2 4000A Cradle in Cradle Retrofill Breaker Fig 31 Emax 6 2 Circuit Breaker Moving Portion Fig 32 Circuit Breaker Projected from Cassette Retrofill K...

Страница 15: ...reakers 600A 4000A 15 12 AKD5 Mechanical drawings The following engineering or assembly drawings describe the layout and dimensions of the AKD 5 Retrofill breaker Figure 36 AK25 Emax 1 2 600A Figure 3...

Страница 16: ...A451011P0000 Rev B Figure 39 AK75 Emax 4 2 3000A Figure 40 AK100 Emax 6 2 4000A Forced cooling Fans for 3000A Rating only Fans Turn ON at 2500A and OFF at 2300A For other detail related to Trip unit c...

Страница 17: ...sonnel install operate service and maintain all electrical equipment Before modifying the switchgear compartment de energize switch off the breaker If the circuit breaker is ON and the springs are cha...

Страница 18: ...18 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 2TSA451011P0000 Rev B Figure 43 Figure 44 Figure 45 AKD5 600A AKD5 1600A 2000A AKD5 3000A 4000A...

Страница 19: ...necessary with a clean lint free rag and isopropyl alcohol or acetone 7 Be sure to apply a thin film of red Mobilgrease 28 to the primary disconnect contact areas for better electrical connections ins...

Страница 20: ...ment Caution Falling Object Do not walk or remain under any heavy assembly while hoisted above head as the chains securing the assembly may give way Ensure lifting equipment has capability for device...

Страница 21: ...number and name plate information 3 Remove the banding straps and lift off the top cover 4 Remove all packaging material 5 Remove all product documentation and store properly Unscrew the mounting scr...

Страница 22: ...s 600A 4000A 2TSA451011P0000 Rev B Figure 46 Emax2 2 4 2 6 2 Moving Portion Lifting Plates Figure 47 Emax2 2 4 2 6 2 Loading Rails Figure 48 Loading Emax2 Breaker Into the Cradle Figure 49 Disengageme...

Страница 23: ...kers if they are not left in their original containers 3 If breakers are not to be placed in service immediately remove them from their shipping cartons and thoroughly inspect them 4 If everything is...

Страница 24: ...ment to rack in and out the breakers while AKT 50 has special EntelliGuard cassette equipped with AK style 7 point bullet connectors which interface with the original AKD 5 secondary disconnect blocks...

Страница 25: ...002 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 Clean those areas if necessary with a clean...

Страница 26: ...eaker 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...

Страница 27: ...3 To install the position switch actuator slide the assembly up from the bottom of the cassette 4 Line up the holes on the cassette side sheet with the holes provided on the actuator assembly 5 Fasten...

Страница 28: ...scribed PPE for the specified tasks Ensure only qualified personnel install operate service and maintain all electrical equipment 1 Remove existing indicator assembly system from AKD 5 cabinet rails F...

Страница 29: ...onducted 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 instal...

Страница 30: ...e cassette on the rails for racking into the switchgear cabinet figure 55 56 3 Slide the retrofit cassette into the compartment till dead stop 4 Lock the rails of the legacy compartment to ensure inne...

Страница 31: ...ofill Circuit Breakers 600A 4000A 31 Figure 58 59 AKD 5 AK25 Cassette To Be Racked In Fig 58 Fig 59 Figure 60 61 AKD 5 AK 25 Cassette or Substructure Rails Extended Fig 60 Fig 61 Figure 62 AKD 5 AK25...

Страница 32: ...elated 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 electrica...

Страница 33: ...for the specified tasks Ensure only qualified personnel install operate service and maintain all electrical equipment 1 Before inserting the retrofit breaker into the cabinet make sure that the break...

Страница 34: ...it is to be installed leaving enough clearance to swing the compartment door open to access the enclosure figure 66 5 When the breaker is lined up with the compartment raise the breaker only slightly...

Страница 35: ...69 Figure 69 Inserting Breaker into Cassette Wheels Lined Up with Roller Arms 11 Lower the circuit breaker gradually at an angle so that the rollers drop over the rails Make sure that the grooves in...

Страница 36: ...NECTED position figure 72 15 Push back both the extended rails of the cassette to the stowed position 16 If the circuit breaker is ON and the springs are charged to turn the breaker off press the OPEN...

Страница 37: ...ing tool It resembles a vehicle ignition lock See figure 76 Figure 75 Shutter 20 Insert the tool so it engages the racking mechanism inside the hole 21 Then crank clockwise so that the breaker starts...

Страница 38: ...ions of the switchgear bus stabs 26 Remove and store the racking handle in its storage location Note that the circuit breaker is now ready for normal operation 21 AK AKT50 Kirkey Interlock The Emax 2...

Страница 39: ...identified with wire markers or tags Each wire on the 21 wire harness is connected to a bullet Each bullet when the cassette is racked in engages with its respective points in the switchgear The wires...

Страница 40: ...to the AKD 5 AK25 the AKD 5 AK50 breaker roll in replacement uses a similar wire harness and is mounted on the cassette Get these tools needed for task Philips head screw driver wire strippers crimps...

Страница 41: ...2TSA451011P0000 Rev B 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 41 Figure 82 Example wiring diagram for AK25 secondary disconnects...

Страница 42: ...42 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 2TSA451011P0000 Rev B Figure 83 Figure 84 Example of AK25 Secondary Disconnects Images...

Страница 43: ...0A 43 Below are tables 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 Table 6 AKT50 Emax 2 Retrofill Poi...

Страница 44: ...44 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 2TSA451011P0000 Rev B Table 7 AKT50 Emax 2 Retrofill Point Secondary B Block...

Страница 45: ...AK25 50 Photo in Figure 85 shows you the B block harness and Figure 86 is a close up photo of the harness Figure 87 shows you the secondary bullets Figure 85 AK25 B Block Harness Figure 86 AK25 Wirin...

Страница 46: ...nual Number AKD5 AK25 Emax 1 2 2TSA451017P0000 AKD5 AK50 Emax 2 2 1SDH001000R0709 AKD5 AKT50 Emax 2 2 DEH 41304 Below representations are provided only to show the overview of the interlock assemblies...

Страница 47: ...daptor 1 Remove existing compartment door s and remove hinge block using 2 Phillips headed screw driver 2 To install new door follow the instructions below De energize switch off the LVS section that...

Страница 48: ...oor Adaptor kit assembly 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 break...

Страница 49: ...ent levels on a 4 wire circuit the Neutral Iron Core CT in the cable compartment needs to be replaced with a Rogowski style CT The Rogowski CT comes mounted on copper bars matching the same hole patte...

Страница 50: ...d to the existing CT assemblies and place them such that they do not interfere with the replacement of the CT assemblies 5 Unfasten and remove the bolts that hold the neutral disconnect assemblies to...

Страница 51: ...ill allow the new breaker to operate with the existing Neutral CT in most cases Example Neutral sensor Cat numbers beginning with TSVG CT part s 139C4970G s Please note that these neutral CT adapters...

Страница 52: ...nections between the 2k 1 signalling unit relay and fans Refer Relay diagram 1SDH001000R0524 to identify the terminal marking in circuit diagram Note U1 U2 Emax 2 motor operator 120 V terminal NOTE 1...

Страница 53: ...2TSA451011P0000 Rev B 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 53 Figure 98 Wiring of WP 4000A Breaker with Fan Control Unit Routing wire to the fans...

Страница 54: ...cuit Breakers 600A 4000A 2TSA451011P0000 Rev B Configuring Ekip Touch Hi Touch Trip unit 30 Connecting Ekip Touch Figure 99 Connet Ekip Touch or Hi Touch Trip unit using Ekip connect 3 0 357 9 or late...

Страница 55: ...us and correct communication with Ekip Touch Off module off Fixed or flashing light synchronized on power LED of Ekip Touch module ON and communication with Trip unit present Flashing not synchronized...

Страница 56: ...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...

Страница 57: ...l Circuit Breakers 600A 4000A 57 33 Programing 2K 1 signaling contacts output Figure 103 Figure 104 The output of 2K 1 module consists of 2 contacts K11 K12 and K13 K14 Configure these two output cont...

Страница 58: ...the fans 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 and LEDs off 2...

Страница 59: ...2TSA451011P0000 Rev B 2020 Emax 2 Retrofill Circuit Breakers 600A 4000A 59 Revisions Overhaul ECN Description B ECN000122590 Second version...

Страница 60: ...ht 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...

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