2019 DR Masterpact M to Emax 2 Direct Replacement Retrofitting Solution EPPC Global Product Service Management EPPC Global Service 2/25/20 1-Installation and commissioning 6-Engineering and consulting An investment in long-term equipments reliability Application recommendations and environmental best practices. 2-Training 7-Extensions, upgrades and retrofits The best way to teach how to respond efficiently in different critical situations Enhance existing equipment with the latest technologies. 3-Spares and consumables 8-End of life services All original and genuine spare parts and upgrade kits. Equipments recycling in line with environmental requirements 4-Maintenance 9-Replacements Maintenance to guarantee the systems continuous operation Replacing old equipment can dramatically increase performance and reduce costs. 5-Repairs 10-Advanced services Workshop and on site repairs by our service engineers Predictive Maintenance into ABB Ability EDCS Ekip-Up to upgrade your installations Slide 2 New Service Product Portfolio Extension, upgrades and retrofits Time to upgrade? Modernize by Retrofit kits Modernize Safety Technology Service years Saving in Maintenance Environment-friendly
Equipment health Retrofit kit Modern Circuit Breaker Low cost solution Profitable investment 2/25/20 Slide 3 Product Portfolio - Retrofitting Kit Solutions ABB knows how to upgrade your installations 1. Hard Bus Retrofill (RF) 2. Cradle in Cradle (CiC) 3. Direct Replacement (DR) The existing fixed part is removed from the switchboard and the new one is installed using a pre-designed bus bar connection and protection shields. The fixed part of the new CB is modified to be inserted in the old fixed part. The moving part of the new CB has to be modified to simulate the moving part of the old CB. It requires a very short shutdown. Portfolio ABB: Megamax, Novomax, Otomax, Isomax Portfolio Competitors: Schneider, Siemens, Terasaki, AEG H&W, Mitsubishi Competitors: GE, Federal Pacific, Allis Chalmers ABB: Isol, Fusol, Otomax, BBC K-Line Portfolio ABB: Emax (New in Old), Megamax (OD and CD), Novomax, Modul, ASEA ALG New Competitors: Schneider (Mastepact M) 2/25/20 Slide 4 Retrofit kits Direct Replacement Retrofit Solution Direct Replacement Who? Anyone can do it (also customers!) What? New circuit breaker already modified in order to be racked in/out the existing fixed part. Accessories and connections are already pre-cabled. Installation instructions When? Withdrawable version
The Old Fixed part still in good conditions How? Replacing only the moving part of the old circuit breaker Why? Easy to install Short down-time due to installation 2/25/20 Slide 5 EPPC Retrofit kits Masterpact M to Emax 2 ABB available Retrofitting Solutions Retrofitting Solutions RF: Hard bus Retrofill CIRCUIT BREAKER DR: Direct Replacement M08 M10 M12 M16 M20 2/25/20 Slide 6 Fixed N1 H1 H2 N1 H1 H2 N1 H1 H2 N1 H1 H2 N1 H1 H2 Version Withdrawable 3p 4p 3p 4p RF RF RF RF RF
N1 H1 H2 N1 H1 N1 H1 N1 H1 N1 H1 Version Withdrawable 3p 4p 3p 4p RF RF RF RF RF RF RF RF RF RF RF RF RF RF RF-DR RF-DR RF RF RF RF RF RF RF RF RF RF-DR RF-DR RF RF RF RF RF RF RF Direct Replacement Masterpact M to Emax 2 Value Proposition From Circuit Breaker to Power Manager Increase the Total Life Cycle of the Switchgear Cost reduction of maintenance and spare parts Easy to Install Replacement requires few minutes and no removal of main voltage on busbar system in the switchgear
Easy to Control All original and genuine spare parts and upgrade kits. Easy to Connect to SCADA and into the IoT Ekip PowerController to improve energy efficiency and saving Easy to Mantain Diagnosis and installation with Ekip Connect Software ABB Ability EDCS is also available with Emax 2 for Predictive Maintenance & Audits 2/25/20 Slide 7 Direct Replacement Masterpact M to Emax 2 Product details Corrispondences Masterpact M to Emax 2 Original CB: MasterPact M M08 M10 M12 M16 M20 M25 Performance Levels N1 H1 N1 H1 N1 H1 N1 H1 N1 H1 N1 H1 [email protected] 800 800 1000 1000
N N N N N B N N S N S 800 800 1000 1000 1250 1250 1600 1600 2000 2000 2500 2500 (1) (1) 800 800 1000 1000 1250 1250 1600 1600 2000 2000
2500 2500 (1) (1) lcu 400-415 V 40 65 40 65 40 65 40 65 55 75 55 75 lcu 440-500 V 40 65 40 65 40 65 40 65 55 75 55 75 lcuis690 V of Icu for all the sizes - Icw 40 65 for all40 Ics 100% (1s) = Icu 690V the sizes 65 40
65 40 65 55 75 55 75 Performance Levels [email protected] In (rating plug) (1) = Derating up to 2300A with fixed part with HR terminals 2/25/20 Slide 8 Direct Replacement Masterpact M to Emax 2 Product details Emax 2 Moving part The Emax 2 dedicated moving part: Has special terminals, lower slides and lateral sides Is assembled and tested in the factory Is ready to be inserted in the Masterpact M fixed part Masterpact M fixed part Dedicated lateral side Lower slides Terminals 2/25/20 Slide 9 Direct Replacement Masterpact M to Emax 2 Product details Masterpact M Fixed part On the fixed part, it is necessary to replace the existing components with the following ones: Drawer side plates Base panel for fixed part Rack-in plates Female sliding contacts to rewire according the electrical drawing Emax 2 door flange and with dedicated metallic Support for fixed part Support plates Installation instruction 2/25/20 Slide 10 Direct Replacement Masterpact M to Emax 2 Product details Masterpact M Fixed part
On the fixed part, it is necessary to replace the existing components with the following ones: Drawer side plates Base panel for fixed part Rack-in plates Female sliding contacts to rewire according the electrical drawing Emax 2 door flange and with dedicated metallic Support for fixed part Support plates 2/25/20 Slide 11 Female sliding contacts Rack-in plates Drawer side plates Base panel for fixed part Direct Replacement Masterpact M to Emax 2 Product details Masterpact M Fixed part Support plates On the fixed part, it is necessary to replace the existing components with the following ones: Drawer side plates Base panel for fixed part Rack-in plates Female sliding contacts to rewire according the electrical drawing Support for fixed part Emax 2 door flange and with dedicated metallic Support for fixed part Support plates Emax 2 door flange 2/25/20 Slide 12 Direct Replacement Masterpact M to Emax 2 Product details Conditions of the existing cradle Cubicle dimensions it is always necessary to verify that the Masterpact M Fixed Part is in good conditions as prescribed in the document 1SDH001279R0002. It is important to check the dimension of the high D of the cubicle In particular, it is important to check the jaw
contacts, the protecting coatings and the opening linkage mechanism of the jaw contacts shutters. In case of cubicles with dimensions less than 485mm, the special version with low-cubicle is available. Panel Dimension DR E2.2 [mm] Distance from fixed part to slide [mm] A (3p) 535 50 to left / 50 to right A (4p) 650 50 to left / 50 to right C 367 - D* 485 46 to Top * A special retrofit kits version is under development for a cubicle with the dimension D from 440 to 485 mm 2/25/20 Slide 13 Direct Replacement Masterpact M to Emax 2 Product details DR for low cubicle version The Direct Replacement of Masterpact M with Emax 2 for low-cubicle circuit breakers is a special solution that fits to the model with dimension D lower than 485mm. In this case, the commutation function is performed by cables through female and male socket that replace the sliding contact on the cradle and on the moving part. 2/25/20 Slide 14 Direct Replacement Masterpact M to Emax 2 Trip Unit Functions in Masterpact M and Emax 2 Trip Units It is strongly recommended to use the table to select the most suitable Trip Unit STR 1 8M Long time Ir curve Protection against Time delay tr
overloads Thermal memory STR 28 D STR 38 S STR 58 U STR 68 U Ekip Dip Ekip Touch Ekip Hi-Touch l l l l l l l l l l l l l l l l l l l l l l l l o o o o
l l l l l o o o o o o o o o o o o o o o o o o o o l l l Short time Im Protection against Time delay tsd short circuits Adjustable instantaneous l l Fixed instantaneous I l o o Protection against Earth fault ground faults Time delay Zone selective interlocking Zsi Load shedding and reconnection o current Real-time measurements
o voltage power energy frequency Demand measurement Basic functions 2/25/20 Maintenance indicators and records Communication capability Optional functions Slide 15 o o l l o o l l o o o o l l l l l l o o Direct Replacement Masterpact M to Emax 2 Accessories and compatibility Accessories and compatibility The following accessories, instead, are not compatible with the Emax 2 Direct Replacement kit: External 15 O/C AUX AUX CB connected/ insulated position (CE CD CT) Mechanical lock for compartment door All accessories of the Emax 2 fixed part Terminal shield for auxiliary board (CB) Breaker mismatch protection While the following Emax 2 accessories can be installed, but need to be externally cabled with local adaption: Electronical Delay for MN
Current sensor for neutral conductor outside circuit-breaker Ekip Supply, Communication and external Signaling modules Ekip Multimeter; Ekip Control Panel ; Ekip View 2/25/20 Slide 16 Mastepact M SACE Emax 2 M (motor for charging spings) Emax 2 standard Spring charge motor M MX and MX2 (shunt opening release) Emax 2 standard YO and YO2 XF (shunt closing release) Emax 2 standard YC MN (undervoltage release) Emax 2 standard YU MNR (electronical Delay for MN - into the switchboard) Remove the Masterpact version and add the external one of Emax 2 - D Current sensor for neutral conductor outside circuit-breaker (into the switchboard) Remove the Masterpact version and add the external one of Emax 2 standard AUX CB internal Open/closed (O F - OF) AUX Spring charged (CH) Emax 2 standard changeover contacts - Q Emax 2 standard - S33/M AUX CB tripped (SDE) Emax 2 standard changeover contacts - S5 AUX CB ready to close (PF) Emax 2 standard - RTC
AUX programmable contacts (M1..16) Emax 2 standard Ekip Signaling Key lock in open position (VSPA) Emax 2 standard - KLC Padlock in open position (VBP) Emax 2 standard - PLC Key lock in disconnected/connected position (VSPEC) Emax 2 standard - KLP 1 - 2 Padlock in disconnected/connected position (VSE) Emax 2 standard - PLP Mechanical operation counter (CDM) Emax 2 standard - MOC IP54 door protection (CCP) Emax 2 standard - IP54 Transparent protective cover for O/C pushbuttons Emax 2 standard - PBC Arc chute cover (CC) If not present on installed fixed part use fixing support for lateral sides of fixed part, supplied in the kit
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