ABB Emax 2 Retrofill AKR-30-800A Product manual

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.)
Installation and maintenance guide
Emax 2 Retrofill Circuit Breakers
Direct Replacement of Legacy GE AK 800A - 4000A
Circuit Breakers Used in AKD-6 & Substructures
Emax 2 Retrofill Circuit Breakers
Installation and maintenance guide

PREFACE............................................................................................................................................................3
....................................................................................................................................................................31- Hazards
...................................................................................................................................................................52- Warranty
......................................................................................................................................53- Trademarks and patents
................................................................................................................................................................54- Standards
........................................................................................................................................55- Document Conventions
.............................................................................................................................................66- Related Publications
.............................................................................................................................................67- Service and Support
..................................................................................................................68- Estimated Time to Complete Tasks
........................................................................................................................................................79- Product Specs
.......................................................................................................................................9HISTORY AND TYPES
......................................................................................................................................................910- History of AKD
.........................................................................................................................11AKD-6, RETROFILL BREAKER
.......................................................................................................................................1111- AKD-6, Breaker Models
............................................................................................................................1212- AKD-6, Mechanical drawings
...................................................................................................................................14AKD-6 COMPARTMENT
.........................................................................................................................................................1413- Interior View
..................................................................................................16MODIFY AKD-6 , SWITCHGEAR COMPARTMENT
.........................................................................................................................1614- Cut Power to AKD-6: Switchgear
............................................................................................................................1615- Rack Out AKD-6, Legacy/Existing CB
................................................................................................1616- Check, Clean, Grease AKD-6, Compartment
....................................................................................................................................17UNPACK CIRCUIT BREAKER
...................................................................................................................................................................1817- Quality
...............................................................................................................................................1818- Information Label
.............................................................................................................1819- Product and Catalog Serial Numbers
..................................................................................................1820- Remove Circuit Breaker from Container
...............................................................................................................................19STORE CIRCUIT BREAKER
.........................................................................................................................20CHECK BEFORE INSTALLING.
.......................................................................................................................20CLEAN AND GREASE BREAKER
........................................................................................................................................21MODIFY RETROFILL
......................................................................................................22PREPARE SWITCHGEAR COMPARTMENT.
......................................................................................24INSTALLING AKD-6 RETROFILL CIRCUIT BREAKER
................................................................................................................2421- Breaker Installation Overview.
..................................................................................................2522- For AKR 30/50/T50 AKD-6 Retrofill Breaker
...........................................................................................26INSTALL OR INSERT AKD-6 RETROFILL
......................................................................................29INSTALLATION OF AKD-6 AKR 75/100 Retrofill Breaker
AKD-6 - INSTALL ACCESSORIES................................................................................................................................30
.........................................................................................................3023- AKD-6, Secondary Disconnects, Bullets
.................................................................................3624- 19 pin Programmer Secondary Disconnect (Breaker)
...................................................3925- Install 19 Pin Programmer Secondary Disconnect (Compartment)
...........................................................................................................4126- AKD-6: Position Switch Actuator
................................................................................................................................42DOOR INTERLOCK SYSTEM
.........................................................44INSTALLING NEUTRAL DISCONNECT ASSEMBLY(BREAKER SIDE)
.............45AKR 100 - 4000A , FAN CONTROL UNIT WIRING & TRIP UNIT PROGRAMMING INSTRUCTIONS
.....................................................................................47CONFIGURING EKIP TOUCH, HI TOUCH TRIP UNIT
.....................................................................................................................................4727- Connecting Ekip Touch
...........................................................................4828- Synchronizing 2K-1 signalling module with the trip unit
....................................................................................................................4929- Configuring threshould currents
................................................................................................5030- Programing 2K-1 signaling contacts output
............................................................................................................................5131- Contact readiness Auto Test
©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 2
2TSA451014P0000 Rev-B

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.
This indicates a hazardous situation which, if not avoided, results in death or serious injury. A
variety of electrical hazards warnings are displayed here & are applied to installation manuals.
These are standard or generic alerts & labels that must be taken quite seriously when install-
-ing Retrofill circuit breakers in AKD & other OEM's switchgear and when working with pote-
-ntially dangerous electrical equipment (Table 1).
This indicates a hazardous situation, which, if not avoided, would result in death or serious
injury. A variety of electrical hazards warnings are displayed here and are applied to instal-
-lation manuals. These are standard or generic alerts and labels that must be taken quite
seriously when installing Retrofill circuit breakers in AKD switchgear and when working
equipment that can cause injury, but may not be necessarily fatal (Table 2).
Danger
Table 1
Warning
Table 2
Overview
1 - Hazards
Preface
Generic Danger Alerts
Generic Warning Alerts
©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 3
2TSA451014P0000 Rev-B

Table 4
Table 3
Notice or Note
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).
This indicates important information in that it aids in job performance, that is, a notice or
note is used to notify practices not related to personal injury (Table 4).
Custom Caution Alerts
Custom Notice Alerts
4 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 2TSA451014P0000 Rev-B

2 - Warranty
3 - Trademarks and Patents
4 - Standards
5 - Document Conventions
This document is based on information available at the time of its publication. While efforts
have been made to 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, operation, and maintenance.
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. No warrantees
of merchantability or fitness for purpose shall apply.
Contact Email: , Phone: [phone], if further information is [email protected]
required concerning any aspect of Emax 2 Retrofill Circuit breaker operation or maintenance.
Emax 2 Retrofill
Emax 2 Retrofill TU, Ekip DIP, Ekip Touch, Ekip Hi-Touch, Ekip G Touch, Ekip G Hi-Touch,
Kip Measuring, Ekip Measuring Pro
Emax 2 Retrofill Trip Unit
Emax 2
Warranty
requirements
Details
Agency
Certification
Details
Topics and text are divided into primary, secondary, and tertiary paragraph headings.
Standard Number Title
Low-Voltage AC Power Circuit Breakers & switchgears
Low-Voltage Power Circuit Breakers
ANSI C37.13,16,17,20.1,50,51,59
NEMA SG 3,5
NEMA AB1 - -
Low-Voltage AC and DC Power Circuit Breakers Used in
Enclosures
UL 1066
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2TSA451014P0000 Rev-B

6 - Related Publications
7 - Service and Support
8 - Estimated Time to Complete Tasks
Service and support are available from ABB Inc USA.
Email: [email protected]
Phone: [phone]
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. Once the retrofill breaker is
fully prepared, it should take about 20 minutes to swap out the old breaker and rack in the
new Emax 2 Retrofill circuit breaker if the proper lifting bar and hoist are available, it may take
an additional 30 min to replace the door.
The Emax 2 Retrofill, when ordered with 4 wire ground fault, will be equipped with a Neutral
CT adapter. The adapter will modify the GE MicroVersa Trip type Neutral CT output to a
Rogowski sensor output compatible with the Emax 2 Retrofill Trip Unit. With this device, it
will not be necessary to change the neutral CT in the switchgear to a Rogowski sensor. If the
trip unit types used are CS, SST or PS-1 POWER SENSOR™, then the CT should be replaced
with the Microversa Trip type.
6 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 2TSA451014P0000 Rev-B
Installation Manual AKD 10
Installation Manual AKD 8
Installation Manual AKD 6
Installation Manual AKD 5
Accessory: Door Interlock (Door Interlock Kit)
Accessory: Kirk Key Installation Manual
Accessory: Retrofill Direct Replacement / CiC Full Door Kits AKD-5, 6, 8 & 10
Accessory: Retrofill Direct Replacement / CiC Adaptors Kits AKD-5, 6, 8 & 10
Accessory: OEM Direct Replacement Adaptor kits AKD-8 & 10
Accessory OEM Direct Replacement Adaptor kits, AKD8 &10, AKR 75/100, B&F TYPE
Accessory OEM Direct Replacement Adaptor kits, AKD8 & 10, only for AKR30S
Accessory: Position Switch Plate, Assembly & Wiring
Accessory: Neutral CT Adapters Installation Instructions
Accessory: Programmer Disconnects Installation Instructions
Accessory: Primary Disconnects Installation Instructions
Accessory: Secondary Disconnects, Installation Instructions
E2.2, 4.2, 6.2 Breakers Installation, Operation & Maintenance Manual
Instructions for using Ekip touch protection releases & accesories
Emax 2 Family Trip units Engineering manual
2TSA451010P0000
2TSA451009P0000
2TSA451014P0000
2TSA451011P0000
2TSA451017P0000
2TSA451013P0000
2TSA451007P0000
2TSA451008P0000
2TSE431967R1000
2TSE431968R1000
2TSE431996R1000
2TSA451019P0000
2TSA451018P0000
2TSA451012P0000
2TSA451015P0000
2TSA451016P0000
1SDH001000R0002
1SDH001316R0002
1SDH001330R0002
Publication Publication Number

Figure 1 AKD 6 - AKR30\50 Breaker in Cassette (Front View)
Weight (lbs)
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
2
3**
4**
5**
6**
7
8
9
10
N
Figures 2 & 3 Fig 2. AKD 6 - AKR30 Breaker in Cassette (Rear View) Fig 3. AKD 6 - AKR50 Breaker in Cassette (Rear View)
©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 7
2TSA451014P0000 Rev-B
Retrofill Breaker
which replaces
AKR-30-800A
AKR-50-1600A
AKRT-50-2000A
AKR75-3200A w/o Fans
AKR100-4000A w/Fans
Weight
184
230
270
552
572
11
11
11
15
15
BOX
Weight
24
24
24
30
30
Pallet
Weight
2
2
2
2
2
Accessories
Weight
221
267
307
599
619
Total
Weight

Figure 4
AKD-6, AKR75\75H\100 Breaker in Cassette
AKD-6 - AKRT-50 Breaker in Cassette (Rear View)
Figure 5
Emax 2 Retrofill Circuit Breaker is suitable for application on power systems up to 635 VAC
50/60 Hz.
8 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 2TSA451014P0000 Rev-B
Figure 5a Front View
Figure 5b Rear View

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. Breakers were painted ANSI61, light gray,
manufactured in Philadelphia from 1951 to the mid-60s and in Burlington, Iowa from the
mid-60s to 1975.
The breaker compartment was a welded assembly, and the equipment frame was bolted.
Breaker boxes were stacked to make a vertical section with equipment frame around the
breaker boxes. There were no bus compartment barriers, just an open bus design. Ring
silver-plating was applied to bolted connections.
AKD - 5 Manufactured from 1960 until 1977, the aluminum bus had copper that was “flash-butt
welded” to the aluminum at bolted connections. During that time, AK-2A, 3A -25 / 50 / T50 /
75 / 100 (“A” signifies AKD-5 drawout) were produced. Breakers up to 2000A had primary
finger clusters. 3000 & 4000A breakers had a circular primary finger cluster arrangement in
the switchgear compartment. Pull-lanyard drawout mechanism in the switchgear on early
designs was replaced by a single jackscrew mechanism and then later replaced by a double
jack-screw mechanism. Featured is a closed-door, drawout with inner house breaker
compartment, where door moves with the breaker as it is racked in or out. Two bus levels
are available with a ring bus used at 4000A. Particulars include: 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 copper,
and aluminum bus un-plated (welded connections). The switchgear is painted sand-gray
(beige), with some instrument doors painted blue. AKR-30/50 in 22"-wide sections were
introduced in 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”.
AKD-6 was manufactured in Salisbury, NC from 1977 to 1981. Some AKD-5s, which were built
in Salisbury from 1975 until 1977, got name-plated as AKD-6. There is no “flash-butt” welded
aluminum to copper. Aluminum bus is tin-plated and bolted at shipping splits (but welded
everywhere else). Copper bus design has ring silver plating at bolted joints. AKR-75 / 100s
were introduced during this time. Stab-and-finger connections on 3200A and 4000A breakers
were improvements, versus the round the primary disconnects on the AKD-5. The 4000A
breaker was also narrowed to same width and phase-phase spacing as the 3200A.
The AKD-6 uses inner-house drawout breaker compartments on the 800 - 2000A breaker
compartments. They are painted ANSI 61 light gray and breakers have ECS or SST trip units.
AKD-6 should mark a shift away from all AK breakers and to AKR breakers. The AKR-30/50/
50H/T50 breakers used in AKD6 have a shallow 1” steel front escutcheon are drawout letter
code “A” i.e. AKR-4A-30. The AKR-30/50/50H/T50/75/100 breakers sold to OEMs for their
switchgear have a 5” deep plastic front escutcheon & spring loaded sliding “picture frame”.
These are draw out letter code “B” i.e. AKR-4B-30.The AKR-75/100 breakers used in AKD-6 have
a shallow 1” steel front escutcheon and vertical primary fingers. They are drawout letter code
”C” i.e. AKR-4C-75.
None of the Emax 2 Retrofill breakers utilize fans except for 4000A rating only.
AKD - 6
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AKD - 8
AKD - 10
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. Model 3 was introduced in 1991, using a flat bar vertical bus.
AKR breakers use MicroVersaTrip 9, MVT RMS9, EPIC, MVT Plus, MVT PM or EntelliGuard TU.
Aluminum bus was removed from the design in 1996 in favor of the standard tin-plated
copper bus (silver plated optional).
The AKR-30/50/50H/T50 breakers used in AKD8 have 5” deep plastic front escutcheon &
spring loaded sliding “picture frame”. They are drawout letter code “D” i.e. AKR-7D-30. In
AKD-8, most 800-2000A breakers are “feeder” breakers with vertical lower stud & primary
disconnect fingers clusters, but 800-2000A breakers designated as “Main” breakers, have
horizontal lower finger clusters, which is the same as “D” letter code breakers sold to OEM's.
A lower stud rejection bracket differentiates between lower stud orientations.
AKR-75/100/125 circuit breakers used in AKD-8 switchgear have a 5” deep plastic front
escutcheon & spring loaded sliding “picture frame” 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 code “D”. OEM
versions are drawout letter code “B” and GE Switchboard versions are drawout letter code “F”.
“B” & “F” breakers only differed by appearance items. All Primary disconnect stabs are
vertically oriented.
The AKR-125 is a 5000A breaker that had 2 cooling fans. It was release in 1995. None of the
Emax 2 Retrofill breakers utilize fans except for 4000A rating only.
AKD-10 was manufactured in Burlington, IA from 1999 thru 2015. The switchgear
compartment sizes and main & vertical bus arrangements are the same as AKD-8 Model 3.
The compartments have pull-out rails. AKD-10 uses WavePro * drawout-only style breakers.
All breakers have 4 rollers which align with the compartment rails.
The secondary control wiring for all functions is connected thru either one or two 36 point
secondary disconnects with gold plated contacts. Secondary control wiring terminates at
fixed standard locations on the 36 point disconnects. Each breaker has a pump style manual
charging handle and manual push OPEN and Push CLOSE buttons. The front escutcheon is
5” deep with a sliding picture frame, but is wide enough so the trip unit and new style bell
alarm are visible thru the front door of the switchgear.
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.
(W1 & W2 Catalog numbers on legacy WavePro breakers designate additional dead front
shields)
10 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 2TSA451014P0000 Rev-B

Table 5
The 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
AKD-6: Retrofill Breaker
11 - AKD-6, Breaker Models
©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 11
2TSA451014P0000 Rev-B
Feature
AKR 30/50, AKRT50 Retrofill
Breaker (800A, 1600A &
2000A)
AKR 75/100 Retrofill Breaker
(3200A & 4000A)
Rail latch
defeat
Breaker mounted mechanism
is removed. No levers on the
breaker side panels. Needs
Spring clip installation in the
compartment to achieve rail
latch defeat.
Existing AKD6 Racking Mechanism
will be reused. Rail Latch Defeats
are not requred or installed on the
loading rails.
Secondary
Disc Bullet
mounting
Secondary disconnect bullets
mounted directly on metal
bracket
Secondary disconnect bullets
mounted directly on metal bracket
Kirklock
Actuator

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

Figure 9 AKD-6, AKR75/100, Retrofill Breaker Dimensions
©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 13
2TSA451014P0000 Rev-B
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.

13 - Interior View
AKD-6 Compartment
The figures 10&11 below represent typical AKR-30/50/T50 and figure 12 represents typical
AKR-75/100 AKD-6 compartment.
Figure 10 AKD-6 Switchgear, Empty Compartment
Figure 11 AKD-6 Compartment Distinctions
14 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 2TSA451014P0000 Rev-B
AKD-6 3200A/4000A Compartment
Figure 12

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. In this figure, there is also a photo showing a mechanically-
operated status indicator (connect/disconnect) that worked with the original breaker. This
device, if left in the compartment as is, won't interfere with the retrofill breaker; it can,
however, be disassembled by removing its hardware. Figure 14 displays the bus inside the
gear.
Figure 14
Figure 13 AKD6 Breaker Compartment (Upper and Lower Compartments)
Bus, Interior View
©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 15
2TSA451014P0000 Rev-B

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
Ensure only qualified personnel install, operate, service and maintain all electrical
equipment.
Danger
14 - Cut Power to AKD-6: Switchgear
Modify AKD-6 , Switchgear Compartment
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.
To rack-out legacy (old or original) breaker from compartment, refer to your legacybreaker's
manual on how to remove the existing breaker.
15 - Rack Out AKD-6, Legacy/Existing CB
16 - Check, Clean, Grease AKD-6, Compartment
1. Inspect the compartment for damage or signs of overheating.
2. Check the orientation of primary finger clusters match the switchgear stabs.
3. Check racking pin diameters agree with breaker racking cam slots.
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.
7. Inside the compartment, check the contact areas on each primary disconnect bar or cluster
of fingers for foreign matter that may have accumulated. Clean those areas if necessary
with a clean, lint-free rag and isopropyl alcohol or acetone.
8. Be sure to apply a thin film of electrical grease (red, D50H387) to the contact areas for
better electrical connections inside the compartment.
16 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 2TSA451014P0000 Rev-B

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.
Always wear personal protection equipment
according to OSHA standards and appropriate
to the severity of potential burns.
Ensure only qualified personnel install, operate, service and maintain all electrical
equipment.
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 being lifted.
Wear hard hat, gloves, and safety shoes.
Failure to comply with these instructions could result in serious injury.
PRODUCT DAMAGE
Ensure circuit breaker and its accessories are always
used within their designated ratings.
Do not allow the circuit breaker to hit a hard surface
while handling.
Do not drag or slide the circuit breaker across a hard
or rough surface.
A factory-installed rejection feature prevents mismatching circuit breakers and
cassettes/ substructure, preventing the insertion of a circuit breaker with a lower rating
into a higher rated cassette/substructure, or the insertion of a higher rated
circuit breaker into a lower rated cassette/substructure.
Danger
Caution
Notice
Unpack Circuit Breaker
By following the procedures below, one should be able to install the breaker with minimum
effort and time.
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2TSA451014P0000 Rev-B

17 - Quality
18 - Information Label
All Emax 2 Retrofill circuit breakers have been designed and manufactured to ANSI standards.
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.
On the front of each circuit breaker there is a factory-assembled label that details all electrical
accessories included on the circuit breaker.
19 - Product and Catalog Serial Numbers
Product catalog and serial numbers should be kept handy when communicating about the
circuit breaker. Each circuit breaker has a unique serial number (S/N) located on the front
fascia.
20 - Remove Circuit Breaker from Container
1. Inspect the shipping container for obvious signs of rough handling and/or external
damage incurred during transportation.
2. Record any observed damage for reporting to the carrier. Ensure all recorded reports and
claims include the order number and name plate information.
3. Remove the banding straps and lift the top cover.
4. Remove all packaging material.
5. Remove all product documentation and store properly.
6. Unscrew the mounting screws that fasten the circuit breaker to the bottom of the
shipping pallet and remove the circuit breaker.
7. Remove the two shipping brackets and discard them.
1. Use a lifting device for moving circuit breaker in order to avoid personal injury and
damaging the breaker.
2. Use a proper overhead lifting device to mount breaker into the switchgear.
Contact Email: , Phone: [phone] for availability of a[email protected]
hoisting device.
LiftingBar for AKD5/6/8/10/OEM, Emax2 Retrofit kits ratings upto 2000A (Except 1600A):
2TSE431929R1000
LiftingBar AKD5/6/8/10 OEM, 1600A, 3000A-4000A :
2TSE431931R1000
Inspect and
Prepare
Use Lifting Device
18 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 2TSA451014P0000 Rev-B

If you decide not to install the Retrofill breaker until a later time, then you can store it away
for installing it later.
1. Store the circuit breakers in a clean, dry location in an upright position.
2. Make sure that the breakers are properly supported to prevent bending of the studs or
damage to any of the breaker parts. Do not remove any protective grease until the
assemblies are ready to be installed. A covering of draft or other non-absorbent paper
prevents dust from settling on the breakers.
3. If breakers are not to be placed in service at once, remove them from their shipping
cartons and thoroughly inspect them for damage.
4. If everything is in satisfactory condition, replace the breakers in their shipping cartons
for storage. If it is necessary to store the equipment for any length of time, use the
following precautions to prevent corrosion or deterioration.
5. Store in a clean, dry, rodent-free location with moderate temperature and provide
protective coverings to prevent dirt, water, or other foreign substances from entering the
breaker.
6. If dampness or condensation is encountered in the storage location, heaters can be used
to prevent moisture damage.
7. After prolonged storage, Level 1 maintenance is needed under two years of storage. While
Level 2 maintenance is needed over two years of storage. Refer to circuit breaker manual
in maintenance L1-L2 descriptions.
Refer to Emax2 Installation, Operation and Maintenance Instructions – Publication
#1SDH001000R0002 pages 99-112.
Notice
Store Circuit Breaker
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.
©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 19
2TSA451014P0000 Rev-B

These breakers are supported on a rollout track in the same manner as the AKR breakers.
Racking cams on both sides of the breaker frame engage the drawout mechanism pins
fastened to both sides of the compartment.
Check to see that the breaker or breakers match their respective compartments. Look on
the breaker summary sheet, the front view drawings, breaker nameplate, and on the
identification card on the breaker shipping carton.
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.
Ensure only qualified personnel install, operate, service and maintain all electrical
equipment.
Danger
Check Before Installing
20 ©2022 Emax 2 Retrofill Circuit Breakers 800A-4000A 2TSA451014P0000 Rev-B
1. Before installing or operating a breaker, refer to the breaker instruction manual for pre-
operation inspection and test.
2. Check thoroughly for any damaged or loose parts and for any dirt or foreign matter
which may be in the breaker.
3. Clean 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 15).
Clean and Grease Breaker
Figure 15 AKD-6, (2000A-4000A) Primary Contacts or “Fingers” (Apply Grease to sliding surfaces)