ABB SACE Emax 2 Product manual

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
Emax 2 Retrofill Circuit Breakers
Installation and maintenance guide

2| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A 2TSA451011P0000 Rev-B
Contents
CONTENTS..........................................................................................2
PREFACE.............................................................................................. 3
1 - Hazards................................................................................................3
2 - Warranty...............................................................................................4
3 - Trademarksand Patents.................................................................5
4- Standards............................................................................................5
5 - Document Conventions...................................................................5
6 - Related Publications.........................................................................5
7 - Service and Support.........................................................................6
8 - Estimated Time to Complete Tasks............................................6
9 - ProductSpecs....................................................................................6
HISTORY ANDTYPES.........................................................................8
10 - History of AKD....................................................................................8
AKD - 5, RETROFILL BREAKER......................................................... 10
11 - AKD-5, BreakerModels..................................................................10
12 - AKD5 Mechanical drawings..........................................................15
MODIFY AKD-5, SWITCHGEAR COMPARTMENT............................17
13 - Turn OFF/OPEN the legacy circuit breaker.............................17
14 - Rack Out legacy circuit breaker...................................................17
15- Empty compartment legacy breakerremoved.......................17
16- Check, Clean andGrease Compartment..................................19
UNPACK RETROFILL CIRCUIT BREAKER........................................20
17 - Quality.................................................................................................21
18 - Information Label............................................................................21
19 - Product and Catalog Serial Numbers........................................21
20- Remove Circuit Breaker from Container...................................21
STORE CIRCUIT BREAKER ............................................................... 23
CHECK BEFORE INSTALLING..........................................................24
CLEAN AND GREASEBREAKER.......................................................25
CUSTOMIZE RETROFILLSECONDARY 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 CASSETTE RAIL LEVERLOCKOUT BRACKETS AK/AKT50
COMPT’S ONLY.................................................................................32
INSTALL AKD5 RETROFILL BREAKER.............................................33
21 - AK/AKT50 Kirkey Interlock............................................................38
22 - Secondary Disconnects, Bullets..................................................39
23 - Wiring diagram and Block info (AK25)......................................40
24- AK25 Wiring Harness, B block AK25/50................................... 45
INSTALL DOOR INTERLOCK ACCESSORY.....................................46
NEWDOOR INSTALLATION............................................................. 47
INSTALL AKD-5, NEUTRAL SENSING FOR4 WIRE GROUNDFAULT
49
25- AKD-5,Neutral Disconnect Assembly.......................................49
26 - AKD-5, Neutral Disconnect Assembly, Bus Compartment.49
27- AKD-5, Neutral CT Adapter upto 5000A..................................49
28- Procedures.......................................................................................50
29 - AKD-5, Multi-Source Ground Fault.............................................51
AK 75 - 3000A, FAN CONTROL UNIT WIRING & TRIP UNIT
PROGRAMMING INSTRUCTIONS....................................................52
CONFIGURING EKIP TOUCH, HI TOUCH TRIPUNIT.....................54
30 - Connecting Ekip Touch................................................................. 54
31- Synchronizing 2K-1 signalling modul withthe trip unit.......55
32 - Configuring threshould currents...............................................56
33- Programing 2K-1 signaling contacts output........................... 57
34- Contact readiness Auto Test.......................................................58

2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 3
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 familiarwith the devices before trying to install,
operate, service, or maintain this equipment.
Danger
Table 1
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 installingRetrofill circuitbreakers in AKD&other OEM’s switchgearandwhenworking
with potentially dangerous electrical equipment (Table 1).
Generic Danger Alerts
Warning
Table 2
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
installation manuals. These are standard or generic alerts and labels that must be taken
quite seriouslywhen installingRetrofill circuit breakersin AKD &otherOEMs switchgearand
when working equipmentthat can causeinjury, but may not be necessarily fatal (Table 2)
Generic Warning Alerts

4| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A 2TSA451011P0000 Rev-B
Caution
Table 3
This pertainsto a hazard thathas 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)
Custom Caution Alerts
Noticeor Note
Table 4
This indicates important information in that it aids in job performance, that is, a notice or
note is used tonotify practicesnot relatedto personal injury (Table 4).
Custom NoticeAlerts
2 - Warranty
Warranty
requirements This document is basedon information available at thetimeof its publication. Whileefforts 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, andmaintenance.
Featuresmaybedescribedhereinthatarenotpresentinallhardwareandsoftwaresystems.
ABB Inc USA assumes no obligation of notice to holders of this document with respect to
changes subsequently made. ABB Inc USA makesno representation or warranty, expressed,
implied, or statutory, with respect to, and assumes no responsibility for the accuracy,
completeness,sufficiency,orusefulnessoftheinformationcontainedherein.Nowarrantees
of merchantability or fitnessfor purpose shall apply.
Contact Email: [e-mail], Phone: [phone], if further information is
requiredconcerninganyaspectofEmax2RetrofillCircuitbreakeroperationormaintenance.

2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 5
3 - Trademarks and Patents
Details Emax 2 Retrofill
Emax 2 Retrofill TU, EkipDIP, Ekip Touch
Emax 2 Retrofill TripUnit

Emax 2
4 - Standards
Agency
Certification Standard Number Title
ANSI C37.13,16,17,20.1,50,51,59 Low-Voltage AC Power Circuit Breakers & switchgears
UL 1066 Low-Voltage AC and DC Power Circuit Breakers Usedin
Enclosures
5 - Document Conventions
Details
Topics andtext are divided into primary, secondary,and tertiary paragraph headings.
6 - Related Publications
Publication Publication
Number
Installation Manual AKD 10 2TSA451010P0000
Installation Manual AKD 8 2TSA451009P0000
Installation Manual AKD 6 2TSA451014P0000
Installation Manual AKD 5 2TSA451011P0000
Accessory: Door Interlock (Door Interlock Kit) 2TSA451017P0000
Accessory: Kirk Key installation Manual 2TSA451013P0000
Accessory Retrofill Direct 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 Replacement Adaptor kits AKD8 & 10 2TSE431967R1000
Accessory OEM Direct Replacement Door Adaptor kits, AKD8 &10, AKR 75/100, B&F TYPE 2TSE431968R1000
Accessory OEM Direct Replacement Door Adaptor kits, AKD8 & 10, only for AKR30S 2TSE431996R1000
Accessory: Position Switch Plate, Assembly & Wiring 2TSA451019P0000
Accessory: Neutral CT Adapters Installation Instructions 2TSA451018P0000
Accessory: Programmer Disconnects Installation Instructions 2TSA451012P0000
Accessory: Primary Disconnects Installation Instructions 2TSA451015P0000
Accessory: Secondary Disconnects, Installation Instructions 2TSA451016P0000
E2.2, 4.2, 6.2 Breakers Installation, Operation & Maintenance Manual 1SDH001000R0002
E1.2 Breakers Installation, Operation & Maintenance Manual 1SDH000999R0002
Instructions for using Ekip touch protection releases &accesories 1SDH001316R0002
Emax 2 Family Trip units Engineering manual 1SDH001330R0002

6| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A 2TSA451011P0000 Rev-B
7 - Service and Support
Service and support are availablefrom ABB Inc USA.
Email: [e-mail]
Phone: 888
-
385
-
1221
8 - Estimated Time to Complete Tasks
It takes about 20 minutes to install a feature-for-feature LSIassembly. This includesracking
out the old breaker, racking in the new breaker, and replacing the door. If new options are
desired, or if it’s a 4-wire LSIG circuit or modifications are needed to the cubicle, then
additional time is required. Time also doesnot include wiring the secondary disconnect on
theRetrofill
9 - Product Specs
GEAKD-5LowVoltageSwitchgear (LVS)is afree-standing assemblyof metal-enclosedANSI
power circuit breakers. It mayalso be a part of a single-ended or double-ended load center
unit substation. AK25/AK50 Retrofill are based on Cradle in Cradle (CiC) solution whereas
for AKT50 is
a Backles
s
Cradlein Cradle (
B
CiC) 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. EachRetrofill isconstructed by permanently joining
an Emax 2 circuit breaker in a steel frame, installing primary and secondary disconnects
and driving drawout racking cams thru what lookthe Emax 2 Cassette’sfront dashboard.
With least modifications to bemade to existing switchgear, Emax 2 Retrofill breakers are
cost effective solutionto upgradethe existing electrical system. Direct Replacement isthe
solution where the moving part of circuit breaker is removed and a new circuit breaker is
provided, which racksinto the existing switchgear compartment. The direct replacement
retrofitting kit allows a reliable upgradeof the old GE legacy breakers to new Emax 2
Retrofill Breakers Range.
Below figures (front and back views with finger clusters) present Emax 2Retrofill breakers,
which can replace AKR breakers.
Figure 1 & 2 AKD-5 600A Breaker in Cassette
Fig 1. Front View Fig 2. Rear View

2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 7
Figure 3 & 4 AKD-5 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-53000A Breaker in Cassette
Fig 7. Front View Fig 8. Rear View
Figure 9 & 10 AKD-5 4000A Breaker in Cassette
Fig 9. Front View Fig 10. Rear View

8| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A 2TSA451011P0000 Rev-B
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” tothe aluminumat boltedconnections. 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 andthen 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 barrierson 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 forOEMs to build around customer gear.
None of the Emax 2 Retrofill breakers utilize fans except for3000A rating only.
Note: AlllegacyAK & AKR breakers have a draw out letter code “A”.
AKD - 6 AKD-6 was manufacturedin Salisbury,NC from 1977to 1981. SomeAKD-5s, which werebuilt
in Salisbury from 1975 until 1977, gotname-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 breakerwas also narrowed to same width and phase-phase spacing as the3200A.
The AKD-6 uses inner-house drawout breaker compartments on the 800 - 2000A breaker
compartments. They are paintedANSI61 lightgray and breakers haveECSor SST trip units.
AKD-6 should mark a shift away from all AK breakers and to AKR breakers. The AKR-
30/50/50H/T50 breakersusedinAKD6have ashallow 1” steel front escutcheonare 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”.

2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 9
These are draw out letter code “B” i.e. AKR-4B-30.The AKR-75/100 breakers used in AKD-6
havea shallow1” steelfrontescutcheonand verticalprimaryfingers. They are drawoutletter
code”C” i.e. AKR-4C-75.
None of the Emax 2 Retrofill breakers utilize fans except for4000A rating only.
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 wasavailable thru
2015.
Model 1 and 2 haveextruded vertical bus. Model 2 was introduced in 1983to accommodate
revised wire harness routing. Model 3 was introduced in 1991, using a flat bar vertical bus.
AKR breakers use MicroVersaTrip9, 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 platedoptional).
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 lowerfinger clusters,which is the same as“D” letter code breakers soldto 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 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 compartmentshave 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
fixedstandardlocationson the 36pointdisconnects. Each breakerhasa pumpstyle manual
charging handle and manual push OPEN and PushCLOSE 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
breakerhadcoolingfans. NoneoftheEmax 2Retrofill breakers utilizefans except the 4000A
fully rated breaker.
(W1 & W2 Catalog numbers on legacy WavePro breakers designate additional dead front
shields)

10| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A 2TSA451011P0000 Rev-B
AKD - 5, Retrofill Breaker
11 - AKD-5, Breaker Models
The following figures depictsthe AKD5 Retrofill breakers (600-4000A)
AKD5
AK25 , Emax 1.2 600A CiC (Cradle in Cradle) Retrofill
Kit
Figure 11 & 12
Fig
1
1.
Emax 1.2 Circuit Breaker
(Moving Portion)
Fig
1
2.
Circuit Breaker
Projected
from Cassette
Figure 13
Retrofill
Kit
Figure 14 & 15 Fig 14. Rear View of Retrofill Kit Fig 15. Front view inside SwitchGear

2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 11
AKD5 AK50,Emax2.2 1600A CiC (Cradle inCradle ) Retrofill Kit
Figure 16 & 17
Fig
1
6.
Emax 2.2
Circuit
Breaker
(Moving Portion)
Fig
1
7.
Circuit Breaker
Projected
from Cassette
Figure 18
Retrofill
Kit
Figure 19 & 20
Fig
1
9.
Rear View
of Retrofill Kit
Fig
2
0.
Front View
of Retrofill Kit

12| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A 2TSA451011P0000 Rev-B
AKD5 AKT50,Emax 2.2 2000A DR (Direct Replacement) Retrofill Kit
Figure 21 & 22
Fig
2
1.
Emax 2.2 C
ircuit Breaker
Front view
Fig
2
2.
Emax 2.2
Circuit Breaker
Rear view
Figure
2
3
Circuit Breaker Projected from Cassette
Figure 24 & 25 Fig 24. Rear View of Retrofill Kit Fig 25. Front View of Retrofill Kit
The Emax 1.2 & Emax 2.2 Circuit Breaker is suitable for application on power systems up to
600 VAC 50/60 Hz.

2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 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 Kit
Fig 29. Rear View of Retrofill Kit Fig 30. Front View of Retrofill Kit

14| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A 2TSA451011P0000 Rev-B
Figure 31 & 32
Figure33
Figure 34 & 35
AK100, Emax 6.2 , 4000A Cradle inCradle RetrofillBreaker
Fig
3
1. Emax 6.2
Circuit Breaker
(Moving Portion) Fig
3
2.
Circuit Breaker Projected from Cassette
Retrofill Kit
Fig 34. Rear View of Retrofill Kit Fig 35. Front View of Retrofill Kit

2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 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 37 AK50 , Emax 2.2 1600A
Figure 38 AKT50 , Emax 2.2 2000A

16| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A 2TSA451011P0000 Rev-B
Figure 39 AK75 , Emax 4.2 3000A
Figure 40 AK100 , Emax 6.2 4000A
Forced cooling (Fans)for 3000ARatingonly.
Fans Turn ON at 2500A and OFF at 2300A
For other detail related to Trip unit config and
wiring refer to Fan control section in manual.

2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 17
Modify AKD-5, Switchgear Compartment
13 - Turn OFF/OPEN the legacy 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
conductedon it.
During the installation and related work on the
equipment, it must be ensuredthat the operator
is using the prescribed PPE for the specified
tasks
Ensure only qualified personnel 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 charged, to turn it off, press the OPEN button on
the circuit breaker fascia and ensure that the circuit breaker contacts are open. Discharge
the closing spring before removingthe breaker fromthe switchgear.
14 - Rack Out legacy circuit breaker
To rack-out legacy old breaker from compartment, refer to your legacy breaker’s manual on
how to remove the existing breaker.
15 - Empty compartment legacy breaker removed
The followingfigures (Figure 41, 42 & 43)show a legacy breaker removed from enclosure or
compartment.
Figure 41 & 42 Fig 41 Fig 42

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

2TSA451011P0000 Rev-B © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A | 19
16 - Check, Clean and Grease Compartment
1. Inspect the compartment for damage or rework.
2. Check theorientation of primary finger clusters match the switchgear stabs.
3. Check the secondary disconnect integrity & mounting supports for any damage or
cracks .
4. Ifswitchgearpartsshowcracksordamage contactABBpostsalesservice888-437-3765.
5. Check each breaker compartment for bolted joints in the primary disconnect bars.
Where such joints exist, check the bolts for tightness.
6. Inside the compartment, check the contact areas on each primary disconnect bar for
foreign matter that may have accumulated. Clean those areas if necessarywith a clean,
lint-free rag and isopropyl alcohol oracetone.
7. Be sure to apply a thin film of red Mobilgrease 28 to the primary disconnect contact
areas for better electrical connections inside the compartment.
8. After removingthe originalAKbreaker from the compartment, install the AKD-5 retrofill
cassette. (Note: If compartment has a position switch and a position switch actuator
will be added to the cassette, see Install Position Switch Actuator below.
9. Locate and replace Kirk key slide return spring on left side of compartment. Supplied
withthecassette assemblyasa retrofillkit. Inspect the Kirk keyslide mechanism, grease
withMobilgrease #28)if required.
10. Install the cap, label and ¼-20 set screw to disable old racking mechanism. Also
assemble Kirkkey side bracket,label and (2) ¼-20 Thread forming screws, see figure 41
& 42. Supplied with the cassette assembly as a retrofill kit.

20| © 2020 Emax 2 Retrofill Circuit Breakers 600A-4000A 2TSA451011P0000 Rev-B
Unpack Retrofill Circuit Breaker
By following the procedures below, one should be able to install the breaker with minimum
effort andtime.
Danger Turn off all power to switchgear. Tagout
and lockout main source, up-stream or main
breaker.
Failure to comply with these instructions
willresultindeathorseriousinjuryfromsevere
burns caused by arc flashing that has
exceedingly high temperatures.
Always wear personal protection equipment
accordingto OSHA standardsand appropriate
to the severity of potential burns.
Ensure only qualified personnel install, operate, service and maintain all electrical
equipment.
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 being lifted.
Wear hard hat, gloves and safety shoes.
Failure to comply with these instructions could result in seriousinjury.
Notice PRODUCT DAMAGE
Ensure circuit breaker and its accessories are always
used withintheir designated ratings.
Do not allow the circuit breaker to hit a hard surface
while handling.
Do not drag or slidethe circuit breaker acrossa 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.