ABB KP-800 User manual

This retrofitting kit is designed for replacing the KP-800 800A, KP-1600 1600A, or KP-2000 2000A air circuit breaker
in the KP-line switchgear. It allows an Emax 2 withdrawable air circuit breaker of the same size as indicated in Table
A to be attached to the original switchgear cradle assembly and racked into the switchgear enclosure.
IMPORTANT !
Retrofitting allows an obsolete control and protection device to be replaced, but does not allow the ratings of the
original switchboard to be altered in any way.
The retrofitting kits are dimensioned and validated for the obsolete device performances which may be lower than the
new Emax 2 ratings.
Consult ABB for further details.
Full correspondence of the electrical characteristics is guaranteed (rated current excluding derating if indicated in the
table, and breaking capacity) so long as the kit is chosen in accordance with the indications in the ABB technical
catalogues dedicated to retrofitting products. The kit has been designed also to preserve the insertion/extraction
operations functionality and the optional auxiliary (secondary) circuits of the obsolete circuit breaker. The CiC is
installed and then locked on the switchgear cradle, thus making use of the of its plug-in features as established in the
operation and maintenance manual of the new Emax 2 circuit breaker without having to modify any of the live parts
of the switchgear.
ATTENTION !
The instructions concern the sole assembly of the retrofitting kit. They do not substitute for the instruction in the
installation, operation, and maintenance manual of the Emax 2 circuit breaker installation instructions document
number, 1SDH001000R0002.
If optional auxiliary (secondary) circuits are required, refer to section 12.
Structure Details
The fixed part of the new Emax 2 is mounted to a steel sheet structure (CiC) that is then mounted into the KP-line
switchgear cell. The Emax 2 cradle is fitted with custom silver flashed copper run backs and finger clusters that align
to and mate with the existing KP-line switchgear power circuit stabs. The entire assembly mounts on the original K-
line cell rails. No additional phase barriers were required for this CiC. The weight of the low voltage cradle-in-cradle
assembly is listed in table B.
Doc. N.° 2TSA451037P0000 REV A
KP-800, KP-1600, or KP-2000 TO EMAX 2
n
2TSA451021P0000
Retrofitting between KP-800 800A, KP-1600 1600A, or KP-2000 2000A, and an Emax
circuit breaker with a cradle-in-cradle (CiC) adapter.
CiC Model
Weight (lbs./kg)
KP-800
160/73
KP-1600
200/91
KP-2000
235/107
Table B
Table A
RATING
EMAX 2
RATING
KP-800
800A
E-2.2 (S)
800A
KP-1600
1600A
E-2.2 (S)
1600A
KP-2000
2000A
E-4.2 (V)
2000A

1
MAKING THE SYSTEM SAFE FOR INSTALLATION
The following warnings and precautions must be respected before installing the CiC and circuit breaker in the
switchgear.
ŸPlace the switchgear housing and the circuit breaker out of service.
ŸDisconnect the power from the switchgear (power circuit and auxiliary circuits) and verify it is disconnected
from all sources of energy.
ŸSet the obsolete circuit breaker to the open position with the springs unloaded.
ŸDouble-check to ensure that the line has been placed out of service.
NOTE: The trained personnel in charge of handling and lifting must use appropriate safety equipment.
Remove the obsolete OEM circuit breaker.
•Open the door of the switchgear.
•Refer to the OEM installation manual for instructions to remove the breaker
from service.
WARNING: THE CIRCUIT BREAKER COULD DROP DURING THIS
OPERATION. BEFORE PROCEEDING REFER TO THE OEM MANUAL
FOR LIFTING AND REMOVAL INSTRUCTIONS AND USE
APPROPRIATELY SIZED AND RATED LIFTING DEVICE BEFORE
PROCEEDING.
•(Optional) Disconnect and remove any auxiliary signaling or measuring
devices that will not be used with the new Emax 2 CiC.
•Remove all the tools and equipment used for the operations and clean off
the processing residues and metal scraps.
Tools Required:
All
Emax 2 Cradle in Cradle Installation Procedure
1-1/4 inch
Open-end Wrench
10-15 inch long
All
Screwdrivers
#1 Phillips
1/4 inch
Flat-Blade
Fig. 1
1A 2A
KP-800
1
KP-1600
1
KP-2000
1
1B
3A

4
3
2
•Extend the switchgear cradle rails (a)(fig. 2) out
from the cell until the side levers (b) drop down to
hold the stop (c) on the rail.
Fig. 2
KP-800 (fig. 4), KP-1600 (fig. 5), and KP-2000
•Lower the CiC on to the rails. The studs (e) on both sides
of the CiC should line up with and drop into the cutouts (f)
in the rails on each side of the CiC.
•Rotate the cam lever (g) on both sides into the position as
shown.
The CiC cannot be installed in the gear with the
Emax 2 breaker installed.
•Unscrew the breaker lock out pin (d)(fig. 3) on
both sides where shown until it stops and the
cam levers are free to rotate. Do not force them
past the stop or remove them.
Fig. 3
Fig. 4
Fig. 5
d
WARNING: THE CiC COULD DROP DURING THIS OPERATION. BEFORE PROCEEDING ATTACH
APPROPRIATELY SIZED AND RATED LIFTING DEVICE.
b
a
c
(both sides)
e
f
Lifting Points
e
f
g
g
1A
2A
Lifting Points

6
5
h
•Slide the CiC to the back of the cutouts (f)(fig. 5) so
that the locking lever (h)(fig. 6) drops down.
Fig. 6
•Press down on the rail levers on the KP-800, KP-
1600, and KP-2000 (b)(fig. 7) on both sides to
release the rails.
•Slide the CiC and rails into the gear cradle until
the cam lever spindle (j) stops in the gear cradle
racking slot guide (k).
Fig. 7
k
b
j

7
Fig. 8
•Rack in the CiC into the gear cradle by placing
both 1-1/4 inch wrenches (l)(fig. 8) on to the cam
lever protrusions (m)(fig. 9). Simultaneously pull
them down to and use the extra cam lever
protrusions to continue rotating them until the cam
levers reach their stop position (n)(fig 9).
Note: Extra force will be required as the finger
clusters of the CiC engage the gear power
contacts, however it should rack in smoothly to
the cam stop.
•If the CiC stops before being fully racked in, pull it
back out and investigate what is blocking it and
clear it so that racking in can be completed.
Fig. 9
n
m
KP-800, KP-1600, and KP-2000
l

8
9
The Emax 2 breaker cannot be installed into its
cradle (fixed part) if the lock out pins are unscrewed
into the breaker (moveable part) space.
•Screw in the breaker lock out pins (d)(figs. 10, 11)
on both sides where shown until it stops. Do not
force them past the stop or remove them.
•Lock out pins should protrude into the path of the
cam levers and prevent them from being rotated
when the breaker is installed in its cradle.
Fig. 10
d
KP-800, KP-1600, and KP-2000 (fig. 11)
d
Fig. 15
Fig. 12
•If a flange for the old circuit breaker exists on the
door, disassemble and dispose it. (fig. 12).

10
Fig. 13
•To make it easier to make the hole in the existing switchgear door, the kit
comes complete with an adhesive template for attaching as shown (fig. 13).
•See 2TSE431186P1000.
•Position the template by aligning the dotted lines with the existing cut out.
•Cut the door along the unbroken line and drill holes in the positions marked
by the holes (fig. 14).
•Mount the dust guard escutcheon (s)(fig. 15) provided with the breaker to the
door.
1B
Fig. 15
Cut lines
14x 0.2 in (5 mm)Ø
Fig. 14
s
KP-800, KP-1600, and KP-2000
13.28 lb in
(1.5 Nm)
NOTE: If the dotted line on the adhesive template fails to perfectly match the existing opening in the door, refer to the
instructions for installing the dust guard escutcheon provided with the circuit breaker.

11
12
13
•Install Emax 2 Breaker
•Install the moving part of the circuit breaker into the fixed part per instructions in the Emax 2 installation,
operation and maintenance manual 1SDH001000R0002.
•Comply with the instructions in that manual for commissioning the new circuit breaker .
•Refer to the section in the manual for the circuit breaker requirements for clearances within the compartment.
Optional Auxiliary (Secondary) Circuits Notes:
•The installed auxiliary circuits have been wired in accordance with the supplied wiring diagrams which are
based on customer furnished information. Review the wiring diagrams for integration and compliance to the
switchgear circuitry.
•Prior to energizing the auxiliary circuits, verify that the secondary contacts are properly engaged by performing
a continuity test on each installed circuit.
•Review the “Putting into service” section of the Emax 2 installation, operation, and maintenance manual
1SDH001000R0002 for specific checks of the installed accessories.
•Fan operation on CiC adapters which include forced cooling (as noted in Table A on page 1) should be verified
during the installation accessory checks and during second level maintenance schedule operations.
MAKING THE SYSTEM SAFE FOR REMOVAL
The following warnings and precautions must be respected before removing the circuit breaker and CiC from the
switchgear.
•The trained personnel in charge of handling and lifting must use appropriate safety equipment.
•Place the switchgear housing and the circuit breaker out of service.
•Disconnect the power from the switchgear (power circuit and auxiliary circuits) and verify it is disconnected
from all sources of energy.
•Set the circuit breaker to the open position with the springs unloaded.
•Double-check to ensure that the line has been placed out of service.
•Removal is done in the reverse order of the
installation steps in sections 6, 5, 4, 3, and 2. The
CiC should rack out smoothly without mechanical
interference.
•Note: If any unusual resistance is detected that
could be abnormal interference between the CiC
and compartment parts, stop immediately and
examine what is causing the interference and
correct the situation.
Remove the Emax 2 Cradle in Cradle

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