Megamax Novomax to Emax 2 2019 Retrofitting kit



























- Slides: 27
— — Megamax & Novomax to Emax 2 2019 Retrofitting kit solutions ELSP Global Product Service Management
— EPPC Global Service Product Portfolio 1 -Installation and commissioning 6 -Engineering and consulting An investment in long-term equipment’s reliability Application recommendations and environmental best practices. 2 -Training The best way to teach how to respond efficiently in different critical situations 7 -Extensions, upgrades and retrofits Enhance existing equipment with the latest technologies. 8 -End of life services 3 -Spares and consumables All original and genuine spare parts and upgrade kits. Equipment’s recycling in line with environmental requirements 9 -Replacements Replacing old equipment can dramatically increase performance and reduce costs. 4 -Maintenance to guarantee the system’s continuous operation 5 -Repairs Workshop and on site repairs by our service engineers March 11, 2021 Slide 2 10 -Advanced services Predictive Maintenance into ABB Ability EDCS Ekip Up to upgrade your installations 11 -Service agreements Customer support agreements for low voltage equipments
— 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 March 11, 2021 Slide 3
— Product Portfolio - Retrofitting Kit Solutions How to upgrade your installations 1. Hard Bus Retrofill (RF) 2. Cradle in Cradle (Ci. C) 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. Portfolio – ABB: Megamax, Novomax, Otomax, Isomax, Entelli. Guard G (GE) – ABB: Isol, Fusol, Otomax, BBC K-Line – ABB: Emax (New/Old), Megamax (OD and CD), Novomax, Modul, ASEA ALG – Competitors: Schneider, Siemens, Terasaki, AEG H&W, Mitsubishi March 11, 2021 Slide 4 – Competitors: GE, Federal Pacific, Allis Chalmers – Competitors: Schneider (Mastepact M)
— Megamax/Novomax to Emax 2 Retrofitting solutions Hard Bus Retrofill (RF) What? – Hard bus retrofill consists of: • Pre-designed and cut bus bars to link new terminals to existing copper busbars. • Insulating shields prevent live parts from being exposed • Sticker drilling template to cut the door • Mounting instructions When? – Fixed and withdrawable circuit breakers when the mounted fixed part of the old breaker is in bad conditions How? – The chassis of the old breaker has to be removed Who? – Anyone can do it (also customers) Why? – Easy installation allows to replace the complete product March 11, 2021 Slide 5
— Megamax/Novomax to Emax 2 Advanced retrofitting solutions Direct Replacement (DR) – Cradle in Cradle (Ci. C) 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 March 11, 2021 Slide 6
— Megamax to Emax 2 Retrofitting solutions Megamax devices are used to protect and control low voltage distribution systems. Megamax is a complete range offering a large selection of performance levels: – Rating currents Iu from 1250 to 6300 A – Breaking capacity Icu up to 130 k. A at 415 V AC – Operational voltage up to 690 V AC and 1000 V DC Megamax Life Cycle – Launch: 1990 – End of sales: 2013 March 11, 2021 Slide 7
— Novomax to Emax 2 Retrofitting solutions Novomax devices are used to protect and control low voltage distribution systems. Novomax is a complete range offering a large selection of performance levels: – Rating currents Iu from 800 to 6300 A – Breaking capacity Icu up to 100 k. A at 460 V AC Novomax Life Cycle – Launch: 1971 – End of sales: 2000 March 11, 2021 Slide 8
— Megamax to Emax 2 Retrofitting solutions Megamax devices Open door (OD) Megamax is available in: It requires to open the panel door to rack in and out the moving part – Fixed version – Withdrawable version Megamax is used to have 2 different racking in/out mechanism concept, Open Door and Closed Door Closed door (CD) It not requires to open the door to rack in and out the moving part March 11, 2021 Slide 9
— Megamax to Emax 2 Retrofitting solutions ABB available solutions – Megamax to Emax 2 F 1 1250 1600 2000 Rated Current [A] Version F 2 1250 1600 Pole F 1 B F 1 N F 1 S F 1 H 3 P RF RF - 4 P RF RF F 3 2000 2500 F 1 V F 1 L F 4 2500 3000 2000 2500 3000 3200 3600 F 5 F 6 3200 4000 5000 6300 F 2 H F 2 V F 2 L F 2 S F 3 S F 4 S F 5 H F 6 S F 6 H - RF - - RF RF RF - - FIXED CB WITHDRAWABLE CB 3 P RF-DR - - RF-DR - - RF(1)-DR(2) RF RF-DR RF-Ci. C(3) - - 4 P RF-DR - - RF-DR - - RF(1)-DR(2 RF RF-DR RF-Ci. C(3) RF RF (1) Under development for the version F 2 S 3000 A (2) Direct Replacement available only for the F 2 S 2500 A (3) Cradle in Cradle available only for the 3200… 4000 A versions RF: Hard bus Retrofill, DR: Direct Replacement, Ci. C: Cradle in Cradle March 11, 2021 Slide 10
— Novomax to Emax 2 Retrofitting solutions ABB available solutions – Megamax to Emax 2 G 30 Rated Current [A] 800 1250 1600 Version G 2 1250 1600 2000 3 P 4 P G 3 G 4 G 5 G 6 3200 3600 3200 4000 4500 5000 6300 2500 3000 1600 2000 2500 3000 RF - RF RF RF - Pole FIXED CB WITHDRAWABLE CB 3 P RF-DR DR(1) RF RF 4 P RF-DR DR(1) RF RF (1) Direct Replacement available only for the F 2 S 2500 A (2) Cradle in Cradle available only for the 3200… 4000 A versions RF: Hard bus Retrofill, DR: Direct Replacement, Ci. C: Cradle in Cradle March 11, 2021 Slide 11 DR - RF Ci. C(2)_R F RF Ci. C(2)_RF RF
— Megamax & Novomax to Emax 2 Advanced retrofitting kit solutions – Value propositions Direct Replacment & Cradle in Cradle Extend the Total Life Cycle of the Switchgear Reduction of maintenance cost and spare parts availability. Easy to install Fast and easy installation. Upgrading of the device with a limited downtime and without dismantle the fixed part. Easy to Control and to Connect to SCADA and into the Io. T Ekip Power. Controller to improve energy efficiency. Integration into systems with different communication protocols: Modbus RS-485, Modbus TCP, Profibus, Device. Net, Ether. Net/IP, IEC 61850, Bluethooth are available. Easy to Maintain Diagnosis and installation with Ekip Connect Software. Automatic notifications to remind maintenance activities. ABB Ablity EDCS is also available with Emax 2 for Predictive Maintenance. March 11, 2021 Slide 12
— Megamax to Emax 2 Advanced retrofitting solutions – Corrispondance table Automatic circuit breakers – Megamax F 1 F 2 Megamax F 1 Performance Levels F 2 B B B N N N S S S H H Iu @40°C [A] 1250 1600 2000 1250 1600 2500 2000 2500 Poles 3 p/4 p 3 p/4 p 3 p/4 p 3 p/4 p Emax 2 E 2. 2 DR DR DR DR B B B N N N H H Iu @40°C [A] 1600 2000 1250 1600 2500** 2000 2500** In (Rating Plug) [A] 1250 1600 2000 1250 1600 2500 2000 2500 Icu/Ics 400 -415 V [k. A] 40 40 40 50* 50* 55 55 55 85 85 65 85 85 Icu/Ics 440 -500 V [k. A] 40 40 40 50 50 50 70 70 60 70 70 Icu/Ics 690 V [k. A] 35 35 35 45 45 45 55 55 55 Icw (1 s) 690 V [k. A] 35 35 35 45 45 45 55 55 55 Advanced retrofit solution Performance Levels * Ics =40 k. A ** Derating up to 2400 A with Fixed Part with HR terminals; no derating with Fixed part with VR terminals March 11, 2021 Slide 13
— Megamax to Emax 2 Advanced retrofitting solutions –Corrispondance table Automatic circuit breakers – Megamax F 4 F 5 Megamax F 4 Performance Levels F 5 S S S H Iu @40°C [A] 3200 3600 3200 4000 Poles 3 p/4 p 3 p/4 p Emax 2 E 4. 2 DR DR Ci. C H H V V Iu @40°C [A] 3200 4000*** In (Rating Plug) [A] 3200 3600 3200 4000 Icu/Ics 400 -415 V [k. A] 75 80 100 100 Icu/Ics 440 -500 V [k. A] 75 75 100 100 Icu/Ics 690 V [k. A] 65 65 75 85 Icw (1 s) 690 V [k. A] 65 65 75 85 Advanced retrofit solution Performance Levels *** Derating up to 3600 A March 11, 2021 Slide 14
— Megamax to Emax 2 Advanced retrofitting solutions –Corrispondance table Switch disconnectors – Megamax F 1, F 2, F 4, F 5 Megamax/MS Performance Levels F 1 F 2 F 4 F 5 B B B S S S S H Iu @40°C [A] 1250 1600 2000 2500 3200 3600 3200 4000 Poles 3 p/4 p 3 p/4 p 3 p/4 p 3 p/4 p Icw (1 s)/MS - 415 V 40 40 40 50 50 75 80 100 100 Icw (1 s)/MS IEC 60947 -2 -690 V 35 35 35 45 45 65 65 75 85 Emax 2/MS E 2. 2 E 2. 2 E 4. 2 Emax 2/MS B B B N N H H V V 1600 2000 1250 1600 2000 2500** 3200 4000*** 35 35 35 45 45 45 55 65/75(1) 65/80(1) Iu @40°C [A] Icw (1 s) 690 V [k. A] ** Derating up to 2400 A (1) Icw(1 s) up to 690 V according to IEC 60947 -3 *** Derating up to 3600 A March 11, 2021 Slide 15 75/100(1) 85/100(1)
— Novomax to Emax 2 Advanced retrofitting solutions – Corrispondance table Automatic circuit breakers / Switch disconnectors Novomax G 30 -G 2 -G 4 -G 5 Megamax G 30 Iu @40°C [A] G 2 G 4 G 5 1250 1600 2000 2500 3200 4000 Poles 3 p/4 p 3 p/4 p Emax 2 E 2. 2 DR DR B B B N N N 1250 1600 2000 2500** 3200 4000*** - - - 3600 - - Icu/Ics 400 -415 V [k. A] 55 55 55 60 75 80 100 Icu/Ics 440 -500 V [k. A] 50 50 50 60 75 75 100 Icu/Ics 690 V [k. A] 45 45 45 55 65 65 75 75 Icw (1 s) 415 V [k. A] 50 50 50 60 75 75 100 Advanced retrofit solution Performance Levels Iu @40°C [A] In (Rating Plug) [A] ** Derating up to 2400 A with Fixed Part with HR terminals; no derating with Fixed part with VR terminals *** Derating up to 3600 A March 11, 2021 Slide 16
— Megamax & Novomax to Emax 2 Advanced retrofitting kit solutions - Product details DR retrofitting kit – Megamax F 1 -F 2/Novomax G 2 to Emax E 2. 2 The kit consists: – Special mobile part developed and tested in the ABB service factory and ready to be fitted into the old fixed part. It includes: • Sliding contacts • Mechanical signaling • Anti-insertion lock • Racking in/out lever for the closed door version – Kit for the door’s adaption It is always necessary to verify that the Megamax fixed part is in good conditions as prescribed in the document 1 SDH 001279 R 0002. March 11, 2021 Slide 17 Special Emax E 2. 2 moving part
— Megamax & Novomax to Emax 2 Advanced retrofitting kit solutions - Product details DR retrofitting kit – Megamax F 4/Novomax G 4 to Emax E 4. 2 Special Emax E 4. 2 moving part The kit consists: – Special mobile part developed and tested in the ABB service factory and ready to be fitted into the old fixed part. It includes: • Sliding contacts • Mechanical signaling • Anti-insertion lock • Racking in/out lever for the close door version – Kit for the door’s adaption It is always necessary to verify that the Megamax fixed part is in good conditions as prescribed in the document 1 SDH 001279 R 0002. March 11, 2021 Slide 18
— Megamax/Novomax to Emax 2 Advanced retrofitting kit solutions - Product details Ci. C – Megamax F 5/Novomax G 5 to Emax E 4. 2 The kit is suitable for Open and Closed Door Megamax and Novomax Special Emax E 4. 2 fixed part The kit consists of: – Special fixed part developed and tested in the ABB service factory and ready to be fitted into the old fixed part. It includes sliding contacts with 4 Q and dedicated wiring for 6 Q – Emax 2 mobile part (it can be ordered separately) – Racking-in lever – Kit for the door’s adaption It is always necessary to verify that the Megamax fixed part is in good conditions as prescribed in the document 1 SDH 001279 R 0002. March 11, 2021 Slide 19 Special Emax E 4. 2 fixed part connected with E 4. 2 moving part
— Megamax to Emax 2 Trip Unit Functions in Megamax and Emax 2 Trip Units March 11, 2021 Slide 20
— Novomax to Emax 2 Trip Unit Functions in Novomax and Emax 2 Trip Units March 11, 2021 Slide 21
— Megamax/Novomax to Emax 2 Accessories and compatibility – Direct Replacement and Cradle in Cradle Accessories and compatibility SACE Megamax/Novomax YO – YO 2 – YC – YU M (motor for charging springs) Q 1…Q 25 (O/C AUX contacts) AUX Spring charged (S 33 M) AUX CB tripped - S 51/1 AUX CB tripped - S 51/2 CB tripped mechanical indication AUX CB connected/ insulated position - S 75 S-S 75 I AUX YU (YU energized) → → → → → TV 051 (voltage transformer) → Megamax Shutter padlock device Key lock in open position Padlock in open position Key lock in Racked in/out position Padlock in Racked in/out position Mechanical operation counter IP 54 door protection Transparent protective cover for O/C pushbuttons Mechanical interlock system with other CBs Time-delay device D SOR Test Unit → → → March 11, 2021 Slide 22 SACE Emax 2 DR Emax 2 standard YO – YO 2 – YC - YU Emax 2 standard Spring charge motor Use the ones of Megamax Fixed Part Emax 2 standard S 33 M/2 Emax 2 standard contact (N/O) S 51/1 (standard supply for automatic CBs) Emax 2 special contacts (N/C) S 51/2 supplied under request Emax 2 standard - TU reset (standard supply for automatic CBs) Included in the Emax 2 sliding contacts (standard supply) Emax 2 RTC contact - check compatibility before ordering No longer available - same function in Ekip Hi Touch, Ekip Touch with Ekip Measuring Megamax shutter padlock Emax 2 standard - KLC Emax 2 standard - PLC Emax 2 standard - KLP Emax 2 standard - PLP Emax 2 standard - MOC Emax 2 standard - IP 54 Emax 2 standard - PBC Not compatible Emax 2 UVD - Necessary a re-wiring on the cubicle Emax 2 YO/YU Test Unit - Necessary a re-wiring Ci. C Emax 2 standard YO – YO 2 – YC - YU Emax 2 standard Spring charge motor Limitatation to Q 10 ( Emax 2 Q 4 + Q 10) Emax 2 standard S 33 M/2 Emax 2 standard contact (N/O) S 51/1 (standard supply for automatic CBs) Emax 2 special contacts (N/C) S 51/2 supplied under request Emax 2 standard - TU reset (standard supply for automatic CBs) Emax 2 AUP - Necessary a re-wiring to accessorize the Megamax/Novomax FP Emax 2 RTC contact - check compatibility before ordering No longer available - same function in Ekip Hi Touch, Ekip Touch with Ekip Measuring Emax 2 Shutter lock – SL Emax 2 standard - KLC Emax 2 standard - PLC Emax 2 standard - KLP Emax 2 standard - PLP Emax 2 standard - MOC Emax 2 standard - IP 54 Emax 2 standard - PBC Not compatible Emax 2 UVD - Necessary a re-wiring on the cubicle Emax 2 YO/YU Test Unit - Necessary a re-wiring
— Megamax/Novomax to Emax 2 Accessories and compatibility – Direct Replacement and Cradle in Cradle Accessories and compatibility The following accessories are not compatible with these retrofit kit solutions – Mechanical lock for compartment door; – Mechanical interlock system with other CBs; – All accessories of the Emax 2 fixed part (for Ci. C contacts for signaling of circuit breaker in racked-in are compatible) While the following Emax 2 accessories can be installed, but need to be externally cabled with local adaption: – YO/YU Test Unit – Current sensor for neutral conductor outside circuit-breaker; – Ekip Supply, Communication and external signaling modules; – Ekip Multimeter; – Ekip Control Panel; – Ekip View; – Remote reset YR The introduction of Ekip Modules is possible using the Ekip Cartiridge, external accessory that can be installed on a DIN guide. The introduction of Zone Selectivity Gzi/Gzo - Szi/Szo function it is possible using external Plug Sockets. March 11, 2021 Slide 23
— Retrofit kits Why would you choose our retrofits? Introduce easily new technologies in old systems – Emax 2: all in one innovation March 11, 2021 Slide 24
— Retrofit kit Why would you choose our retrofit kits? Introduce easily new technologies in old systems - Emax 2: cloud-based Energy and Asset Management March 11, 2021 Slide 25 Monitor Optimize Discover plant performance, supervise the electrical system and allocate costs Analyze the relevant information, improve the use of your assets and take the right business decision Predict Control Supervise the system health conditions and predict next maintenance actions Remotely implement an effective power management strategy to simply achieve energy savings
— Retrofit kits Why would you choose our retrofits? Introduce easily new technologies in old systems– High quality and easy installation ABB Retrofit kits have high quality as: – Tested in accredited laboratory and completed with compatibility declarations – Developed by the same R&D team that has developed both old and new circuit breakers Behind the kits there are studies to respect the Driving factors: – Thermal behavior – Short circuit withstand current – Dielectric properties – Mechanical fits: installation, compatibility, auxiliary connections Easy installation – Equipped with clear mounting instruction/video tutorials March 11, 2021 Slide 26
March 11, 2021 Slide 27