2018 Megamax to Emax - PowerPoint Presentation

2018 Megamax to Emax 2 Retrofitting kit solutions EPPC Global Product Service Management

EPPC Global Service March 25, 2019 Slide 2 Service Product Portfolio 1-Installation and commissioning An investment in long-term equipment’s reliability 2-TrainingThe best way to teach how to respond efficiently in different critical situations 3-Spares and consumablesAll original and genuine spare parts and upgrade kits. 4-MaintenanceMaintenance to guarantee the system’s continuous operation 5-RepairsWorkshop and on site repairs by our service engineers 6-Engineering and consultingApplication recommendations and environmental best practices. 7-Extensions, upgrades and retrofitsEnhance existing equipment with the latest technologies. 8-End of life servicesEquipment’s recycling in line with environmental requirements 9-ReplacementsReplacing old equipment can dramatically increase performance and reduce costs. 10-Advanced servicesPredictive Maintenance into ABB Ability EDCSEkip Up to upgrade your installations 11-Service agreements Customer support agreements for low voltage equipments

Extension, upgrades and retrofits March 25, 2019 Slide 3 Time to upgrade? Modernize by Retrofit kitsModernizeSafetyTechnologyService yearsSaving in Maintenance Environment-friendlyEquipment healthRetrofit kitModern Circuit BreakerLow cost solutionProfitable investment

Product Portfolio - Retrofitting Kit Solutions March 25, 2019 Slide 4 How to upgrade your installations 1. Hard Bus Retrofill (RF) 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. 2. Cradle in Cradle ( CiC)The fixed part of the new CB is modified to be inserted in the old fixed part. 3. Direct Replacement (DR)The moving part of the new CB has to be modified to simulate the moving part of the old CB.PortfolioABB: Megamax, Novomax, Otomax, IsomaxCompetitors: Schneider, Siemens, Terasaki, AEG H&W, MitsubishiPortfolioABB: Emax (New in Old), Megamax (OD and CD), Novomax, Modul, ASEA ALGCompetitors: Schneider (Mastepact M) PortfolioABB: Isol, Fusol, Otomax, BBC K-LineCompetitors: GE, Federal Pacific, Allis Chalmers

Megamax to Emax 2 March 25, 2019 Slide 5 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 doorMounting instructionsWhen?Fixed and withdrawable circuit breakers when the mounted fixed part of the old breaker is in bad conditionsHow?The chassis of the old breaker has to be removedWho?Anyone can do it (also customers) Why?Easy installation allows to replace the complete product

Megamax to Emax 2March 25, 2019 Slide 6 Advanced retrofitting solutions Direct Replacement (DR) – Cradle in Cradle (CiC) 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 instructionsWhen?Withdrawable version The old fixed part still in good conditions How?Replacing only the moving part of the old circuit breakerWhy?Easy to install Short down-time due to installation

Megamax to Emax 2March 25, 2019 Slide 7 Retrofitting solutions Megamax devices 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 6300ABreaking capacity Icu up to 130kA at 415V ACOperational voltage up to 690 V AC and 1000 V DCMegamax Life CycleLaunch: 1990End of sales: 2013

Megamax to Emax 2March 25, 2019 Slide 8 Retrofitting solutions Megamax devicesOpen door (OD) Closed door (CD)It requires to open the panel door to rack in and out the moving partMegamax is available in:Fixed version Withdrawable version Megamax is used to have 2 different racking in/out mechanism concept, Open Door and Closed DoorIt not requires to open the door to rack in and out the moving part

Megamax to Emax 2 March 25, 2019 Slide 9 Retrofitting solutions ABB available solutions – Megamax to Emax 2  F1 F2F3F4F5 F6Rated Current [A]1250 16002000125016002000 250025003000 2000250030003200 3600320040005000 6300 VersionPoleF1BF1NF1SF1H F1VF1LF2HF2VF2LF2S F3SF4SF4SF5SF5HF6S F6H FIXED CB 3P RF RF RF RF - - RF -- RF (1) RF RF RF RF RF - - 4P RF RF RF RF - - RF - - RF (1) RF RF RF RF RF RF (1) RF (1) WITHDRAWABLE CB 3P RF-DR RF-DR RF-DR RF-DR - - RF-DR - - RF (2) -DR (3) RF RF-DR RF-DR RF- CiC (4) RF-CiC (4) - - 4P RF-DR RF-DR RF-DR RF-DR - - RF-DR - - RF (2) -DR (3) RF RF-DR RF-DR RF- CiC (4) RF-CiC (4) - - Under development Under development for the version F2S 3000 A Direct Replacement available only for the F2S 2500 A Cradle in Cradle available only for the 3200…4000 A versions RF: Hard bus Retrofill , DR: Direct Replacement, CiC : Cradle in Cradle

Megamax to Emax 2 March 25, 2019 Slide 10 Advanced retrofitting kit solutions – Value propositionsDirect Replacment & Cradle in Cradle Extend the Total Life Cycle of the SwitchgearReduction of maintenance cost and spare parts availability.Easy to installFast 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 IoTEkip PowerController to improve energy efficiency.Integration into systems with different communication protocols: Modbus RS-485, Modbus TCP, Profibus, DeviceNet , EtherNet/IP, IEC61850, Bluethooth are available.Easy to MaintainDiagnosis and installation with Ekip Connect Software. Automatic notifications to remind maintenance activities. ABB Ablity EDCS is also available with Emax 2 for Predictive Maintenance.

Megamax to Emax 2 March 25, 2019 Slide 11 Advanced retrofitting solutions – Corrispondance tableAutomatic circuit breakers – Megamax F1 F2 Megamax F1 F2 Performance LevelsBBB NNNSSS HHSHHIu @40°C [A] 125016002000125016002000 125016002000125016002500 20002500Poles3p/4p3p/4p3p/4p 3p/4p3p/4p3p/4p3p/4p3p/4p3p/4p3p/4p 3p/4p 3p/4p 3p/4p 3p/4p Emax 2 E2.2 E2.2 E2.2 E2.2 E2.2E2.2 E2.2 E2.2 E2.2 E2.2 E2.2 E2.2 E2.2 E2.2 Advanced retrofit solution DR DR DR DR DR DR DR DR DR DR DR DR DR DR Performance Levels B B B N N N N N N H H N H H Iu @40°C [A] 1600 1600 2000 1250 1600 2000 1250 1600 2000 1250 1600 2500** 2000 2500** In (Rating Plug ) [A] 1250 1600 2000 1250 1600 2000 1250 1600 2000 1250 1600 2500 2000 2500 Icu /Ics 400-415V [ kA ] 40 40 40 50* 50* 50* 55 55 55 85 85 65 85 85 Icu /Ics 440-500V [ kA ] 40 40404040405050 50 70 70 60 70 70 Icu /Ics 690 V [ kA ] 35 35 35 35 35 35 45 45 45 55 55 55 55 55 Icw (1s ) 690 V [ kA]3535353535354545455555555555* Ics =40 kA** Derating up to 2400 A with Fixed Part with HR terminals; no derating with Fixed part with VR terminals

Megamax to Emax 2 March 25, 2019 Slide 12 Advanced retrofitting solutions –Corrispondance tableAutomatic circuit breakers – Megamax F4 F5 Megamax F4 ****F5 Performance LevelsSSS HSHIu @40°C [A]32003600 3200320040004000Poles3p/4p 3p/4p3p/4p3p/4p3p/4p3p/4pEmax 2 E4.2E4.2E4.2E4.2E4.2E4.2 Advanced retrofit solutionDRDRCiCCiC CiCCiCPerformance LevelsHHV VVVIu @40°C [A]320040003200 3200 4000*** 4000*** In (Rating Plug) [A] 3200 3600 3200 3200 4000 4000 Icu/Ics 400-415V [kA] 75 80 100 100 100 100 Icu/Ics 440-500V [kA] 75 75 100 100 100 100 Icu /Ics 690 V [ kA ] 65 65 75 85 75 85 Icw (1s) 690 V [ kA ] 65 65 75 85 75 85 *** Derating up to 3600 A **** Direct Replacement for open door version is under development

Megamax to Emax 2 March 25, 2019 Slide 13 Advanced retrofitting solutions –Corrispondance tableSwitch disconnectors – Megamax F1, F2, F4, F5 Megamax/MSF1 F2 F4****F5 Performance LevelsBBBS SSSSSS HSHIu @40°C [A]12501600 200012501600200025003200 36003200320040004000Poles 3p/4p3p/4p3p/4p3p/4p3p/4p3p/4p3p/4p 3p/4p3p/4p3p/4p3p/4p3p/4p3p/4p Icw (1s)/MS - 415 V 40 40 40 50 50 50 50 75 80100 100 100 100 Icw (1s)/MS IEC 60947-2 -690 V 35 35 35 45 45 45 45 65 65 75 85 75 85 Emax 2/MS E2.2 E2.2 E2.2 E2.2 E2.2 E2.2 E2.2 E4.2 E4.2 E4.2 E4.2 E4.2 E4.2 Emax 2/MS B B B N N N N H H V V V V Iu @40°C [A] 1600 1600 2000 1250 1600 2000 2500** 3200 4000 3200 3200 4000*** 4000*** Icw (1s) 690 V [ kA ] 35 35 35 45 45 45 55 65/75(1) 65/80(1) 75/100(1) 85/100(1) 75/100(1) 85/100(1) ** Derating up to 2400 A **** Direct Replacement for Open Door version is under development (1) Icw (1) up to 690V according to IEC 60947-3*** Derating up to 3600 A

Megamax to Emax 2 March 25, 2019 Slide 14 Advanced retrofitting kit solutions - Product details DR retrofitting kit – Megamax F1-F2 to Emax E2.2 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 contactsMechanical signalingAnti-insertion lockRacking in/out lever for the closed door versionKit for the door’s adaptionIt is always necessary to verify that the Megamax fixed part is in good conditions as prescribed in the document 1SDH001279R0002. Special Emax E2.2 moving part

Megamax to Emax 2 March 25, 2019 Slide 15 Advanced retrofitting kit solutions - Product details DR retrofitting kit – Megamax F1-F2 Open Door and Closed door version 1° version – only Open DoorFixed part’s base without any blockDR is under development 2° version – Open Door and Closed Door- Fixed part’s base with one welded block- DR is suitable installing an additional device3° version – Open Door and Closed Door- Fixed part’snbase with two welded blocks - DR is suitable without any additional installationWelded block Additional blockWelded blocks

Megamax to Emax 2 March 25, 2019 Slide 16 Advanced retrofitting kit solutions - Product details DR retrofitting kit – Megamax F4 to Emax E4.2 – Closed Door 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 contactsMechanical signalingAnti-insertion lockRacking in/out lever for the close door versionKit for the door’s adaptionIt is always necessary to verify that the Megamax fixed part is in good conditions as prescribed in the document 1SDH001279R0002. Special Emax E4.2 moving part

Megamax to Emax 2 March 25, 2019 Slide 17 Advanced retrofitting kit solutions - Product details DR retrofitting kit – Megamax F4 Closed Door vs Open Door version Closed Door Megamax F4 fixed partPresence of a block on the lateral side of the fixed partDR retrofitting kit is available on the market Open Door Megamax F4 fixed partPresence of a support on the lateral side of the fixed partDR retrofitting kit is available under development

Megamax to Emax 2 March 25, 2019 Slide 18 Advanced retrofitting kit solutions - Product details CiC retrofitting kit – Megamax F5 to Emax E4.2 The kit is suitable for Open and Closed Door versions and it 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 4Q and dedicated wiring for 6QEmax 2 mobile part (it can be ordered separately)Racking-in leverKit for the door’s adaptionIt is always necessary to verify that the Megamax fixed part is in good conditions as prescribed in the document 1SDH001279R0002. Special Emax E4.2 fixed partSpecial Emax E4.2 fixed part connected with E4.2 moving part

Megamax to Emax 2 March 25, 2019 Slide 19 Trip Unit Functions in Megamax and Emax 2 Trip Units Suggested correspondence           AR1 LIAR1 LS PR1/PPR1/P with PR1/APR1/P with PR1/CPR1/P with PR1/C & PR1/D Ekip DIPEkip TouchEkip Hi-TouchProtection functions LILSLI - LSI - LSIGLI - LSI - LSIG LI - LSI - LSIGLI - LSI - LSIGLI - LSI - LSIG LI - LSI - LSIGLI - LSI - LSIGOverload - L           Inverse long-time delayed trip ● ● ● ● ●●●● ● Thermal memory - - ● ● ● ● ● ● ● Time-delayed overcurrent -S         Constant tripping time ( t=k ) ● - ● ● ● ● ● ● ● Constant specific let-through energy (t = k/l^2) - - ● ● ● ● ● ● ● Start-up function - -   - ● ● Zone selectivity - - - - ● ● - ● ● Instantaneous overcurrents - I         Tripping time without intentional delay - ● ● ● ● ● ● ● ● Start-up function - - - - - - - ● ● Ground fault - G         Constant tripping time ( t=k ) - - ● ● ● ● ● ● ● Constant specific let-through energy (t = k/l^2) - - ● ● ● ● ● ●●Instantaneous ground fault--●●●●-●●Start up function----- - - ● ● Zone selectivity - - - - ● ● - ● ● Grand fault ext - - - - - - - ● ● Ground fault - 2G - - - - - - - - ● Instantaneous overcurrent - 2I     - - ● Time-delayed overcurrent - S2 - - - - - - - - ● Directional overcurrent - D     - - ● Current imbalance   - - - - - - ● ● Power Control - - - - - - - ○ ○ Network analyzer - - - - - - - - ● Real-time monitoring and preotection         Current - - - ● ● ● ○ ● ● Voltage - Power -Energy - Frequency - - ○ ○ - ○●Maintenance indicators and records--●●●●●Communication capability--   ○-○○● Available ○ Available with additional device        Megamax Emax 2 AR1 LI-LS Ekip DIP *     PR1/P Ekip DIP *  PR1/P with PR1/AEkip Touch **  PR1/P with PR1/CEkip Touch **  PR1/P with PR1/C & PR1/DEkip Hi Touch * Ekip Touch – Ekip Hi Touch can also replace AR1 and PR1/P Megamax Trip Unit ** Ekip Hi Touch can also replace PR1/P with PR1/A and PR1/P with PR1/C Trip Unit

Megamax to Emax 2 March 25, 2019 Slide 20 Accessories and compatibility – Direct Replacement and Cradle in CradleAccessories and compatibility SACE Megamax SACE Emax 2 DRCiCYO (shunt opening release)→Emax 2 standard YO Emax 2 standard YOYO2 (shunt opening release)→Emax 2 standard YO2 (alternative YU)Emax 2 standard YO2 (alternative YU) YC (shunt closing release)→Emax 2 standard YCEmax 2 standard YCYU (undervoltage release)→Emax 2 standard YUEmax 2 standard YUM (motor for charging springs) →Emax 2 standard Spring charge motorEmax 2 standard Spring charge motorQ1…Q25 (O/C AUX contacts)→ Use the ones of Megamax Fixed PartLimitatation to Q10 ( Emax 2 Q4 + Q10)AUX Spring charged (S33M)→ Emax 2 standard S33 M/2Emax 2 standard S33 M/2AUX CB tripped - S51/1→Emax 2 standard contact (N/O) S51/1 (standard supply for automatic CBs) Emax 2 standard contact (N/O) S51/1 (standard supply for automatic CBs) AUX CB tripped - S51/2→Emax 2 special contacts (N/C) S51/2 supplied under request Emax 2 special contacts (N/C) S51/2 supplied under request CB tripped mechanical indication → Emax 2 standard - TU reset (standard supply for automatic CBs) Emax 2 standard - TU reset (standard supply for automatic CBs) AUX CB connected/ insulated position - S75S-S75I→Included in the Emax 2 sliding contacts (standard supply)Emax 2 AUP - Necessary a re-wiring to accessorize the Megamax FP AUX YU ( YU energized ) → Emax 2 RTC contact - check compatibility before ordering Emax 2 RTC contact - check compatibility before ordering PR1/A ( Amperometric unit ) → No longer available - same function in Ekip Hi Touch, Ekip Touch, Ekip DIP with Ekip Multimeter No longer available - same function in Ekip Hi Touch, Ekip Touch, Ekip DIP with Ekip Multimeter PR1/C ( Control unit ) → No longer available - same function in Ekip Hi Touch, Ekip Touch No longer available - same function in Ekip Hi Touch, Ekip Touch PR1/D (Dialog unit) → No longer available - same function in Ekip Hi Touch, Ekip Touch No longer available - same function in Ekip Hi Touch, Ekip Touch TV051 ( voltage transformer) → No longer available - same function in Ekip Hi Touch, Ekip Touch with Ekip Measuring No longer available - same function in Ekip Hi Touch, Ekip Touch with Ekip Measuring Megamax Shutter padlock device → Megamax shutter padlock Emax 2 Shutter lock – SLKey lock in open position→Emax 2 standard - KLCEmax 2 standard - KLCPadlock in open position→Emax 2 standard - PLCEmax 2 standard - PLCKey lock in Racked in/out position→Emax 2 standard - KLPEmax 2 standard - KLPPadlock in Racked in/out position→Emax 2 standard - PLPEmax 2 standard - PLPMechanical operation counter→Emax 2 standard - MOCEmax 2 standard - MOCIP54 door protection→Emax 2 standard - IP54Emax 2 standard - IP54Transparent protective cover for O/C pushbuttons→Emax 2 standard - PBCEmax 2 standard - PBCMechanical interlock system with other CBs →Not compatibleNot compatibleTime-delay device D→Emax 2 UVD - Necessary a re-wiring on the cubicleEmax 2 UVD - Necessary a re-wiring on the cubicleSOR Test Unit →Emax 2 YO/YU Test Unit - Necessary a re-wiringEmax 2 YO/YU Test Unit - Necessary a re-wiring

Megamax to Emax 2 March 25, 2019 Slide 21 Accessories and compatibility – Direct Replacement and Cradle in CradleAccessories and compatibilityThe following accessories are not compatible with these retrofit kit solutionsExternal 15 O/C AUX Mechanical lock for compartment door;Mechanical interlock system with other CBs;All accessories of the Emax 2 fixed part (for CiC 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 UnitCurrent sensor for neutral conductor outside circuit-breaker;Ekip Supply, Communication and external signaling modules;Ekip Multimeter;Ekip Control Panel; Ekip View;Remote reset YR

Retrofit kits March 25, 2019 Slide 22 Why would you choose our retrofits? Introduce easily new technologies in old systems – Emax 2: all in one innovation

Retrofit kit March 25, 2019 Slide 23 Why would you choose our retrofit kits? Predict ControlSupervise the system health conditions and predict next maintenance actionsRemotely implement an effective power management strategy to simply achieve energy savings MonitorOptimizeDiscover plant performance, supervise the electrical system and allocate costsAnalyze the relevant information, improve the use of your assets and take the right business decision Introduce easily new technologies in old systems - Emax 2: cloud-based Energy and Asset Management

Retrofit kits March 25, 2019 Slide 24 Why would you choose our retrofits? Introduce easily new technologies in old systems– High quality and easy installationABB Retrofit kits have high quality as: Tested in accredited laboratory and completed with compatibility declarationsDeveloped by the same R&D team that has developed both old and new circuit breakersBehind the kits there are studies to respect the Driving factors:Thermal behaviorShort circuit withstand current Dielectric properties Mechanical fits: installation, compatibility, auxiliary connectionsEasy installationEquipped with clear mounting instruction/video tutorials

March 25, 2019 Slide 25