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

2. Service Product Portfolio
EPPC Global Service
Service Product Portfolio
1-Installation and commissioning An investment in long-term equipment’s reliability
6-Engineering and consulting Application recommendations and environmental best practices.
7-Extensions, upgrades and retrofits Enhance existing equipment with the latest technologies.
2-Training The best way to teach how to respond efficiently in different critical situations
8-End of life services Equipment’s recycling in line with environmental requirements
3-Spares and consumables All original and genuine spare parts and upgrade kits.
9-Replacements Replacing old equipment can dramatically increase performance and reduce costs.
4-Maintenance Maintenance to guarantee the system’s continuous operation
10-Advanced services Predictive Maintenance into ABB Ability EDCS Ekip Up to upgrade your installations
5-Repairs Workshop and on site repairs by our service engineers
11-Service agreements Customer support agreements for low voltage equipments
November 27, 2018

3. 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
November 27, 2018

4. Product Portfolio - Retrofitting Kit Solutions
How to upgrade your installations
1. Hard Bus Retrofill (RF)
2. Cradle in Cradle (CiC)
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
Competitors: Schneider, Siemens, Terasaki, AEG H&W, Mitsubishi
Portfolio
ABB: Isol, Fusol, Otomax, BBC K-Line
Competitors: GE, Federal Pacific, Allis Chalmers
Portfolio
ABB: Emax (New in Old), Megamax (OD and CD), Novomax, Modul, ASEA ALG
Competitors: Schneider (Mastepact M)
November 27, 2018

5. Retrofitting solutions
Megamax 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
November 27, 2018

6. Advanced retrofitting solutions
Megamax to Emax 2
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 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
November 27, 2018

7. Retrofitting solutions
Megamax to Emax 2
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 6300A
Breaking capacity Icu up to 130kA at 415V AC
Operational voltage up to 690 V AC and 1000 V DC
Megamax Life Cycle
Launch: 1990
End of sales: 2013
November 27, 2018

8. Retrofitting solutions
Megamax to Emax 2
Retrofitting solutions
Megamax devices
Open door (OD)
Megamax is available in:
Fixed version
Withdrawable version
Megamax is used to have 2 different racking in/out mechanism concept, Open Door and Closed Door
It requires to open the panel door to rack in and out the moving part
Closed door (CD)
It not requires to open the door to rack in and out the moving part
November 27, 2018

9. Retrofitting solutions
Megamax to Emax 2
Retrofitting solutions
ABB available solutions – Megamax to Emax 2 F1 F2 F3 F4 F5 F6
Rated Current [A]
3200
3600
6300
Version
Pole
F1B
F1N
F1S
F1H
F1V
F1L
F2H
F2V
F2L
F2S
F3S
F4S
F5S
F5H
F6S
F6H
FIXED CB 3P RF -
RF(1) 4P
WITHDRAWABLE CB
RF-DR
RF(2)-DR(3)
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
November 27, 2018

10. Advanced retrofitting kit solutions – Value propositions
Megamax 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 Control and to Connect to SCADA and into the IoT Ekip 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 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.
November 27, 2018

11. Advanced retrofitting solutions – Corrispondance table
Megamax to Emax 2
Advanced retrofitting solutions – Corrispondance table
Automatic circuit breakers – Megamax F1 F2
Megamax F1 F2
Performance Levels B N S H
[A]
1250
1600
2000
2500
Poles
3p/4p
Emax 2
E2.2
Advanced retrofit solution DR
2500**
In (Rating Plug) [A]
Icu/Ics V [kA] 40
50* 55 85 65
Icu/Ics V [kA] 50 70 60
Icu/Ics 690 V [kA] 35 45
Icw (1s) 690 V [kA]
* Ics =40 kA
** Derating up to 2400 A with Fixed Part with HR terminals; no derating with Fixed part with VR terminals
November 27, 2018

12. Advanced retrofitting solutions –Corrispondance table
Megamax to Emax 2
Advanced retrofitting solutions –Corrispondance table
Automatic circuit breakers – Megamax F4 F5
Megamax
F4 **** F5
Performance Levels S H
[A]
3200
3600
4000
Poles
3p/4p
Emax 2
E4.2
Advanced retrofit solution DR
CiC V
4000***
In (Rating Plug) [A]
Icu/Ics V [kA] 75 80
100
Icu/Ics V [kA]
Icu/Ics 690 V [kA] 65 85
Icw (1s) 690 V [kA]
*** Derating up to 3600 A **** Direct Replacement for open door version is under development
November 27, 2018

13. Advanced retrofitting solutions –Corrispondance table
Megamax to Emax 2
Advanced retrofitting solutions –Corrispondance table
Switch disconnectors – Megamax F1, F2, F4, F5
Megamax/MS F1 F2
F4**** F5
Performance Levels B S H
[A]
1250
1600
2000
2500
3200
3600
4000
Poles
3p/4p
Icw (1s)/MS V 40 50 75 80
100
Icw (1s)/MS IEC V 35 45 65 85
Emax 2/MS
E2.2
E4.2 N V
2500**
4000***
Icw (1s) 690 V [kA] 55
** Derating up to 2400 A **** Direct Replacement for Open Door version is under development
*** Derating up to 3600 A
November 27, 2018

14. Advanced retrofitting kit solutions - Product details
Megamax to Emax 2
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 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 1SDH001279R0002.
Special Emax E2.2 moving part
November 27, 2018

15. Advanced retrofitting kit solutions - Product details
Megamax to Emax 2
Advanced retrofitting kit solutions - Product details
DR retrofitting kit – Megamax F1-F2 Open Door and Closed door version
1° version – only Open Door
Fixed part’s base without any block
DR is under development
2° version – Open Door and Closed Door
- Fixed part’s base with one welded block
- DR is suitable installing an additional device
3° version – Open Door and Closed Door
- Fixed part’snbase with two welded blocks
- DR is suitable without any additional installation
Welded blocks
Welded block
Additional block
November 27, 2018

16. Advanced retrofitting kit solutions - Product details
Megamax to Emax 2
Advanced retrofitting kit solutions - Product details
DR retrofitting kit – Megamax F4 to Emax E4.2 – Closed Door
Special Emax E4.2 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 1SDH001279R0002.
November 27, 2018

17. Advanced retrofitting kit solutions - Product details
Megamax to Emax 2
Advanced retrofitting kit solutions - Product details
DR retrofitting kit – Megamax F4 Closed Door vs Open Door version
Closed Door Megamax F4 fixed part
Presence of a block on the lateral side of the fixed part
DR retrofitting kit is available on the market
Open Door Megamax F4 fixed part
Presence of a support on the lateral side of the fixed part
DR retrofitting kit is available under development
November 27, 2018

18. Advanced retrofitting kit solutions - Product details
Megamax to Emax 2
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 6Q
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 1SDH001279R0002.
Special Emax E4.2 fixed part
Special Emax E4.2 fixed part connected with E4.2 moving part
November 27, 2018

19. Megamax to Emax 2 Trip Unit Functions in Megamax and Emax 2 Trip Units
Suggested correspondence
AR1 LI
AR1 LS
PR1/P
PR1/P with PR1/A
PR1/P with PR1/C
PR1/P with PR1/C & PR1/D
Ekip DIP
Ekip Touch
Ekip Hi-Touch
Protection functions LI LS
LI - LSI - LSIG
Overload - 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
Ground fault - G
Instantaneous ground fault
Start up function
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
PR1/P with PR1/A
Ekip Touch **
PR1/P with PR1/C
PR1/P with PR1/C & PR1/D
Ekip 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
November 27, 2018

20. Megamax to Emax 2
Accessories and compatibility – Direct Replacement and Cradle in Cradle
Accessories and compatibility
SACE Megamax
SACE Emax 2 DR
CiC
YO (shunt opening release) →
Emax 2 standard YO
YO2 (shunt opening release)
Emax 2 standard YO2 (alternative YU)
YC (shunt closing release)
Emax 2 standard YC
YU (undervoltage release)
Emax 2 standard YU
M (motor for charging springs)
Emax 2 standard Spring charge motor
Q1…Q25 (O/C AUX contacts)
Use the ones of Megamax Fixed Part
Limitatation to Q10 ( Emax 2 Q4 + Q10)
AUX Spring charged (S33M)
Emax 2 standard S33 M/2
AUX CB tripped - S51/1
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
CB tripped mechanical indication
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
PR1/A (Amperometric unit)
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
PR1/D (Dialog unit)
TV051 (voltage transformer)
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 – SL
Key lock in open position
Emax 2 standard - KLC
Padlock in open position
Emax 2 standard - PLC
Key lock in Racked in/out position
Emax 2 standard - KLP
Padlock in Racked in/out position
Emax 2 standard - PLP
Mechanical operation counter
Emax 2 standard - MOC
IP54 door protection
Emax 2 standard - IP54
Transparent protective cover for O/C pushbuttons
Emax 2 standard - PBC
Mechanical interlock system with other CBs
Not compatible
Time-delay device D
Emax 2 UVD - Necessary a re-wiring on the cubicle
SOR Test Unit
Emax 2 YO/YU Test Unit - Necessary a re-wiring
November 27, 2018

21. Megamax 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
External 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 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
November 27, 2018

22. Why would you choose our retrofits?
Retrofit kits
Why would you choose our retrofits?
Introduce easily new technologies in old systems – Emax 2: all in one innovation
November 27, 2018

23. Why would you choose our retrofit kits?
Introduce easily new technologies in old systems - Emax 2: cloud-based Energy and Asset Management
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
24k€ Energy efficiency certificates  no need for expensive and time consuming audits by 3rd parties, automatic reports via EDCS!
30% savings on operational costs  Thanks to remote supervision and alerting, reduction of time and costs for commuting around the different sites and intervene proactively and quickly to restore normal condition avoiding faults, perform maintenance, or fix downtimes + avoiding downtimes and penalties due to bad power quality
November 27, 2018

24. Why would you choose our retrofits?
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
November 27, 2018

25. November 27, 2018