1. Direct Replacement Retrofitting Solution
2018
DR Masterpact M to Emax 2
Direct Replacement Retrofitting Solution
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.
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.
New
3-Spares and consumables
All original and genuine spare parts and upgrade kits.
8-End of life services
Equipment’s recycling in line with environmental requirements
4-Maintenance
Maintenance to guarantee the system’s continuous operation
9-Replacements
Replacing old equipment can dramatically increase performance and reduce costs.
5-Repairs
Workshop and on site repairs by our service engineers
10-Advanced services
Predictive Maintenance into ABB Ability EDCS Ekip-Up to upgrade your installations
November 7, 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 7, 2018

4. Product Portfolio - Retrofitting Kit Solutions
ABB knows 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.
Portfolio
ABB: Megamax, Novomax, Otomax, Isomax
Competitors: Schneider, Siemens, Terasaki, AEG H&W, Mitsubishi
The fixed part of the new CB is modified to be inserted in the old fixed part.
Portfolio
ABB: Isol, Fusol, Otomax, BBC K-Line
Competitors: GE, Federal Pacific, Allis Chalmers
The moving part of the new CB has to be modified to simulate the moving part of the old CB. It requires a very short shutdown.
Portfolio
ABB: Emax (New in Old), Megamax (OD and CD), Novomax, Modul, ASEA ALG
Competitors: Schneider (Mastepact M)
New
November 7, 2018

5. Direct Replacement Retrofit Solution
Retrofit kits
Direct Replacement Retrofit Solution
Direct Replacement
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 7, 2018

6. EPPC – Retrofit kits Masterpact M to Emax 2
ABB available Retrofitting Solutions
Retrofitting Solutions
RF: Hard bus Retrofill
DR: Direct Replacement
Next Releases
DR: July 2018
CIRCUIT BREAKER
Version
Fixed
Withdrawable 3p 4p
M08 N1 RF
RF-DR H1 H2
M10
M12
M16
M20
CIRCUIT BREAKER
Version
Fixed
Withdrawable 3p 4p
M25 N1 RF
RF-DR H1 H2
M32
M40
M50
M63
November 7, 2018

7. Direct Replacement Masterpact M to Emax 2
Value Proposition
From Circuit Breaker to Power Manager
Increase the Total Life Cycle of the Switchgear
Cost reduction of maintenance and spare parts
Easy to Install
Replacement requires few minutes and no removal of main voltage on busbar system in the switchgear
Easy to Control
All original and genuine spare parts and upgrade kits.
Easy to Connect to SCADA and into the IoT
Ekip PowerController to improve energy efficiency and saving
Easy to Mantain
Diagnosis and installation with Ekip Connect Software
ABB Ability EDCS is also available with Emax 2 for Predictive Maintenance & Audits
November 7, 2018

8. Direct Replacement Masterpact M to Emax 2
Product details
Corrispondences Masterpact M to Emax 2
Original CB:
MasterPact M
M08
M10
M12
M16
M20
M25
Performance Levels N1 H1
800
1000
1250
1600
2000
2500
Poles 3p
Emax 2 Advanced Direct Replacement Solution
E2.2 N B H
2500 (1)
In (rating plug)
lcu V 40 65 55 75
lcu V
lcu 690 V
● (1) Derating up to 2300 A with fixed part with HR terminals
● For all the sizes: Ics = 100% Icu; Icw (1s) =Icu
November 7, 2018

9. Direct Replacement Masterpact M to Emax 2
Product details
Emax 2 Moving part
The Emax 2 dedicated moving part:
Has special terminals, lower slides and lateral sides
Is assembled and tested in the factory
Is ready to be inserted in the Masterpact M fixed part
Masterpact
M fixed part
Dedicated lateral side
Lower slides
Terminals
November 7, 2018

10. Direct Replacement Masterpact M to Emax 2
Product details
Masterpact M Fixed part
On the fixed part, it is necessary to replace the existing components with the following ones:
Drawer side plates
Base panel for fixed part
Rack-in plates
Female sliding contacts to rewire according the electrical drawing
Emax 2 door flange and with dedicated metallic
Support for fixed part
Support plates
Installation instruction
November 7, 2018

11. Direct Replacement Masterpact M to Emax 2
Product details
Masterpact M Fixed part
On the fixed part, it is necessary to replace the existing components with the following ones:
Drawer side plates
Base panel for fixed part
Rack-in plates
Female sliding contacts to rewire according the electrical drawing
Emax 2 door flange and with dedicated metallic
Support for fixed part
Support plates
Female sliding contacts
Rack-in plates
Drawer side plates
Base panel for fixed part
November 7, 2018

12. Direct Replacement Masterpact M to Emax 2
Product details
Masterpact M Fixed part
Support plates
On the fixed part, it is necessary to replace the existing components with the following ones:
Drawer side plates
Base panel for fixed part
Rack-in plates
Female sliding contacts to rewire according the electrical drawing
Emax 2 door flange and with dedicated metallic
Support for fixed part
Support plates
Support for fixed part
Emax 2 door flange
November 7, 2018

13. Direct Replacement Masterpact M to Emax 2
Product details
Masterpact M fixed part – Checks before ordering
it is always necessary to verify the Masterpact M Fixed Part is in good conditions as prescribed in the document 1SDH001279R0002.
In particular, it is important to check the jaw contacts, the protecting coatings and the opening linkage mechanism of the jaw contacts shutters.
The minimum panel dimensions have to allow the insertion of the Emax 2 moving part.
Panel Dimension
DR E2.2 [mm]
Distance from fixed part to slide [mm]
A (3p)
535
50 to left / 50 to right
A (4p)
650 C
367 - D
485
46 to Top
November 7, 2018

14. Direct Replacement Masterpact M to Emax 2
Trip Unit
Functions in Masterpact M and Emax 2 Trip Units
It is strongly recommended to use the table to select the most suitable Trip Unit
STR 1 8M
STR 28 D
STR 38 S
STR 58 U
STR 68 U
Ekip Dip
Ekip Touch
Ekip Hi-Touch
Protection against overloads
Long time Ir curve l
Time delay tr
Thermal memory
Protection against short circuits
Short time Im o
Time delay tsd
Adjustable instantaneous
Fixed instantaneous I
Protection against ground faults
Earth fault
Time delay
Zone selective interlocking Zsi
Load shedding and reconnection
Real-time measurements
current
voltage
power
energy
frequency
Demand measurement
Maintenance indicators and records
Communication capability
● Basic functions ○ Optional functions
November 7, 2018

15. Direct Replacement Masterpact M to Emax 2
Accessories and compatibility
Accessories and compatibility
Mastepact M
SACE Emax 2
M (motor for charging spings)
Emax 2 standard Spring charge motor M
MX and MX2 (shunt opening release)
Emax 2 standard YO and YO2
XF (shunt closing release)
Emax 2 standard YC
MN (undervoltage release)
Emax 2 standard YU
MNR (electronical Delay for MN - into the switchboard)
Remove the Masterpact version and add the external one of Emax 2 - D
Current sensor for neutral conductor outside circuit-breaker (into the switchboard)
Remove the Masterpact version and add the external one of Emax 2 standard
AUX CB internal Open/closed – (O – F - OF)
Emax 2 standard changeover contacts - Q
AUX Spring charged (CH)
Emax 2 standard - S33/M
AUX CB tripped – (SDE)
Emax 2 standard changeover contacts - S5
AUX CB ready to close (PF)
Emax 2 standard - RTC
AUX programmable contacts (M1..16)
Emax 2 standard Ekip Signaling
Key lock in open position (VSPA)
Emax 2 standard - KLC
Padlock in open position (VBP)
Emax 2 standard - PLC
Key lock in disconnected/connected position (VSPEC)
Emax 2 standard - KLP 1 - 2
Padlock in disconnected/connected position (VSE)
Emax 2 standard - PLP
Mechanical operation counter (CDM)
Emax 2 standard - MOC
IP54 door protection (CCP)
Emax 2 standard - IP54
Transparent protective cover for O/C pushbuttons
Emax 2 standard - PBC
Arc chute cover (CC)
If not present on installed fixed part use fixing support for lateral sides of fixed part, supplied in the kit
The following accessories, instead, are not compatible with the Emax 2 Direct Replacement kit:
External 15 O/C AUX
AUX CB connected/ insulated position – (CE – CD – CT)
Mechanical lock for compartment door
Mechanical interlock system with other CBs
All accessories of the Emax 2 fixed part
Terminal shield for auxiliary board (CB)
Breaker mismatch protection
While the following Emax 2 accessories can be installed, but need to be externally cabled with local adaption:
Electronical Delay for MN
Current sensor for neutral conductor outside circuit-breaker
Ekip Supply, Communication and external Signaling modules
Ekip Multimeter; Ekip Control Panel ; Ekip View
November 7, 2018