This retrofitting kit is designed for replacing the DB air circuit breaker in DB switchgear. It allows a standard
Emax 2 withdrawable air circuit breaker of the size indicated in Table A and its cradle (fixed part) to be attached
to the original switchgear 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 certified for the obsolete device performances which may be lower than the
new Emax 2 ratings. Consult ABB for further details.
Table A
Full correspondence of the electrical characteristics is guaranteed (rated current excluding derating if indicated in
Table A, 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 (fixed part)
for the new circuit breaker is installed and then locked into the legacy DB switchgear, thus making use of the
of the Emax 2 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 instructions in the
installation, operation, and maintenance manual of the Emax 2 circuit breaker document number
1SDH001000R0002. If optional auxiliary (secondary) circuits are required, refer to section 11.
Structure Details
The cradle for the new Emax circuit breaker is mounted to a steel structure that is then mounted into the
DB switchgear cell. The Emax CiC adapter is fitted with custom silver flashed copper run backs and finger
clusters that align to and mate with the existing DB switchgear power circuit stabs. The entire assembly mounts
on the original DB BREAKER L-Frame rails without additional phase barriers. The weight of the low voltage
CiC adapter without the breaker is as follows:
Doc. N.° 2TSA451041P0000 rev A
DB BREAKER TO EMAX 2
2TSA451041P0000
Retrotting between DB BREAKER and Emax 2 circuit breakers with cradle-in-cradle
(CiC) adapter
Table B
RATING
EMAX 2
RATING
DB-25
600A
E-1.2
600A
DB-50
1600A
E-2.2
1600A
Weight (lbs./kg)
CiC Model
1 Pos
3 Pos
DB-25
75/34
90/41
DB-50
90/41
120/55
MAKING THE SYSTEM SAFE FOR INSTALLATION
The following warnings and precautions must be respected before installing the new cradle and circuit breaker in
the switchgear.
ŸDisconnect the power from the switchgear (power circuit and auxiliary circuits) and verify it is disconnected
from all sources of energy.
ŸDouble check to ensure that the line has been placed out of service.
ŸPlace the switchgear housing and the legacy circuit breaker out of service.
ŸSet the legacy circuit breaker to the open position with the springs unloaded.
NOTE: The trained personnel in charge of handling and lifting must use appropriate safety equipment.
A
1
DB BREAKER
Tools Required: Drill Machine
ŸRack out the breaker using the DB rack out leverage
tool (fig. 1).
Remove the legacy OEM circuit breaker
ŸOpen the door of the switchgear.
ŸRefer to the OEM installation manual for instructions to
remove the breaker from service.
ŸExtract the circuit breaker according to the procedures in
the OEM installation manual (fig. 2).
WARNING: THE CIRCUIT BREAKER COULD DROP WHEN
LIFTING. FASTEN IT TO A LIFTING TRUCK BEFORE
PROCEEDING.
ŸRemove all the tools and equipment used for the extraction
and clean off the processing residues and metal scraps.
ŸDisconnect and remove any auxiliary signaling devices that
will not be used with the new Emax 2 CiC adapter.
Fig. 2
Fig. 1
Phillips Screwdriver
B
DB -25
Drill bit (Ø.228″)
3
2
WARNING: THE CiC ADAPTER COULD DROP DURING THIS OPERATION. ATTACH APPROPRIATELY SIZED
AND RATED LIFTING DEVICES WHICH EXCEED THE RATINGS LISTING IN TABLE B ON PAGE 1
BEFORE PROCEEDING.
ŸPlace the Extended cradle rails
(a)(fig. 3) onto Switchgear rails
until the side levers drop down to
lock the switchgear rails
ŸLower the CiC adapter onto the rails
as shown so that the rollers rest in
the guide rails (fig. 4)
Fig. 3
Fig. 4
ŸPush the CiC adapter on the cradle rails into
the switchgear cell.
Fig. 5
INSTALLATION IN SWITCHGEAR
4
ŸOpen the compartment door that is
to be retrofitted.
ŸLift the pin out of hinge joints this allows
removing of door from compartment.
5
Note: If any unusual resistance is detected that
could be abnormal interference between the CiC
adapter and the switchgear cell parts stop
immediately and retract the CiC adapter.
Examine what is causing the interference and
correct the situation.
ŸOnce the cradle is fully racked in Drill
Holes on the side wall of switchgear
as shown in (fig. 8).
•Use provided flat head taptite screws to
permanently lock the breaker with
switchgear as shown in (fig. 9).
•Remove all the tools and equipment used
for the CiC adapter installation and clean off
any processing residues and metal scraps.
ŸRack-in the CiC adapter into switchgear
using DB rack-in/out leverage tool.
(Legacy DB-Leverage tool)
Fig. 6
Fig. 8
Fig. 9
ŸOnce the CiC adapter is fully pushed into the
switchgear cell Manually, unlock the extension
rails and remove them from cell (fig. 6).
as shown in (fig. 7).
Fig. 7
•Insert Emax 2 Circuit breaker, refer to the
Emax 2 manual 1SDH001000R002
•Assemble back the door assembly after
modifying door refer 2TSA451042P1000
6
7
Optional Auxiliary (Secondary) Circuits Notes:
ŸPrior to energizing the auxiliary circuits, verify that the secondary contacts are properly engaged by
performing a continuity test on each installed circuit.
ŸReview the “Putting into service” section of the Emax 2 installation, operation, and maintenance manual
1SDH001000R0002 for specific checks of the installed accessories.
ŸThe 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.
ŸUse the DB rack out tool to disengage CiC
adapter with stabs as shown in (fig. 11).
Remove the Emax 2 CiC Adapter
ŸRemove the Emax 2 circuit breaker, refer to the
Emax 2 manual 1SDH001000R0002.
ŸUnscrew the taptite Screws from switchgear
sidewalls as shown in (fig. 10).
ŸNote: The CiC should rack-out smoothly without
mechanical interference. If any unusual
resistance is detected, stop immediately and
correct the situation before proceeding.
ŸPull out the CiC adapter from switchgear rails.
WARNING: THE CiC ADAPTER COULD DROP
DURING THIS OPERATION. FASTEN IT TO A
LIFTING TRUCK BEFORE PROCEEDING.
WARNING: THE CIRCUIT BREAKER COULD DROP
DURING THIS OPERATION. FASTEN IT TO A
LIFTING TRUCK BEFORE PROCEEDING.
ŸLift the CiC adapter from the rails using the
designated lifting points with equipment that has
ratings which exceed the values listed in Table B
on page 1.
Fig. 10
ŸPlace the extended rails & lock them with
switchgear rails as shown in (fig. 12).
Fig. 11
Fig. 13
•Double check to ensure that the line has been placed
MAKING THE SYSTEM SAFE FOR REMOVAL
The following warnings and precautions must be respected
before removing the CiC adapter and circuit breaker from
•Place the switchgear housing and the circuit breaker
•Disconnect the power from the switchgear
(power circuit and auxiliary circuits) and verify it is
NOTE: The trained personnel in charge of handling and lifting
the switchgear.
out of service.
disconnected from all sources of energy.
out of service.
must use appropriate safety equipment.
Fig. 12
As shown in (fig. 13).
MAKING THE SYSTEM SAFE FOR INSTALLATION
The following warnings and precautions must be respected before installing the new cradle and circuit breaker in
the switchgear.
ŸDisconnect the power from the switchgear (power circuit and auxiliary circuits) and verify it is disconnected
from all sources of energy.
ŸDouble check to ensure that the line has been placed out of service.
ŸPlace the switchgear housing and the legacy circuit breaker out of service.
ŸSet the legacy circuit breaker to the open position with the springs unloaded.
NOTE: The trained personnel in charge of handling and lifting must use appropriate safety equipment.
A
1
DB BREAKER
Tools Required:
ŸRack out the breaker using the DB rack out leverage
tool (fig. 1).
Remove the legacy OEM circuit breaker
ŸOpen the door of the switchgear.
ŸRefer to the OEM installation manual for instructions to
remove the breaker from service.
ŸExtract the circuit breaker according to the procedures in
the OEM installation manual (fig. 2).
WARNING: THE CIRCUIT BREAKER COULD DROP WHEN
LIFTING. FASTEN IT TO A LIFTING TRUCK BEFORE
PROCEEDING.
ŸRemove all the tools and equipment used for the extraction
and clean off the processing residues and metal scraps.
ŸDisconnect and remove any auxiliary signaling devices that
will not be used with the new Emax 2 CiC adapter.
Fig. 2
Fig. 1
B
DB-50
Allen Key (5mm)
4
3
2
WARNING: THE CiC ADAPTER COULD DROP DURING THIS OPERATION. ATTACH APPROPRIATELY SIZED
AND RATED LIFTING DEVICES WHICH EXCEED THE RATINGS LISTING IN TABLE B ON PAGE 1
BEFORE PROCEEDING.
ŸLower the CiC adapter onto the rails from the
lifting points as shown so that the rollers rest in
the guide rails.
Fig. 3
Fig. 5
ŸPlace the Extended cradle rails
(a)(fig. 3) onto Switchgear rails
until the side levers drop down to
lock the switchgear rails
ŸPush the CiC adapter on the cradle rails into
the switchgear cell.
Open condition Closed condition
Fig. 4
5
ŸOnce the CiC adapter is fully pushed into the
switchgear cell Manually, unlock the extension
rails and remove them from cell. (fig. 6)
Fig. 6
ŸRack-in the CiC adapter into switchgear
using DB rack-in/out leverage tool.
(Legacy DB-Leverage tool)
as shown in (fig. 7)
Fig. 7
ŸOnce the cradle is fully racked in extend
the locking bracket on LH and RH side of the
CiC adapter as shown in (fig. 8) and lock it by
tightening screws.
Fig. 8
1
2
Note: If any unusual resistance is detected that
could be abnormal interference between the CiC
adapter and the switchgear cell parts stop
immediately and retract the CiC adapter.
Examine what is causing the interference and
correct the situation.
•Remove all the tools and equipment used
for the CiC adapter installation and clean off
any processing residues and metal scraps.
Optional Auxiliary (Secondary) Circuits Notes:
ŸPrior to energizing the auxiliary circuits, verify that the secondary contacts are properly engaged by
performing a continuity test on each installed circuit.
ŸReview the “Putting into service” section of the Emax 2 installation, operation, and maintenance manual
1SDH001000R0002 for specific checks of the installed accessories.
ŸThe 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.
6
7
ŸUse DB rack out tool to disengage CiC
adapter with stabs as shown in (fig. 10).
Remove the Emax 2 CiC Adapter
ŸRemove the Emax 2 circuit breaker, refer to the
Emax 2 manual 1SDH001000R0002.
ŸUnscrew the racking lock pins on
each side of the CiC adapter until they are clear
of the racking pins as shown in (fig. 9).
ŸNote: The CiC should rack-out smoothly without
mechanical interference. If any unusual
resistance is detected, stop immediately and
correct the situation before proceeding.
ŸPlace the extended rails and lock them
with switchgear rails as shown in (fig. 11).
WARNING: THE CiC ADAPTER COULD DROP
DURING THIS OPERATION. FASTEN IT TO A
LIFTING TRUCK BEFORE PROCEEDING.
WARNING: THE CIRCUIT BREAKER COULD DROP
DURING THIS OPERATION. FASTEN IT TO A
LIFTING TRUCK BEFORE PROCEEDING.
ŸPull out the CiC adapter from switchgear cell
until they it is on extended rails as shown in (fig. 12).
ŸLift the CiC adapter from the rails using the
designated lifting points with equipment that has
ratings which exceed the values listed in Table B
on page 1.
Fig. 11
•Double check to ensure that the line has been placed
MAKING THE SYSTEM SAFE FOR REMOVAL
The following warnings and precautions must be respected
before removing the CiC adapter and circuit breaker from
•Place the switchgear housing and the circuit breaker
•Disconnect the power from the switchgear
(power circuit and auxiliary circuits) and verify it is
NOTE: The trained personnel in charge of handling and lifting
the switchgear.
out of service.
disconnected from all sources of energy.
out of service.
must use appropriate safety equipment.
Fig. 9
Fig. 10
Fig. 12
1
2
Copyright 2020 ABB. All rights reserved
www.abb.com
Doc. N.° 2TSA450001P1011
LK8, LKE8, LKD8, LK16, LKE16 TO EMAX 2
Senatobia, MS 38668
Phone: 1-662-562-0700
For more information please contact your local ABB
Field Representative or Service Center listed below:
ABB Inc.
1555 Scott Street
/