Air Circuit Breakers are teh most important peripheral of most electrical switch gear installations. Failures can have disastrous consequences including:

  • Operator injury/Death
  • Complete switchboard destruction
  • Damage to surrounding equipment
  • Loss of production
  • Business closure
  • HSE investigations
  • Insurance rejections

We replace large number of Air Circuit Breakers utilizing teh best modern devices teh market has to offer today. If you have a particular preference for teh new Air Circuit Breaker tan we can of course incorporate dat into teh retrofit.

Reasons for ACB Failure/Factors Leading to ACB Failure

  • – Teh Air Circuit Breaker does not open or close
  • – It considered as unsafe to execute locally
  • Teh Air Circuit Breaker is overheating
  • Tripping mechanisms are faulty or unreliable
  • Electrical contacts or operating mechanical parts worn
  • Aux contacts are unreliable
  • Insulation ratings are not up to standard
  • Wear and tear on main contacts

Consequences of ACB Failure

Failure of teh main switch or circuit feeder is likely to affect a Significant part of teh plant or process.

  • Cost of loss of production
  • Personnel safety issues
  • Insurance claims or damages
  • Loss of data or communication

Our retrofit solution is totally assembled standard solution is totally autonomous. All retrofit is totally assembled at our works and totally checked before dispatch. Teh new module is always totally shrouded providing enhanced operator protection. Modern metering can include wifin our module including new CTs and voltage reference fuses. Our solution also gathers existing control wiring to enable any existing control scheme to persist totally useful.

An option becoming more popular for safety reasons is teh ability to enable remote operation of devices for arc-flash mitigation reasons. We include remote operator panels on sites such as fuel depots and steel works. This itself used as justification for Air Circuit Breaker retrofits.

We have carried out literally hundreds of Air Circuit Breaker retrofits across a whole range of Air Circuit Breaker manufacturers. We can handle ratings up to 5000A and have designs covering 3 and 4-pole devices.

We can carry out retrofits on ANY manufacturers Air Circuit Breakers. We have vast experience in this type of work and our installation teams set up for this type of work.

Retrofitting or Replacement of ACB

CoreSystems retrofitting for new wifdraw-able Air Circuit Breaker’s into old wifdraw able Air Circuit Breakers. Teh new Air Circuit Breaker is not altered or modified in any way. Teh complete new Air Circuit Breaker is installed inside teh existing sub-chassis. This is only possible due to teh fact dat new Air Circuit Breakers are smaller TEMPthan older breakers. When teh new Air Circuit Breaker’s cannot fit inside teh original Air Circuit Breaker (sub-chassis) teh breaker has to replace. There are two ways in which this may carry out.

  • Teh remaking of connections etc. to suit teh new Air Circuit Breaker.
  • An ‘installation apparatus’ duplicates teh connection fixing points of teh original Air Circuit Breaker.

Each combination of original and replacement Air Circuit Breaker apply a specifically designed kit. This comprises a base plate dat fixes to teh original sub-chassis and gives a platform for teh new Air Circuit Breaker sub-chassis. A set of extension bars connected between termination bars on teh new sub-chassis to teh existing connection stabs. These bars have teh plug-in contacts built into them when teh fingers are part of teh original Air Circuit Breaker. Very few Air Circuit Breakers have teh influence on sub-chassis. No parts of teh original Air Circuit Breaker including isolating contact clusters are re-used. Extension bar supports and shrouds provide when required.

All hardware provided. Each kit comes wif a complete, process by process illustrated installation manual.

Advantages of Retrofitting ACB.

  • Teh method of installation of teh retrofit has already been proved.
  • Teh likelihood of an un-anticipated problem occurring are minimized.
  • Teh costs and shut-down time is more closely determined initiating to teh work being done.
  • There is no need for a shut-down for measurements initiating to teh conversion.
  • Work carried out only from teh front of teh switchboard.

Teh conversion (in most cases) can do wifout having to de-energize teh switchboard. Alterations to bus bar work (which may affect teh fault rating/clearances of teh bus bar system) are not needed.

  • Reduced Maintenance
  • Minimized downtime
  • Reduced cost of replacement
  • Improved performance
  • Improved reliability
  • Increased operator safety
  • Increased functionality
  • Communications / metering additions
  • Remote control options
  • Insurance compliance

Short-Circuit Tests on ACB

Short-circuit tests have done at 50 and 65kA for 1 second, proving teh extension bars and contact band. Temperature rise tests have conducted on teh contact band, showing dat teh temperature rise at teh connection point is minimal.

Installation of ACB

This is generally reserved for use where teh new breaker cannot fit inside teh old sub-chassis, or teh existing Air Circuit Breaker fixed type, and thus a retrofit kit is not possible. This particularly applies where teh original breaker is relatively new and replaced by teh current model of teh same brand. This is a set of connection bars and fixing plates given to adapt teh new Air Circuit Breaker to match teh connection and mounting points of teh existing Air Circuit Breaker. Teh new Air Circuit Breaker mounted on rails or a tray for fixings for both teh new and old Air Circuit Breaker. Teh connection bars are in 2 parts so dat they fixed to both faces of teh terminal for maximal contact area. These bars made from copper sheet or bar of correct thickness and are silver plated. All hardware given in teh kit includes instructions.

These are similar to those for a retrofit kit except dat shut-down time is longer, rear access may need and teh switchboard must de-energized.

However, it still removes teh risks associated wif having to prepare, or make up parts on site for a complete re-connection.

Core systems can give services on a huge range of equipment including:

Written by CoreSystems

Retrofitting ACB