WHAT IS RETROFIT CONCEPT ?

 



                               

       Throughout the world, there are many old, low-voltage circuit breakers protecting essential industrial processes that have been operational for a significant period ‘beyond’ their functional design life. Obtaining spares for obsolete circuit breakers of this age can prove to be impossible and replacing the entire switchboard can have a serious impact on production downtime and budget constraints.   

        Retrofitting refers to the addition of new technology to older systems. Retrofit ACBs can replace ageing, unsafe switches, and circuit breakers.

Terasaki’s Retrofit Services

                             Ageing switchgear often needs to be upgraded to meet modern operational and safety requirements. Retrofitting of circuit breakers offers huge cost savings compared with the replacement of entire switchboards. The prime functional components of the system can be quickly replaced, leaving the existing copperwork and steelwork intact.

Terasaki's retrofit kits allow easy replacement of many makes and models of circuit breakers with a brand new TemPower 2 ACB. New designs are continually being added to our range.

 

        We prefer to conduct a site survey for every retrofit project – even if the breaker to be replaced is already on our design database. This ensures that the installation is as quick as possible, with minimum disruption to the client’s supply.

Mechanical and electrical interfaces are modeled using state-of-the-art 3-D CAD.

Manufacture, assembly, and routine testing are carried out at Terasakis’s facility in Glasgow, Scotland. The factory and processes are certified to the ISO 9001 quality management standard

Retrofit ACB Specification :

  • The Retrofit ACB shall be with a complete body and Chassis.
  • No site busbar modification to keep the original type test of the switchboard
  • The ACB busbars shall fit the existing Switchboard busbar without any busbar modification
  • The Retrofit ACB shall be design verified with similar designs as per IEC61439
  • Maximum 4 to 5 hours for Retrofit (Visit site for inspection)
  • The ACB shall comply with IEC 60947-2
  • Upgrade with Motorised with Closing coil and Shunt Trip
  • Aux changeover contacts as per existing ACBs or more for any upgrade requirements to BOM connectivity
  • control wiring document shall be provided to match the old control diagram
  • Icw, Icu, and Ics will be as per existing or higher
  • The ACB shall have a Padlock / Interlock for safety 
  • ACB shall have an Auto-discharge mechanism facility for safety during maintenance. The charging spring must be automatically discharged when the ACB is withdrawn from the Chassis
  • ACB shall show 3 positions, Service, Test, and Isolated
  • The ON/ OFF push button shall have a flap to prevent accidental operation and with Padlocking facility. The Padlocking facility shall also prevent the ACB from switching ON even when the ACBs are closed remotely through the closing coil
  • The ACB shall have Pad Locking / Interlocking
  • The ACB shall be of Double Break type and not have a total Tripping time of more than 30 m seconds
  • If the ACB is ON the draw-out handle shall not be inserted to draw out the ACB
  • The ACB is maintenance-free, The cluster contacts are on the ACB body to clean the cluster contacts without switching OFF the main incomer ACB during maintenance.
  • The ACB shall have a counter to know the no of operations
  • IP 31 or IP55 Door Flange as per site requirement
  • The Trip Unit shall be LSI or LSIG as per the existing type.
  • The Trip Unit is Self Powerd type and free from control supply for protection
  • The Trip unit will have an LCD Ammeter Display to show current values/fault Values / Type of fault/ fault history
  • The Trip Unit will have a facility for Secondary Injection to test the Trip Unit. Fault simulation is possible without using Secondary injection to test the healthiness of the ACB without tripping the ACB



Top 5 reasons to use Retrofit

1. Improve safety and functionality

monitoring Modern circuit breakers offer safer interlocks, remote switching and circuits.

2. Optimise existing plant

Static components in a switchboard (the steelwork and busbar system) can be retained. Only the functional, moving parts (the circuit breakers) are replaced. Retrofitting is typically 80% cheaper than switchboard replacement with minimum downtime.

3. Guaranteed spares availability

Terasaki guarantees spare parts availability for at least 10 years after the withdrawal from the sale of a circuit breaker.

4. Modernise the protection system

Old protection relays can be removed and replaced with modern microprocessor protection which is integral to the ACB. It is then easier to interface the ACB with automatic plc controls.

5. Reduce arc flash hazard

Modern ACBs clear short circuits much faster than older types. This means that the incident arc energy is correspondingly lower.


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