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ABB SACE EMAX 2 E1.2 Instruction Handbook Manual

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INSTRUCTION HANDBOOK
1SDH002303A1001 - ECN000285442
EMAX 2 E1.2
Disassembly instructions

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Summary of Contents for ABB SACE EMAX 2 E1.2

  • Page 1 — INSTRUCTION HANDBOOK 1SDH002303A1001 - ECN000285442 EMAX 2 E1.2 Disassembly instructions...

  • Page 3: Safety Notes

    Disassembly instruction emaX 2 e1.2 1. SCOPE Scope of this document is to illustrate the step-by-step disassembly process of ABB SACE Emax 2 E1.2 air case circuit breaker equipped with an electronic trip unit (type Ekip TOUCH LSIG). Document is focused on Emax 2 E1.2 3p IEC version, anyway it allows to cover other versions of Emax 2 E1.2 circuit breaker equipped with a electronic trip unit with just few slight differences to be taken into...
  • Page 4 INSTRUCTION HANDBOOK 5. SEPARATE TREATMENT Table below lists parts requiring a separate treatment adding information about part location inside circuit breakers and related quantity. Description Position inside circuit breaker Quantity Lever In the T.U. reset group Lever support In the T.U. reset group Right side wall Mounted on the sliding contacts block Flat cables assemblies...

  • Page 5: Disassembly Process

    Disassembly instruction emaX 2 e1.2 6. DISASSEMBLY PROCESS Circuit breakers disassembly process is constituted by a sequence of operations to be performed on products after their dismounting from original installation. For each phase following information is provided: • Part/parts to be disassembled (title of the phase) •...
  • Page 6 INSTRUCTION HANDBOOK 6.1 PHASE 1 – CIRCUIT BREAKER FRONT COVER, COVERS AND OPERA- TING MECHANISM COVER Tools Actions to be performed Cross screwdriver Manually push the trip unit transparent By means of the cross screwdriver unscrew the protection as indicated by the arrow and 3 screws fixing the cover.
  • Page 7 Disassembly instruction emaX 2 e1.2 Manually complete the removal of the By means of the cross screwdriver unscrew the withdrawable terminals cover. 2 screws located in the lower part of the circuit breaker fixing the circuit breaker front cover to the circuit breaker main structure.
  • Page 8 INSTRUCTION HANDBOOK Manually separate the lever support and the lever. Manually remove the spring from the lever. Manually remove the reset spring from the lever By means of the tork key remove the screw support. fixing the operation counter cap to the circuit breaker front cover and after manually remove the operation counter cap.
  • Page 9 Disassembly instruction emaX 2 e1.2 By means of the cross screwdriver unscrew the screw located on the right of the operating mechanism cover fixing the operating mechanism cover to the circuit breaker main structure and manually complete the removal of the operating mechanism cover. Disassembled parts •...
  • Page 10 INSTRUCTION HANDBOOK 6.2 PHASE 2 – SLIDING CONTACTS BLOCK Tools Actions to be performed Pliers Manually push the sliding contacts block as By means of the pliers unhook the 2 springs indicated by the arrow. mounted at the extreme sides of the sliding contacts block, keeping them mounted on the Flat screwdriver sliding contacts block.
  • Page 11 Disassembly instruction emaX 2 e1.2 By means of the flat screwdriver unhook the right Manually complete the removal of the right side side wall from the sliding contacts block main wall. assembly. By means of the cutter start removing the sliding By means of the pliers remove the 2 springs from contacts label located on the right side wall and the sliding contacts block.
  • Page 12 INSTRUCTION HANDBOOK Manually complete the removal of the 2 bars. By means of the pliers remove the 4 pins and the related nuts mounted at both sides of the sliding contact base. Disassembled parts • 1 right side wall (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) •...
  • Page 13 Disassembly instruction emaX 2 e1.2 6.3 PHASE 3 – SHOULDERS Tools Actions to be performed Cross screwdriver By means of the cross screwdriver unscrew the Manually complete the removal of the cover. 2 screws fixing the cover to the circuit breaker main structure.
  • Page 14 INSTRUCTION HANDBOOK Manually remove the left shoulder. By means of the pliers remove the 2 springs mounted on the left side support. By means of the cutter start removing the 3 By means of the cross screwdriver unscrew the labels located on the left shoulder and manually 2 screws fixing the right shoulder to the circuit complete the operation.
  • Page 15 Disassembly instruction emaX 2 e1.2 Manually remove the slide mounted on the right By means of the pliers remove the spring shoulder. mounted on the right shoulder. Disassembled parts • 2 + 2 + 2 + 2 + 2 + 2 screws (Metal) •...
  • Page 16 INSTRUCTION HANDBOOK 6.4 PHASE 4 – TRIP UNIT Tools Actions to be performed Cross screwdriver By means of the cross screwdriver unscrew the By means of the cross screwdriver unscrew 2 screws located in the upper part of the circuit the 2 screws located on the front of the circuit Flat screwdriver breaker fixing the trip unt to the circuit breaker...
  • Page 17 Disassembly instruction emaX 2 e1.2 By means of the flat screw driver unhook the Manually unhook the last cabling connecting the white connector from the trip unit. trip unit to the circuit breaker main structure. By means of the scissors cut the cabling By means of the torx key unscrew the 4 screws completing the removal of the trip unit from the fixing the 2 plugs to the trip unit.
  • Page 18 INSTRUCTION HANDBOOK By means of the flat screwdriver remove the Manually push the rating plug case appendix as rating plug from the trip unit. indicated by the arrow and by means of the pliers remove the rating plug printed circuit board. By means of the cutter start removing the label By means of the cutter start removing the rating located on the front of the rating plug case and by...
  • Page 19 Disassembly instruction emaX 2 e1.2 By means of the cutter start removing the label By means of the cutter start removing the data located on the Ekip measuring blind plug and by matrix label located in the back part of the Ekip means of the pliers complete the operation.
  • Page 20 INSTRUCTION HANDBOOK By means of the flat screwdriver unhook the Manually complete the removal of the display. display from the trip unit main structure. By means of the cutter start removing the By means of the flat screwdriver remove the trip unit front label and by means of the pliers battery cover on the right side of the display.
  • Page 21 Disassembly instruction emaX 2 e1.2 Manually complete the removal of the HMI box. By means of the cutter start removing the 2 data matrix labels located in the back part of the HMI box and by means of the pliers complete the operation.
  • Page 22 INSTRUCTION HANDBOOK Manually remove the display support. Manually separate the display from its printed circuit board. Manually separate the gasket from the display. By means of the torx key unscrew the 4 screws fixing the backplane to the trip unit main structure.
  • Page 23 Disassembly instruction emaX 2 e1.2 By means of the cutter start removing the blind By means of the flat screwdriver unhook the trip label located on the side of the trip unit main unit case from the trip unit back cover. structure and by means of the pliers complete the operation.
  • Page 24 INSTRUCTION HANDBOOK By means of the cutter start removing the 2 labels located on the trip unit back cover and by means of the pliers complete the operation. Disassembled parts • 2 + 2 + 4 + 2 + 1 + 4 + 4 screws (Metal) •...
  • Page 25 Disassembly instruction emaX 2 e1.2 6.5 PHASE 5 – TERMINALS AND CLAW CONTACTS Tools Actions to be performed Allen key By means of the allen key unscrew the screws Push as indicated by the arrow the terminals fixing the terminals to the circuit breaker main and the related protections and manually structure.
  • Page 26 INSTRUCTION HANDBOOK Circuit breakers in UL version show significant differences at level of this disassembly phase, consequently here below an analogous section is provided for these circuit breakers. Actions to be performed 97 UL 98 UL By means of the allen key unscrew the screws Push as indicated by the arrow the claw fixing the claw contacts to the circuit breaker contacts and the related protections and...
  • Page 27 Disassembly instruction emaX 2 e1.2 6.6 PHASE 6 – ASSEMBLIES MOUNTED ON CIRCUIT BREAKER LEFT SIDE Tools Actions to be performed Cross screwdriver By means of the cross screwdriver unscrew the By means of the flat screwdriver slightly push 2 screws fixing the motor PCS support to the the appendix as indicated by the arrow in order Flat screwdriver circuit breaker main structure.
  • Page 28 INSTRUCTION HANDBOOK By means of the cross screwdriver unscrew the By means of the flat screwdriver unhook the 2 screws fixing the trip coil group to the circuit connector from the trip coil group. breaker main structure. By means of the flat screwdriver lift the trip coil Manually remove the trip coil group.
  • Page 29 Disassembly instruction emaX 2 e1.2 By means of the flat screwdriver push out from the trip coil group the trip coil. Disassembled parts • 2 + 1 + 2 + 1 screws (Metal) • 1 PCS cover (Plastic) • 1 motor PCS support (Plastic, Metal and Electronic components) SEPARATE TREATMENT (Printed circuit board) •...
  • Page 30 INSTRUCTION HANDBOOK 6.7 PHASE 7 – ASSEMBLIES ON CIRCUIT BREAKER RIGHT SIDE Tools Actions to be performed Torx key By means of the torx key unscrew the screw By means of the allen key unscrew the 2 screws fixing the support key block over the MID to fixing the support key block over the MID to the operating mechanism.
  • Page 31 Disassembly instruction emaX 2 e1.2 By means of the flat screwdriver push the By means of the cross screwdriver unscrew the 4 appendix as indicated by the arrow and after screws fixing the MID to the circuit breaker main manually remove the 2 couples of auxiliary structure.
  • Page 32 INSTRUCTION HANDBOOK By means of the flat screwdriver push as indicated By means of the flat screwdriver unhook the by the arrow the microswitch I/O assembly and printed circuit board mounted inside the manually remove it. microswitch I/O assembly. Manually remove the printed circuit board. Manually remove the auxiliary contacts lever mounted on the MID.
  • Page 33 Disassembly instruction emaX 2 e1.2 Disassembled parts • 1 + 2 + 4 + 1 + 1 screws (Metal) • 1 support key block (Metal) • 1 key lock support (Metal) • 1 shunt opening release plug (Plastic) • 1 connector (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) •...
  • Page 34 INSTRUCTION HANDBOOK 6.8 PHASE 8 – OPERATING MECHANISM Tools Actions to be performed Flat screwdriver By means of the flat screwdriver remove the By means of the cutter start removing the cover cap on the left side of the circuit breaker. protection plate located on the left side of Cutter circuit breaker and manually complete the...
  • Page 35 Disassembly instruction emaX 2 e1.2 Close the circuit breaker pushing the close button. By means of the allen key unscrew the 2 screws located on the left side of the operating mechanism. By means of the flat screwdriver push the shaft By means of the allen key unscrew the 2 screws support as indicated by the arrow.
  • Page 36 INSTRUCTION HANDBOOK By means of the torx key (size 15) unscrew the Manually remove the RTC lever. screw fixing the RTC lever to the operating mechanism. By means of the flat screwdriver push the shaft Put the circuit breaker with the left side up and support as indicated by the arrow.
  • Page 37 Disassembly instruction emaX 2 e1.2 Manually push the lever mounted on the bottom By means of the torx key (size 6) unscrew the 9 right part of the circuit breaker main structure. screws fixing the 2 rear plates mounted on the back part of the circuit breaker.
  • Page 38 INSTRUCTION HANDBOOK Manually pull the conduit on the front part of the By means of the torx key (size 25) unscrew the circuit breaker main structure. 6 screws located in the back part of the circuit breaker. By means of the torx key (size 20) unscrew the Manually remove the upper case assembly.
  • Page 39 Operating mechanism contains springs: their removal constitutes a potential hazard if not performed in the proper way and using dedicated tools. Based on this ABB indication is not to remove them from the operating mechanism and to manage the assembly with the maximum level of attention during disassembly and dismantle phases.
  • Page 40 INSTRUCTION HANDBOOK Disassembled parts • 1 cover cap (Plastic) • 2 protection plate (Polyesther tape) • 1 + 1 + 1 pin (Metal) • 1 open lever (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 1 withdrawable pin (Metal) •...
  • Page 41 Disassembly instruction emaX 2 e1.2 6.9 PHASE 9 – UPPER CASE ASSEMBLY AND UPPER FIXED CONTACTS Tools Actions to be performed Allen key Manually remove the 2 protections located in By means of the allen key unscrew the 6 screws the upper part of the upper case assembly.
  • Page 42 INSTRUCTION HANDBOOK 6.10 PHASE 10 – LOWER CASE ASSEMBLY, MOVING CONTACTS ASSEMBLY AND SENSORS Tools Actions to be performed Allen key Manually lift the lower case assembly and By means of the allen key unscrew the 6 screws complete the removal. located in the back part of the lower case assembly.
  • Page 43 Disassembly instruction emaX 2 e1.2 Manually remove the moving contacts By means of the flat screwdriver unhook from assembly. both sides the insulation protection and after manually complete the removal. Disassembled parts • 6 screws (Metal) • 6 screws and related washers (Metal) •...
  • Page 44 INSTRUCTION HANDBOOK 6.11 PHASE 11 –CIRCUIT BREAKER COVER Tools Actions to be performed Cross screwdriver By means of the cross screwdriver unscrew the Manually complete the removal of the screw fixing the metallic command protection command protection. to the circuit breaker cover. Cutter Torx key No.
  • Page 45 Disassembly instruction emaX 2 e1.2 7. ENERGY CONSUMPTION FOR CIRCUIT BREAKERS DISASSEMBLY Since all disassembly operations illustrated in this document are manual, the CO equivalent emissions can be considered null/negligible.
  • Page 46 INSTRUCTION HANDBOOK...
  • Page 47 Disassembly instruction emaX 2 e1.2...
  • Page 48 — ABB SACE A division of ABB S.p.A. L.V. Breakers Via Pescaria 5, 24123 Bergamo - Italy Phone: +39 035 395.111 Fax: +39 035 395.306-433 abb.it/lowvoltage © Copyright 2022 ABB. All rights reserved. Specifications subject to change without notice.