ABB SACE Emax 2 E1.2 Manual
—
INSTRUCTION HANDBOOK
1SDH002303A1001 - ECN000285442
EMAX 2 E1.2
Disassembly instructions
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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
account.
Gloves Glasses Safety shoes Protective clothes
4. TOOLS
Disassembly operations require the use of tools (e.g. screwdriver, torx key, pliers, …); tools to be used
are specified inside each phase of the disassembly process (see Chapter 6).
3. PERSONAL PROTECTIVE EQUIMENT (PPE)
When performing disassembly, following safety Personal Protective Equipment (PPE) must be worn:
2. SAFETY NOTES
Before proceeding with any disassembly operation, it’s mandatory to put the circuit breaker in open
position and make sure that the springs of the operating mechanism are discharged.
Disassembly operations of circuit breakers must be performed by qualified and skilled personnel in
the electrical field (IEV 195-04-01: person with relevant education and experience to enable him or her
to perceive risks and to avoid hazards which electricity can create) and having a detailed knowledge of
circuit breakers.
Disassembly activites must be performed in an ergonomic workspace able to ensure protection of per-
sons demanded to perform disassembly activities.
Applicable national legislation and international standards in force at the time of disassembly of circuit
breakers must be taken into account in addition to prescriptions illustrated in this document.
ABB declines any responsibility for injury to people or damage to property resulting from a failure to
comply with the instructions set out in this document and with any applicable safety standard.
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INSTRUCTION HANDBOOK
If disassembled parts require a separate treatment a specific indication is provided inside each phase
with reason why for the separate treatment (see Chapter 6).
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 Mounted on the sliding contacts block
Connector cables assembly Mounted on the sliding contacts block
Sliding contacts base Mounted on the sliding contacts block
Slide Mounted on the right shoulder
Support Mounted on the upper part of the circuit breaker
Cables protection Mounted on the back part of the trip unit
Rating plug case Mounted on the front of the trip unit
Rating plug printed circuit board In the rating plug case
Ekip measuring blind printed circuit board On the trip unit
Battery cover On the trip unit
Battery On the trip unit
Display printed circuit board On the trip unit
Display On the trip unit
Backplane Mounted on the back part of the trip unit
Trip unit case On the trip unit
Trip unit back cover On the trip unit
Trip unit printed circuit board In the trip unit
Measuring module connector On the trip unit
Protections Mounted on the back part of the circuit breaker
Motor PCS support Mounted on the left part of the circuit breaker
Microswitch support Mounted on the left part of the circuit breaker
Mounted on the left part of the circuit breaker
Trip coil In the trip coil group
Trip coil group Mounted on the left part of the circuit breaker
Connector On the MID
Auxiliary contacts On the MID
Microswitch I/O On the MID
Microswitch I/O support On the MID
MID Mounted on the right part of the circuit breaker
Wires cover Mounted on the left part of the circuit breaker
Wiring Mounted on the left part of the circuit breaker
Open lever On the right side of the circuit breaker
RTC lever Mounted on the right side of the operating mechanism
Conduit Behind the trip unit
Operating mechanism Mounted on the center of the circuit breaker
Unlocking shaft appendices Mounted on the pin of the operating mechanism
Springs charging lever Mounted on the left side of the operating mechanism
Protections Mounted on the upper case assembly
Plastic parts Mounted on the fixed contacts
Covers Below the sensors
Sensors In the bottom part of the circuit breaker
Insulation protections On the moving contacts assembly
5. SEPARATE TREATMENT
Table below lists parts requiring a separate treatment adding information about part location inside
circuit breakers and related quantity.
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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:
applicable)
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INSTRUCTION HANDBOOK
Tools
Flat screwdriver
6.1 PHASE 1 – CIRCUIT BREAKER FRONT COVER, COVERS AND OPERA-
TING MECHANISM COVER
1
Manually push the trip unit transparent
protection as indicated by the arrow and
remove it.
3
Manually complete the removal of the cover.
5
By means of the cross screwdriver unscrew the
2 screws located in the upper part of the circuit
breaker fixing the circuit breaker front cover to
the circuit breaker main structure.
2
By means of the cross screwdriver unscrew the
3 screws fixing the cover.
4
Lift the spring charging lever and by means
of the cross screwdriver unscrew the screw
located below the springs charging lever fixing
the circuit breaker cover to the circuit breaker
main structure.
6
By means of the cross screwdriver unscrew
the 2 screws fixing the withdrawable terminals
cover.
Actions to be performed
Cross screwdriver
Torx key
No. 8
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Disassembly instruction emaX 2 e1.2
7
Manually complete the removal of the
withdrawable terminals cover.
11
Manually lift the T.U. reset group and complete the
removal.
12
By means of the flat screwdriver unhook the reset
lever from the reset support of the T.U. reset group.
9
Manually lift the circuit breaker front cover to
complete the removal.
8
By means of the cross screwdriver unscrew the
2 screws located in the lower part of the circuit
breaker fixing the circuit breaker front cover to
the circuit breaker main structure.
10
By means of the cross screwdriver unscrew the
screw fixing the T.U. reset group to the circuit
breaker front cover.
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INSTRUCTION HANDBOOK
13
Manually separate the lever support and the lever.
17
By means of the tork key remove the 2 screws
fixing the front cap to the circuit breaker front
cover and after manually remove the front cap.
18
By means of the cross screwdriver unscrew the 2
screws located in the lower part of the operating
mechanism cover fixing the operating mechanism
cover to the circuit breaker main structure.
15
Manually remove the reset spring from the lever
support.
14
Manually remove the spring from the lever.
16
By means of the tork key remove the screw
fixing the operation counter cap to the circuit
breaker front cover and after manually remove the
operation counter cap.
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Disassembly instruction emaX 2 e1.2
19
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
(Thermoplastics containing brominated flame
retardants)
(Thermoplastics containing brominated flame
retardants)
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INSTRUCTION HANDBOOK
Tools
Flat screwdriver
Cutter
Pliers
6.2 PHASE 2 – SLIDING CONTACTS BLOCK
20
Manually push the sliding contacts block as
indicated by the arrow.
22
Using one hand manually slightly push as
indicated by the arrow the right shoulder
and using the other hand unhook the sliding
contacts block from main circuit breaker
structure.
24
By means of the flat screwdriver unhook the
3 flat cables assemblies and the connector
cables assembly.
21
By means of the pliers unhook the 2 springs
mounted at the extreme sides of the sliding
contacts block, keeping them mounted on the
sliding contacts block.
23
After completion of previous operation, sliding
contacts block must be put as indicated in
picture here below.
25
Manually complete the removal of the sliding
contacts block from the circuit breaker main
structure.
Actions to be performed
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