ABB SACE Emax 2 E4.2 Instruction Handbook Manual Download

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INSTRUCTION HANDBOOK

1SDH002305A1001 - ECN000285442

EMAX 2 E4.2

Disassembly instructions

Summary of Contents for SACE Emax 2 E4.2

Page 1: ... INSTRUCTION HANDBOOK 1SDH002305A1001 ECN000285442 EMAX 2 E4 2 Disassembly instructions ...

Page 2: ......

Page 3: ...er to section Unpacking and handling of Emax 2 Installa tion operation and maintenance instructions for the installer and the user document Improper lifting can result in death serious injury to persons and damage to the equipment never lift a circuit breaker above other people The trained personnel in charge of handling and lifting must use appropriate safe ty equipment Disassembly operations of ...

Page 4: ...t 1 Trip unit back cover Mounted on the trip unit 1 Trip unit printed circuit board Mounted in the trip unit 1 4 micro I O assembly base Mounted on the terminal box 1 4 auxiliary contacts Mounted in the terminal box 1 Connectors Mounted on the terminal box 2 Connector with 2 microswitches Mounted on the terminal box 1 I O shaft Mounted on the terminal box 1 Terminal box case Mounted on the termina...

Page 5: ... breaker Quantity Auxiliary flat assembly Mounted on the MID 1 RTC micro lever Mounted in the MID 1 MID main structure Mounted in the MID 1 Springs charging lever Mounted on the operating mechanism 1 Operating mechanism Mounted on the center of the circuit breaker 1 Auxiliary contacts cam Mounted on operating shaft assembly 1 Cam Mounted on operating shaft assembly 1 Lever Mounted on operating sha...

Page 6: ...it breaker 4 By means of the cross screwdriver unscrew the 4 screws fixing the front cover to the circuit breaker main structure 6 By means of the torx key unscrew the 2 screws fixing the 2 plugs to the front cover 3 Manually remove the racking in and out lever located in the bottom part of the circuit breaker 5 Manually remove the front cover 2 Manually remove the trip unit transparent cover Acti...

Page 7: ...alling plug automatically separate from the T U Reset metal support 9 Manually remove the T U Reset assembly 8 By means of thr torx key unscrew the 2 screws fixing the T U Reset assembly to the front cover 12 By means of the torx key remove the 2 screws fixing the plug to the circuit breaker front cover 10 By means of the flat screwdriver remove the 2 benzings mounted on the T U Reset assembly ...

Page 8: ... means of the cross screwdriver unscrew the 2 screws located behind the springs charging lever fixing the operating mechanism cover to the circuit breaker main structure and always by means of the cross screwdriver unscrew the screw located in the bottom right part of the operating mechanism cover fixing it to the circuit breaker main structure 16 Manually complete the removal of the operating mec...

Page 9: ... 3 plugs Plastic 2 benzings Metal 1 pin Metal 1 spring Metal 1 T U Reset signalling plug Plastic 1 T U Reset support Metal 1 circuit breaker front cover Plastic 1 operating mechanism cover Plastic 2 shields Plastic 17 By means of the cross screwdriver unscrew the 2 2 screws fixing the left and the right shields to the circuit breaker 18 Manually remove the left and the right shields ...

Page 10: ...ides of the sliding contacts block to the circuit breaker main structure 22 Move the sliding contacts block as shown in the picture and by means of the torx key unscrew the 6 screws fixing the base and the cover 21 Manually remove the 2 side walls 20 By means of the cross screwdriver unscrew the 1 1 screws fixing the 2 sides walls located at both sides of the sliding contacts block to the circuit ...

Page 11: ...ding contacts block 26 Manually remove the 2 springs located at both sides of the sdling contacts block 28 By means of the flat screwdriver unhook the right side wall from the sliding contacts main assembly as indicated in the picture 24 By means of the flat screwdriver push up the 3 flat cables assemblies and the connector cables assembly 23 Manually remove the base and the cover ...

Page 12: ...hem 32 By means of the cutter start removing the sliding contacts label located on the on the right side wall and manually complete the operation 34 Lift the sliding contacts base and let the 2 bars mounted inside exit 29 By means of the flat screwdriver unhook the right side wall from the sliding contacts main assembly as indicated in the picture 30 By means of the flat screwdriver unhook the rig...

Page 13: ...l Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 sliding contacts label Adhesive paper 3 flat cables assemblies Plastic and Metal SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 connector cables assembly Plastic and Metal SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 2 bars Metal 4 pins and related nuts Metal...

Page 14: ...s of the torx key unscrew the 2 screws fixing the Ekip measuring blind plug to the Ekip measuring blind case 41 Manually remove the printed circuit board 38 By means of the cutter start removing the label located on the Ekip measuring blind module and by means of the pliers complete the removal operation 40 Manually remove the Ekip measuring blind case 37 By means of the flat screwdriver unhook th...

Page 15: ...ip unit 47 By means of the flat screwdriver push the black connector as indicated by the arrow until it s totally unhooked and after manually complete the removal of the trip unit from the circuit breaker main structure 43 By means of the cross screwdriver unscrew the 4 screws fixing the trip unit to the circuit breaker main structure 42 By means of the flat screwdriver unhook the white connector ...

Page 16: ...ated by the arrow and by means of the pliers remove the rating plug printed circuit board 51 By means of the flat screwdriver remove the rating plug from the trip unit 53 By means of the cutter start removing the label located on the front of the rating plug case and by means of the pliers complete the operation 49 Manually remove the plug 48 By means of the torx key unscrew the screw fixing the p...

Page 17: ...driver unhook the display from the trip unit main structure 57 By means of the torx key unscrew the screw fixing the display to the trip unit main structure 59 Manually remove the display from the trip unit main structure 55 Manually remove the Ekip signaling 4K plug from the trip unit main structure 54 By means of the torx key unscrew the 2 screws fixing the Ekip signalling 4K plug to the trip un...

Page 18: ...he flat screwdriver unhook the HMI box from the display 65 Manually separate the display and the HMI LCD cover 61 By means of the flat screwdriver remove the battery cover on the left side of the display 60 By means of the cutter start removing the trip unit front label and by means of the pliers complete the operation ...

Page 19: ...t board from the display support 70 Manually separate the display from its printed circuit board 69 Manually remove the display support 71 Manually separate the gasket from the display 67 Manually remove the battery gasket 66 By means of the flat screwdriver remove the i TEST pushbutton from the HMI LCD cover ...

Page 20: ...the trip unit back cover 75 By means of the cutter start removing the blind label located on the side of the trip unit main structure and by means of the pliers complete the operation 77 Manually remove the release case from the cover 73 Manually complete the removal operation of the backplane 72 By means of the torx key unscrew the 4 screws fixing the backplane to the trip unit main structure ...

Page 21: ...g label Adhesive paper 1 Ekip signalling 4K plug Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 trip unit front label Adhesive paper 1 battery cover Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 battery Battery SEPARATE TREATMENT Battery 1 HMI box Plastic 1 HMI LCD cover Plastic 1 i Test pushbutton Rubber 1 battery gasket Rub...

Page 22: ...ure 85 By means of the torx key unscrew the 2 screws fixing the 4 micro I O assembly to the circuit breaker main structure 82 Manually unhook the connector indicated by the arrow fixing the terminal box case to the circuit breaker main structure 84 Insert the flat screwdriver as indicated in the picture slightly push it in the direction indicated by the arrow and after complete the removal of the ...

Page 23: ...e 3 screws fixing the terminal box case to the circuit breaker main structure 91 Manually pull and remove the connector located in the right part of the terminal box case 87 By means of the flat screwdriver separate the 4 micro I O assembly cover from the 4 micro I O assembly base 86 Push the flat srewdriver in the direction indicated by the arrow and after manually remove the microswitch assembly...

Page 24: ...p 95 Manually remove the I O shaft group 97 By means of the flat screwdriver remove the benzing mounted on the I O shaft group 93 By means of the flat screwdriver push the 2 connectors as indicated by the arrow and after manually complete the removal 92 By means of the flat screwdriver unhook the 2 microswitches from their support and after separate the microswitches support from the rest of the c...

Page 25: ...contacts Plastic and Metal SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 2 connectors Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 connector with 2 microswitches Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 microswtiches support Plastic 1 spring Metal 1 benzing Metal 1 pin Metal 1 I O shaft Plast...

Page 26: ...he cable guide to the circuit breaker main structure 104 By means of the flat screwdriver unhook the flap from the cable guide and complete the removal of the cable guide 101 By means of the torx key unscrew the 2 screws fixing the cable guide to the circuit breaker main structure 103 Manually unhook the connector fixing the cable guide to the circuit breaker main structure 100 Manually remove the...

Page 27: ...f the flat screwdriver remove the clip and after manually complete the removal Disassembled parts 1 2 1 screws Metal 1 left MID Plastic and Metal SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 cable guide Plastic 1 clip Plastic ...

Page 28: ...onnect by gravity 111 Manually remove the cover 108 By means of the allen key unscrew the screw locatedinthefrontpartofthecircuitbreakerfixing the CD to the circuit breaker main structure 110 By means of the cross screwdriver unscrew the 2 screws fixing the cover to the CD 107 By means of the allen key unscrew the screw locatedinthefrontpartofthecircuitbreaker fixing the CD to the circuit breaker ...

Page 29: ...e CD main structure 116 Manually remove the position indicator 115 Manually remove the front of the CD 117 Manually remove the screw group 113 By means of the flat screwdriver push the pin as indicated by the arrow and let the spring and the CD block cover separate from the cover 112 By means of flat screwdriver remove the benzing ...

Page 30: ...g and let the pin and the CD block lever separate from the CD base 119 by means of the pliers remove the spring and let the pin and the CD block lever separate from the CD base 118 By means of the flat screwdriver remove the benzing and after manually remove the feeler ...

Page 31: ... CD Plastic and Metal SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 position indicator Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 screw group Metal 1 1 benzings Metal 1 feeler Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 pin Metal 1 CD block lever Plastic SEPARATE TREATMENT Thermoplastics con...

Page 32: ...ure 124 By means of the cross screwdriver unscrew the screw fixing the releases door to the MID main structure 126 By means of the pliers unhook and remove the spring indicated by the arrow mounted on the MID main structure 123 Manually remove the MID 125 Manually remove the releases door 122 By means of the cross screwdriver unscrew the 2 screws fixing the MID to the circuit breaker main structur...

Page 33: ...nually and by gravity remove the parts 6 pins 2 springs 2 metal parts and 3 plastic parts from the MID main structure 132 By means of the flat screwdriver remove the 2 pins 128 By means of the pliers unhook and remove the spring indicated by the arrow mounted on the MID main structure 127 By means of the pliers unhook and remove the spring indicated by the arrow mounted on the MID main structure ...

Page 34: ...parate 137 Let fall by gravity the mechanical reset anchor 136 By means of the pliers unhook the spring and let the spring and the MID reset lever fall by gravity 138 Manually remove the microswitch 134 By means of the flat screwdriver remove the 2 benzings mounted on the assembly mounted on the MID main structure 133 Manually remove the assembly mounted on the MID main structure ...

Page 35: ...s of the torx key size 8 unscrew the screw fixing the flat cover to the MID main structure 144 By means of the flat screwdriver unhook as indicated by the arrowthe flat cover from the MID main structure 140 By means of the torx key size 6 unscrew the 2 screws fixing the trip coil support base to the trip coil cover 139 By means of the flat screwdriver slightly lift up the appendix as indicated by ...

Page 36: ...nd the SA lever 148 By means of the flat screwdriver remove the benzing 150 By means of the flat screwdriver push the pin as indicated by the arrow and after by means of the pliers remove the pin the RTC micro lever will fall by gravity 146 Manually remove the flat cover 145 By means of the flat screwdriver unhook as indicated by the arrow the flat cover from the MID main structure ...

Page 37: ...reset anchor Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 microswitch Plastic and Metal 1 trip coil support base Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 trip coil cover Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 trip coil Plastic Metal and Magnets SEPARATE TREATMENT Magnets 1 fl...

Page 38: ...d after manually remove it 154 By means of the torx key unscrew the 2 screws fixing the docking support to the right shoulder and after manually remove it 156 Manually remove the right support from the right shoulder 153 Manually remove the left support from the left shoulder 155 By means of the torx key unscrew the 2 screws fixing the right support to the right shoulder 152 By means of the torx k...

Page 39: ...crews fixing the spacers to the circuit breaker main structure 162 By means of the torx key unscrew the 4 screws fixing the left shoulder to the circuit breaker main structure 158 By means of the torx key unscrew the 3 screws fixing the motor fixing plate and the support mounted in the bottom part of the circuit breaker main structure and after manually remove the motor fixing plate and the suppor...

Page 40: ... the picture and slightly push it down and after manually remove the right shoulder 163 Manually remove the left shoulder from the circuit breaker main structure 165 By means of the torx key unscrew the 4 screws fixing the right shoulder to the circuit breaker main structure 167 By means of the cutter start removing the label located on the right shoulder and manually complete the operation ...

Page 41: ...MAX 2 E4 2 Disassembled parts 2 2 2 2 3 2 2 4 4 screws Metal 2 docking supports Plastic 2 supports Metal 1 assembly shaft Metal 1 motor fixing plate Metal 1 support Metal 2 spacers Metal 2 shoulders Metal 3 1 labels Adhesive paper ...

Page 42: ...m 171 Manually remove the upper cross beam 173 Manually remove the 2 blocks 170 By means of the torx key unscrew the 6 screws fixing the upper cross beam to the circuit breaker main structure 172 By means of the cross screwdriver unscrew the 1 1 screws fixing the 2 blocks to the upper cross beam 169 Manually remove the setting plate Cross screwdriver Torx key No 30 Flat screwdriver ...

Page 43: ...nism 178 By means of the flat screwdriver remove the 2 benzings 177 Unhook the 2 levers from the operating mechanism 179 By means of the flat screwdriver remove the benzing 175 Manually remove the mechanical release 174 By means of the cross screwdriver unscrew the 2 screws fixing the mechanical release to the circuit breaker main structure ...

Page 44: ...y the arrow and after unhook the opening springs group 183 By means of the flat screwdriver remove the benzing 185 Lift the operating mechanism and by means of the flat screwdriver unhook and remove the lever 181 Manually remove the springs charging lever from the circuit breaker main structure and the spring behind the springs charging lever 180 Manually remove the pin and the nut ...

Page 45: ...ng mechanism towards the upper part of the circuit breaker main structure 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 46: ...mechanical release Metal 2 1 1 1 1 1 benzings Metal 1 1 1 pins Metal 1 nut Metal 1 1 levers Metal 1 spring Metal 1 springs charging lever Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 operating mechanism Plastic and Metal SEPARATE TREATMENT Thermoplastics containing brominated flame retardants ...

Page 47: ...oss screwdriver unscrew the screw fixing the auxiliary contacts cam to the operating shaft assembly 194 By means of the cross screwdriver unscrew the screw fixing the cam to the operating shaft assembly 191 Manually remove the operating shaft assembly 193 Manually remove the auxiliary contacts cam 190 Manually lift the operating shaft assembly and by means of the flat screwdriver remove the 3 pins...

Page 48: ...48 INSTRUCTION HANDBOOK 195 Manually remove the cam 197 Manually remove the lever 196 By means of 2 flat screwdrivers remove the benzing ...

Page 49: ...uxiliary contacts cam Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 cam Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 lever Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 operating shaft assembly Metal ...

Page 50: ...e removal 203 By means of the scissors cut the cables coming out from the poles and after separate the 3 poles 200 By means of the rod push as indicated by the arrow the 2 tie rods 202 By means of the flat screwdriver unscrew the screws fixing the 3 wires connecting the measuring module connector to the sensors mounted inside the poles 199 Manually remove the operating mechanism fixing plate and t...

Page 51: ...ixing plate metal 1 lower cross beam 2 tie rods Metal 1 measuring module connector Plastic and Metal SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 cables set Plastic and Metal 3 poles Plastic and Metal Poles will be furtherly disassembled see Phases 6 12 6 13 and 6 14 ...

Page 52: ...x key size 40 unscrew the 6 screws fixing the terminals and their protections to the pole 206 Manually separate the terminals and their protections 205 Manually remove the terminals and their protections Torx key No 40 Disassembly operations illustrated at pictures 204 205 and 206 must be performed on the other 2 poles ...

Page 53: ...53 Disassembly instruction EMAX 2 E4 2 Disassembled parts 18 screws Metal 6 terminals Metal 6 protections Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants ...

Page 54: ...e terminals and their protections 208 Manually remove the terminals and their protections Disassembly operations illustrated at pictures 207 208 and 209 must be performed on the other 2 poles Circuit breakers in IEC version characterized by a current rating up to 3200A show differences at level of parts involved in this disassembly phase consequently here below an analogous section is provided for...

Page 55: ...55 Disassembly instruction EMAX 2 E4 2 18 screws Metal 6 terminals Metal 6 protections Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants Disassembled parts ...

Page 56: ...rews fixing the terminals and their protections to the pole 211 Push the claw contacts as indicated by the arrows and after manually remove the claw contacts 213 Manually remove the terminals from the pole Circuit breakers in UL version characterized by a current rating of 3200A show differences at level of parts involved in this disassembly phase consequently here below an analogous section is pr...

Page 57: ...om the pole Disassembly operations illustrated at pictures 210 214 must be performed on the other 2 poles 30 18 screws Metal 30 claw contacts Metal 6 terminals Metal 6 protections Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants Disassembled parts ...

Page 58: ...ntly here below an analogous section is provided for these circuit breakers 215 By means of the torx key size 15 unscrew the 10 screws fixing the claw contacts to the pole 217 Manually remove the spacers located below the claw contacts 216 Push the claw contacts as indicated by the arrows and after manually remove the claw contacts 218 By means of the torx key size 40 unscrew the 6 screws fixing t...

Page 59: ...claw contacts Metal 30 spacers Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 6 terminals Metal 6 protections Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants Disassembled parts 219 Manually remove the terminals and their protections 220 Manually separate the terminals and their protections ...

Page 60: ...hing and the plate from the arching chamber main structure operation to be repeated on the other side of the arching chamber main structure 223 By means of the flat screwdriver unhook the 2 appendices fixing the arc quenching and the plate to the arching chamber main structure 222 Manually remove the arching chamber 2 addititional screws must be unscrewed on circuit breakers with V breaking capaci...

Page 61: ... out from the arching chamber main structure 225 Manually separate the arc quenching and the plate 227 By means of the cross screwdriver unscrew the 6 screws fixing the arching chamber cover to the arching chamber main structure 228 Manually remove the arching chamber cover ...

Page 62: ...tal 6 arc quenchings Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 6 plates GP0 3 48 plates Metal 3 arching chambers covers Plastic 3 3 filters GP0 3 3 spacers Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 3 arching chambers shells Plastic Disassembled parts ...

Page 63: ... the flat screwdriver remove the cables cover and after manually remove the wire 235 Manually remove the sensor 232 By means of the torx key size 10 unscrew the screw fixing the wire to the pole 234 By means of the flat screwdriver unhook the sensor plug mounted below the sensor and after manually remove the sensor plug 231 Manually remove the sensor cover 4mm Flat screwdriver Hammer Cross screwdr...

Page 64: ...ng the pole cases 240 Manually remove the 4 plates 239 Manually complete the separation operation 241 Manually remove the bush 237 By means of the torx key size 25 unscrew the 3 screws located in the left side of the pole 236 Manually unhook the cable from the sensor ...

Page 65: ...lly remove the jumper 245 By means of the cross screwdriver unscrew the 2 screws fixing the jumper to the mobile contact assembly 247 By means of the flat screwdriver push the pin as indicated by the arrow 243 Manually remove the fixed contact 242 Manually remove the insulating protection ...

Page 66: ...251 Place the mobile contact assembly as shown in the picture and then by means of the hammer and of the rod push out the pin 253 Manually separate the mobile contact from its contacts holder 249 Manually unhook both appendixes of the insulation protection 248 Manually remove the pin and the tie rod ...

Page 67: ...67 Disassembly instruction EMAX 2 E4 2 256 Manually remove the 3 shoulders 255 Manually remove the 10 springs mounted on the contacts holder 254 Manually remove the contacts spacer ...

Page 68: ...containing brominated flame retardants 6 poles cases Plastic 12 plates Metal 3 bushes Plastic 3 insulating protections Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 3 fixed contacts Metal 3 jumpers Metal 6 pins Metal 3 tie rods Plastic 3 insulation protections Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 3 mobile contacts Metal...

Page 69: ...y instruction EMAX 2 E4 2 7 ENERGY CONSUMPTION FOR CIRCUIT BREAKERS DISASSEMBLY Since all disassembly operations illustrated in this document are manual the CO2 equivalent emissions can be considered null negligible ...

Page 70: ...70 INSTRUCTION HANDBOOK ...

Page 71: ...71 Disassembly instruction EMAX 2 E4 2 ...

Page 72: ...442 Copyright 2022 ABB All rights reserved Specifications subject to change without notice 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 ...

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ABB SACE Emax 2 E4.2, Instruction Handbook Manual

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