ABB SACE Emax 2 E6.2, Instruction Handbook Manual

Page 1: ... INSTRUCTION HANDBOOK 1SDH002306A1001 ECN000285442 EMAX 2 E6 2 Disassembly instructions ...

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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: ...ed 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 terminal box 1 Left MID On the left p...

Page 5: ...D 1 Trip coil Mounted in the MID 1 Flat cover Mounted on the MID 1 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 operatin...

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

Page 7: ...et assembly 10 By means of the flat screwdriver remove the 2 benzings mounted on the T U Reset assembly 11 By means of the flat screwdriver push the pin as indicated by the arrow and after let the the spring and the T U Reset signalling plug automatically separate from the T U Reset metal support 12 By means of the torx key remove the 2 screws fixing the plug to the circuit breaker front cover ...

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: ...nstruction EMAX 2 E6 2 17 By means of the cross screwdriver unscrew the 4 4 4 screws fixing the left and the right shields to the circuit breaker 18 Manually remove the left shields 19 Manually remove the right shield ...

Page 10: ...tal 1 racking in and out lever Plastic and Metal 4 2 2 2 2 1 4 4 4 screws Metal 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 3 shields Plastic ...

Page 11: ...h sides of the sliding contacts block to the circuit breaker main structure 23 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 22 Manually remove the 2 side walls 21 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 circu...

Page 12: ...embly 24 Manually remove the base and the cover 28 Manually remove the auxiliary position contacts cap located on the left side of the sliding contacts block 27 Manually remove the 2 springs located at both sides of the sdling contacts block 29 By means of the flat screwdriver unhook the right side wall from the sliding contacts main assembly as indicated in the picture ...

Page 13: ...lling them 33 By means of the cutter start removing the sliding contacts label located on the on the right side wall and manually complete the operation 35 Lift the sliding contacts base and let the 2 bars mounted inside exit 30 By means of the flat screwdriver unhook the right side wall from the sliding contacts main assembly as indicated in the picture 31 By means of the flat screwdriver unhook ...

Page 14: ...ic 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 1 slid...

Page 15: ...By means of the torx key unscrew the 2 screws fixing the Ekip measuring blind plug to the Ekip measuring blind case 42 Manually remove the printed circuit board 39 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 41 Manually remove the Ekip measuring blind case 38 By means of the flat screwdriver un...

Page 16: ... 48 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 44 By means of the cross screwdriver unscrew the 4 screws fixing the trip unit to the circuit breaker main structure 43 By means of the flat screwdriver unhook the white connector located...

Page 17: ...as indicated by the arrow and by means of the pliers remove the rating plug printed circuit board 52 By means of the flat screwdriver remove the rating plug from the trip unit 54 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 50 Manually remove the plug 49 By means of the torx key unscrew the screw fixi...

Page 18: ...nhook the display from the trip unit main structure 58 By means of the torx key unscrew the screw fixing the display to the trip unit main structure 60 Manually remove the display from the trip unit main structure 56 Manually remove the Ekip signaling 4K plug from the trip unit main structure 55 By means of the torx key unscrew the 2 screws fixing the Ekip signalling 4K plug to the trip unit main ...

Page 19: ...ans of the flat screwdriver unhook the HMI box from the display 66 Manually separate the display and the HMI LCD cover 62 By means of the flat screwdriver remove the battery cover on the left side of the display 61 By means of the cutter start removing the trip unit front label and by means of the pliers complete the operation ...

Page 20: ...from the display support 71 Manually separate the display from its printed circuit board 70 Manually remove the display support 72 Manually separate the gasket from the display 68 Manually remove the battery gasket 67 By means of the flat screwdriver remove the i TEST pushbutton from the HMI LCD cover ...

Page 21: ...e from the trip unit back cover 76 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 78 Manually remove the release case from the cover 74 Manually complete the removal operation of the backplane 73 By means of the torx key unscrew the 4 screws fixing the backplane to the trip unit main struct...

Page 22: ...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 Rubber 1 di...

Page 23: ...n structure 86 By means of the torx key unscrew the 2 screws fixing the 4 micro I O assembly to the circuit breaker main structure 83 Manually unhook the connector indicated by the arrow fixing the terminal box case to the circuit breaker main structure 85 Insert the flat screwdriver as indicated in the picture slightly push it in the direction indicated by the arrow and after complete the removal...

Page 24: ...ews fixing the terminal box case to the circuit breaker main structure 92 Manually pull and remove the connector located in the right part of the terminal box case 88 By means of the flat screwdriver separate the 4 micro I O assembly cover from the 4 micro I O assembly base 87 Push the flat srewdriver in the direction indicated by the arrow and after manually remove the microswitch assembly ...

Page 25: ...aft group 96 Manually remove the I O shaft group 98 By means of the flat screwdriver remove the benzing mounted on the I O shaft group 94 By means of the flat screwdriver push the 2 connectors as indicated by the arrow and after manually complete the removal 93 By means of the flat screwdriver unhook the 2 microswitches from their support and after separate the microswitches support from the rest ...

Page 26: ... 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 Plastic SEPAR...

Page 27: ...rew fixing the cable guide to the circuit breaker main structure 105 By means of the flat screwdriver unhook the flap from the cable guide and complete the removal of the cable guide 102 By means of the torx key unscrew the 2 screws fixing the cable guide to the circuit breaker main structure 104 Manually unhook the connector fixing the cable guide to the circuit breaker main structure 101 Manuall...

Page 28: ...circuit breaker main structure 109 By means of the torx key unscrew the 4 screws fixing the CS adapter printed circuit board from the CS adapter 111 Manually remove the CS adapter printed circuit board 107 By means of the allen key unscrew the 2 screws fixing the CS adapter to the circuit breaker main structure 106 By means of the flat screwdriver remove the 2 clips and after manually complete the...

Page 29: ...29 Disassembly instruction EMAX 2 E6 2 114 By means of the flat screwdriver remove the 3 clips 113 Manually unhook the cables from the clips 112 Manually pull and remove the wiring cables set ...

Page 30: ...de Plastic 2 3 clips Plastic 1 CS adapter box Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 1 CS adapter printed circuit board Plastic Metal and Electronic components SEPARATE TREATMENT Printed circuit board 1 wiring cables set Plastic and Metal 1 CS adapter cover Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants ...

Page 31: ...CD disconnect by gravity 120 Manually remove the cover 117 By means of the allen key unscrew the screw locatedinthefrontpartofthecircuitbreakerfixing the CD to the circuit breaker main structure 119 By means of the cross screwdriver unscrew the 2 screws fixing the cover to the CD 116 By means of the allen key unscrew the screw locatedinthefrontpartofthecircuitbreaker fixing the CD to the circuit b...

Page 32: ...n structure 125 Manually remove the position indicator 124 Manually remove the front of the CD 126 Manually remove the screw group 122 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 121 By means of flat screwdriver remove the benzing ...

Page 33: ...e spring and let the pin and the CD block lever separate from the CD base 128 By means of the pliers remove the spring and let the pin and the CD block lever separate from the CD base 127 By means of the flat screwdriver remove the benzing and after manually remove the feeler ...

Page 34: ...stic 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 containing...

Page 35: ...n structure 133 By means of the cross screwdriver unscrew the screw fixing the releases door to the MID main structure 132 Manually remove the MID 135 By means of the pliers unhook and remove the spring indicated by the arrow mounted on the MID main structure 134 Manually remove the releases door 131 By means of the cross screwdriver unscrew the 2 screws fixing the MID to the circuit breaker main ...

Page 36: ...nd by gravity remove the parts 6 pins 2 springs 2 metal parts and 3 plastic parts from the MID main structure 141 By means of the flat screwdriver remove the 2 pins 137 By means of the pliers unhook and remove the spring indicated by the arrow mounted on the MID main structure 136 By means of the pliers unhook and remove the spring indicated by the arrow mounted on the MID main structure ...

Page 37: ...part separate 146 Let fall by gravity the mechanical reset anchor 145 By means of the pliers unhook the spring and let the spring and the MID reset lever fall by gravity 147 Manually remove the microswitch 143 By means of the flat screwdriver remove the 2 benzings mounted on the assembly mounted on the MID main structure 142 Manually remove the assembly mounted on the MID main structure ...

Page 38: ... torx key size 8 unscrew the screw fixing the flat cover to the MID main structure 153 By means of the flat screwdriver unhook as indicated by the arrowthe flat cover from the MID main structure 149 By means of the torx key size 6 unscrew the 2 screws fixing the trip coil support base to the trip coil cover 148 By means of the flat screwdriver slightly lift up the appendix as indicated by the arro...

Page 39: ...he pin and the SA lever 157 By means of the flat screwdriver remove the benzing 159 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 155 Manually remove the flat cover 154 By means of the flat screwdriver unhook as indicated by the arrow the flat cover from the MID main structure ...

Page 40: ...chor 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 flat cover...

Page 41: ...after manually remove it 163 By means of the torx key unscrew the 2 screws fixing the docking support to the right shoulder and after manually remove it 165 Manually remove the right support from the right shoulder 162 Manually remove the left support from the left shoulder 164 By means of the torx key unscrew the 2 screws fixing the right support to the right shoulder 161 By means of the torx key...

Page 42: ...breaker main structure 169 Manually remove the left support 167 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 support 166 Manually remove the assembly shaft ...

Page 43: ...171 manually remove the right support 173 Manually remove the spacer 175 Manually remove the left shoulder from the circuit breaker main structure 172 By means of the torx key unscrew the screw fixing the spacer to the circuit breaker main structure 174 By means of the torx key unscrew the 4 screws fixing the left shoulder to the circuit breaker main structure ...

Page 44: ...rt the flat screwdriver as indicated in the picture and slightly push it down and after manually remove the right shoulder 177 By means of the torx key unscrew the 4 screws fixing the right shoulder to the circuit breaker main structure 179 By means of the cutter start removing the label located on the right shoulder and manually complete the operation ...

Page 45: ...X 2 E6 2 Disassembled parts 2 2 2 2 3 3 2 1 4 4 screws Metal 2 docking supports Plastic 2 2 supports Metal 1 assembly shaft Metal 1 motor fixing plate Metal 1 support Metal 1 spacer Metal 2 shoulders Metal 3 1 labels Adhesive paper ...

Page 46: ...ng plate to the upper cross beam 182 By means of the torx key unscrew the 12 screws fixing the upper cross beam to the circuit breaker main structure 183 By means of the torx key unscrew the 2 screws fixing the upper cross beam to the circuit breaker main structure 181 Manually remove the setting plate Cross screwdriver Torx key No 30 Flat screwdriver ...

Page 47: ... the cross screwdriver unscrew the 3 screws fixing the 3 blocks to the upper cross beam and after let them fall down by gravity 186 By means of the cross screwdriver unscrew the 2 screws fixing the mechanical release to the circuit breaker main structure 187 Manually remove the mechanical release ...

Page 48: ...crewdriver remove the 2 benzings 192 Manually remove the pin and the nut 189 Unhook the 2 levers from the operating mechanism 191 By means of the flat screwdriver remove the benzing 193 Manually remove the springs charging lever from the circuit breaker main structure and the spring behind the springs charging lever 192 Manually remove the pin and the nut ...

Page 49: ...ated by the arrow the pin and remove the pin 197 Lift the operating mechanism and by means of the flat screwdriver unhook and remove the lever 199 Pull the operating mechanism towards the upper part of the circuit breaker main structure 194 By means of the flat screwdriver remove the benzing and let the pin and the lever separate by gravity 195 By means of the flat screwdriver remove the benzing ...

Page 50: ...y with the maximum level of attention during disassembly and dismantle phases Disassembled parts 4 12 2 3 2 screws Metal 1 setting plate Metal 1 upper cross beam Metal 3 blocks Rubber 1 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 retard...

Page 51: ...lat screwdriver 201 By means of the torx key unscrew the 2 screws fixing the 2 intermediate plates to the circuit breaker main structure 202 Manually lift the operating shaft assembly and by means of the flat screwdriver remove the 6 benzings 203 Manually lift the operating shaft assembly and by means of the flat screwdriver remove the 6 pins ...

Page 52: ... remove the auxiliary contacts cam 205 By means of the cross screwdriver unscrew the screw fixing the auxiliary contacts cam to the operating shaft assembly 207 By means of the cross screwdriver unscrew the screw fixing the cam to the operating shaft assembly 208 Manually remove the cam ...

Page 53: ...gs Metal 6 pins Metal 2 1 1 screws Metal 1 auxiliary 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 54: ...the operating mechanism fixing plate and the lower cross beam to the poles 212 Manually remove the operating mechanism fixing plate and the lower cross beam 214 Manually pull the 2 tie rods in order to complete the removal 213 By means of the rod push as indicated by the arrow the 2 tie rods Flat screwdriver Torx key Rod Ø5mm No 30 Min 200mm ...

Page 55: ...the sensors mounted inside the poles Poles will be furtherly disassembled see Phases 6 12 6 13 and 6 14 Disassembled parts 4 screws Metal 1 operating mechanism fixing plate metal 1 lower cross beam 2 tie rods Metal 1 measuring module connector Plastic and Metal SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 6 poles Plastic and Metal ...

Page 56: ...x key size 40 unscrew the 6 screws fixing the terminals and their protections to the pole 218 Manually separate the terminals and their protections 217 Manually remove the terminals and their protections Torx key No 40 Disassembly operations illustrated at pictures 216 217 and 218 must be performed on the other 5 poles ...

Page 57: ...57 Disassembly instruction EMAX 2 E6 2 Disassembled parts 36 screws Metal 12 terminals Metal 12 protections Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants ...

Page 58: ...means of the torx key size 40 unscrew the 6 screws fixing the terminals and their protections to the pole 220 Push the claw contacts as indicated by the arrows and after manually remove the claw contacts Circuit breakers in UL version characterized by a current rating up to 5000A show differences at level of parts involved in this disassembly phase consequently here below an analogous section is p...

Page 59: ...assembly operations illustrated at pictures 219 224 must be performed on the other 5 poles 60 36 screws Metal 60 claw contacts Metal 60 spacers Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 12 terminals Metal 12 protections Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants Disassembled parts ...

Page 60: ... arching chamber main structure operation to be repeated on the other side of the arching chamber main structure 227 By means of the flat screwdriver unhook the 2 appendices fixing the arc quenching and the plate to the arching chamber main structure 226 Manually remove the arching chamber 2 addititional screws must be unscrewed on circuit breakers in IEC version with H breaking capacity and on ci...

Page 61: ... out from the arching chamber main structure 229 Manually separate the arc quenching and the plate 231 By means of the cross screwdriver unscrew the 6 screws fixing the arching chamber cover to the arching chamber main structure 232 Manually remove the arching chamber cover ...

Page 62: ...al 12 arc quenchings Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 12 plates GP0 3 96 plates Metal 6 arching chambers covers Plastic 6 6 filters GP0 3 6 spacers Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 6 arching chambers shells Plastic Disassembled parts ...

Page 63: ... the flat screwdriver remove the cables cover and after manually remove the wire 239 Manually remove the sensor 236 By means of the torx key size 10 unscrew the screw fixing the wire to the pole 238 By means of the flat screwdriver unhook the sensor plug mounted below the sensor and after manually remove the sensor plug 235 Manually remove the sensor cover 4mm Flat screwdriver Hammer Cross screwdr...

Page 64: ...ng the pole cases 244 Manually remove the 4 plates 243 Manually complete the separation operation 245 Manually remove the bush 241 By means of the torx key size 25 unscrew the 3 screws located in the left side of the pole 240 Manually unhook the cable from the sensor ...

Page 65: ...lly remove the jumper 249 By means of the cross screwdriver unscrew the 2 screws fixing the jumper to the mobile contact assembly 251 By means of the flat screwdriver push the pin as indicated by the arrow 247 Manually remove the fixed contact 246 Manually remove the insulating protection ...

Page 66: ...255 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 257 Manually separate the mobile contact from its contacts holder 253 Manually unhook both appendixes of the insulation protection 252 Manually remove the pin and the tie rod ...

Page 67: ...67 Disassembly instruction EMAX 2 E6 2 260 Manually remove the 3 shoulders 259 Manually remove the 10 springs mounted on the contacts holder 258 Manually remove the contacts spacer ...

Page 68: ...containing brominated flame retardants 12 poles cases Plastic 24 plates Metal 6 bushes Plastic 6 insulating protections Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 6 fixed contacts Metal 6 jumpers Metal 12 pins Metal 6 tie rods Plastic 6 insulation protections Plastic SEPARATE TREATMENT Thermoplastics containing brominated flame retardants 6 mobile contacts Met...

Page 69: ...y instruction EMAX 2 E6 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 ...

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Page 72: ... 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 ...