ABB SACE Emax 2 Manual

SACE Emax 2
DOC. N° 1SDH000999R0002 - ECN000297030
EN
EMAX E1.2 LOW VOLTAGE AIR CIRCUIT-BREAKERS
Sace Emax 2
Installation, operation and maintenance instructions for the instal-
ler and the user
Sace Emax 2 DOC. N° 1SDH000999R0002 - ECN000297030

ABB | SACE Emax 2ABB | SACE Emax 2
© 2022 ABB | 1SDH000999R0002 - ECN000297030

1SDH000999R0002 - ECN0002970301 | © 2022 ABB | SACE Emax 2
Contents
Glossary .................................................................................................3
Introduction ......................................................................................... 4
1 - Contents......................................................................................4
2 - Safety...........................................................................................5
3 - Regulations ................................................................................6
Management operations .....................................................................7
1 - Transport and checking on receipt........................................7
2 - Unpacking and handling........................................................10
3 - Description...............................................................................12
4 - Environmental conditions.................................................... 20
5 - Installation............................................................................... 20
Ekip Dip............................................................................................... 29
1 - General characteristics ......................................................... 29
2 - Operator interface ................................................................. 30
3 - Protections - Introduction.....................................................32
4 - List of alarms and signals .................................................... 38
5 - Default parameters ............................................................... 39
Accessories.........................................................................................40
1 - Overview................................................................................... 40
Putting into service and maintenance ............................................ 41
1 - Putting into service.................................................................41
2 - Identification of alarms or failures ..................................... 46
3 - Maintenance............................................................................ 50
4 - Decommissioning and treatment at end of life............... 50

2 | © 2022 ABB | SACE Emax 2 1SDH000999R0002 - ECN000297030

ABB | SACE Emax 2ABB | SACE Emax 2
Glossary3 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Glossary
Term Description
SACE Emax 2 New series of ABB SACE air circuit-breakers
CB Circuit-breaker
Trip unit Electronic unit connected to the CB, which provides measuring, monitoring and protection functions
for the CB if faulty operating conditions occur. In the event of an alarm, it commands a TRIP
Ekip Dip Trip unit SACE Emax 2 CBs, equipped with dip-switch type interface
Trip coil CB opening actuator controlled directly by Trip unit
TRIP
Concluding action of protection timing or a test command which, except in special configurations
applicable to the trip unit, coincides with activation of the trip coil, which instantly opens the bars of
each pole and interrupts the circulating current
Vaux Auxiliary power supply
4P / 3P / 3P + N CB configuration: four-pole (4P), three-pole (3P) and three-pole with external neutral (3P + N)
If Fault current measured by Trip unit, useful for calculating the trip time t t

ABB | SACE Emax 2
Introduction
1 - Contents
4 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Introduction
1 - Contents
Overview
This manual contains instructions on the operations to be performed on EMAX circuit-breakers E1.2
throughout their life cycle, from reception to installation, and from commissioning to subsequent
maintenance during operation, with particular attention to the environment at the end of the life cycle of
the product.
Reception Installation Commissioning Maintenance Disposal
Figure 1
Integrated informations
A full description of Emax 2 circuit-breakers is available in document 1SDH001330R1002 (Emax 2
engineering manual) available on the website ABB library.
IMPORTANT: all codes and documents mentioned in this document refer to Emax 2
configured with Trip unit Firmware version= 3.xx.
If the Firmware version of the Trip unit on the Emax 2 circuit-breaker =2.xx, consult
document 1SDH001330R0002 available on the website ABB library.
recipients
This manual refers to two user profiles, as defined by standard IEC 60050:
• Electrically Skilled Person (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.
• Trained Persons in the electrical field (IEV 195-04-02): person adequately advised or supervised
by electrically skilled persons to enable him or her to perceive risks and to avoid danger which
electricity can create.
IMPORTANT: This manual specifically indicates what operations can be performed by
people trained in the field of electricity. All the remaining operations described in the
handbook must be performed by skilled persons, in the electrical field. ABB declines all
liability for damage to persons or property caused by failure to comply with the instructions
in this document.
Specifications and supporting
documents
To ensure that the Emax 2 circuit-breaker is installed and configured correctly, please read the information
in this manual and in the technical documentation of the product, supplied with the circuit-breaker or
available in the website ABB liBRARy
Document Description
1SDH001330R1002 Manual for design engineers with full information about the trip units
and accessories for Emax 2
1SDH001316R1002 Manual of Ekip Touch trip units for Emax 2 circuit-breakers
1SDC200023D0906 Sace Emax 2 CBs General catalog
1SDM000091R0001 Sace Emax 2 CBs Circuit diagrams
1SDH001140R0001 Communication System Interface for Emax 2 CBs
Design notes
The information in this manual was written in Italian and then translated into other languages to conform
to the laws and/or commercial requirements concerning the product.

ABB | SACE Emax 2
Introduction
2 - Safety
5 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
2 - Safety
Warnings
HAZARD
ACCIDENTAL CONTACT WITH LIVE POINTS
CAN CAUSE SHOCK, BURNS AND RESULT
IN DEATH.
Do not try to use the product in any way, before having
read this instruction manual
Figure 2
The following warnings must be respected:
• READ THE INSTRUCTIONS CAREFULLY BEFORE TRYING TO INSTALL, OPERATE OR REPAIR THE
CIRCUIT BREAKER.
• Store these instructions along with other documents for instruction, maintenance and installation,
drawings and descriptive notes on the circuit-breaker.
• Keep these documents available during the installation, operation and maintenance of the appliance.
The use of these instructions facilitates proper maintenance.
• install the circuit-breaker within the limits of the project described in the instruction manual
shipped with the unit. These circuit-breakers are designed to operate with values of voltage and
current within the limits of plate ratings. Do not install this equipment in systems operating at
nominal values exceeding these limits.
• follow the safety procedures indicated by Your Company.
• Do not open any covers or doors, do not work on devices before removing power from all circuits,
and after making sure of that with a measuring instrument.
WARNING!
• Detailed descriptions of standard procedures for installation, use, maintenance and principles
for safe operation are not included. It is important to note that this document contains safety
instructions and caution against certain methods (installation, operation and maintenance) that
could cause injury to personnel, damage equipment, or make them unsafe.
• these warnings and alarms do not include all the conceivable methods of performing the installation,
operation and maintenance operations recommended by ABB and others, which could be performed,
or the possible consequences and complications of each conceivable method, neither will ABB
investigate all those methods.
• anyoneusingmaintenanceproceduresor devices,recommendedbyABB ornot,must check thoroughly
that neither personal safety nor the safety devices are endangered by mode of installation, use,
maintenance or the instruments used. For more information, questions or specific problems contact
your nearest ABB representative.
• This manual is written for qualified personnel only and is not intended as a substitute for a proper
course, or experience about safety procedures for this device.
• regarding products equipped with communication systems, the purchaser, installer or end customer
are responsible for applying all the IT security measures to prevent risks deriving from connection
to communication networks; among others, these risks include use of the product by unauthorized
persons, alteration of its normal operation, access to and modification of the information.
• the purchaser, installer or end customer are responsible for ensuring that safety warnings and
notices are affixed and moreover, that all points of access and operating devices are securely
blocked when the switchgear is left even momentarily unattended.
• all the information contained in this document reflects the latest product information available
at the time of printing. We reserve the right to edit the document at any time and without notice

ABB | SACE Emax 2
Introduction
3 - Regulations
6 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
3 - Regulations
Standards
The SACE Emax 2 circuit-breakers and their accessories comply with the following international standards:
• IEC 60947
• EN 60947
• CEI EN 60947
• IEC 61000
• UL 1066
They comply with the following EC directives:
• "Low Voltage Directives" (LVD) No. 2006/95/EC
• "Electromagnetic Compatibility Directive" (EMC) No. 2004/108/EC
The SACE Emax 2 circuit-breakers also feature a range certified according to these standards:
• Russian - GOST (Russia Certificate of Conformity)
• Chinese - China CCC (China Compulsory Certification)

ABB | SACE Emax 2
Management operations
1 - Transport and checking on receipt
7 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Management operations
1 - Transport and checking on receipt
Introduction
The SACE Emax 2 circuit-breakers, on account of their weight, require special attention during transport
and handling.
They are distributed with following packages:
• one package for fixed circuit-breaker
• two packages for withdrawable circuit-breakers (one package for the fixed part and one for the
mobile part).
WARNING! comply with the following instructions during each transport phase:
• The movable part of the circuit-breaker must be removed from the switchgear and/or
from the relative fixed part even if this latter is not installed in the switchgear.
• The circuit-breaker must be in the open position.
• The circuit-breaker must be protected and fastened in its original packing.
• The closing springs of the circuit-breaker must be completely discharged.
Weight of the circuit-breakers
with packaging
The following table specifies the weights of the circuit-breakers with packaging:
Fixed Moving part of withdra-
wable device
Fixed part of withdra-
wable device
III IV III IV III IV
E1.2 16 Kg / 35
lbs
18 Kg / 39
lbs
20 Kg / 44
lbs
23 Kg / 51
lbs
23 Kg / 51
lbs
26 Kg / 57
lbs
E1.2-A 16 Kg / 35
lbs
18 Kg / 39
lbs
22 Kg / 48
lbs
25.5 Kg / 56
lbs
24 Kg / 52
lbs
27 Kg / 59
lbs
NOTE:
•
weights are indicated with reference to the basic circuit-breakers including protection trip
unit and its sensors, without terminals and without accessories.
• the weights of the fixed part of withdrawable circuit-breakers refer to the version with
horizontal rear terminals.
Transport of the packaged
circuit-breaker
Consult the table "Weight of the circuit-breakers with packaging" before proceeding with the transport.
WARNING! improper lifting can result in death, serious injury to persons and damage to
the equipment. Never lift a circuit-breaker and/or a fixed part above other people.
IMPORTANT: The trained personnel in charge of handling and lifting must use appropriate
safety equipment.

ABB | SACE Emax 2
Management operations
1 - Transport and checking on receipt
8 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Identification of packaging
Examine the state of the packaging and check that:
• The data from the packaging nameplate match the data in the order.
• The box is intact and perfectly closed.
SACE EMAX E1.2 N 800
VERSION
FIXED
POL3
TERMINALS
REAR HORIZONTAL TERMINALS
WITH ASSEMBLED ACCESSORIES
YO 48V AC-DC
CODE
A.B.
FB.NR.
80156446401183
8031004035
1SDA055987R1
1130055770 001100
BB45005188
1
2
4
5
3
6
Designed by ABB SACE Division
Figure 3
Pos. Description
1Short description of the circuit-breaker
2Description of accessories
3Commercial code
4Confirmation number and location
5Circuit-breaker serial number
6Features of the circuit-breaker
Packaging checks
Examine the state of the material received and verify that:
• The circuit-breaker or the fixed part are consistent with the order.
• The circuit-breaker or the fixed part are completely intact.
IMPORTANT:
• check the material before any storage. For opening the packaging, follow the procedures
outlined in the section "Unpacking and handling - opening the packages" on page 10
• in the case of inconsistencies report it within five days of receipt. See the paragraph
"Damage and Discrepancy Report" in this chapter.
Damage and Discrepancy
Report
If there is any damage to the packaging upon receipt and / or inconsistencies between order and product
identification label or product please contact ABB. Damage to the packaging must be reported no later
than seven days from receipt of the material.
NOTE: The notification must indicate the Packing List number.

ABB | SACE Emax 2
Management operations
1 - Transport and checking on receipt
9 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Storage method
Place the packaging (circuit-breakers and / or fixed parts) on a horizontal plane, not in contact with the
floor. If the circuit-breaker has been removed and reinserted in the package ensure, prior to storage that:
• the circuit-breaker is in the open position and springs discharged. See the chapter "Description
- circuit-breaker opening/closing operations" on page 15
• the circuit-breaker is protected and locked in its original packaging
Figure 4

ABB | SACE Emax 2
Management operations
2 - Unpacking and handling
10 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
2 - Unpacking and handling
Opening the packaging
NOTE: to unpack the circuit-breaker safely refer to the instruction sheet in the zipped
packaging pouch.
The following is the procedure for opening the packaging:
1. Cut the tape that seals the box. See Figure 5 and Figure 6.
Figure 5 Figure 6
2. Open the upper part of the packing box and remove the upper containment protection. See Figure
7 and Figure 8.
Figure 7 Figure 8
Continued on the next page

ABB | SACE Emax 2
Management operations
2 - Unpacking and handling
11 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Continued from the previous page
3. Remove the side containment protections from the packing box. See Figure 9.
Figure 9
Weight of circuit-breakers
without packaging
The following table specifies the weights of the circuit-breakers without packaging:
Fixed Moving part of withdra-
wable device
Fixed part of withdra-
wable device
III IV III IV III IV
E1.2 14 Kg / 31 lbs 16 Kg / 35
lbs
18 Kg / 40
lbs
20 Kg / 44
lbs
20 Kg / 44
lbs
23 Kg / 51
lbs
E1.2-A 14 Kg / 31 lbs 16 Kg / 35
lbs
20 Kg / 44
lbs
22.5 Kg / 49
lbs
21 Kg / 46
lbs
24 Kg / 52
lbs
Disposal of packing materials
For disposal of the packaging materials see the chapter " 4 - Decommissioning and treatment at end of
life " on page 50.

ABB | SACE Emax 2
Management operations
3 - Description
12 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
3 - Description
Description of circuit-breaker
Emax E1.2 circuit-breakers consist of a structure containing the poles, the operating mechanism and the
auxiliary parts. Each pole, enclosed in a plastic box, consists of a breaking part and a current transformer.
The circuit-breaker is available in two types:
• fixed version
• withdrawable
The circuit-breaker in fixed version (see Figure 10) has its own terminals for connection to the power
circuit.
The withdrawable circuit breaker consists of a mobile part (see Figure 11 for IEC and Figure 12 for UL) and
of a fixed part (see Figure 13 for IEC and Figure 14 for UL) for connection through its own terminals to the
power circuit.
The coupling between the mobile part and the fixed part is via disconnection contacts mounted on the
fixed part.
Figure 10 Figure 11
Figure 12 Figure 13
Figure 14

ABB | SACE Emax 2
Management operations
3 - Description
13 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Description of the circuit-
breaker front panel
The following are the main components of the circuit-breaker:
1
3
4
5
6
7
8
9
2
Figure 15
Pos. Description
1Lever for manually charging the closing springs
2SACE Ekip protection trip unit
3Name of the circuit-breaker
4CB open (O) / closed (I) indicator
5Closing pushbutton
6Opening pushbutton
7Mechanical signalling of tripped TU
8Springs charged-discharged signalling device
9Electrical data plate
Description of electrical data
plate IEC
1 2 3 4
5
9
8
7
6
10
11
12
Uimp 12Kv
Figure 16
Pos. Description
1Type of circuit-breaker
2Utilization category
3Device type: Circuit-breaker or switch-disconnector
4Rated current
5Rated operating frequency
6Admissible rated short-time current
7Rated duty short-circuit breaking capacity
8Rated ultimate short-circuit breaking capacity
9Rated service voltage
10 Standards
11 Circuit-breaker serial number
12 Impulse voltage
Continued on the next page

ABB | SACE Emax 2
Management operations
3 - Description
14 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Description of electrical data
plate UL 12
3
7
6
5
4
8
SACE E1.2S- Iu 1200A
S/ N: 000000000000000 ABB SA CE Made in Italy
FXXXXXXXXXX
ANSI C37.13 -UL106650-60Hz
RatedMaximum Volt age(V) 254 635
RatedShort-Circuit(kA) 66 42
ShortTime(kA)
508
66
Low-VoltageAC
PowerCircuit Br aker 63FA
42
A
Figure 17
Pos. Description
1Type of circuit-breaker
2Rated current
3Rated operating frequency
4Admissible rated short-time current
5Rated short-circuit breaking capacity
6Rated service voltage
7Standards
8Circuit-breaker serial number

ABB | SACE Emax 2
Management operations
3 - Description
15 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Manual operations for opening
and closing the circuit-breaker
The following is the sequence of steps for closing and opening the circuit-breaker:
1. Check that the circuit-breaker is open (open / closed indicator "O - OPEN"), and check that the
springs are discharged (spring signalling device "white - DISCHARGED SPRING") as indicated in
Figure 18.
2. Charging the springs - Pull the lever [A] downwards several times until the springs charged
signalling device [B] is “yellow - CHARGED SPRING” as indicated in Figure 19.
Figure 18
AB
Figure 19
3. Check that the circuit-breaker is open (open/closed signalling device “O - OPEN”), and check that
the springs are charged (springs signalling device “yellow - CHARGED SPRING”) as indicated in
Figure 20.
4. Closing - Press the closing pushbutton “I - Push ON” as indicated in Figure 21.
Figure 20 Figure 21
5. Check that the circuit-breaker is closed (open/closed indicator "I - CLOSED"), and check that the
springs are discharged (spring signalling device "white - DISCHARGED SPRING" as indicated in
Figure 22.
6. Opening - Press the opening pushbutton “O - Push OFF” as indicated in Figure 23.
Figure 22 Figure 23
Continued on the next page

ABB | SACE Emax 2
Management operations
3 - Description
16 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Continued from the previous page
7. Check that the circuit-breaker is open (open / closed indicator "O - OPEN"), and check that the
springs are discharged (spring signalling device "white - DISCHARGED SPRING") as indicated in
Figure 24.
Figure 24
Mechanical status indicators
The following are the possible states in which you can find the circuit-breaker:
1. Circuit-breaker open with springs discharged (see Figure 25).
2. Circuit-breaker open with springs charged (see Figure 26).
3. Circuit-breaker closed with springs discharged (see Figure 27).
4. Circuit-breaker closed with springs charged (see Figure 28). This state occurs when after closing
(see step 4 - Figure 28) the springs are recharged manually or automatically by the gearmotor (if
provided).
Figure 25 Figure 26 Figure 27
Figure 28

ABB | SACE Emax 2
Management operations
3 - Description
17 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Circuit breaker racking-in/
racking-out operations
The following is the procedure for the insertion of the moving part in the fixed part:
WARNING!
• Make sure the circuit-breaker is disconnected from all sources of energy.
• Switch the circuit-breaker to the open position with springs discharged.
WARNING! Before proceeding, remove all equipment used during the work and remove
processing waste and materials used.
1. Turn plate through 90° before inserting the moving part.
“CLICK”
Figure 29
2. Make sure that signalling device on the fixed part indicates the DISCONNECT position. See Figure
30.
Figure 30
3. Position the moving part in the fixed part and push until it comes to a stop. See Figure 31 and
Figure 32.
Figure 31 Figure 32
Continued on the next page

ABB | SACE Emax 2
Management operations
3 - Description
18 | © 2022 ABB | 1SDH000999R0002 - ECN000297030
Continued from the previous page
4. Extract the disconnection crank from its housing See Figure 33.
5. Press the lock pushbutton and fit the handle into the moving part. In this phase, the moving part
will still be in the DISCONNECT position. See Figure 34.
Figure 33
2
1
Figure 34
6. Keep breaker pushed. Turn the crank clockwise until the pushbutton comes out and the indicator
shows that the circuit-breaker is in TEST position. See Figure 35.
2
1
Figure 35
7. Press the lock button and then rotate the crank clockwise until the button comes out and the
indicator shows that the circuit-breaker is in the CONNECT position. See Figure 36.
2
1
Figure 36
Continued on the next page