ABB Emax VF Quick guide

Emax VF
Installation, service and maintenance
instructions for low voltage air
circuit-breakers
Installation and
service instructions
1SDH000909R0001 B2342

L5272 Emax
ABB SACE Doc. no.
Model Apparatus
Dwg. Title
App.
Resp. Off.
Take over Off.
Scale
Language
EN
1SDH000909R0001
Installation, service and maintenance
instructions for low voltage air
circuit-breakers
L5712
L6567
B2204

Index
1. Description . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. General characteristics . . . . . . . . . . . . . . . . . 5
1.2. External front view of the circuit-breaker . . . . . . . . 5
1.3. Rating plate . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.1. Circuit-breaker rating plate . . . . . . . . . . . . . . . 5
1.4. Moving part construction characteristics . . . . . . . . 6
1.5. Fixed part construction characteristics . . . . . . . . . 6
2. Checking on receipt . . . . . . . . . . . . . . . . . . . 7
3. Storage, lifting and weights . . . . . . . . . . . . . . . 7
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1. Installation room. . . . . . . . . . . . . . . . . . . . . 8
4.2. Installation of the fixed circuit-breaker . . . . . . . . . 8
4.3. Installation of the fixed part of the withdrawable circuit-
breaker . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.1. Preparation of the fixed part . . . . . . . . . . . . . . 8
4.3.2. Installation of the fixed part (Fig. 12) . . . . . . . . . . 9
4.4. Installation of the flange on the compartment door
(Fig. 13) . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. Electrical connections . . . . . . . . . . . . . . . . . 10
5.1. Connections to the power circuit . . . . . . . . . . . 10
5.1.1. Shapes of the terminals . . . . . . . . . . . . . . . . 10
5.1.2. Examples of positioning the connection busbars
according to the types of terminals . . . . . . . . . . 10
5.1.3. Assembly procedure for the connection busbars . . . 11
5.2. Earthing . . . . . . . . . . . . . . . . . . . . . . . . 11
5.3. Wiring the circuit-breaker auxiliary circuits . . . . . . 11
5.3.1. Interfacing elements for fixed circuit-breakers . . . . 11
5.3.2. Withdrawable circuit-breaker . . . . . . . . . . . . . 12
5.4. Conversion of the auxiliary contacts or of the signalling
contacts (disconnected - test isolated - connected), from
normally closed (opening) to normally open (closing) or
vice versa . . . . . . . . . . . . . . . . . . . . . . . 12
6. Putting into service . . . . . . . . . . . . . . . . . . 14
6.1. General procedures . . . . . . . . . . . . . . . . . . 14
7. Instructions for use . . . . . . . . . . . . . . . . . . 15
7.1. Operating and signalling parts . . . . . . . . . . . . 15
7.2. Circuit-breaker closing and opening procedures . . . 16
7.3. Racking-in/out operation . . . . . . . . . . . . . . . 17
8. Maintenance. . . . . . . . . . . . . . . . . . . . . . 19
8.1. Warning . . . . . . . . . . . . . . . . . . . . . . . . 19
8.2. Maintenance programme . . . . . . . . . . . . . . . 19
8.2.1. Circuit-breaker life . . . . . . . . . . . . . . . . . . . 19
8.2.2. Maintenance program . . . . . . . . . . . . . . . . . 19
8.3. First level maintenance operations . . . . . . . . . . 19
8.3.1. Preliminary operations: . . . . . . . . . . . . . . . . 19
8.3.2. Checks and general cleaning:. . . . . . . . . . . . . 19
8.3.3. Circuit-breaker connections and connections between
the circuit-breaker and the control panel . . . . . . . 20
8.3.4. Dismantling tab and cap . . . . . . . . . . . . . . . 20
8.3.5. Mechanical control . . . . . . . . . . . . . . . . . . 21
8.3.6. Electrical and mechanical accessories . . . . . . . . 21
8.3.7. Protection releases . . . . . . . . . . . . . . . . . . 21
8.3.8. Test with Ekip Connect (optional) . . . . . . . . . . . 21
8.3.9. Maintenance operations; final checks. . . . . . . . . 22
8.3.10. Interlock . . . . . . . . . . . . . . . . . . . . . . . . 22
8.4. Second level maintenance operations . . . . . . . . 22
8.4.1. Preliminary operations: . . . . . . . . . . . . . . . . 22
8.4.2. General checks and cleaning:. . . . . . . . . . . . . 22
8.4.3. Connections between the circuit-breaker and the control
panel. . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4.4. Dismantling the tab, cap and arcing chambers . . . . 23
8.4.5. Mechanical control . . . . . . . . . . . . . . . . . . 24
8.4.6. Electrical and mechanical accessories . . . . . . . . 24
8.4.7. Checking contact wear . . . . . . . . . . . . . . . . 25
8.4.8. Protection releases . . . . . . . . . . . . . . . . . . 25
8.4.9. Test with Ekip Connect (optional) . . . . . . . . . . . 25
8.4.10. Maintenance operations; final checks: . . . . . . . . 26
8.4.11. Interlock . . . . . . . . . . . . . . . . . . . . . . . . 26
8.4.12. Withdrawable . . . . . . . . . . . . . . . . . . . . . 26
9. Measures to be taken for any operating anomalies. . 27
10. Accessories . . . . . . . . . . . . . . . . . . . . . . 28
10.1. Electrical accessories . . . . . . . . . . . . . . . . . 28
10.2. Mechanical locks . . . . . . . . . . . . . . . . . . . 30
10.3. Notes for Emax LTT Low Temperature accessories. . 31
10.4. Spare parts and retrofitting . . . . . . . . . . . . . . 31
11. Protection releases - General notes. . . . . . . . . . 32
11.1. Notes for dielectric stiffness tests. . . . . . . . . . . 32
11.2. Abbreviations and notes . . . . . . . . . . . . . . . 33
11.2.1. Abbrevations . . . . . . . . . . . . . . . . . . . . . 33
11.2.2. Notes . . . . . . . . . . . . . . . . . . . . . . . . . 33
12. SACE PR122/VF Release - Identification . . . . . . . 34
12.1. General . . . . . . . . . . . . . . . . . . . . . . . . 34
12.1.1. Main Features . . . . . . . . . . . . . . . . . . . . . 34
12.1.2. Standard Reference . . . . . . . . . . . . . . . . . . 34
12.1.3. Operation condition . . . . . . . . . . . . . . . . . . 34
12.1.3.1. Environmental condition. . . . . . . . . . . . . . . . 34
12.1.3.2. Power Supply specifications . . . . . . . . . . . . . 35
12.2. User Interface . . . . . . . . . . . . . . . . . . . . . 35
12.2.1. LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . 35
12.2.2. Display. . . . . . . . . . . . . . . . . . . . . . . . . 36
12.2.2.1. Ammeters on Display . . . . . . . . . . . . . . . . . 36
12.2.2.2. CB and Trip Unit Error . . . . . . . . . . . . . . . . . 36
12.2.2.3. Working ICON . . . . . . . . . . . . . . . . . . . . . 37
12.2.3. Push Button . . . . . . . . . . . . . . . . . . . . . . 37
12.2.4. Rating plug . . . . . . . . . . . . . . . . . . . . . . 37
12.2.5. Optional Module. . . . . . . . . . . . . . . . . . . . 37
12.2.6. External Module . . . . . . . . . . . . . . . . . . . . 37
12.3. User Menu. . . . . . . . . . . . . . . . . . . . . . . 37
12.3.1. Main Area . . . . . . . . . . . . . . . . . . . . . . . 38
12.3.2. Menu Area . . . . . . . . . . . . . . . . . . . . . . . 38
12.3.2.1. Changing of parameters. . . . . . . . . . . . . . . . 38
12.3.3. Protections . . . . . . . . . . . . . . . . . . . . . . 38
12.3.3.1. L Protection . . . . . . . . . . . . . . . . . . . . . . 39
12.3.3.2. I Protection . . . . . . . . . . . . . . . . . . . . . . 39
12.3.3.3. T Protection . . . . . . . . . . . . . . . . . . . . . . 39
12.3.3.4. Load Protection . . . . . . . . . . . . . . . . . . . . 40
12.3.3.5. Trip performances and activation time . . . . . . . . 40
12.3.3.6. Curves . . . . . . . . . . . . . . . . . . . . . . . . . 41
12.3.4. Measurements. . . . . . . . . . . . . . . . . . . . . 41
12.3.4.1. Trip. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12.3.4.2. Events . . . . . . . . . . . . . . . . . . . . . . . . . 41
12.3.4.3. Measurements. . . . . . . . . . . . . . . . . . . . . 42
12.3.4.4. Contact Wear . . . . . . . . . . . . . . . . . . . . . 42
12.3.5. Settings . . . . . . . . . . . . . . . . . . . . . . . . 42
12.3.5.1. Circuit Breaker. . . . . . . . . . . . . . . . . . . . . 42
12.3.5.2. HW trip . . . . . . . . . . . . . . . . . . . . . . . . 42
12.3.5.3. Modules . . . . . . . . . . . . . . . . . . . . . . . . 43
12.3.5.4. Datalogger. . . . . . . . . . . . . . . . . . . . . . . 43
12.3.5.5. Measure Store Time . . . . . . . . . . . . . . . . . . 44
12.3.5.6. System . . . . . . . . . . . . . . . . . . . . . . . . 44
12.3.5.7. Display contrast . . . . . . . . . . . . . . . . . . . . 44
12.3.6. Test . . . . . . . . . . . . . . . . . . . . . . . . . . 44
12.3.6.1. CB Status . . . . . . . . . . . . . . . . . . . . . . . 44
12.3.6.2. Autotest . . . . . . . . . . . . . . . . . . . . . . . . 44
12.3.6.3. Trip Test . . . . . . . . . . . . . . . . . . . . . . . . 44
12.3.6.4. COM Module . . . . . . . . . . . . . . . . . . . . . 44
12.3.6.5. SIGNALLING Module . . . . . . . . . . . . . . . . . 45
12.3.7. About this section . . . . . . . . . . . . . . . . . . . 45
12.4. Modules . . . . . . . . . . . . . . . . . . . . . . . . 45
12.4.1. PR120/D-M . . . . . . . . . . . . . . . . . . . . . . 45
12.4.2. PR120/K . . . . . . . . . . . . . . . . . . . . . . . . 45
12.4.2.1. Digital Input . . . . . . . . . . . . . . . . . . . . . . 45
12.4.2.2. Output Contact . . . . . . . . . . . . . . . . . . . . 46
12.4.3. PR030/B . . . . . . . . . . . . . . . . . . . . . . . . 46
12.4.4. BT030-USB . . . . . . . . . . . . . . . . . . . . . . 46
12.4.5. Ekip T&P. . . . . . . . . . . . . . . . . . . . . . . . 47
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12.4.6. Ekip Connect . . . . . . . . . . . . . . . . . . . . . 47
12.5. Default Settings . . . . . . . . . . . . . . . . . . . . 48
12.6. Help . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12.6.1. Error Messages . . . . . . . . . . . . . . . . . . . . 48
12.6.2. Troubleshooting . . . . . . . . . . . . . . . . . . . . 49
13. Overall dimensions . . . . . . . . . . . . . . . . . . 50
14. Circuit diagrams . . . . . . . . . . . . . . . . . . . . 57
14.1. Caption . . . . . . . . . . . . . . . . . . . . . . . . 57
14.2. Description of figures . . . . . . . . . . . . . . . . . 58
14.3. Incompatibilities . . . . . . . . . . . . . . . . . . . . 58
14.4. Notes . . . . . . . . . . . . . . . . . . . . . . . . . 58
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1. Description
1.1. General characteristics
The SACE Emax series of circuit-breakers consists of a steel sheet structure which houses the operating mechanism, the poles and
the auxiliary parts. Each pole, insulated from the others, contains the circuit-breaking parts and the current sensing resistor of the
corresponding phase.
The fixed version circuit-breaker has its own terminals for connection to the power circuit; in the withdrawable version the circuit-
breaker comprises the moving part of the apparatus, which is completed with a fixed part fitted with the terminals for connection to
the power circuit of the installation. The moving part and the fixed part coupled by means of special contacts installed in the fixed part.
1.2. External front view of the circuit-breaker
Fig. 1
1
2
3
4
Fixed circuit-breaker
1 PR122/VF electronic
microprocessor-based
release
2 Trade mark
3 Operating and control parts
of the operating mechanism
and release tripped signals
4 Rating plate
1.3. Rating plate
1.3.1. Circuit-breaker rating plate
Fig. 2
E2N/VF12 Iu=1200A Ue=1000V
Ue (V )
Icu(kA)
Ics(kA)
690 1000
15 10
15 10
cat.A 50-60Hz
ABB SACE
Italy
Uimp=8kV
Icw(1s)=10kA
IEC 60947-2
The SACE Emax VF circuit breakers can be used in applications with variable frequency from 1Hz to 60Hz, with rated voltage up to
1000V. The rated impulse withstand voltage of the circuit breakers is 8kV.
The SACE Emax VF switch disconnectors up to 2500A are available also in LTT version; this special version, designed for low tem-
perature environment, permits to extend the operating temperature range from -40°C to +70°C.

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6
8
13
18
14
19
11
17
16
21
7
9
12
15
1.4. Moving part construction characteristics
Fig. 3
1.5. Fixed part construction characteristics
Fig. 4
1
2
3
4
5
6
7
8
9
10
1 Steel sheet supporting structure
2 Earthing contacts
3 Safety shutters (IP20 degree of
protection)
4 Insulating terminal support base
5 Terminals
6 Contacts for signalling connected/test
isolated/disconnected (on request)
7 Sliding contacts
8 Padlock for safety shutters (on request))
9 Anti-racking-in lock for circuit-breakers of
different size
10 Fixing holes (qty 4)
2
3
4b
4a
5a
5b
1
7
8
12
10
9
SACEPR12 2/VF
1 Supporting structure made of steel sheet
2 Terminal supporting insulating box
3 Horizontal rear terminals
4a Main fixed contact plates
4b Fixed arcing contact plates
5a Main moving contact plates
5b Moving arcing contact plates
6 Arcing chamber
7 Terminal box for the fixed version-Sliding
contacts for the withdrawable version
8 Protection release
9 Circuit-breaker closing and opening
mechanism
10 Closing springs
11 Spring loading geared motor (on request)
12 Lever for manually loading the closing
springs
13 Racking-out device (only for withdrawable
circuit-breakers)
14 Service releases (shunt closing release, shunt
opening release, undervoltage release)(on
request)
15 Support for releases
16 Operation counter
17 Earthing
18 Auxiliary contacts
19 Key lock and padlocks in the open position –
extracted test – extracted
20 Key lock in the open position

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2. Checking on receipt
Examine the state of the material received and its consistency with the content of the order. Should any damage or errors be found
on unpacking, which must be carried out carefully, make the relative notification within and not over 5 days from the receipt of the
material. The notification must indicate the number of the shipping note.
3. Storage, lifting and weights
The circuit-breaker, protected by an external wooden crate, is fixed by means of screws to the transport pallet or to the bottom of
the packing case.
If the circuit-breaker has to remain in the warehouse even for a short time before being put into service, after checking it on receipt,
it must be put back in its container and covered with a waterproof sheet.
CAUTION:
-Use a dry, dust-free room free of aggressive chemical agents as a storage room,
-Position the circuit-breaker and any fixed part on a horizontal surface, not in direct contact with the floor,
but on a suitable support surface (Fig. 5);
-The maximum number of stackable circuit-breakers is indicated in figure 6.
-Keep the circuit-breaker in the open position and with the closing springs unloaded to avoid unnecessary stresses
and the risk of accidents to the person.
-Storage temperature: -40°C … + 70°C
Fig. 5 Fig. 6
With regard to lifting, follow the instructions: the circuit-breakers must be placed on a sturdy supporting surface and lifted, preferably,
by means of a special fork-lift truck. However, the use of ropes is allowed. In this case, the lifting ropes must be hooked up as shown
in the figures (the lifting plates are always supplied with the circuit-breaker).
Fig. 7
Table of the circuit-breaker weights (Kg.)
Selective
circuit-
breaker
Fixed
version
Withdrawable
version
E2 50 78
E3 66 104
Notes:
• The weights indicated in the table are intended
for circuit-breakers complete with PR122/VF
release, excluding the accessories.
• The withdrawable version includes the moving
part in the same conditions as above, and the
fixed part with horizontal rear terminals.

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4. Installation
4.1. Installation room
Install the circuit-breaker in a dry, dust-free, non-corrosive room,
and in such a way that it is not subject to shocks or vibrations.
Where this is not possible, install it inside a switchboard with a
suitable degree of protection.
For the preparation of the installation room, please refer to the
“Overall dimensions” paragraph, which gives information on the
following points:
- minimum installation volumes of the circuit-breakers and de-
rived versions
- distances to be respected for circuit-breakers in compartments
- overall dimensions of the circuit-breakers
- fixing drillings
- compartment door drillings.
The installation, commissioning and any ordinary and extraordi-
nary maintenance have to be done by skilled personnel, with a
detailed knowledge of the apparatus.
WARNING: The installation, commissioning and
any ordinary and extraordinary maintenance of the
circuit-breaker and accessories must be performed
by skilled personnel, with a detailed knowledge of the equipment.
WARNING ELECTRICAL SHOCK HAZARD:
Disconnect and lock and tag out all electrical power feeds to avoid any potential shock hazard when you are
assembling, installing maintaining or removing the circuit breaker from service. Some operations must be per-
formed when the circuit-breaker is energized. In this case, reasonable care and compliance with all safe working
practices is required.
4.2. Installation of the fixed circuit-breaker
Fix the circuit-breaker to a horizontal surface using the screws (M10 x 12 min.).
4.3. Installation of the fixed part of the withdrawable circuit-breaker
4.3.1. Preparation of the fixed part
Assembly of the anti-racking-in lock
Before installing the fixed part, it is necessary to check the presence of the anti-racking-in lock for circuit-breakers with different electrical
characteristics from those of the fixed part. If the anti-racking-in lock has been supplied separately, proceed to assemble it as follows.
- On the self-adhesive plate (4), find the assembly position of the stop bolts in relation to the circuit-breaker which has to be housed
in the fixed part.
- Insert the hexagonal-head screws (1) in the holes found in the previous item as shown in the figure.
- Fix the screws with the washers (2) and the hexagonal stops (3).
Make sure that the anti-racking-in lock corresponding to the one installed on the fixed part is present on the circuit-breaker (moving part).
- Anti-racking-in plate on the moving part (5).
E2N/VF
E3N/VF
3
4
2
1
1
2
3
5
Fig. 9 Fig. 10
Example for E2N 16 according to the nameplate diagram
Fig.8

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4.3.2. Installation of the fixed part (Fig. 12)
Attach the fixed part by means of the screws (1), washers (2) and nuts (3) (M8 x 16), supplied by ABB SACE. if other screws are used,
make sure that the head of the screws does not extend more than 5.5 mm from the base of the fixed part.
4.4. Installation of the flange on the compartment door
(Fig. 13)
- Make the compartment door drillings specified in the “Overall dimensions” paragraph.
- Attach the flange (1) on the front of the compartment door, fixing it from the inside by means of the self-tapping screws (2).
1
2
1
2
3
Fig. 12
Note
(*) For the E2-E3 fixed parts, there
are four fixing points.
Fig. 13

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5. Electrical connections
5.1. Connections to the power circuit
5.1.1. Shapes of the terminals
Note
The drawings are provided to show the type of terminal in graphic form. The exact shape of the terminals is given in the “Overall
dimensions” chapter.
5.1.2. Examples of positioning the connection busbars according to the types of terminals
The connection busbars enable the connection between the terminals of the circuit-breakers and the busbars of the switchgear. Their
sizing must be carefully studied by the switchgear designer. Some examples of possible constructions in relation to the shape and
size of the circuit-breaker terminals are given in this paragraph. The various types of terminals are of constant dimensions for each
size of circuit-breaker: it is normally advisable to exploit the whole contact surface of the terminal, so the width of the connection
busbars should be the same as that of the terminal. Different connection capacities can be obtained by adjusting the thickness and
number of busbars in parallel. In some cases, reductions in the width of the connection in relation to that of the terminal are allowable
as shown in the following examples.
Vertical terminals Horizontal terminals
Circuit-breaker Iu [A]
Continuous current-
carrying capacity
Busbar cross-
section
Continuous current-
carrying capacity
Busbar cross-
section
[A] (50÷60Hz) [mm2] [A](50÷60Hz) [mm2]
35°C 45°C 55°C 35°C 45°C 55°C
E2N/VF 12 1200 1200 1200 1200 1x(60x10) 1200 1200 1200 1x(60x10)
E2N/VF 16 1600 1600 1600 1600 2x(60x10) 1600 1600 1530 2x(60x10)
E3H/VF 20 2000 2000 2000 2000 2x(100x10) 2000 2000 2000 2x(100x10)
E3H/VF 25 2500 2500 2500 2500 2x(100x10) 2500 2450 2400 2x(100x10)
Fig. 16
Positioning the first anchoring baffle of the busbars according to the short-circuit current
Fig. 17
Anchoring to the switchgear
VERTICAL
HORIZONTAL
P E2 E3
HORIZONTAL 250 150
VERTICAL 250 150
HR VR HR VR
Fig. 14
Fixed part for withdrawable circuit-breaker
Fig. 15
Fixed circuit-breaker
Horizontal rear terminals Vertical rear terminals
Horizontal rear terminals Vertical rear terminals

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5.1.3. Assembly procedure for the connection busbars
Check the state of the contact surfaces of the connections very carefully: they must be very clean with no burrs, dents or traces of
rust which must be eliminated using a fine file or an emery cloth to prevent localized increases in temperature. On completion of the
operation, remove all traces of grease or dust with a cloth soaked in a suitable solvent. When alluminium connections the contact
surfaces must be tinned.
The connections must not exert any strain on the terminals in any direction.
Always insert a large-diameter flat washer and a spring washer between them (to spread the tightening pressure over a greater area).
Make the contact between connection and terminal and tighten the fixing screws completely.
Always use two wrenches (so as not to strain the insulating parts excessively), applying the tightening torque indicated in Fig. 18.
Check tightness after 24 hours.
Fig. 18
M12 high strength screws
Tightening torque of the main terminals: 70 Nm
2 2
No. of screws
for phase
No. of screws
for neutral
3 3
5.2. Earthing
The fixed circuit-breaker and the fixed part of the withdrawable circuit-breaker have one or two terminals on the rear, marked with the
special symbol, for connection to earth (Fig. 9 and Fig. 12).
Each terminal is complete with a bolt for fixing the connection. A conductor with a cross-section conforming to current standards
must be used for the connection.
Before assembling the connection, clean and degrease the area around the screw.
After the assembly, tighten the bolt with a torque of 70 Nm.
5.3. Wiring the circuit-breaker auxiliary circuits
5.3.1. Interfacing elements for fixed circuit-breakers
A special terminal box is provided, fitted with screw terminals for connecting the auxiliary circuits.
The terminals are marked with alphanumerical identification codes as for the electrical circuit diagram.
The terminal box is identified by code XV on the electrical circuit diagram.
The terminal box is immediately accessible when the compartment door is open.
Fig. 19
XV

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5.3.2. Withdrawable circuit-breaker
For connection of the moving part to the auxiliary circuits, a connection with sliding contacts is available on the fixed part (see figure),
identified by code X on the electrical circuit diagram.
The terminals of the fixed connector are immediately accessible when the compartment door is open.
Furthermore a terminal box identified by code XF is available for connecting the position contacts of the moving part in relation to
the fixed part.
The connector and terminal box have screw terminals.
Fig. 20
1
2
3
E2 - E3
5 contacts in position
1
2
3
E2 - E3
10 contacts in position
Caption
1 Sliding contacts (X)
2 Terminal box for position contacts (XF)
3 Position contacts
5.4. Conversion of the auxiliary contacts or of the signalling contacts (disconnected - test isolated - connected), from normally
closed (opening) to normally open (closing) or vice versa
The contacts are wired at the factory as shown on the electrical circuit diagram. If it is necessary to change their state for installation
requirements, proceed as follows.
a) Auxiliary contacts
To access the auxiliary contacts, carry out the following operations:
-remove the front protection (3) of the release by taking action on the blocks (1) as shown in the figure
-remove the protection release (4) removing the side nuts (2) and then sliding the release out from the front of the circuit-breaker.
Fig. 21
SACE PR122/VF
1
3
4
2
Being of the two-way type (changeover contacts), the auxiliary contacts can be modified from break contacts to make contacts and
vice versa simply by moving the output conductor from one position to the other, as shown in the figure.

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Fig. 22
N.C. contact Sliding contacts N.O. contact Terminal box
b) Signalling contacts disconnected - test isolated - connected
To change the state of the position contact, proceed in the same
way as explained for the auxiliary contacts.

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6. Putting into service
6.1. General procedures
WARNING: The external auxiliary power supply must be always provided to the terminal box (terminal: K1 and
K2) to turn on the trip unit. Without the auxiliary power supply the trip unit does not work and the circuit break-
er is not protected. It is recommended to use a backup battery to guarantee the presence of the Vaux or to add
in the circuit breaker an undervoltage release (YU) to open the circuit breaker even when the auxiliary Vaux does
not work.
- Check tightness of the power connections at the circuit-breaker terminals
- Carry out all the preparatory operations on the release
- Make sure that the value of the auxiliary circuit power supply voltage is between 85 and 110% of the rated voltage of the electrical
applications
- Make sure that there is an adequate air circulation in the place of installation to avoid overheating
- Also carry out the checks specified in the following table.
Item inspected Procedure Positive check
1 Auxiliary power supply Open the CB.
Supply the trip unit at 24V DC.
The graphic display turns on.
The word “ABB” scrolls in the bottom left-
hand corner of the display.
2 Manual operating mechanism Carry out some opening and closing operations
(see the chapter 7.2).
CAUTION
When there is an undervoltage release, the
circuit-breaker can only be closed after the
release has been electrically energized.
The spring loading lever moves correctly
3 Geared motor (if any) Supply the spring loading geared motor at the
corresponding rated voltage.
Carry out some closing and opening operations.
Note. Supply the undervoltage release at the cor-
responding rated voltage (if any).
The springs are loaded correctly.
The signals are correct.
The geared motor stops with the springs
loaded.
The geared motor reloads the springs
after each closing operation.
4 Undervoltage release (if any) Supply the undervoltage release at the corre-
sponding rated voltage and carry out the circuit-
breaker closing operation.
Disconnect voltage to the release.
Supply the undervoltage release at the corre-
sponding rated voltage and carry out the circuit-
breaker closing operation.
The circuit-breaker closes correctly. The
signals are correct.
The circuit-breaker opens. The signal
changes over..
5 Shunt opening release (if any) Close the circuit-breaker.
Supply the shunt opening release at the corre-
sponding rated voltage.
The circuit-breaker opens correctly. The
signals are correct..
6 Shunt closing release (if any) Open the circuit-breaker.
Loading the springs.
Supply the shunt closing release at its rated volt-
age.
The circuit-breaker closes correctly. The
signals are correct.
7 Circuit-breaker lock in the open
position (with key or padlocks)
Open the circuit-breaker, turn the key and remove
it from its seat. Attempt circuit-breaker closing
operation.
Both manual and electrical closing are
prevented.
8 Auxiliary contacts of the circuit-
breaker
Insert the auxiliary contacts in suitable signalling
circuits. Carry out some circuit-breaker closing
and opening operations.
The signals are given correctly..
9 Auxiliary contacts for signalling
circuit-breaker connected, test
isolated and disconnected
Insert the auxiliary contacts in suitable signalling
circuits. Then put the circuit-breaker in the con-
nected, test isolated and disconnected position.
The signals due to the relative operations
are given correctly..
10 Lock devices for circuit-break-
ers connected and discon-
nected. Interlocking devices
between circuit-breakers side
by side and one on top of an-
other (if any)
Carry out the operating tests. The locks function correctly.
11 For withdrawable circuit-break-
ers: racking -in/out device
Carry out some racking-in and out operations. Racking-in operation: the circuit-breaker
racks in correctly. The first turns of the
crank handle do not meet with particular
resistance.
WARNING: When undervoltage release has been activated by an undervoltage event, the circuit-breaker can
only be closed after the release has been electrically energized. Ensure that an undervoltage condition existed
at the time the release was activated. If not, investigate circuit-breaker and associated equipment to ensure they
are in proper working order. If application is critical, investigate immediately.

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7. Instructions for use
7.1. Operating and signalling parts
1 Pushbutton for the manual opening operation
2 Lever for manual loading of the closing springs
3 Mechanical indicator for circuit-breaker open “O” and closed “I”
4 Mechanical indicator for protection release tripped (on request)
5 Pushbutton for the manual closing operation
6 Signalling device for springs loaded - unloaded
7 Operation counter (on request)
8 Key lock on the closing operation
9 Mechanical indicator for circuit-breaker connected, test isolated and disconnected
10 Seat for the racking-in/out lever
11 Lever releasing the racking-in/out operation
12 Key lock on the racking-in/out operation (on request)
13 Padlock on the manual closing operation (on request)
14 Padlock on the racking-in/out operation (on request)
Fig. 23
1
8
2
3
4
6
5
7
1
8
2
3
4
6
5
7
10
11
9
12
14
13
Fixed circuit-breaker Withdrawable circuit-breaker
Note On request, a transparent cover can be installed on the front of the circuit-breaker to increase the degree of protection to IP54. The cover has a
locking key.
As an alternative to the transparent cover, a protection can be mounted on the manual closing and opening controls, which only allows operation of
the pushbuttons by means of a special tool.
Fig. 24

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7.2. Circuit-breaker closing and opening procedures
The operation of the circuit-breaker can be either manual or electrical.
a) Manual loading of the closing springs
- Make sure that the indicator (3) shows “O” (circuit-breaker open)
- Make sure that the indicator (6) is WHITE (springs unloaded)
- Repeatedly activate the lever (2) until the indicator (6) changes
its color to YELLOW.
b) Electrical loading of the closing springs
The electrical loading of the circuit-breaker is possible when the
following accessories (supplied on request) are present:
- geared motor for automatic loading of the closing springs
- shunt closing release
- shunt opening release.
The geared motor automatically reloads the springs after each
closing operation until the yellow indicator appears (6, Fig. 25).
When the power is cut off during loading, the geared motor stops
and automatically starts reloading the springs again when the
power returns. It is, in any case, always possible to complete the
reloading operation manually.
c) Closing the circuit-breaker
The operation can only be carried out with the closing springs fully
loaded. For manual closing, press the pushbutton (5) marked with the letter “I”. When there is a shunt closing release, the operation
can be carried out remotely by means of the special control circuit. The special indicator (3) changes to indicate “I” to signal that the
circuit-breaker has closed. Furthermore, the indicator of the state of the springs (6) goes to the WHITE position. Even with the closing
springs unloaded, the operating mechanism retains enough energy for the opening operation. The geared motor, if any, immediately
starts the automatic spring reloading operation.
Fig. 26
3
5
6
Press
d) Opening the circuit-breaker
For manual opening of the circuit-breaker, press pushbutton “O” (1). When there is a shunt opening release, the operation can also
be carried out remotely by means of the special control circuit. Opening having taken place is signaled by the letter “O” appearing
in the indicator (3).
3
1
Fig. 27
Press
2
36
Fig. 25

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7.3. Racking-in/out operation
WARNING
A) Open the circuit-breaker before carrying out any racking-in/out operation.
B) The circuit-breaker (moving part) and fixed part are fitted with a lock which prevents the fixed part from being racked into the
circuit-breakers with a different rated current: the congruence of the anti-racking-in lock must be checked by the operator before
carrying out the racking-in operation to avoid any unnecessary stress.
C) Before the racking-in operation, remove any padlock on the segregation shutter of the isolation terminals on the fixed part.
WARNING ELECTRICAL SHOCK HAZARD: Ensure that the circuit-breaker is either disconnected from all power
sources and that the circuit breaker is open before performing any racking-in/out operation.
A
B C
Fig. 28
Press
NOTE
In relation to the fixed part, the circuit-breaker (moving part) can
take up different positions, identified as follows:
-DISCONNECTED: the moving part is inserted in the fixed part
WITHOUT any connection between the power terminals and
WITHOUT coupling the sliding contacts for the auxiliary circuits:
in this position all electrical operation of the circuit-breaker is
prevented. On the front the indicator (9, Fig. 23) indicates DIS-
CONNECTED. The switchgear compartment door can be closed.
-TEST ISOLATED: the moving part is inserted in the fixed part
WITHOUT any connection between the power terminals, but
WITH the sliding contacts coupled for the auxiliary circuits. In
this position, the circuit-breaker can be operated for the offline
tests. The indicator (9, Fig. 23) indicates TEST ISOLATED.
-CONNECTED: the moving part is fully inserted in the fixed
part WITH the connection of both the power terminals and the
sliding contacts for the auxiliary circuits. The circuit-breaker is
operational. The indicator (9, Fig. 23) indicates CONNECTED.
a) Positioning the moving part in the fixed part in the
DISCONNECTED position
Lift the moving part as shown in the paragraph (3) and insert it in
the fixed part guide, tilting it as shown in figure 29.
The manual connection must allow the edge (E) of the circuit-
breaker guide to slide under the blocks (D) of the fixed part.
Remove the lifting devices.
Push the moving part as far as the stop in the fixed part.
Close the compartment door.
Fig. 29

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b) Passing from the DISCONNECTED to the TEST ISOLATED position.
- Make sure that the indicator (9) is in the DISCONNECTED position.
- For the connection procedure, make sure that the key (12) is in the correct position and/or the padlock (14), if any, has been removed.
- Make sure that the circuit-breaker is open.
- Push the moving part right into the fixed part.
- Lower the releasing lever (11).
- Insert the crank handle in the corresponding coupling (10).
- Proceed to turn the crank handle clockwise until the TEST ISOLATED indication appears on the indicator (9). During the initial turns,
the crank handle must oppose no any particular resistance to rotation.
- Should it be necessary to carry out offline circuit-breaker operations, the crank handle must be removed.
12 14 10 9
11
Fig. 30
c) Passing from the TEST ISOLATED position to the CONNECTED position
- Make sure that the circuit-breaker is open.
- Lower the releasing lever (11).
- Insert the crank handle in the corresponding coupling (10).
- Proceed to turn the crank handle clockwise until the CONNECTED indication appears on the indicator (9).
- Remove the crank handle to enable the circuit-breaker to close.
11 10 9
Fig. 31
d) Passing from the CONNECTED position, to the TEST ISOLATED position, to the DISCONNECTED position
- Repeat the connection procedures changing the direction for turning the crank handle to anti-clockwise. Open the door in the
disconnected position.

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8. Maintenance
8.1. Warning
WARNING: Before carrying out any maintenance task, you must:
-Open the circuit-breaker and check that the operating mechanism springs are unloaded;
-In the case of a withdrawable circuit breaker, remove the circuit breaker from the fixed part before working on it;
-For action on fixed version circuit-breakers or on fixed parts disconnect the power circuit and the auxiliary circuits
and visibly earth the terminals both on the power supply side and on the load side;
-Make safe in compliance with current laws.
WARNING ELECTRICAL SHOCK HAZARD: Shock Hazard or Injury.
ABB declines all responsibility for damage to things and injury to people due to failure to comply with the instructions contained in
this document. Maintenance tasks must be performed by qualified staff with a detailed knowledge of the unit.
8.2. Maintenance programme
8.2.1. Circuit-breaker life
With regular maintenance, SACE Emax circuit-breakers, either with or without opening or closing releases, can withstand the following
operation without replacement of parts. (1)
Rated uninterrupted current Mechanical life (2) Electrical life (50Hz/60Hz) (2) (3)
Iu (40 °C)
[A]
No. of operations
x 1000
Frequency
operations/hour
690 V ~
No. of operations x
1000
Frequency
operations/hour
E2N/VF 1200 12 30 10 30
1600 12 30 10 30
E3H/VF 2000 10 30 7 20
2500 10 30 7 20
LTT Low termperature version
E2 LTT(4) 1200 - 1600 8 30 8 30
E3 LTT(4) 2000 - 2500 8 30 7 30
(1) Data referring to standard installation conforming to product standards. For other applications, please consult ABB Sace.
(2) Extreme atmospheric conditions, polluted atmosphere or vibrations may shorten the application’s life. Please consult ABB Sace.
(3) For different frequency please consult ABB Sace.
(4) Switch disconnectors
8.2.2. Maintenance program
The table shows the maintenance intervals and the frequency of periodical intervention and routine maintenance tasks. The following
rules should also be followed:
- Even circuit-breakers that are little used or remain on or off for long periods should be subject to the maintenance programme.
- The SACE PR122/VF release enable the number of operations performed by the circuit breaker in use to be displayed at any mo-
ment on the display.
- During operation, inspect the circuit-breaker from the outside to check for dust, dirt or damage of any kind.
Maintenance operations
Interval
Installation in normal environments
Installation in dusty environments ( 1)/( 2)
and low temperature environment(3)
[ (1) = level of measured dust > 1 mg/m³ ]
First level One year or 20% mechanical life
or 20% electric life
6 months or 10% mechanical life
or 10% electric life
Second level
Three years or 50% mechanical life
or 50% electric life
or after intervention on short circuit
18 months or 25% mechanical life
or 25% electric life
or after intervention on short circuit
(1) Data referring to standard installation in accordance with product standards. For other applications, please consult ABB Sace.
(2) Extreme atmospheric conditions, polluted atmosphere or vibrations may shorten the life of the application. Please consult ABB Sace.
(3) Emax LTT Low temperature environment application.
8.3. First level maintenance operations
8.3.1. Preliminary operations:
-open the circuit-breaker and check that the control springs are unloaded
-in the case of a withdrawable circuit breaker, remove the circuit breaker from the fixed part before working on it
WARNING: before working on fixed circuit-breakers or on fixed part, disconnect the supply to the power circuit
and to the auxiliary circuits and earth the terminals in a visible manner both on the supply and on the load side.
8.3.2. Checks and general cleaning:
- Check that the apparatus (switching part) is clean, removing dust and any traces of excess oil or grease using dry and clean rags
(possibly using non-corrosive detergent.

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- For excessive deposits, a dilutant such as Henkel 273471 or the equivalent can be used.
- Check that the rating plates of the apparatus are in place.
- Clean the rating plates with dry and clean cloths.
- Eliminate any dust, mould, traces of condensation or oxidation also inside the fixed part if the circuit-breaker is a withdrawable version.
- Check that there are no foreign bodies in the circuit-breaker cabinet.
8.3.3. Circuit-breaker connections and connections between the circuit-breaker and the control panel
- Use brushes and dry cloths to remove any dust or dirt (if necessary, use non-corrosive detergent.)
- For excessive deposits, a dilutant such as Henkel 273471 or the equivalent can be used.
- Check that there are no traces of overheating on the terminals. This problem is due to discolouring of the contact parts; the contact
parts are normally silver in colour.
- Check that the bolts fixing the connections to the terminals are tight (M12 - 70Nm).
WARNING: before working on fixed circuit-breakers or on fixed part, disconnect the supply to the power circuit
and to the auxiliary circuits and earth the terminals in a visible manner both on the supply and on the load side.
- Check that the connecting screws of the cables of the terminal boards are tight (0.7 Nm).
Fig. 32
8.3.4. Dismantling tab and cap
- The tab (1) of the release by rotating the screws (2) as shown in figure 33.
- Remove the front cap (3) by loosening the four screws (4).
1
2
3
4
SACEPR122/VF
Fig. 33
- If there is an undervoltage release, remove the coils support and release the control springs, closing and opening the circuit-breaker.
SACE PR122/VF
Fig. 34