ABB SACE Emax 2 E1.2 manual 

—
INSTRUCTION HANDBOOK
1SDH002303A1001 - ECN000285442
EMAX 2 E1.2
Disassembly instructions

3
Disassembly instruction emaX 2 e1.2
1. SCOPE
Scope of this document is to illustrate the step-by-step disassembly process of ABB SACE Emax 2 E1.2
air case circuit breaker equipped with an electronic trip unit (type Ekip TOUCH LSIG).
Document is focused on Emax 2 E1.2 3p IEC version, anyway it allows to cover other versions of Emax 2
E1.2 circuit breaker equipped with a electronic trip unit with just few slight differences to be taken into
account.
Gloves Glasses Safety shoes Protective clothes
4. TOOLS
Disassembly operations require the use of tools (e.g. screwdriver, torx key, pliers, …); tools to be used
are specified inside each phase of the disassembly process (see Chapter 6).
3. PERSONAL PROTECTIVE EQUIMENT (PPE)
When performing disassembly, following safety Personal Protective Equipment (PPE) must be worn:
2. SAFETY NOTES
Before proceeding with any disassembly operation, it’s mandatory to put the circuit breaker in open
position and make sure that the springs of the operating mechanism are discharged.
Disassembly operations of circuit breakers must be performed by qualified and skilled personnel in
the electrical field (IEV 195-04-01: person with relevant education and experience to enable him or her
to perceive risks and to avoid hazards which electricity can create) and having a detailed knowledge of
circuit breakers.
Disassembly activites must be performed in an ergonomic workspace able to ensure protection of per-
sons demanded to perform disassembly activities.
Applicable national legislation and international standards in force at the time of disassembly of circuit
breakers must be taken into account in addition to prescriptions illustrated in this document.
ABB declines any responsibility for injury to people or damage to property resulting from a failure to
comply with the instructions set out in this document and with any applicable safety standard.

4
INSTRUCTION HANDBOOK
If disassembled parts require a separate treatment a specific indication is provided inside each phase
with reason why for the separate treatment (see Chapter 6).
Description Position inside circuit breaker Quantity
Lever In the T.U. reset group 
Lever support In the T.U. reset group 
Right side wall Mounted on the sliding contacts block 
Flat cables assemblies Mounted on the sliding contacts block 
Connector cables assembly Mounted on the sliding contacts block 
Sliding contacts base Mounted on the sliding contacts block 
Slide Mounted on the right shoulder 
Support Mounted on the upper part of the circuit breaker 
Cables protection Mounted on the back part of the trip unit 
Rating plug case Mounted on the front of the trip unit 
Rating plug printed circuit board In the rating plug case 
Ekip measuring blind printed circuit board On the trip unit 
Battery cover On the trip unit 
Battery On the trip unit 
Display printed circuit board On the trip unit 
Display On the trip unit 
Backplane Mounted on the back part of the trip unit 
Trip unit case On the trip unit 
Trip unit back cover On the trip unit 
Trip unit printed circuit board In the trip unit 
Measuring module connector On the trip unit 
Protections Mounted on the back part of the circuit breaker 
Motor PCS support Mounted on the left part of the circuit breaker 
Microswitch support Mounted on the left part of the circuit breaker 
 Mounted on the left part of the circuit breaker 
Trip coil In the trip coil group 
Trip coil group Mounted on the left part of the circuit breaker 
Connector On the MID 
Auxiliary contacts On the MID 
Microswitch I/O On the MID 
Microswitch I/O support On the MID 
MID Mounted on the right part of the circuit breaker 
Wires cover Mounted on the left part of the circuit breaker 
Wiring Mounted on the left part of the circuit breaker 
Open lever On the right side of the circuit breaker 
RTC lever Mounted on the right side of the operating mechanism 
Conduit Behind the trip unit 
Operating mechanism Mounted on the center of the circuit breaker 
Unlocking shaft appendices Mounted on the pin of the operating mechanism 
Springs charging lever Mounted on the left side of the operating mechanism 
Protections Mounted on the upper case assembly 
Plastic parts Mounted on the fixed contacts 
Covers Below the sensors 
Sensors In the bottom part of the circuit breaker 
Insulation protections On the moving contacts assembly 
5. SEPARATE TREATMENT
Table below lists parts requiring a separate treatment adding information about part location inside
circuit breakers and related quantity.

5
Disassembly instruction emaX 2 e1.2
6. DISASSEMBLY PROCESS
Circuit breakers disassembly process is constituted by a sequence of operations to be performed on
products after their dismounting from original installation. For each phase following information is
provided:
 
 
 
 
 
applicable)
 

6
INSTRUCTION HANDBOOK
Tools
Flat screwdriver
6.1 PHASE 1 – CIRCUIT BREAKER FRONT COVER, COVERS AND OPERA-
TING MECHANISM COVER
1
Manually push the trip unit transparent
protection as indicated by the arrow and
remove it.
3
Manually complete the removal of the cover.
5
By means of the cross screwdriver unscrew the
2 screws located in the upper part of the circuit
breaker fixing the circuit breaker front cover to
the circuit breaker main structure.
2
By means of the cross screwdriver unscrew the
3 screws fixing the cover.
4
Lift the spring charging lever and by means
of the cross screwdriver unscrew the screw
located below the springs charging lever fixing
the circuit breaker cover to the circuit breaker
main structure.
6
By means of the cross screwdriver unscrew
the 2 screws fixing the withdrawable terminals
cover.
Actions to be performed
Cross screwdriver
Torx key
No. 8

7
Disassembly instruction emaX 2 e1.2
7
Manually complete the removal of the
withdrawable terminals cover.
11
Manually lift the T.U. reset group and complete the
removal.
12
By means of the flat screwdriver unhook the reset
lever from the reset support of the T.U. reset group.
9
Manually lift the circuit breaker front cover to
complete the removal.
8
By means of the cross screwdriver unscrew the
2 screws located in the lower part of the circuit
breaker fixing the circuit breaker front cover to
the circuit breaker main structure.
10
By means of the cross screwdriver unscrew the
screw fixing the T.U. reset group to the circuit
breaker front cover.

8
INSTRUCTION HANDBOOK
13
Manually separate the lever support and the lever.
17
By means of the tork key remove the 2 screws
fixing the front cap to the circuit breaker front
cover and after manually remove the front cap.
18
By means of the cross screwdriver unscrew the 2
screws located in the lower part of the operating
mechanism cover fixing the operating mechanism
cover to the circuit breaker main structure.
15
Manually remove the reset spring from the lever
support.
14
Manually remove the spring from the lever.
16
By means of the tork key remove the screw
fixing the operation counter cap to the circuit
breaker front cover and after manually remove the
operation counter cap.

9
Disassembly instruction emaX 2 e1.2
19
By means of the cross screwdriver unscrew the screw
located on the right of the operating mechanism
cover fixing the operating mechanism cover to the
circuit breaker main structure and manually complete
the removal of the operating mechanism cover.
Disassembled parts
 
 
 
 
 
 
(Thermoplastics containing brominated flame
retardants)
 
 
(Thermoplastics containing brominated flame
retardants)
 
 
 
 
 
 

10
INSTRUCTION HANDBOOK
Tools
Flat screwdriver
Cutter
Pliers
6.2 PHASE 2 – SLIDING CONTACTS BLOCK
20
Manually push the sliding contacts block as
indicated by the arrow.
22
Using one hand manually slightly push as
indicated by the arrow the right shoulder
and using the other hand unhook the sliding
contacts block from main circuit breaker
structure.
24
By means of the flat screwdriver unhook the
3 flat cables assemblies and the connector
cables assembly.
21
By means of the pliers unhook the 2 springs
mounted at the extreme sides of the sliding
contacts block, keeping them mounted on the
sliding contacts block.
23
After completion of previous operation, sliding
contacts block must be put as indicated in
picture here below.
25
Manually complete the removal of the sliding
contacts block from the circuit breaker main
structure.
Actions to be performed

11
Disassembly instruction emaX 2 e1.2
26
By means of the flat screwdriver unhook the right
side wall from the sliding contacts block main
assembly.
30
Inser 2 flat screwdrivers at the sides of each block,
slightly push them as indicated by the arrow
and complete the removal of the 3 flat cables
assemblies and of the connector cables assembly
manually pulling them.
31
By means of the flat screwdriver push as indicated
by the arrow the 2 bars mounted inside the sliding
contacts block.
28
By means of the cutter start removing the sliding
contacts label located on the right side wall and
manually complete the operation.
27
Manually complete the removal of the right side
wall.
29
By means of the pliers remove the 2 springs from
the sliding contacts block.

12
INSTRUCTION HANDBOOK
32
Manually complete the removal of the 2 bars.
33
By means of the pliers remove the 4 pins and the
related nuts mounted at both sides of the sliding
contact base.
Disassembled parts
 
(Thermoplastics containing brominated flame
retardants)
 
 
 

containing brominated flame retardants)
 

containing brominated flame retardants)
 
 
 

brominated flame retardants)

13
Disassembly instruction emaX 2 e1.2
Tools
Cutter
Pliers
6.3 PHASE 3 – SHOULDERS
34
By means of the cross screwdriver unscrew the
2 screws fixing the cover to the circuit breaker
main structure.
36
By means of the cross screwdriver unscrew
the 2 screws fixing the withdrawable terminals
cover to the circuit breaker main structure.
38
By means of the cross screwdriver unscrew the
2 screws fixing the left shoulder to the circuit
breaker main structure.
35
Manually complete the removal of the cover.
37
Manually complete the removal of the
withdrawable terminals cover.
39
By means of the cross screwdriver unscrew the
2 screws fixing the left shoulder to the circuit
breaker main structure and collect the 2 nuts
mounted behind the 2 screws
Actions to be performed
Cross screwdriver

14
INSTRUCTION HANDBOOK
40
Manually remove the left shoulder.
44
By means of the cross screwdriver unscrew the
2 screws fixing the right shoulder to the circuit
breaker main structure and collect the 2 nuts
mounted behind the 2 screws.
45
Manually remove the right shoulder.
42
By means of the cutter start removing the 3
labels located on the left shoulder and manually
complete the operation.
41
By means of the pliers remove the 2 springs
mounted on the left side support.
43
By means of the cross screwdriver unscrew the
2 screws fixing the right shoulder to the circuit
breaker main structure.

15
Disassembly instruction emaX 2 e1.2
46
Manually remove the slide mounted on the right
shoulder.
47
By means of the pliers remove the spring
mounted on the right shoulder.
Disassembled parts
 
 
 
 
 
 
 
 
(Thermoplastics containing brominated flame
retardants)

16
INSTRUCTION HANDBOOK
Tools
Flat screwdriver
Scissors
Cutter
Torx key
6.4 PHASE 4 – TRIP UNIT
48
By means of the cross screwdriver unscrew the
2 screws located in the upper part of the circuit
breaker fixing the trip unt to the circuit breaker
main structure.
50
By means of the flat screwdriver unhook the
white connector from the trip unit.
52
By means of the flat screwdriver unhook the
cable protection from the trip unit and after
manually complete the removal.
49
By means of the cross screwdriver unscrew
the 2 screws located on the front of the circuit
breaker fixing the trip unt to the circuit breaker
main structure.
51
Manually complete the removal of the white
connector.
53
By means of the flat screw driver unhook the
white connector from the trip unit.
Actions to be performed
No. 8
Cross screwdriver
Pliers

17
Disassembly instruction emaX 2 e1.2
54
By means of the flat screw driver unhook the
white connector from the trip unit.
59
By means of the cutter start removing the label
mounted over the plug removed at step before and
manually complete the removal operation.
58
Manually remove the plug mounted on the left part of
the trip unit.
56
By means of the scissors cut the cabling
completing the removal of the trip unit from the
circuit breaker main structure.
55
Manually unhook the last cabling connecting the
trip unit to the circuit breaker main structure.
57
By means of the torx key unscrew the 4 screws
fixing the 2 plugs to the trip unit.

18
INSTRUCTION HANDBOOK
60
By means of the flat screwdriver remove the
rating plug from the trip unit.
65
Manually complete the removal of the Ekip measuring
blind plug.
64
By means of the flat screwdriver unhook the Ekip
measuring blind plug from the trip unit.
62
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.
61
Manually push the rating plug case appendix as
indicated by the arrow and by means of the pliers
remove the rating plug printed circuit board.
63
By means of the cutter start removing the rating
plug data matrix label located on the rating plug
case and by means of the pliers complete the
operation.

19
Disassembly instruction emaX 2 e1.2
66
By means of the cutter start removing the label
located on the Ekip measuring blind plug and by
means of the pliers complete the operation.
71
By means of the torx key unscrew the screw fixing the
display to the trip unit main structure.
70
Manually remove the printed circuit board from the
Ekip measuring blind cover.
68
By means of the torx key unscrew the 2 screws
fixing the Ekip measuring blind case to the Ekip
measuring blind cover.
67
By means of the cutter start removing the data
matrix label located in the back part of the Ekip
measuring blind plug and by means of the pliers
complete the operation.
69
Manually remove the Ekip measuring blind case.

20
INSTRUCTION HANDBOOK
72
By means of the flat screwdriver unhook the
display from the trip unit main structure.
77
By means of the flat screwdriver unhook the HMI box
from the display.
76
Manually remove the battery.
74
By means of the cutter start removing the
trip unit front label and by means of the pliers
complete the operation.
73
Manually complete the removal of the display.
75
By means of the flat screwdriver remove the
battery cover on the right side of the display.