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ABB EMAX 2 E6.2 Instruction Handbook Manual

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INSTRUCTION HANDBOOK
1SDH002306A1001 - ECN000285442
EMAX 2 E6.2
Disassembly instructions

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Summary of Contents for ABB EMAX 2 E6.2

  • Page 1 — INSTRUCTION HANDBOOK 1SDH002306A1001 - ECN000285442 EMAX 2 E6.2 Disassembly instructions...

  • Page 3: Safety Notes

    (type Ekip TOUCH). Document is focused on Emax 2 E6.2 3p IEC version, anyway it allows to cover other versions of Emax 2 E6.2 circuit breaker equipped with an electronic trip unit with just few slight differences to be taken into account.
  • Page 4 INSTRUCTION HANDBOOK 5. SEPARATE TREATMENT Table below lists parts requiring a separate treatment adding information about part location inside circuit breakers and related quantity. Description Position inside circuit breaker Quantity Base In sliding contacts block Cover In sliding contacts block Auxiliary position contacts cap In sliding contacts block Right side wall...

  • Page 5: Disassembly Process

    Disassembly instruction emaX 2 e6.2 Description Position inside circuit breaker Quantity Trip coil cover Mounted in the MID Trip coil Mounted in the MID Flat cover Mounted on the MID Auxiliary flat assembly Mounted on the MID RTC micro lever...
  • Page 6 INSTRUCTION HANDBOOK 6.1 PHASE 1 – CIRCUIT BREAKER FRONT COVER AND OPERATING MECHANISM COVER Actions to be performed Tools Flat screwdriver Manually remove the trip unit transparent By means of the flat screwdriver turn of 90° cover. the 2 screws fixing the trip unit transparent protection to the circuit breaker.
  • Page 7 Disassembly instruction emaX 2 e6.2 Manually remove the 2 plugs. By means of thr torx key unscrew the 2 screws fixing the T.U. Reset assembly to the front cover. Manually remove the T.U. Reset assembly. By means of the flat screwdriver remove the 2 benzings mounted on the T.U.
  • Page 8 INSTRUCTION HANDBOOK Manually push down the springs charging lever Manually remove the plug. and by 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...
  • Page 9 Disassembly instruction emaX 2 e6.2 By means of the cross screwdriver unscrew the 4 + 4 + 4 screws fixing the left and the right shields to the circuit breaker. Manually remove the left shields. Manually remove the right shield.
  • Page 10 INSTRUCTION HANDBOOK Disassembled parts • 1 trip unit transparent protection (Plastic and Metal) • 1 racking in and out lever (Plastic and Metal) • 4 + 2 + 2 + 2 + 2 + 1 + 4 + 4 + 4 screws (Metal) •...
  • Page 11 Disassembly instruction emaX 2 e6.2 6.2 PHASE 2 – SLIDING CONTACTS BLOCK Actions to be performed Tools Cross screwdriver By means of the cross screwdriver unscrew the By means of the cross screwdriver unscrew the 1 + 1 screws fixing the 2 sides walls located at...
  • Page 12 INSTRUCTION HANDBOOK Manually remove the base and the cover. By means of the flat screwdriver push up the 3 flat cables assemblies and the connector cables assembly. Manually remove the 2 springs located at both Manually remove the sliding contacts block. sides of the sdling contacts block.
  • Page 13 Disassembly instruction emaX 2 e6.2 By means of the flat screwdriver unhook the By means of the flat screwdriver unhook the right side wall from the sliding contacts main right side wall from the sliding contacts main assembly as indicated in the picture.
  • Page 14 INSTRUCTION HANDBOOK By means of the pliers remove the 4 pins and the related nuts mounted at both sides of the sliding contacts base. Disassembled parts • 2 + 2 + 6 screws (Metal) • 2 side walls (Metal) • 1 base (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) •...
  • Page 15 Disassembly instruction emaX 2 e6.2 6.3 PHASE 3 – TRIP UNIT Actions to be performed Tools Torx key By means of the flat screwdriver unhook the By means of the torx key unscrew the 2 screws Ekip measuring blind module from the trip unit fixing the Ekip measuring blind module located No.
  • Page 16 INSTRUCTION HANDBOOK By means of the flat screwdriver unhook the By means of the cross screwdriver unscrew white connector located in the upper part of the 4 screws fixing the trip unit to the circuit the trip unit. breaker main structure. Manually unhook the connector located in the Manually unhook the connector located in the back part of the trip unit.
  • Page 17 Disassembly instruction emaX 2 e6.2 By means of the torx key unscrew the screw Manually remove the plug. fixing the plug to the trip unit. By means of the cutter start removing the label By means of the flat screwdriver remove the mounted over the plug removed at step before rating plug from the trip unit.
  • Page 18 INSTRUCTION HANDBOOK By means of the torx key unscrew the 2 screws Manually remove the Ekip signaling 4K plug fixing the Ekip signalling 4K plug to the trip from the trip unit main structure. unit main structure. By means of the cutter start removing the By means of the torx key unscrew the screw label located on the front of the Ekip signalling fixing the display to the trip unit main...
  • Page 19 Disassembly instruction emaX 2 e6.2 By means of the cutter start removing the By means of the flat screwdriver remove the trip unit front label and by means of the pliers battery cover on the left side of the display.
  • Page 20 INSTRUCTION HANDBOOK By means of the flat screwdriver remove the Manually remove the battery gasket. “i TEST” pushbutton from the HMI LCD cover. By means of the flat screwdriver unhook the Manually remove the display support. display printed circuit board from the display support.
  • Page 21 Disassembly instruction emaX 2 e6.2 By means of the torx key unscrew the 4 screws Manually complete the removal operation of fixing the backplane to the trip unit main the backplane. structure. By means of the torx key unscrew the 4 screws...
  • Page 22 INSTRUCTION HANDBOOK By means of the flat screwdriver unhook the Manually remove the trip unit printed circuit trip unit printed circuit board. board. Disassembled parts • 2 + 2 + 4 + 1 + 2 + 1 + 4 + 4 screws (Metal) •...
  • Page 23 Disassembly instruction emaX 2 e6.2 6.4 PHASE 4 – TERMINAL BOX Actions to be performed Tools Flat screwdriver Manually unhook the connector indicated by Manually unhook the connector indicated by the arrow fixing the terminal box case to the the arrow fixing the terminal box case to the Torx key circuit breaker main structure.
  • Page 24 INSTRUCTION HANDBOOK Push the flat srewdriver in the direction By means of the flat screwdriver separate the indicated by the arrow and after manually 4 micro I/O assembly cover from the 4 micro remove the microswitch assembly. I/O assembly base. Pull out the 4 auxiliary contacts from the 4 By means of the cross screwdriver unscrew the micro I/O assembly base.
  • Page 25 Disassembly instruction emaX 2 e6.2 By means of the flat screwdriver unhook the By means of the flat screwdriver push the 2 2 microswitches from their support and after connectors as indicated by the arrow and after separate the microswitches support from the manually complete the removal.
  • Page 26 INSTRUCTION HANDBOOK By means of the flat screwdriver push the pin as indicated by the arrow and let the the I/O shaft, the I/O shaft group support and the leaf spring constituting the I/O shaft group separate. Disassembled parts • 2 + 3 + 2 screws (Metal) •...
  • Page 27 Disassembly instruction emaX 2 e6.2 6.5 PHASE 5 – LEFT MID, CABLE GUIDE AND CS ADAPTER Actions to be performed Tools Cross screwdriver Manually remove the left MID from the circuit By means of the cross screwdriver unscrew the breaker main structure.
  • Page 28 INSTRUCTION HANDBOOK By means of the flat screwdriver remove the 2 By means of the allen key unscrew the 2 screws clips and after manually complete the removal. fixing the CS adapter to the circuit breaker main structure. By means of the flat screwdriver unhook the CS By means of the torx key unscrew the 4 screws adapter box from the CS adapter.
  • Page 29 Disassembly instruction emaX 2 e6.2 Manually pull and remove the wiring cables set. Manually unhook the cables from the clips. By means of the flat screwdriver remove the 3 clips.
  • Page 30 INSTRUCTION HANDBOOK Disassembled parts • 1 + 2 + 1 + 2 + 4 screws (Metal) • 1 left MID (Plastic and Metal) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 1 cable guide (Plastic) • 2 + 3 clips (Plastic) •...
  • Page 31 Disassembly instruction emaX 2 e6.2 6.6 PHASE 6 – CD Actions to be performed Tools Cross screwdriver By means of the allen key unscrew the screw By means of the allen key unscrew the 2 screws located in the front part of the circuit breaker fixing...
  • Page 32 INSTRUCTION HANDBOOK By means of flat screwdriver remove the By means of the flat screwdriver push the pin benzing. as indicated by the arrow and let the spring and the CD block cover separate from the cover. By means of the cross screwdriver unscrew the Manually remove the front of the CD.
  • Page 33 Disassembly instruction emaX 2 e6.2 By means of the flat screwdriver remove the By means of the pliers remove the spring and benzing and after manually remove the feeler. let the pin and the CD block lever separate from the CD base.
  • Page 34 INSTRUCTION HANDBOOK Disassembled parts • 2 + 1 + 1 + 2 + 2 screws (Metal) • 1 cover (Metal) • 1 benzing (Metal) • 1 pin (Metal) • 1 spring (Metal) • 1 CD block cover (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) •...
  • Page 35 Disassembly instruction emaX 2 e6.2 6.7 PHASE 7 – MID Actions to be performed Tools Cross screwdriver By means of the cross screwdriver unscrew the By means of the cross screwdriver unscrew 2 screws fixing the MID to the circuit breaker...
  • Page 36 INSTRUCTION HANDBOOK By means of the pliers unhook and remove the By means of the pliers unhook and remove the spring indicated by the arrow mounted on the spring indicated by the arrow mounted on the MID main structure. MID main structure. By means of the flat screwdriver remove the 6 By means of the flat screwdriver, manually and benzings.
  • Page 37 Disassembly instruction emaX 2 e6.2 Manually remove the assembly mounted on the By means of the flat screwdriver remove the 2 MID main structure. benzings mounted on the assembly mounted on the MID main structure. Manually remove the pin and let all the other...
  • Page 38 INSTRUCTION HANDBOOK By means of the flat screwdriver slightly lift By means of the torx key (size 6) unscrew the 2 up the appendix as indicated by the arrow and screws fixing the trip coil support base to the manually remove the trip coil assembly. trip coil cover.
  • Page 39 Disassembly instruction emaX 2 e6.2 Manually remove the flat cover. By means of the flat screwdriver unhook as indicated by the arrow the flat cover from the MID main structure. Manually remove the auxiliary flat assembly. By means of the flat screwdriver remove the benzing.
  • Page 40 INSTRUCTION HANDBOOK Disassembled parts • 1 + 2 + 1 + 2 + 1 screws (Metal) • 1 releases door (Plastic + Metal) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 1 + 1 + 1 + 2 + 1 springs (Metal) •...
  • Page 41 Disassembly instruction emaX 2 e6.2 6.8 PHASE 8 – SHOULDERS Actions to be performed Tools Torx key By means of the torx key unscrew the 2 screws Put the circuit breaker in horizontal position fixing the left support to the left shoulder.
  • Page 42 INSTRUCTION HANDBOOK Manually remove the assembly shaft. 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.
  • Page 43 Disassembly instruction emaX 2 e6.2 By means of the cross screwdriver unscrew the manually remove the right support. 2 screws fixing the right support to the circuit breaker main structure. Manually remove the spacer. By means of the torx key unscrew the screw fixing the spacer to the circuit breaker main structure.
  • Page 44 INSTRUCTION HANDBOOK By means of the cutter start removing the By means of the torx key unscrew the 4 screws 3 labels located on the left shoulder and fixing the right shoulder to the circuit breaker manually complete the operation. main structure.
  • Page 45 Disassembly instruction emaX 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) •...
  • Page 46 INSTRUCTION HANDBOOK 6.9 PHASE 9 – OPERATING MECHANISM Actions to be performed Tools Torx key Manually remove the setting plate. By means of the torx key unscrew the 4 screws fixing the setting plate to the upper cross beam. No. 30 Cross screwdriver Flat screwdriver By means of the torx key unscrew the 12 screws fixing the upper cross beam to the circuit...
  • Page 47 Disassembly instruction emaX 2 e6.2 Manually remove the upper cross beam. By means of the cross screwdriver unscrew the 3 screws fixing the 3 blocks to the upper cross beam and after let them fall down by gravity. By means of the cross screwdriver unscrew the Manually remove the mechanical release.
  • Page 48 INSTRUCTION HANDBOOK By means of the flat screwdriver remove the 2 Unhook the 2 levers from the operating benzings fixing the 2 levers to the operating mechanism. mechanism. By means of the flat screwdriver remove the 2 By means of the flat screwdriver remove the benzings.
  • Page 49 Disassembly instruction emaX 2 e6.2 By means of the flat screwdriver remove the By means of the flat screwdriver remove the benzing and let the pin and the lever separate benzing. by gravity. Slightly push the flat screwdriver as indicated...
  • Page 50 Operating mechanism contains springs: their removal constitutes a potential hazard if not performed in the proper way and using dedicated tools. Based on this ABB indication is not to remove them from the operating mechanism and to manage the assembly with the maximum level of attention during disassembly and dismantle phases.
  • Page 51 Disassembly instruction emaX 2 e6.2 6.10 PHASE 10 – OPERATING SHAFT ASSEMBLY Tools Actions to be performed Torx key By means of the torx key unscrew the 2 screws fixing the 2 intermediate plates to the circuit breaker main structure.
  • Page 52 INSTRUCTION HANDBOOK Manually remove the operating shaft assembly. By means of the cross screwdriver unscrew the Manually remove the auxiliary contacts cam. screw fixing the auxiliary contacts cam to the operating shaft assembly. Manually remove the cam. By means of the cross screwdriver unscrew the screw fixing the cam to the operating shaft assembly.
  • Page 53 Disassembly instruction emaX 2 e6.2 By means of 2 flat screwdrivers remove the Manually remove the lever. benzing. Disassembled parts • 6 + 1 benzings (Metal) • 6 pins (Metal) • 2 + 1 + 1 screws (Metal) • 1 auxiliary contacts cam (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) •...
  • Page 54 INSTRUCTION HANDBOOK 6.11 PHASE 11 – POLES SEPARATION Actions to be performed Tools Torx key By means of the torx key unscrew the 4 screws fixing the operating mechanism fixing plate and the lower cross beam to the poles. No. 30 Rod Ø5mm Min.
  • Page 55 Disassembly instruction emaX 2 e6.2 By means of the flat screwdriver unscrew the screws fixing the 3 wires connecting the measuring module connector to the sensors mounted inside the poles. Disassembled parts • 4 screws (Metal) • 1 operating mechanism fixing plate (metal) •...
  • Page 56 INSTRUCTION HANDBOOK 6.12 PHASE 12 – TERMINALS AND CLAW CONTACTS Actions to be performed Tools Torx key Manually remove the terminals and their By means of the torx key (size 40) unscrew protections. the 6 screws fixing the terminals and their No.
  • Page 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 INSTRUCTION HANDBOOK 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 provided for these circuit breakers. Tools Torx key UL version - Current rating up to 5000A No.
  • Page 59 Disassembly instruction emaX 2 e6.2 Manually remove the terminals and their Manually separate the terminals and their protections. protections. Disassembly operations illustrated at pictures 219, … , 224 must be performed on the other 5 poles. Disassembled parts • 60 + 36 screws (Metal) •...
  • Page 60 INSTRUCTION HANDBOOK 6.13 PHASE 13 – ARCHING CHAMBERS Actions to be performed Tools Torx key Manually remove the arching chamber. By means of the torx key unscrew the 2 screws fixing the arching chamber to the pole. * No. 30 Cross screwdriver Flat screwdriver * 2 addititional screws must be unscrewed on circuit breakers...
  • Page 61 Disassembly instruction emaX 2 e6.2 Manually separate the arc quenching and the By gravity let the plates come out from the plate. arching chamber main structure. By means of the cross screwdriver unscrew the Manually remove the arching chamber cover.
  • Page 62 INSTRUCTION HANDBOOK By gravity let the 2 filters and the spacer separate from the arching chamber shell. Disassembled parts • 12 + 36 screws (Metal) • 12 arc quenchings (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 12 plates (GP0-3) •...
  • Page 63 Disassembly instruction emaX 2 e6.2 6.14 PHASE 14 – POLES Actions to be performed Tools Allen key Manually remove the sensor cover. By means of the allen key unscrew the 2 screws fixing the sensor cover to the pole. Torx key No.
  • Page 64 INSTRUCTION HANDBOOK By means of the torx key (size 25) unscrew the Manually unhook the cable from the sensor. 3 screws located in the left side of the pole. By means of the hammer start separating the Manually complete the separation operation. pole cases.
  • Page 65 Disassembly instruction emaX 2 e6.2 Manually remove the fixed contact. Manually remove the insulating protection. Manually remove the mobile contact. By means of the cross screwdriver unscrew the 2 screws fixing the jumper to the mobile contact assembly. Manually remove the jumper.
  • Page 66 INSTRUCTION HANDBOOK Manually unhook both appendixes of the Manually remove the pin and the tie rod. insulation protection. Manually remove the insulation protection. 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.
  • Page 67 Disassembly instruction emaX 2 e6.2 Manually remove the 10 springs mounted on Manually remove the contacts spacer. the contacts holder. Manually remove the 3 shoulders.
  • Page 68 INSTRUCTION HANDBOOK Disassembled parts • 12 + 6 + 18 + 12 screws (Metal) • 6 sensor covers (Plastic) • 6 cables covers (Plastic) • 3 wires (Plastic and Metal) • 6 sensor plugs (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) •...
  • Page 69 Disassembly instruction emaX 2 e6.2 7. ENERGY CONSUMPTION FOR CIRCUIT BREAKERS DISASSEMBLY Since all disassembly operations illustrated in this document are manual, the CO equivalent emissions can be considered null/negligible.
  • Page 70 INSTRUCTION HANDBOOK...
  • Page 72 — 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 © Copyright 2022 ABB. All rights reserved. Specifications subject to change without notice.