(type Ekip TOUCH). Document is focused on Emax 2 E4.2 3p IEC version, anyway it allows to cover other versions of Emax 2 E4.2 circuit breaker equipped with an electronic trip unit with just few slight differences to be taken into account.
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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...
Disassembly instruction emaX 2 e4.2 Description Position inside circuit breaker Quantity Auxiliary flat assembly Mounted on the MID RTC micro lever Mounted in the MID MID main structure Mounted in the MID Springs charging lever Mounted on the operating mechanism...
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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.
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Disassembly instruction emaX 2 e4.2 By means of thr torx key unscrew the 2 screws Manually remove the 2 plugs. fixing the T.U. Reset assembly to the front cover. By means of the flat screwdriver remove the 2 Manually remove the T.U Reset assembly.
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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...
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Disassembly instruction emaX 2 e4.2 By means of the cross screwdriver unscrew the Manually remove the left and the right shields. 2 + 2 screws fixing the left and the right shields to the circuit breaker. Disassembled parts • 1 trip unit transparent protection (Plastic and Metal) •...
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INSTRUCTION HANDBOOK 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 1 + 1 screws fixing the 2 sides walls located at both sides of the sliding contacts block to the both sides of the sliding contacts block to the...
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Disassembly instruction emaX 2 e4.2 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. After manually remove the sliding contacts Manually remove the 2 springs located at both block.
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INSTRUCTION HANDBOOK 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. assembly as indicated in the picture.
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Disassembly instruction emaX 2 e4.2 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) •...
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INSTRUCTION HANDBOOK 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.
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Disassembly instruction emaX 2 e4.2 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.
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INSTRUCTION HANDBOOK 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.
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Disassembly instruction emaX 2 e4.2 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.
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INSTRUCTION HANDBOOK 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. complete the operation. Manually remove the battery.
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Disassembly instruction emaX 2 e4.2 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.
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INSTRUCTION HANDBOOK 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 By means of the cutter start removing the fixing the trip unit case to the trip unit back blind label located on the side of the trip unit cover.
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Disassembly instruction emaX 2 e4.2 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) •...
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INSTRUCTION HANDBOOK 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.
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Disassembly instruction emaX 2 e4.2 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.
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INSTRUCTION HANDBOOK 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.
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Disassembly instruction emaX 2 e4.2 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.
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INSTRUCTION HANDBOOK 6.5 PHASE 5 – LEFT MID AND CABLE GUIDE 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. screw fixing the left MID to the circuit breaker Flat screwdriver main structure.
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Disassembly instruction emaX 2 e4.2 By means of the flat screwdriver remove the clip and after manually complete the removal. Disassembled parts • 1 + 2 + 1 screws (Metal) • 1 left MID (Plastic and Metal) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) •...
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INSTRUCTION HANDBOOK 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 located in the rear part of the circuit breaker fixing Allen key the CD to the circuit breaker main structure.
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Disassembly instruction emaX 2 e4.2 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.
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INSTRUCTION HANDBOOK 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. By means of the pliers remove the spring and let the pin and the CD block lever separate from the CD base.
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INSTRUCTION HANDBOOK 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 the screw fixing the MID to the circuit breaker Pliers main structure.
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Disassembly instruction emaX 2 e4.2 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.
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INSTRUCTION HANDBOOK 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 By means of the pliers unhook the spring and components constituting the assembly let the spring and the MID reset lever fall by...
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Disassembly instruction emaX 2 e4.2 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.
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INSTRUCTION HANDBOOK 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.
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INSTRUCTION HANDBOOK 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. and by means of the torx key unscrew the 2 screws fixing the docking support to the left No.
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Disassembly instruction emaX 2 e4.2 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.
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INSTRUCTION HANDBOOK By means of the cutter start removing the Manually remove the left shoulder from the 3 labels located on the left shoulder and circuit breaker main structure. manually complete the operation. By means of the torx key unscrew the 4 screws Insert the flat screwdriver as indicated in the fixing the right shoulder to the circuit breaker picture and slightly push it down and after...
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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 6 screws...
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Disassembly instruction emaX 2 e4.2 By means of the cross screwdriver unscrew the Manually remove the mechanical release. 2 screws fixing the mechanical release to the circuit breaker main structure. 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.
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INSTRUCTION HANDBOOK Manually remove the springs charging lever Manually remove the pin and the nut. from the circuit breaker main structure and the spring behind the springs charging lever. 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.
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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...
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Disassembly instruction emaX 2 e4.2 6.10 PHASE 10 – OPERATING SHAFT ASSEMBLY Actions to be performed Tools Cross screwdriver Manually lift the operating shaft assembly and Manually lift the operating shaft assembly and by means of the flat screwdriver remove the 3 by means of the flat screwdriver remove the 3 pins.
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INSTRUCTION HANDBOOK By means of 2 flat screwdrivers remove the Manually remove the cam. benzing. Manually remove the lever.
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INSTRUCTION HANDBOOK 6.11 PHASE 11 – POLES SEPARATION Actions to be performed Tools Torx key Manually remove the operating mechanism By means of the torx key unscrew the 2 screws fixing plate and the lower cross beam. fixing the operating mechanism fixing plate No.
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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.
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INSTRUCTION HANDBOOK Circuit breakers in IEC version characterized by a current rating up to 3200A 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 IEC version - Current rating up to 3200A Manually remove the terminals and their No.
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INSTRUCTION HANDBOOK Circuit breakers in UL version characterized by a current rating of 3200A show differences at level of parts involved in this disassembly phase, consequently here below an analogous section is provided for these circuit breakers. Tools UL version - Current rating 3200A Torx key No.
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Disassembly instruction emaX 2 e4.2 Manually remove the protections from the pole. Disassembly operations illustrated at pictures 210, … , 214 must be performed on the other 2 poles. Disassembled parts • 30 + 18 screws (Metal) • 30 claw contacts (Metal) •...
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INSTRUCTION HANDBOOK Circuit breakers in UL version characterized by a current rating up to 2500A 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 2500A No.
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Disassembly instruction emaX 2 e4.2 Manually remove the terminals and their Manually separate the terminals and their protections. protections. Disassembly operations illustrated at pictures 215, … , 220 must be performed on the other 2 poles. Disassembled parts • 30 + 18 screws (Metal) •...
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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...
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Disassembly instruction emaX 2 e4.2 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.
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INSTRUCTION HANDBOOK By gravity let the 2 filters and the spacer separate from the arching chamber shell. Disassembled parts • 6 + 18 screws (Metal) • 6 arc quenchings (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 6 plates (GP0-3) •...
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Disassembly instruction emaX 2 e4.2 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.
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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.
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Disassembly instruction emaX 2 e4.2 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.
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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.
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Disassembly instruction emaX 2 e4.2 Manually remove the 10 springs mounted on Manually remove the contacts spacer. the contacts holder. Manually remove the 3 shoulders.
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Disassembly instruction emaX 2 e4.2 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.