ABB SACE · Ekip
ABB Emax 2 Repair and Refurbishment
Emax 2 is ABB's current air circuit breaker, and its faults are the everyday kind: coils, gear motors, contact wear on busy breakers, Ekip connectors and racking gear. We repair them in the workshop, test the Ekip trip unit with ABB's own test kit and send the breaker back ready to rack in.
- FramesE1.2–E6.2
- Trip unitsEkip Dip · Touch · Hi-Touch
- Turnaround2–5 workshop days
- Warranty24 months on overhauls
Repair, don't replace
A current breaker still has a lead time
Emax 2 is in production, so a new one is always on offer. A new breaker still has to be ordered, configured with the right trip unit, accessories and rating plug, shipped and commissioned. While that happens, the cell stays empty or the load runs without its incomer.
Most Emax 2 faults are a single worn or failed component on an otherwise sound breaker. A closing coil, a gear motor, a damaged Ekip connector or eroded contacts on a high-duty unit don't justify a new frame. We replace the part, test the whole breaker and return it with the configuration it left with. The settings, accessories and secondary wiring stay as your engineers set them up, and the breaker goes back into the same cradle.
For a site that can't take the downtime at all, an exchange unit can fly out while yours is in the workshop, where we hold your model.
- Same breaker, same configuration, same cradle
- Ekip trip unit tested with ABB's own test kit
- Fixed price after inspection
Common faults
What we see on Emax 2
Won't close
Closing coil failure or loss of its supply, or a mechanism that has stiffened. The coil is a bench job; the mechanism is a strip-down.
Won't charge
Gear motor, limit switch or gear train faults. The motor is replaced and charge time checked.
Ekip connector faults
Intermittent connections between the Ekip trip unit and the breaker produce alarms that look like trip unit failure. We find which one it is before replacing anything.
Contact erosion
Main and arcing contacts wear fastest on breakers that switch often. Wear is measured against the OEM limits.
Racking gear
Worn racking mechanisms, cluster contacts and position switches on drawout units and their fixed parts.
Shunt and undervoltage releases
Opening coils and undervoltage releases tested and replaced, then proven at reduced voltage.
The refurbishment
What an Emax 2 overhaul includes
- Strip-down and inspection against ABB wear limits
- Mechanism cleaned, worn parts replaced, re-lubricated, travel and latching checked
- Main and arcing contacts renewed; arc chutes cleaned and inspected
- Closing coil, shunt trip, undervoltage release and gear motor tested and replaced as needed
- Ekip connectors, auxiliary contacts and secondary terminals restored
- Ekip Dip, Touch or Hi-Touch trip unit tested, and set to your protection settings
- Racking gear and cluster contacts checked when the fixed part comes with the breaker
How it is tested
Secondary injection with ABB's Ekip test kit across every enabled protection element, against the published curve. Contact resistance per pole, insulation resistance, and mechanical operation. Results, as-left settings, photos and the parts list go on the certificate.
Coverage
Emax 2 models we repair
| Frames | E1.2 to E6.2, fixed and drawout |
| Trip units | Ekip Dip, Ekip Touch, Ekip Hi-Touch |
| Testing | ABB Ekip test kit, secondary injection |
| Fixed parts | Cluster contacts, racking gear, position switches |
| Earlier generation | See Emax E1–E6 with PR trip units |
From your site and back
Turnaround, Express and exchange
Standard
About 3 days air freight each way and 2–5 working days in the workshop. Typically 8–11 working days door to door, plus customs clearance.
How it worksExpress
A 1–2 day workshop turnaround, about 7–8 working days door to door plus clearance.
Exchange units
We hold many tested units in the UK*, shipped by air the day you report a fault if your model is in stock.
Exchange unitsCustoms
DAP or DDP. We prepare the commercial invoice and the repair-and-return paperwork; your broker confirms duty treatment.
Shipping & customs*Subject to model and rating.
FAQ
Emax 2 questions
Emax 2 is still in production. Why repair instead of buying new?
A new breaker has to be ordered, configured and commissioned, and the cell waits while it happens. Most faults are one worn component on a sound breaker. Repairing it keeps your configuration and settings and is usually the faster route.
How do you test the Ekip trip unit?
With ABB's Ekip test kit, by secondary injection across every enabled element. Each result is recorded against its tolerance band on the certificate.
The Ekip unit shows an alarm. Is the trip unit faulty?
Not always. Connector faults produce similar symptoms. Bench testing separates a trip unit fault from a connection or wiring fault before any part is replaced.
Will the breaker come back with our settings?
Yes. It is tested at your settings, and the as-left settings are printed on the certificate.
Can we have a unit while ours is away?
If we hold your model and rating, an exchange unit ships by air the day you report the fault. Exchange units.
Can you test an Emax 2 without repairing it?
Yes. Secondary injection testing is a service in its own right. It is a useful way to get evidence that an incomer or bus-tie still trips to its curve, for example after a fault or before a planned outage, without stripping anything. If the breaker passes, you get the certificate. If it doesn't, you get a fixed price for the repair before any work starts.
Send us the nameplate
A photo of the nameplate and the fault is enough for a first answer. We reply the same working day with a recommendation and a price for diagnosis and freight.