ABB Sace Tmax XT XT5 THERMOMAGNETIC Installation instructions

—
INSTRUCTION HANDBOOK
1SDH002298A1001 - ECN000285442
TMAX XT XT5 ELECTRONIC
Disassembly instructions

3
Disassembly instruction tmaX Xt Xt5 electronic
1. SCOPE
Scope of this document is to illustrate the step-by-step disassembly process of ABB SACE Tmax XT XT5
moulded case circuit breaker equipped with an electronic trip unit (type Ekip DIP LS/I).
Document is focused on Tmax XT XT5 3p IEC version, anyway it allows to cover other versions of Tmax
XT XT5 circuit breaker equipped with an 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.
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.

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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
Cap kits In correspondence of circuit breaker connection terminals 
UVR rod Mounted on the breaking part cover 
Test lever Mounted on the breaking part cover 
Left hand lever adapter Mounted on the breaking part cover 
RC lever release Mounted on the breaking part cover 
RC lever support Mounted on the breaking part cover 
Right hand op/cl AUX adapter Mounted on the breaking part cover 
Toggle extention Mounted on the toggle 
Toggle protection Mounted on the toggle 
Operating mechanism Mounted on the central pole 
Backplane Mounted on the trip unit 
RC lever Mounted on the trip unit 
Trip unit printed circuit board Mounted on the trip unit 
Trip coil Mounted on the trip unit 
Connector protection Mounted on the trip unit 
Sensors assemblies Mounted on the trip unit 
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 are
provided:
 
 
 
 
 
applicable)
 
5. SEPARATE TREATMENT
Table below lists parts requiring a separate treatment adding information about part location inside
circuit breakers and related quantity.

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Disassembly instruction tmaX Xt Xt5 electronic
Tools
Allen key
Flat screwdriver
6.1 PHASE 1 – CAP KITS
1
By means of the allen key remove the screws
connected with the cap kits.
3
Manually separate the cap kits and their nuts
from circuit breaker main structure.
2
Insert the flat screwdriver as shown in Picture
2 and unhook the cap kits from circuit breaker
main structure.
Actions to be performed
8mm
Disassembled parts
 
 
 
(Thermoplastics containing brominated
flame retardants)

6
INSTRUCTION HANDBOOK
Tools
Cross screwdriver
6.2 PHASE 2 – FRONTAL
4
Manually close the circuit breaker and by
means of the cross screwdriver push the test
button in order to bring the circuit breaker in
trip position.
6
Manually remove the aesthetic front cover.
7
By means of the cross screwdriver unscrew the
4 screws fixing the front cover to the circuit
breaker main structure.
5
Insert the flat screwdriver as shown in the
picture and slightly push the screwdriver as
shown by the arrow in order to raise up and to
unhook the aesthetic front cover from circuit
breaker main structure.
Actions to be performed
Flat screwdriverFlat screwdriver

7
Disassembly instruction tmaX Xt Xt5 electronic
8
Manually remove the front cover.
 
 
 
Disassembled parts

8
INSTRUCTION HANDBOOK
6.3 PHASE 3 – TRIP UNIT
9
By means of the torx key unscrew the 3 screws
fixing the trip unit to the breaking part.
11
Manually remove the trip unit from the
breaking part.
10
By means of the allen key unscrew the 4 screws
located in the bottom part of the circuit
breaker fixing the trip unit to the breaking
part.
Actions to be performed
Tools
Disassembled parts
 
 
Electronic components) *
Allen key
3mm
Torx key
No. 30
*Trip unit will be furtherly disassembled (see Phases 6.7 and 6.8)

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Disassembly instruction tmaX Xt Xt5 electronic
6.4 PHASE 4 – BREAKING PART COVER
12
By means of the cutter start removing the
label on the left side of the breaking part and
manually complete the operation.
14
Manually remove the breaking part cover from
the breaking part main structure.
13
By means of the cross screwdriver unscrew
the 8 screws fixing the breaking part cover to
breaking part main structure.
15
By means of the pliers remove the 2 nuts
mounted on the breaking part cover.
Actions to be performed
Tools
Cross screwdriver
Pliers
Flat screwdriver
Cutter

10
INSTRUCTION HANDBOOK
18
By means of the flat screwdriver turn the test
lever until it comes out from its housing.
19
Manually remove the trip test button and
separate the spring from test lever.
16

mounted on the breaking part cover.
17

rod.

11
Disassembly instruction tmaX Xt Xt5 electronic
20
Manually remove the lever SX assembly and the

breaking part.
22
By means of the flat screwdriver push the pin
as indicated by the arrow and after manually
remove the pin.
21
Manually separate the S52 lever and the spring
from the lever SX assembly.
23
Manually separate the left open/close lever, the
spring and the left hand lever adapter.

12
INSTRUCTION HANDBOOK
26
Manually remove the lever DX assembly located
on the right part of the breaking part.
27
Manually separate the MOE rod indicator and
the related spring from the lever DX assembly.
24
By means of the pliers remove the benzing

25



13
Disassembly instruction tmaX Xt Xt5 electronic
28
By means of the flat screwdriver push the pin
as indicated by the arrow and after manually
remove the pin.
29
Manually separate the right hand open/close
AUX adapter, the open/close AUX lever and the
spring.
Disassembled parts
 
 
 
 
(Thermoplastics containing brominated flame
retardants)
 
 
(Thermoplastics containing brominated flame
retardants)
 
 
 
 

brominated flame retardants)
 
 
(Thermoplastics containing brominated flame
retardants)
 

brominated flame retardants)
 
 

containing brominated flame retardants)
 
 

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INSTRUCTION HANDBOOK
6.5 PHASE 5 – POLES SEPARATION AND OPERATING MECHANISM
30
By means of the torx key unscrew the 5 screws
keeping connected the poles of the breaking
part.
32
Manually separate the poles.
31
Manually remove the 5 screws and the related
inserts.
33
Manually remove the 2 pins and the 2 signalling
devices from the central pole.
Actions to be performed
Cross screwdriver
Torx key
No. 20
Tools

15
Disassembly instruction tmaX Xt Xt5 electronic
34
Manually remove the operating mechanism
from the central pole.
36
Manually remove the toggle extension and the
toggle protection.
35
By means of the cross screwdriver unscrew the
screw fixing the toggle extension to the base
of the toggle.
Disassembled parts
 
 
 
 
 

brominated flame retardants)
 

brominated flame retardants)
 

containing brominated flame retardants)
 
*Poles will be furtherly disassembled (see Phase 6.6)

16
INSTRUCTION HANDBOOK
6.6 PHASE 6 – POLES
37
Manually remove the insert and the I3 lever.
39
By means of the pliers remove the silicone
sheath located in the bottom part of the pole.
38
By gravity let the pin fall down from the pole.
40
By means of the pliers remove the nut located
in the bottom part of the pole.*
Actions to be performed
Cross screwdriver
Torx key
No. 20
Pliers
Flat screwdriver
Tools
*Applicable to lateral poles only

17
Disassembly instruction tmaX Xt Xt5 electronic
41
By means of the flat screwdriver unhook
the rear protection from the pole and after
manually complete the removal operation.
43
By means of the torx key unscrew the 3 screws
located on the side of the pole.
45
Manually separate the let and the right shells.
42
By means of the cross screwdriver unscrew the
2 screws located in the rear part of the pole.
44
Manually remove the 3 screws and the related
short screws.
46
Manually remove the terminal protection.

18
INSTRUCTION HANDBOOK
47
Manually remove the arching chambers.
49
By means of the flat screwdriver remove the
arc quenching from the fixed contacts.
51
By means of the flat screwdriver push the 2
pins as indicated by the arrovw.
48
Manually remove upper and lower fixed
contacts.
50
Manually remove the moving contact assembly.
52
Manually remove the 2 pins.

19
Disassembly instruction tmaX Xt Xt5 electronic
53
Manually separate the moving contact from its
shaft.
Disassembled parts
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Disassembly operations illustrated at pictures from 37 to 53 must be performed on the
other 2 poles.

20
INSTRUCTION HANDBOOK
6.7 PHASE 7 – TRIP UNIT FRONTAL
54
Manually disassemble the transparent
protection from the trip unit frontal.
56
By means of the pliers remove the label with In
current value located on the trip unit frontal.
55
By means of the cutter start removing the label
located on the trip unit frontal and manually
complete the operation.
57
By means of the torx key unscrew the 3 screws
fixing the backplane to the trip unit main
structure.
Actions to be performed
Cutter
Tools
Cross screwdriver
Torx key
No. 8
Pliers