ABB TMAX XT XT2 THERMOMAGNETIC Installation instructions

—
INSTRUCTION HANDBOOK
1SDH002293A1001 - ECN000285442
TMAX XT XT2 ELECTRONIC
Disassembly instructions

3
Disassembly instruction tmaX Xt Xt2 electronic
1. SCOPE
Scope of this document is to illustrate the step-by-step disassembly process of ABB SACE Tmax XT XT2
moulded case circuit breaker equipped with an electronic trip unit (type Ekip DIP).
Document is focused on Tmax XT XT2 3p IEC version, anyway it allows to cover other versions of Tmax
XT XT2 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 
Cases for microswitches In the right hole of the circuit breaker 
Plug In the left hole of the circuit breaker 
Tripping shaft Mounted on the operating mechanism 
Trip lever In the left hole of the circuit breaker 
Open/close lever In the left hole of the circuit breaker 
Printed Circuit Board In the trip unit 
Sensors In the trip unit 
Trip coil In 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 is
provided:
 
 
 
 
 
applicable)
 
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 tmaX Xt Xt2 electronic
Tools
Allen key
Flat screwdriver
 
 
(Thermoplastics containing brominated flame retardants)
6.1 PHASE 1 – CAP KITS
1
By means of the allen key remove the screws
connected with the cap kits.
2
Insert the flat screwdriver as shown in the
picture and push it up in order to remove the
cap kits.
Actions to be performed
Disassembled parts
5mm

6
INSTRUCTION HANDBOOK
Tools
Cross screwdriver
6.2 PHASE 2 – BREAKING PART FRONTAL
3
By means of the cross screwdriver unscrew the
2 screws fixing the braking part frontal to the
circuit breaker main structure.
5
Manually lift a little bit the breaking part
frontal and complete the removal pulling the
breaking part frontal as indicated by the arrow.
6
By means of the flat screwdriver push up the
reset test rod and manually remove the reset
test rod.
4
By means of the cross screwdriver push the
trip test button.
Actions to be performed
Disassembled parts
 
 
 
Flat screwdriverFlat screwdriver

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Disassembly instruction tmaX Xt Xt2 electronic
6.3 PHASE 3 – TOGGLE AND ITS PROTECTION
7
Manually lift the toggle and its protection and
after separate the toggle from its protection.
Actions to be performed
Disassembled parts
 
 
7
Tools
–

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INSTRUCTION HANDBOOK
6.4 PHASE 4 – TRIP UNIT
8
By means of the cross screwdriver unscrew the
2 screws fixing the trip unit frontal to the trip
unit main structure.
10
By means of the cutter start removing the label
located on the trip unit frontal and manually
complete the operation.
9
Manually disassemble the transparent
protection from the trip unit frontal.
11
By means of the torx key unscrew the 3 screws
fixing the trip unit to the circuit breaker
breaking part.
Actions to be performed
Tools
Cross screwdriver
Cutter
Torx key
No. 15

9
Disassembly instruction tmaX Xt Xt2 electronic
12
Manually slightly pull the trip unit as indicated
by the arrow and after lift the trip unit in order
to complete the removal.
Disassembled parts
 
 
 
 
 
components, …) *
*Trip unit will be furtherly disassembled (see Phases 6.11 and 6.12)

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INSTRUCTION HANDBOOK
6.5 PHASE 5 – PLASTIC PARTS MOUNTED ON THE BREAKING PART
13
Manually slightly push the 2 flaps present on
each case for microswitch located in the right
hole of the breaking part as indicated by the
arrows and after manually lift each case for
microswitch to complete the removal.
15
Manually lift the cable crossing cover located in
the upper part of the breaking part.
14
By means of the flat screwdriver lift the plug
located in the left hole of the breaking part and
after manually complete the removal of the
plug.
16
By means of the flat screwdriver lift the white
plastic lever located in the upper part of the
breaking part and after manually complete the
removal of the white plastic lever.
Actions to be performed
Flat screwdriver
Disassembled parts
 

brominated flame retardants)
 
(Thermoplastics containing brominated flame
retardants)
 
 
Tools

11
Disassembly instruction tmaX Xt Xt2 electronic
6.6 PHASE 6 – REAR COVER
17
By means of the cross screwdriver unscrew the
2 screws fixing the rear cover to the breaking
part.
18
Manually remove the rear cover
Actions to be performed
Disassembled parts
 
 
Cross screwdriver
Tools

12
INSTRUCTION HANDBOOK
Torx key
Tools
No. 8
No. 20
Flat screwdriver
Pliers
6.7 PHASE 7 – OPERATING MECHANISM AND TRIPPING SHAFT
Actions to be performed
19
By means of the torx key (size 20) unscrew
the 4 screws located in the back part of the
breaking part.
21
By means of the flat screwdriver unhook the 2
springs mounted on the operating mechanism.
20
By means of the torx key (size 8) unscrew the 4
screws located at the corners of the breaking
part cover.
22
Manually lift the operating mechanism and
after manually complete removal operation.

13
Disassembly instruction tmaX Xt Xt2 electronic
25
By means of the flat screwdriver remove the
metal plate mounted on the tripping shaft.
23
By means of the pliers remove the spring
mounted in the middle of the operating
mechanism.
26
By means of the flat screwdriver and by means
of the pliers dismount the pin and remove
the pin and the 2 springs mounted on the pin
itself.
24
Manually remove the tripping shaft from the
operating mechanism pulling it as indicated by
the arrow.
Disassembled parts
 
 
 
 
(Thermoplastics containing brominated flame
retardants)
 
 

14
INSTRUCTION HANDBOOK
Tools
6.8 PHASE 8 – BREAKING PART COVER AND CONNECTED PARTS
Actions to be performed
Flat screwdriver
Pliers
Cross screwdriver
27
Manually lift the breaking part cover.
29
Manually lift the motor operator lever located
between the hole previously hosting the
operating mechanism and the left hole and
after manually remove the motor operator
lever.
28
By means of the flat screwdriver push down
the block lever located between the hole
previously hosting the operating mechanism
and the right hole and after manually remove
the block lever.
30
By means of the pliers remove the hood
mounted on the motor operator lever removed
at previous step.

15
Disassembly instruction tmaX Xt Xt2 electronic
31
By means of the flat screwdriver slightly push
on the right the trip lever mounted in the
bottom part of the breaking part and then lift
the lever in order to complete the removal.
33
By means of the cross screwdriver unscrew
the 3 screws located in the bottom part of
the breaking part; the terminals connections
between the breaking part and the trip unit
will fall from the breaking part by gravity.
32
By means of the flat screwdriver remove the
3 plugs located in the bottom part of the
breaking part.
34
Manually separate the plastic part from
the metal parts constituting the terminals
connections removed at previous step.

16
INSTRUCTION HANDBOOK
35

close lever and after manually complete the

Disassembled parts
 
 
 
 
 
containing brominated flame retardants)
 
 
 
 
 
(Thermoplastics containing brominated flame retardants)

17
Disassembly instruction tmaX Xt Xt2 electronic
36
Manually lift the moving contacts assembly
together with the arching chambers connected
with the lower part of the moving contacts
assembly.
38
By means of the flat screwdriver lift the arching
chambers still present in the breaking part
base and after manually complete the removal
of the arching chambers.
37
Manually remove the arching chambers from
the lower moving contacts.
39
By means of the flat screwdriver push the
plates mounted inside the arching chambers
out of the arching chambers.
Disassembled parts
6.9 PHASE 9 – MOVING CONTACTS AND ARCHING CHAMBERS
Actions to be performed
Tools
Flat screwdriver
 
 
 

18
INSTRUCTION HANDBOOK
6.10 PHASE 10 – FIXED CONTACTS
Actions to be performed Tools
Flat screwdriver
Cross screwdriver
40
By means of the cross screwdriver unscrew
the 3 screws located in the back part of the
breaking part base.
42
Manually push the fixed contacts as indicated
by the arrow.
41
By means of the cross screwdriver unscrew
other the 3 screws located in the back part of
the breaking part base.
43
Manually separate the plastic part from the
metal part constituting the fixed contacts.

19
Disassembly instruction tmaX Xt Xt2 electronic
44
By means of the flat screwdriver remove the
metal plate mounted on the the plastic part
constituting the fixed contacts.
Disassembled parts
 
 
 
 
 

20
INSTRUCTION HANDBOOK
6.11 PHASE 11 – TRIP UNIT COVER AND I3 ASSEMBLY
Actions to be performed
45
Insert the flat screwdriver between the I3
assembly and the trip unit cover.
47
Manually push the 3 I3 assemblies as
indicated by the arrow always keeping the flat
screwdriver inserted between the I3 assembly
and the trip unit cover.
46
Slightly move the flat screwdriver as indicated
by the arrow.
48
By means of the pliers remove the spring
mounted on the I3 assembly.
49
Manually separate the I3 support and the I3
group.
50
By means of the torx key undescrew the 4
screws fixing the trip unit cover to the trip unit.
Tools
Flat screwdriver
Pliers
Torx key
No. 8