ABB TMAX XT XT7 Installation instructions

—
INSTRUCTION HANDBOOK
1SDH002301A1001 - ECN000285442
TMAX XT XT7
Disassembly instructions

3
Disassembly instruction tmaX Xt Xt7
1. SCOPE
Scope of this document is to illustrate the step-by-step disassembly process of ABB SACE Tmax XT XT7
moulded case circuit breaker equipped with an electronic trip unit (type Ekip DIP LS/I).
Document is focused on Tmax XT XT7 3p IEC version, anyway it allows to cover other versions of Tmax
XT XT7 circuit breaker 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 
Support Mounted on the upper part of the circuit breaker 
Cables protection Mounted on the back part of the trip unit 
Rating plug case Mounted on the front of the trip unit 
Rating plug printed circuit board In the rating plug case 
Backplane Mounted on the back part of the trip unit 
Trip unit case On the trip unit 
Trip unit back cover On the trip unit 
Trip unit printed circuit board In the trip unit 
Left MID cover Mounted on the left part of the circuit breaker 
Left MID Mounted on the left part of the circuit breaker 
Left base Mounted on the left part of the circuit breaker 
Block lever Mounted on the left part of the circuit breaker 
Trip coil In the trip coil group 
Trip coil group Mounted on the left part of the circuit breaker 
Trip test support Mounted on the right part of the circuit breaker 
MID Mounted on the right part of the circuit breaker 
SY lever Mounted on the MID 
Wires cover Mounted on the left part of the circuit breaker 
Wiring Mounted on the left part of the circuit breaker 
Operating mechanism Mounted on the center of the circuit breaker 
Unlocking shaft appendices Mounted on the pin of the operating mechanism 
Lever extension Mounted on the front toggle 
Protections Mounted on the upper case assembly 
Fixed contacts protections Mounted on the fixed contacts 
Covers Below the sensors 
Sensors In the bottom part of the circuit breaker 
Insulation protections On the moving contacts assembly 
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.

5
Disassembly instruction tmaX Xt Xt7
Tools
Allen key
Flat screwdriver
6.1 PHASE 1 – CAP KITS
1
By means of the cross screwdriver unscrew
the 2 screws fixing the terminal clamp to the
circuit breaker main structure.
4
By means of the flat screwdriver push the cap
kits in order to remove them from the circuit
breaker main structure.
3
By means of the allen key remove the screws
connected with the cap kits and after manually
remove the plates.
2
Manually remove the terminal clamp.
Actions to be performed
8mm
Cross screwdriver

6
INSTRUCTION HANDBOOK
 
 
 
(Metal)
 
 

containing brominated flame
retardants)
 
Disassembled parts
5
By means of the flat screwdriver remove the
nuts mounted on the cap kits.

7
Disassembly instruction tmaX Xt Xt7
6.2 PHASE 2 – CIRCUIT BREAKER FRONT COVER AND OPERATING
MECHANISM COVER
6
Manually push the trip unit transparent
protection as indicated by the arrow and
remove it.
8
By means of the cross screwdriver push the
trip test button.
7
Manually close the circuit breaker pushing the
toggle in the direction indicated by the arrow.
9
By means of the cross screwdriver unscrew the
2 screws located in the lower part of the circuit
breaker fixing the circuit breaker front cover to
the circuit breaker main structure.
Actions to be performed
Tools
Torx key
No. 8
Cross screwdriver
Pliers

8
INSTRUCTION HANDBOOK
10
Manually lift the circuit breaker front cover to
complete the removal.
12
By means of the tork key remove the 4 screws
fixing the 2 keylock caps to the circuit breaker
front cover.
11
By means of the pliers remove the trip test
button.
15
By means of the cross screwdriver, unscrew
the 2 screws located in the upper part of the
operating mechanism front cover fixing the
operating mechanism cover to the circuit
breaker main structure.
13
Manually remove the upper keylock cap.
14
Manually remove the lower keylock cap.

9
Disassembly instruction tmaX Xt Xt7
16
By means the cross screwdriver, unscrew the
2 screws located in the bottom part of the
operating mechanism front cover fixing the
operating mechanism cover to the circuit
breaker main structure.
17
Manually lift the operating mechanism cover.
 
protection (Plastic)
 
 
(Plastic)
 
 
 
(Plastic)
Disassembled parts

10
INSTRUCTION HANDBOOK
6.3 PHASE 3 – TRIP UNIT
Actions to be performed Tools
Cross screwdriver
Torx key
No. 20
No. 8
Flat screwdriver
Cutter
Pliers
18
By means of a cross screwdriver unscrew the 2
screws fixing the support to the circuit breaker
main structure.
20
By means of the cross screwdriver unscrew
the 2 screws located in the bottom part of the
trip unit and fixing the trip unit to the circuit
breaker main structure.
19
Manually remove the support.
21
By means of the torx key (size 20) unscrew the
2 screws located over the trip unit fixing the
trip unit to the circuit breaker main structure.

11
Disassembly instruction tmaX Xt Xt7
22
Manually push the cables protection as
indicated by the arrow and remove it.
24
By means of the flat screwdriver remove the
rating plug from the trip unit.
26
Let the rating plug printed circuit board
mounted inside the rating plug let fall by
gravity.
23
By means of the flat screwdriver disconnect
the connector from the trip unit and after
manually complete the removal of the trip unit.
25
By means of the flat screwdriver open the
rating plug.
27
By means of the cutter start removing the label
located on the front of the rating plug case and
manually complete the operation.

12
INSTRUCTION HANDBOOK
28
By means of the cutter start removing the
label located on the front of the trip unit and
manually complete the operation.
30
By means of the torx key (size 8) uncrew the 4
screws fixing the trip unit case to the trip unit
back cover.
32
By means of the cutter start removing the
trip unit Data Matrix label located on the trip
unit back cover and by means of the pliers
complete the operation.
29
By means of the torx key (size 8) unscrew the 2
screws fixing the backplane to the trip unit and
after manually remove the backplane.
31
By means of the flat screwdriver separate the
trip unit case from the trip unit back cover.
33
Manually remove the printed circuit board from
the trip unit case.

13
Disassembly instruction tmaX Xt Xt7
34
By means of the pliers remove the “i TEST”
pushbutton from the trip unit case.
 
(Thermoplastics containing brominated flame
retardants)
 
 
(Thermoplastics containing brominated flame
retardants)
 
(Thermoplastics containing brominated flame
retardants)
 


 
 
 
(Thermoplastics containing brominated flame
retardants)
 
(Thermoplastics containing brominated flame
retardants)
 

brominated flame retardants)
 
 

(Printed circuit board)
 
Disassembled parts

14
INSTRUCTION HANDBOOK
6.4 PHASE 4 – ASSEMBLIES MOUNTED ON CIRCUIT BREAKER LEFT SIDE
Actions to be performed
Cross screwdriver
Torx key
No. 15
Flat screwdriver
Tools
35
By means of the cross screwdriver unscrew the
2 screws fixing left MID to the circuit breaker
main structure.
37
By means of the cross screw driver unscrew the
2 screws fixing the left MID cover to left MID
main structure.
36
Manually remove the left MID.
38
Manually remove the cover left MID cover.
39
By means of the torx key unscrew the 2 screws
fixing the left base group to the circuit breaker
operating mechanism.
40
By means of the cross screw driver unscrew
the 2 screws fixing the left base group to the
circuit breaker main structure.

15
Disassembly instruction tmaX Xt Xt7
41
Manually pull the left base group as indicated
by the arrow and after complete the removal.
43
Manually remove the guide plate pin
42
By means of the cross screwdriver unscrew the
screw fixing the guide plate pin to the left base
group.
44
Manually remove the block lever.
45
Manually remove the pin.
46
Manually remove the pin.

16
INSTRUCTION HANDBOOK
47
Manually separate the spring from the pin
removed at picture 46.
49
By means of the flat screwdriver unhook the
connector from the trip coil group.
51
By means of the cross screwdriver unscrew the
screw fixing the lower plate to the trip coil.
52
Manually push the lower plate in order to
complete the removal.
48
By means of the cross screwdriver unscrew the
3 screws fixing the trip coil group to the circuit
breaker main structure.
50
Manually remove the trip coil group pulling it in
the direction indicated by the arrow.

17
Disassembly instruction tmaX Xt Xt7
53
By means of the flat screwdriver push out from
the trip coil group the trip coil.
 
 
(Thermoplastics containing brominated flame
retardants)
 

circuit board)
 
(Thermoplastics containing brominated flame
retardants)
 
 
 
(Thermoplastics containing brominated flame
retardants)
 
 
 

 

brominated flame retardants)
Disassembled parts

18
INSTRUCTION HANDBOOK
6.5 PHASE 5 – ASSEMBLIES MOUNTED ON CIRCUIT BREAKER RIGHT SIDE
Actions to be performed
Cross screwdriver
Torx key
Allen key
No. 15
Flat screwdriver
Tools
54
By means of the torx key unscrew the screw
fixing the trip test group to the operating
mechanism.
56
By means of the cross screwdriver unscrew the
2 screws located in the lower part of the MID.
55
By means of the cross screwdriver unscrew the
screw located in the upper part of the MID.
57
By means of the allen key unscrew the 2 screws
fixing the trip test group to the MID.
58
Manually complete the removal of the trip test
group.
59
By means of the flat screwdriver push out from
the trip test group the plate.
2.5mm

19
Disassembly instruction tmaX Xt Xt7
60
Manually lift and remove the shunt opening
release plug.
62
Manually complete the removal of the MID.
61
By means of the cross screwdriver unscrew
the screw fixing the MID to the circuit breaker
main structure.
63
Manually remove the auxiliary contacts lever
mounted on the MID.
64
Manually remove the SY lever mounted on the
left side of the operating mechanism.
65
By means of the cross screwdriver unscrew
the screw fixing the wires cover to the circuit
breaker main structure.

20
INSTRUCTION HANDBOOK
66
Manually remove the wires cover and the
wiring.
 
 
(Thermoplastics containing brominated flame
retardants)
 
 
 

 
 
(Thermoplastics containing brominated flame
retardants)
 
(Thermoplastics containing brominated flame
retardants)
 
(Thermoplastics containing brominated flame
retardants)
Disassembled parts