ABB Sace Tmax XT XT5 THERMOMAGNETIC Installation instructions

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INSTRUCTION HANDBOOK
1SDH002297A1001 - ECN000285442
TMAX XT XT5 THERMOMAGNETIC
Disassembly instructions

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Disassembly instruction tmaX Xt Xt5 tHermomaGnetic
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 a thermomagnetic trip unit.
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 a thermomagnetic 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 open/close 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 
Plugs Mounted on the trip unit 
Trimmers Mounted on the trip unit 
Tripping rod Mounted on the trip unit 
Rod 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 tHermomaGnetic
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)

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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

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

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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
 
 
Allen key
3mm
Torx key
No. 30


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Disassembly instruction tmaX Xt Xt5 tHermomaGnetic
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

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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.