ABB TMAX XT XT6 ELECTRONIC manual
—
INSTRUCTION HANDBOOK
1SDH002300A1001 - ECN000285442
TMAX XT XT6 ELECTRONIC
Disassembly instructions
3
Disassembly instruction tmaX Xt Xt6 electronic
1. SCOPE
Scope of this document is to illustrate the step-by-step disassembly process of ABB SACE Tmax XT XT6
moulded case circuit breaker equipped with an electronic trip unit (type Ekip DIP LS/I).
Document is focused on Tmax XT XT6 3p IEC version, anyway it allows to cover other versions of Tmax
XT XT6 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
Plugs In correspondence of circuit breaker upper connection terminals
AUE lever group Mounted at the left of the toggle
Right base accessory Mounted in the bottom right part of the circuit breaker cover
Trip test rod Mounted on the right base accessory
Left base group Mounted in the bottom left part of the circuit breaker cover
Toggle extention Mounted on the toggle
Toggle protection Mounted on the toggle
Toggle holder Mounted on the toggle base
Dowels Mounted in the bottom part of the breaking part
Mobile contacts assembly Mounted in the middle of the breaking part
Sensors cover Mounted in the trip unit
Trip coil Mounted in the trip unit
Trip unit printed circuit board Mounted in the trip unit
Sensors assembly Mounted in the trip unit
Current sensors joints Mounted on the sensors 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.
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Disassembly instruction tmaX Xt Xt6 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 originally
mounted in corresponce of the upper terminals
from their plugs.
4
Insert the flat screwdriver as shown in the
picture and unhook the cap kits from the
circuit breaker.
2
Insert the flat screwdriver as shown in the
picture and unhook the cap kits and their plugs
from the circuit breaker.
Actions to be performed
5mm
Disassembled parts
(Thermoplastics containing brominated flame
retardants)
(Thermoplastics containing brominated flame
retardants)
6
INSTRUCTION HANDBOOK
Tools
Cross screwdriver
6.2 PHASE 2 – FRONTAL
5
By means of the flat screwdriver push the test
button in order to bring the circuit breaker in
trip position.
7
Manually remove the aesthetic front cover.
8
By means of the cross screwdriver unscrew the
6 screws fixing the upper and the lower front
covers to the circuit breaker main structure.
6
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; operation must be
performed even on the other side of the circuit
breaker.
Actions to be performed
Flat screwdriverFlat screwdriver
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Disassembly instruction tmaX Xt Xt6 electronic
9
Manually remove the upper and the lower front
covers.
Disassembled parts
8
INSTRUCTION HANDBOOK
6.3 PHASE 3 – TRIP UNIT
10
By means of the allen key unscrew the 6 screws
fixing the trip unit to the breaking part.
12
Manually remove the trip unit from the
breaking part.
11
By means of the cross screwdriver unscrew
the circuit breaker fixing the trip unit to the
breaking part.
Actions to be performed
Tools
Disassembled parts
components) *
Allen key
4mm
Cross screwdriver
*Trip unit will be furtherly disassembled (see Phases 6.8 and 6.9)
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Disassembly instruction tmaX Xt Xt6 electronic
6.4 PHASE 4 – BREAKING PART COVER
13
By means of the cross screwdriver unscrew the
levers to the breaking part.
15
By means of the cross screwdriver unscrew
breaking part.
14
16
the same time push the toggle in the direction
indicated by the arrow; after manually remove
Actions to be performed
Tools
Cross screwdriver
Torx key
No. 25
Pliers
Flat screwdriver
Cutter
10
INSTRUCTION HANDBOOK
19
Manually remove the breaking part cover.
20
By means of the cross screwdriver unscrew the
4 screws fixing the right base accessory to the
breaking part.
17
By means of the pliers remove the spring
18
By means of the torx key unscrew the 9 screws
fixing the breaking part cover to the breaking
part main structure.
11
Disassembly instruction tmaX Xt Xt6 electronic
21
Manually remove the right base accessory.
23
Manually separate the trip test rod from its
spring.
22
Manually bring the trip test rod and rotate it
of 90° anticlockwise and the trip test button
automatically will separate from the right base
accessory.
24
By means of the cross screwdriver unscrew
the 3 screws fixing the left base group to the
breaking part.
INSTRUCTION HANDBOOK
27
shock absorbers located at both sides of the
breaking part cover.
28
By means of the cutter start removing the
label located on the breaking part cover and
manually complete the operation
25
Manually remove the left base group.
26
By means of the pliers remove the 3 grids
located in the upper part of the breaking part
cover.
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Disassembly instruction tmaX Xt Xt6 electronic
Disassembled parts
brominated flame retardants)
containing brominated flame retardants)
(Thermoplastics containing brominated flame
retardants)
brominated flame retardants)
14
INSTRUCTION HANDBOOK
6.5 PHASE 5 – TOGGLE AND ARCHING CHAMBERS
29
By means of the cross screwdriver unscrew the
screw fixing the toggle extension to the toggle
holder.
31
Manually remove the toggle protection and the
toggle holder.
30
Manually remove the toggle extension.
32
By means of the pliers remove the toggle base.
Actions to be performed
Cross screwdriver
Pliers
Tools
15
Disassembly instruction tmaX Xt Xt6 electronic
33
Manually remove the arching chambers.
Disassembled parts
brominated flame retardants)
brominated flame retardants)
(Thermoplastics containing brominated flame
retardants)
16
INSTRUCTION HANDBOOK
6.6 PHASE 6 – MOBILE CONTACTS ASSEMBLY AND OPERATING MECHANISM
34
By means of the cross screwdriver unscrew
the 6 screws fixing the upper rear plate and
the lower rear plate to the breaking part main
structure.
36
Manually remove the upper rear plate and the
lower rear plate.
35
By means of the flat screwdriver separate the
upper rear plate from the breaking part main
structure.
37
By means of the flat screwdriver separate
the protection plate from the breaking part
main structure and after manually remove the
protection plate.
Actions to be performed
Cross screwdriver
Allen key
4mm
Pliers
Tube key
Flat screwdriver
Tools
17
Disassembly instruction tmaX Xt Xt6 electronic
38
By means of the flat screwdriver clean from
silicone rear part of the breaking part main
structure.
40
By means of pliers remove the washers located
in housing of the nuts removed at previous
step.
42
By means of the flat screwdriver push out from
the breaking part main structure the 3 dowels.
39
By means of the tube key unscrew the 4 nuts
located in the rear part of the breaking part
main structure.
41
By means of the cross screwdriver unscrew the
the breaking part main structure.
43
By means of the allex key unscrew the 6 screws
located in the bottom part of the breaking part
main structure.
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INSTRUCTION HANDBOOK
44
Manually pull the shaft as indicated by the
arrow and by means of the flat screwdriver
remove the 3 benzings.
46
By gravity let the plates fall down from the
breaking part main structure.
48
By gravity let the nuts and washers connected
with screws removed at previous step fall
down from the breaking part main structure.
45
Lift the breaking part main structure and let
the I3 assemblies separate from the breaking
part main structure by gravity.
47
By means of the allen key unscrew the 3 screws
located in the bottom part of the breaking part
main structure.
49
Manually lift the mobile contacts assembly and
remove it.
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Disassembly instruction tmaX Xt Xt6 electronic
50
mounted on the mobile contacts assembly.
51
the mobile contacts assembly.
Disassembled parts
(Thermoplastics containing brominated flame
retardants)
brominated flame retardants)
INSTRUCTION HANDBOOK
6.7 PHASE 7 – BREAKING PART CASE
52
By means of the torx key unscrew the 3 screws
fixing the arc runners to the breaking part
case.
54
By means of the torx key unscrew the 6 screws
located in the back part of the breaking part
case.
53
Manually remove the 3 arc runners.
55
Manually remove the protections.
Actions to be performed
Torx key
No. 30
Cutter
Tools
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