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ABB TMAX XT XT7M Disassembly Instructions Manual

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INSTRUCTION HANDBOOK
1SDH002302A1001 - ECN000285442
TMAX XT XT7M
Disassembly instructions

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Summary of Contents for ABB TMAX XT XT7M

  • Page 1 — INSTRUCTION HANDBOOK 1SDH002302A1001 - ECN000285442 TMAX XT XT7M Disassembly instructions...

  • Page 3: Safety Notes

    XT7M moulded case circuit breaker equipped with an electronic trip unit (type Ekip DIP LS/I). Document is focused on Tmax XT XT7M 3p IEC version, anyway it allows to cover other versions of Tmax XT XT7M circuit breaker with just few slight differences to be taken into account.

  • Page 4: Disassembly Process

    INSTRUCTION HANDBOOK 5. SEPARATE TREATMENT Table below lists parts requiring a separate treatment adding information about part location inside circuit breakers and related quantity. Description Position inside circuit breaker Quantity Cap kits In correspondence of circuit breaker connection terminals Lever In the T.U.
  • Page 5 Disassembly instructiontmaX Xt Xt7m 6.1 PHASE 1 – CAP KITS Tools Actions to be performed Cross screwdriver Manually remove the terminal clamp. By means of the cross screwdriver unscrew the 2 screws fixing the terminal clamp to the circuit breaker main structure. Allen key Flat screwdriver By means of the allen key remove the screws...
  • Page 6 INSTRUCTION HANDBOOK By means of the flat screwdriver remove the nuts mounted on the cap kits. Disassembled parts • 1 terminal clamp (Plastic) • 2 screws (Metal) • 12 screws and related washers (Metal) • 12 plates (Metal) • 6 cap kits (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 12 nuts (Metal)
  • Page 7 Disassembly instructiontmaX Xt Xt7m 6.2 PHASE 2 – CIRCUIT BREAKER FRONT COVER AND OPERATING MECHANISM COVER Tools Actions to be performed Cross screwdriver Manually push the trip unit transparent Lift the springs charging lever and by means protection as indicated by the arrow and of the cross screwdriver unscrew the screw Flat screwdriver remove it.
  • Page 8 INSTRUCTION HANDBOOK By means of the cross screwdriver unscrew the Manually lift the T.U. reset group and complete screw fixing the T.U. reset group to the circuit the removal. breaker front cover. By means of the flat screwdriver unhook the Manually separate the lever support and the reset lever from the lever support of the T.U.
  • Page 9 Disassembly instructiontmaX Xt Xt7m Manually remove the spring from the lever. Manually remove the reset spring from the lever support. By means of the tork key remove the screw By means of the tork key remove the 2 screws fixing the operation counter cap to the circuit fixing the front cap to the circuit breaker front breaker front cover and after manually remove cover and after manually remove the front cap.
  • Page 10 INSTRUCTION HANDBOOK By means the cross screwdriver unscrew By means the cross screwdriver unscrew the the 2 screws located in the lower part of screw located on the right of the operating the operating mechanism cover fixing the mechanism cover fixing the operating operating mechanism cover to the main mechanism cover to the main structure of the structure of the circuit-breaker.
  • Page 11 Disassembly instructiontmaX Xt Xt7m 6.3 PHASE 3 – TRIP UNIT Tools Actions to be performed Cross screwdriver Manually remove the support. By means of a cross screwdriver unscrew the 2 screws fixing the support to the circuit breaker main structure. Flat screwdriver Torx key No.
  • Page 12 INSTRUCTION HANDBOOK By means of the flat screwdriver open the By means of the flat screwdriver remove the rating plug case. rating plug from the trip unit. Let the rating plug printed circuit board By means of the cutter start removing the label mounted inside the rating plug let fall by located on the front of the rating plug case and gravity.
  • Page 13 Disassembly instructiontmaX Xt Xt7m By means of the torx key (size 8) uncrew the 4 By means of the flat screwdriver separate the screws fixing the trip unit case to the trip unit trip unit case from the trip unit back cover. base.
  • Page 14 INSTRUCTION HANDBOOK By means of the pliers remove the “i TEST” pushbutton. Disassembled parts • 1 support (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 2 + 2 + 2 + 2 + 4 screws (Metal) • 1 cables protection (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 1 rating plug case (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 1 rating plug printed circuit board (Plastic, Metal and Electronic components) SEPARATE TREATMENT (Printed circuit board) • 1 rating plug label (Adhesive paper) • 1 trip unit label (Adhesive paper) • 1 backplane (Plastic) SEPARATE TREATMENT...
  • Page 15 Disassembly instructiontmaX Xt Xt7m 6.4 PHASE 4 – ASSEMBLIES ON CIRCUIT BREAKER LEFT SIDE Tools Actions to be performed Cross screwdriver By means of the cross screwdriver unscrew the Manually remove the motor PCS support from 2 screws fixing the motor PCS support to the the circuit breaker main structure.
  • Page 16 INSTRUCTION HANDBOOK By means of the cross screwdriver unscrew the By means of the flat screwdriver unhook the 3 screws fixing the trip coil group to the circuit connector from the trip coil group. breaker main structure. By means of the flat screwdriver lift the trip Manually remove the trip coil group.
  • Page 17 Disassembly instructiontmaX Xt Xt7m By means of the flat screwdriver push out from the trip coil group the trip coil. Disassembled parts • 2 + 1 + 3 + 1 screws (Metal) • 1 PCS cover (Plastic) • 1 motor PCS support (Plastic, Metal and Electronic components) SEPARATE TREATMENT (Printed circuit board) • 1 lower plate (Metal) • 1 trip coil (Plastic, Metal and Magnets) SEPARATE TREATMENT (Magnets) • 1 trip coil group (Plastic and Metal) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants)
  • Page 18 INSTRUCTION HANDBOOK 6.5 PHASE 5 – ASSEMBLIES MOUNTED ON CIRCUIT BREAKER RIGHT SIDE Tools Actions to be performed Torx key By means of the torx key unscrew the screw By means of the allen key unscrew the 2 screws fixing the support key block over the MID to fixing the support key block over the MID to the operating mechanism.
  • Page 19 Disassembly instructiontmaX Xt Xt7m Manually lift and remove the shunt opening By means of the cross screwdriver unscrew the release plug. 4 screws fixing the MID to the circuit breaker main structure. By means of the flat screwdriver remove the Manually remove the lever pulling it as benzing mounted on the lever present on the indicated by the arrow.
  • Page 20 INSTRUCTION HANDBOOK By means of the cross screwdriver unscrew Manually remove the wires cover and the the screw fixing the wires cover to the circuit wiring. breaker main structure. Disassembled parts • 1 + 2 + 4 + 1 screws (Metal) • 1 support key block (Metal) • 1 key lock holder (Metal) • 1 shunt opening release plug (Plastic) • 1 benzing (Metal) • 1 lever (Plastic) • 1 MID (Plastic, Metal and Electronic components) SEPARATE TREATMENT (Printed circuit board)
  • Page 21 Disassembly instructiontmaX Xt Xt7m 6.6 PHASE 6 – OPERATING MECHANISM Actions to be performed Tools Flat screwdriver By means of the flat screwdriver lift the lever By means of the flat screwdriver remove the mounted on the left side of the circuit breaker cover cap on the left side of the circuit breaker.
  • Page 22 INSTRUCTION HANDBOOK Manually charge circuit breaker springs. Close the circuit breaker pushing the close button. By means of the allen key unscrew the 2 screws By means of the flat screwdriver push the shaft located on the left side of the operating support as indicated by the arrow.
  • Page 23 Disassembly instructiontmaX Xt Xt7m By means of the pliers remove the spring. By means of the torx key (size 15) unscrew the screw fixing the RTC lever to the operating mechanism. Manually remove the RTC lever. By means of the flat screwdriver push the shaft support as indicated by the arrow. Put the circuit breaker with the left side up and Push down the rod using the hammer.
  • Page 24 INSTRUCTION HANDBOOK Put the circuit breaker with front up and push Manually push the lever mounted on the the rod as indicated by the arrow until the pin bottom right part of the circuit breaker main comes out from the hole left by the cover cap structure.
  • Page 25 Disassembly instructiontmaX Xt Xt7m Manually remove the rear plate mounted on the By means of the torx key (size 25) unscrew the lower part of the circuit breaker. 6 screws located in the back part of the circuit breaker. By means of the torx key (size 20) unscrew the Manually remove the upper case assembly.
  • Page 26 Operating mechanism contains springs: their removal constitutes a potential hazard if not performed in the proper way and using dedicated tools. Based on this ABB indication is not to remove them from the operating mechanism and to manage the assembly with the maximum level of attention during disassembly and dismantle phases.
  • Page 27 Manually remove the springs charging lever. By means of the flat screwdriver remove the pin mounted on the springs charging lever and the related benzing. Manually remove the spring located on the operating mechanism.
  • Page 28 INSTRUCTION HANDBOOK Disassembled parts • 1 lever (Metal) • 1 lever (Plastic and Metal) • 2 cover caps (Plastic) • 4 + 1 + 9 + 6 + 6 + 2 screws (Metal) • 1 plate (Metal) • 1 + 1 springs (Metal) • 1 RTC lever (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated • 1 + 1 pins (Metal) • 2 rear plates (Plastic) • 1 upper case assembly (Plastic and Metal) * • 1 operating mechanism (Plastic and Metal) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 2 unlocking shafts (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 1 springs charging lever (Plastic and Metal) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants)
  • Page 29 Disassembly instructiontmaX Xt Xt7m 6.7 PHASE 7 – UPPER CASE ASSEMBLY AND UPPER FIXED CONTACTSS Tools Actions to be performed Allen key By means of the allen key unscrew the 6 screws Manually remove the 2 protections located in fixing the fixed contacts and make them fall the upper part of the upper case assembly.
  • Page 30 INSTRUCTION HANDBOOK By means of the cross screwdriver unscrew the 2 screws fixing the fixed contact protection to the upper fixed contact and manually complete the removal operation. Disassembled parts • 2 protections (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 6 + 3 + 6 screws (Metal) • 3 washers (GP0-3) • 3 fixed contacts protections (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants)
  • Page 31 Disassembly instructiontmaX Xt Xt7m 6.8 PHASE 8 – LOWER CASE ASSEMBLY, MOVING CONTACTS ASSEMBLY AND SENSORS Actions to be performed Tools Cutter By means of the cutter start removing the label Manually lift the lower case assembly and located on the side of the lower case assembly complete the removal.
  • Page 32 INSTRUCTION HANDBOOK Manually push the cover mounted below the Manually remove the sensors. sensors as indicated by the arrow. By means of the flat screwdriver lift the Manually remove the moving contacts moving contacts assembly until it’s unhooked assembly. from the lower case.
  • Page 33 Disassembly instructiontmaX Xt Xt7m By means of the flat screwdriver unhook from both sides the insulation protections and after manually complete the removal. Disassembled parts • 1 label (Adhesive paper) • 6 screws (Metal) • 6 screws and related washers (Metal) • 3 fixed contacts (Metal) • 3 covers (Plastic) SEPARATE TREATMENT (Thermoplastics containing brominated flame retardants) • 3 sensors (Plastic and Mixture) SEPARATE TREATMENT (Thermoplastics containing bromintated flame retardants)
  • Page 34 INSTRUCTION HANDBOOK 6.9 PHASE 9 – ARCHING CHAMBERS AND CIRCUIT BREAKER COVER Actions to be performed Tools Cross screwdriver Manually remove the arching chambers. By means of the cross screwdriver unscrew the Cutter screw fixing the metallic command protection to the circuit breaker cover. Torx key No.
  • Page 35 Disassembly instructiontmaX Xt Xt7m Manually remove the cover plug. By means the cutter lift the label located on the side of the circuit breaker cover and manually complete the removal. By means the cutter lift the label located By means the cutter lift the label located on the side of the circuit breaker cover and on the side of the circuit breaker cover and manually complete the removal.
  • Page 36 INSTRUCTION HANDBOOK By means of the flat screwdriver remove the plug from the circuit breaker cover. Disassembled parts • 3 arching chambers (Plastic and Metal) • 1 + 2 screws (Metal) • 1 metallic command protection (Metal) • 1 cover plug (Plastic) • 3 labels (Adhesive paper) • 1 plug (Plastic) separate? • 1 circuit breaker cover (Plastic)
  • Page 37 Disassembly instructiontmaX Xt Xt7m 7. ENERGY CONSUMPTION FOR CIRCUIT BREAKERS DISASSEMBLY Since all disassembly operations illustrated in this document are manual, the CO equivalent emissions can be considered null/negligible.
  • Page 38 INSTRUCTION HANDBOOK...
  • Page 39 Disassembly instructiontmaX Xt Xt7m...
  • Page 40 — ABB SACE A division of ABB S.p.A. L.V. Breakers Via Pescaria 5, 24123 Bergamo - Italy Phone: +39 035 395.111 Fax: +39 035 395.306-433 abb.it/lowvoltage © Copyright 2022 ABB. All rights reserved. Specifications subject to change without notice.