Manuals+

SACE Tmax XT Installation Instructions

Document N.° 1SDH002011A1001 - Rev. H

Product Overview

This document provides installation instructions for the ABB SACE Tmax XT series of circuit breakers, specifically the XT5 3p-4p models. It covers recommended installation conditions, wiring diagrams, dimensional data, and testing procedures.

Recommended Installation Conditions

Proper installation conditions are crucial for the safe and reliable operation of SACE Tmax XT circuit breakers. These conditions vary based on AC/DC voltage levels and specific terminal types.

AC Installation Conditions

Terminal Type Installation Conditions (AC)
Terminal TypeFEF(3)ESRFC CuAl 1x35...185mm²FC CuAl 2x70...240mm²
Ue ≥500 V
Supply side BOTTOM/TOP
Back shieldS (2)S (2)STST-ST
Phase barrier-S1 - 100 mmS1 - 200 mm-S1 - 100 mmS1 - 100 mm
Terminal cover-STSTSTSTST
Ue <500 V
Supply side TOP
Back shield-STSTSTSTST
Phase barrierSCB - 25 mmS1 - 100 mmS1 - 200 mm-SCB - 25 mmS1 - 100 mm
Terminal cover-STSTSTSTST
Ue ≥500 V
Supply side BOTTOM
Back shieldRequired (1)S (4)S (4)STRequired (1)ST
Phase barrierSCB - 25 mmS1 - 100 mmS1 - 200 mm-SCB - 25 mmS1 - 100 mm
Terminal cover-STSTSTSTST

(1) If back panel of the enclosure is bare metal, use back shield code 1SDA112971R1(3p), 1SDA112972R1(4p) or alternatively insulate back panel according to figure 3.
(2) Mandatory only for XT5 with breaking capacity V, X.
(3) At 690V insulate front panel of the enclosures only for XT5 with breaking capacity L, V, X according to figure 3.
(4) In case of installation with double cable terminal, provide 100 mm additional insulation from breaker bottom edge downward.
SCB - Mandatory installation - Supplied as standard with circuit-breaker, not available in the loose terminals kit.
S1 - Mandatory installation - Supplied as standard with the terminals kit.

AC Installation Dimensions

Different installation conditions require specific dimensional clearances. The following table outlines these requirements based on accessories used and voltage levels.

Terminal cover (LTC)High terminal cover (HTC)Phase barriers 25mmPhase Barriers 100mmPhase barriers 200mm
TDLTDLTDLTDLTDL
U < 500V AC3025255025101025101025101025
500V AC < U ≤ 690V ACNot allowed352025404025(7)3520(6)251010250050

(5) In case of ES terminals, this distance shall be assumed from the most external edge of the terminals.
(6) In case of supply side bottom, D=60mm.
(7) With ES and HTC L=50mm.

DC Installation Conditions

Terminal Type Installation Conditions (DC)
Terminal TypeFEFESRFC CuAl 1x35...185mm²FC CuAl 2x70...240mm²
Ue ≥250V
Supply side BOTTOM/TOP
Back shield-STSTST-ST
Phase barrier-S1 - 100 mmS1 - 200 mm-S1 - 100 mmS1 - 100 mm
Terminal cover-STSTSTSTST
250V< Ue ≤500V
Supply side BOTTOM/TOP
Back shieldRequired (1)STSTSTRequired (1)ST
Phase barrierSCB - 25 mmS1 - 100 mmS1 - 200 mm-SCB - 25 mmS1 - 100 mm
Terminal cover(2)STSTST(2)(2)
Ue >500V
Supply side BOTTOM/TOP
Back shieldRequired (3)STSTSTRequired (3)ST
Phase barrierSCB - 25 mmS1 - 100 mmS1 - 200 mm-SCB - 25 mmS1 - 100 mm
Terminal cover(2)STSTST(2)(2)

(1) Use back shield code 1SDA112971R1(3p), 1SDA112972R1(4p) or alternatively insulate back panel of the enclosure, if bare metal, according to figure 4.
(2) Insulation of the panel, shown in figure 4, can be avoided if high terminal covers and back shield are used.
(3) Use back shield code 1SDA112971R1(3p), 1SDA112972R1(4p).
(4) Insulation of the back panel, shown in figure 4, is mandatory.
SCB - Mandatory installation - Supplied as standard with circuit-breaker, not available in the loose terminals kit.
S1 - Mandatory installation - Supplied as standard with the terminals kit.

DC Installation Dimensions

Terminal cover (LTC)High terminal cover (HTC)Phase barriers 25mmPhase Barriers 100mmPhase barriers 200mm
TDLTDLTDLTDLTDL
U ≤ 500V DCNot allowed400254040254040251010250025
500V DC < U < 750V DCNot allowed4020256060506060501010500050

(5) In case of ES terminals, this distance shall be assumed from the most external edge of the terminals.

Dimensional Requirements

Specific dimensional requirements are illustrated for fixed versions of the circuit breakers, detailing the use of insulating plates and clearances. These ensure proper mounting and safety.

AC Fixed Version Dimensions

For fixed versions at Ue ≥ 500 V, with supply from lower terminals, an insulating plate (max thickness 1mm) or code 1SDA112971R1(3p) / 1SDA112972R1(4p) is required. Dimension C must cover the full height of the front door/back panel. To avoid enclosure door insulation, Fd ≥ 156mm.

DC Installation Dimensions

For DC installations, specific clearances and insulating plates are shown for ≤500Vdc and >500Vdc configurations. Dimension C and D must be chosen to cover the full height of the front door/back panel. To avoid enclosure door insulation, Fd ≥ 156mm.

Wiring Diagrams

The document provides wiring diagrams for DC applications, illustrating connections for different voltage ratings and configurations (250V, 500V, 750V) and grounding states (Grounded, Ungrounded).

Installation Procedures and Components

Detailed illustrations show various installation steps, including mounting of the circuit breaker, attachment of components like terminal shields, phase barriers, and terminal covers. Torque specifications are provided for secure connections.

Component Identification

Key components are identified with letters (A-P) and their quantities specified for different breaker configurations (3-pole and 4-pole) and terminal types (F, P, W, etc.).

Specific Terminal Installations

Installation procedures and dimensional data are provided for various terminal types, including:

Cable Rack Assembling

Instructions and diagrams are provided for assembling cable racks, detailing the sequence of steps and component placement.

Crank Operation

Procedures for inserting, operating, and extracting the crank are illustrated. The crank is used to switch the circuit breaker between TEST, DISCONNECTED, and CONNECTED positions. The operation involves turning the crank clockwise until the indicator shows the desired position.

Testing Procedures

LED Indicators

The document details the function of LED indicators on the protection unit, specifying their color and the corresponding condition (e.g., LED ON for device active, LED blinking for alarms or parameter inconsistency).

Ekip Dip Trip Test

A step-by-step procedure for performing the Ekip Dip Trip Test is provided. This includes preparing the circuit breaker (open position), connecting the TT unit, checking the power LED, and then closing the breaker and pressing the trip test button for 2 seconds. The procedure must be followed before connecting the circuit breaker to the system, ensuring primary and auxiliary circuits are inactive.

Current Settings and Calculations

Examples are given for calculating current thresholds (I1, I2) and time delays (t1, t2) based on the nominal current (In) for different trip unit configurations (L, SI, LSI). These calculations are essential for setting up protective functions.

Trip Unit Compatibility

Information is provided regarding the compatibility of Ekip Touch and Hi-Touch trip units with XT5 rating plugs. Trip units with 500A and 630A rating plugs can be equipped with XT5 rating plugs from 250A to 630A, while those up to 400A can use XT5 rating plugs from 250A to 400A.

Dielectric Tests

Instructions related to dielectric tests are available via a separate document (1SDH002267A1001).

Models: XT5 AC, XT5 AC Moulded Case Circuit Breaker, Moulded Case Circuit Breaker, Case Circuit Breaker, Circuit Breaker

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