1
I N S TA L L AT I O N I N S T R U C T I O N S
Retrofit of Spectra G-frame with ABB Tmax XT5
breaker Dual Mount (Bolt-On kits)
WARNING
Danger of electrical shock or injury. Turn OFF power ahead of the panel board or switchboard before working inside the equipment
or removing any component. Equipment is to be installed and maintained by properly trained and qualified personnel only.
General
These instructions are applicable to retrofit of Spectra G-frame with ABB Tmax XT5 breaker.
Table 1 lists the parts included in the bolt-on circuit breaker kits for double branch configurations (400A max).
Installation
Numbers in brackets in the following instructions and figures refer to the item numbers in table below.
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Retrofit Kit
Item Part Description Qty. Item Part Description Qty.
1 1/4 - 20 x 1.50" carriage bolt 6 12 Right link and tap assembly 1
2 1/4 - Belleville Washer 6 13 Phase Barrier 1
3 1/4 - 20 Nut 6 14 Filler Plate 1 2
4 Breaker mounting bracket 2 15 Filler Plate Middle 1
Thread Cutting Screw
16 2
5 Thread-forming screw #10-32 10 #4-20 x 0.375
17 Blankout Plate 1
6 Mounting Stud 4
18 Screw/Washer, steel 10-32X5/16 4
#6 x 32 , 5/16" Length, Pan Head,
7 4
Phillips screw
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Table 1. Retrofit kit
8 Supplied with breaker 6
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Required Tools
9 Supplied with breaker 6
Below listed tools are required for installation
10 Left link and Tap assembly 1 Item Part Description
1 Torque wrench
11 Middle link and Tap assembly 1
2
STEP 1 STEP 2
Prepare the breaker, refer to breaker instruction document for Find the side of the panel interior at which the dimension from the
more information. Install the appropriate lugs as in load side as face of nearest vertical bus to the inner face of the bus support rail
shown in figure 1. is 2.75 inches, as illustrated in figure 2 .
Left side Right side
cable entry cable entry
LOAD LINE LINE LOAD
Lugs installed
on load side 2.75" REF Main Bus
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Figure 1. Breaker preparation Figure 2. Double branch, ABB XT5; Assembly end view
Step 3 Step 4
Install the link assembly - Right link assembly [12] to adjacent pole Install the link assembly - Middle link assembly [11] to middle pole
from 2.75 inches ref. as shown in figure 3. Fasten the complete link as shown in figure 4. Fasten the complete link assembly loosely to
assembly loosely to the vertical bus with carriage bolt [1], Belleville the vertical bus with carriage bolt [1], Belleville washer [2] and nut
washer [2] and nut [3]. Refer figure 3. [3]. Refer figure 4.
2x 2x 2x
2.75"
REF ! 1 2 3
12 11 1 2 3
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2x 2x 2x
Figure 3. Installation of right link assembly Figure 4. Installation of middle link assembly
Step 5 STEP 6
Install the link assembly - Left link assembly [10] to outermost pole Install the breaker mounting bracket [4] on the bus support rail
as shown in figure 5. Fasten the complete link assembly loosely to with the thread forming screw [5], torque the screw to 30 lb-in.
the vertical bus with carriage bolt [1], Belleville washer [2] and nut Refer figure 6.
[3]. Refer figure 5.
10 1 2 3 4 5
— 2x 2x 2x — 2x 4x
Figure 5. Installation of left link assembly Figure 6. Installation of breaker mounting bracket
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STEP 7 STEP 7 Continued
Install the pre-assembled breaker. Attach the breaker assembly to
mounting brackets [4] with mounting stud [6], torque the mount-
ing stud [6] to 18 lb-in. Refer figure 7a. Attach to link assembly with
Hex terminal screw [8] and conical washer [9], torque the screw [8]
to specification in document 1SDH002011A1002. Refer figure 7b.
4x 6 ! 8 9 !
— — 6x 6x
Figure 7a. Installation of breaker Figure 7b. Installation of breaker
STEP 8 STEP 9
Remove the plastic wall (knock out) in terminal cover and install the Note: Use M3 x 8 if the required screw is not available.
terminal cover on load side (slide down in as shown in figure 8). Install the phase barrier [13] on the breaker with Pan head, Phillips
screw [7], torque the screw [7] to 9 lb-in. Refer figure 9.
Remove knock out features before
assembly to breaker
Remove knock out features before
assembly to breaker
4x 7 13
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Figure 8. Installation of terminal cover Figure 9. Installation of phase barrier
STEP 10 STEP 11
Tighten all the three bolted strap connections (carriage bolt as- Prepare the filler plates [14, 15] if single breaker installation is used.
sembly) at the vertical bus to 65 lb-in. It may be necessary to re- Attach the blankout out plate [17] to the filler plate with thread
move adjacent circuit breaker modules to allow access to the forming screw [5], torque the screw [5] to 30 lb-in. Refer figure 11.
bolted connections at the vertical bus.
1x 15 2x 5 1x 14 17
Item 5 - screw to be assembled with screw
head from rear/behind the filler plate and
thread end projecting outside as shown
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Figure 10. Tighten the bolted strap connection Figure 11. Preparation of filler plate
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STEP 12: Tape unused contacts STEP 13
Apply multiple wrappings of insulation to unused strap contact Install the preassembled filler plates [14, 15] with thread forming
surfaces, as illustrated in figure 12. A UL-recognized 105 ° C ther- screw [5], torque the screws [5] to 30 lb-in. Refer figure 13. Mount
moplastic tape (OANZ2, Permacel P-30-105, or 3M66R) is re- the thread cutting screw [16] and screw [18] on filler plates. Torque
quired. Overlap greater than one-half of each preceding turn, as the screw [16] to 6.5 lb-in. Refer figure 13.
shown to achieve a minimum tape thickness of 0.028 inch. This in-
sulation thickness requires two complete layers of overlapping
turns. 14 15 14
Double branch breakers installed
Single breaker and other side
with blank out plate
Apply tape to these unused
strap contact surfaces 4x 5 2x 16 4x 18
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Figure 12. Applying insulating tape to unused contact surfaces Figure 13. Installation of filler plate
STEP 14: Optional - XT5 Kirk lock mounting kit assembly STEP 14: Continued - XT5 Kirk Lock Mounting Kit and Installa-
Pre-assemble Kirk lock mounting kit assembly as shown in figure tion
14a. Choose the appropriate panel width 1x space plate from the kirk
Note: Kirk-lock is not included in the kit. Re-use Kirk lock from lock kit and fit 1x space plate on the panel with thread forming
panel. screw (2x) as shown in figure 14b.
On the 1x space plate install the kirk lock assy with 2x screws fas-
tened or 1x space plate. Verify the lock function after complete in-
stallation.
Remove extensions on punger (if any) !
1X PLATE 40
2x
Kirk Bracket Plate 1X PLATE 44
Panel 1X space plate set
(for Kirk mounti ng only)
Thread forming
4x 4x screw #10 - 32
1x 2x
Panel 1X space plate #10-32 Screw
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Figure 14a. XT5 kirk lock mounting kit assembly Figure 14b. XT5 kirk lock installation on panel
Documentation Number: DET 1053
Disclaimer : These instructions do not cover all details or variations in equipment nor do they provide for every possible contingency that may be met in connection with installation, operation
or maintenance. Should further information be desired or should particular problems arise that are not covered sufficiently for the purchaser's purposes, the matter should be referred to the
ABB Company.
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ABB Inc. We reserve the right to make technical We reserve all rights in this document and in
305 Gregson Drive changes or modify the contents of this doc- the subject matter and illustrations con-
Cary, NC 27511 ument without prior notice. With regard to tained therein. Any reproduction, disclosure
purchase orders, the agreed particulars to third parties or utilization of its contents
shall prevail. ABB AG does not accept any re- – in whole or in parts – is forbidden without
sponsibility whatsoever for potential errors prior written consent of ABB AG. Copy-
or possible lack of information in this docu- right© 2019 ABB
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