ABB Emax E1 Installation And Service Instructions Manual
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ABB Emax E1 Installation And Service Instructions Manual

Low voltage air circuit-breakers emax series
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Installation and
service instructions
1SDH000460R0002
L6555
Installation, service and maintenance
instructions for low voltage air
circuit-breakers
Emax

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  • Page 1 Installation and Installation, service and maintenance service instructions instructions for low voltage air circuit-breakers Emax 1SDH000460R0002 L6555...

  • Page 2: Description 4

    ABB investigate all such ways. • Anyone using service procedures or tools, whether or not recommended by ABB, must satisfy himself thoroughly that neither personal safety, nor equipment safety, will be jeopardized by the service me- thod or tools selected.

  • Page 3: Table Of Contents

    8.4.12. Extractable..... . . 27 Index Measures to be taken for any operating anomalies . . 28 Description ..... . . 4 1.1.

  • Page 4: Description

    Description 1.1. General characteristics The SACE Emax series of circuit-breakers and disconnectors consists of a steel sheet structure which houses the operating mechanism, the poles and the auxiliary parts. Each pole, insulated from the others, contains the circuit-breaking parts and the current transformer of the corresponding phase.

  • Page 5: Moving Part Construction Characteristics

    1.4. Moving part construction characteristics Selective circuit-breaker Current-limiting circuit-breaker 1 Supporting structure made of steel sheet 2 Current sensor for protection release 3 Terminal supporting insulating box 4 Horizontal rear terminals 5a Main fi xed contact plates 5b Fixed arcing contact plates 6a Main moving contact plates 6b Moving arcing contact plates 7 Arcing chamber...

  • Page 6: Checking On Receipt

    Checking on receipt Examine the state of the material received and its consistency with the content of the order. Should any damage or errors be found on unpacking, which must be carried out carefully, make the relative notifi cation within and not over 5 days from the receipt of the material.

  • Page 7: Installation

    Installation 4.1. Installation room Install the circuit-breaker in a dry, dust-free, non-corrosive room, and in such a way that it is not subject to shocks or vibrations. Where this is not possible, install it inside a switchboard with a suitable degree of protection. For the preparation of the installation room, please refer to the “Overall dimensions”...

  • Page 8: Installation Of The Fi Xed Part (Fig. 12)

    Installation of the fi xed part (Fig. 12) Attach the fi xed part by means of the screws (1), washers (2) and nuts (3) (M8 x 16), supplied by ABB SACE. if other screws are used, make sure that the head of the screws does not extend more than 5.5 mm from the base of the fi xed part.

  • Page 9: Electrical Connections

    Electrical connections 5.1. Connections to the power circuit 5.1.1. Shapes of the terminals Fixed circuit-breaker Fixed part for withdrawable circuit-breaker Horizontal rear terminals Vertical rear terminals Horizontal rear terminals Vertical rear terminals Front terminals Front terminals Flat terminals Fig. 14 Fig.
  • Page 10 Vertical terminals Horizontal and front terminalsi Continuous Busbar Continuous Busbar current-carrying capacity cross-section current-carrying capacity cross-section Circuit-breaker Iu [A] 35°C 45°C 55°C 35°C 45°C 55°C E3S/H/V 12 1250 1250 1250 1250 1x(60x10) 1250 1250 1250 1x(60x10) E3S/H/V 16 1600 1600 1600 1600 1x(100x10)

  • Page 11: Assembly Procedure For The Connection Busbars

    5.1.3. Assembly procedure for the connection busbars Check the state of the contact surfaces of the connections very carefully: they must be very clean with no burrs, dents or traces of rust which must be eliminated using a fi ne fi le or an emery cloth to prevent localized increases in temperature. On completion of the operation, remove all traces of grease or dust with a cloth soaked in a suitable solvent.

  • Page 12: Withdrawable Circuit-Breaker

    5.3.2. Withdrawable circuit-breaker For connection of the moving part to the auxiliary circuits, a connection with sliding contacts is available on the fi xed part (see fi gure), identifi ed by code X on the electrical circuit diagram. The terminals of the fi xed connector are immediately accessible when the compartment door is open. Furthermore a terminal box identifi...

  • Page 13: Conversion Of The Auxiliary Contacts Or Of The Signalling Contacts (Disconnected - Test Isolated - Connected), From Normally Closed (Opening) To Normally Open (Closing) Or Vice Versa

    5.4. Conversion of the auxiliary contacts or of the signalling contacts (disconnected - test isolated - connected), from normally closed (opening) to normally open (closing) or vice versa The contacts are wired at the factory as shown on the electrical circuit diagram. If it is necessary to change their state for instal- lation requirements, proceed as follows.

  • Page 14: Putting Into Service

    Putting into service 6.1. General procedures - Check tightness of the power connections at the circuit-breaker terminals - Carry out all the preparatory operations on the release - Make sure that the value of the auxiliary circuit power supply voltage is between 85 and 110% of the rated voltage of the elec- trical applications - Make sure that there is an adequate air circulation in the place of installation to avoid overheating - Also carry out the checks specifi...

  • Page 15: Instructions For Use

    Instructions for use 7.1. Operating and signalling parts 1 Pushbutton for the manual opening operation 2 Lever for manual loading of the closing springs 3 Mechanical indicator for circuit-breaker open “O” and closed “I” 4 Mechanical indicator for protection release tripped (on request) 5 Pushbutton for the manual closing operation 6 Signalling device for springs loaded - unloaded 7 Operation counter (on request)

  • Page 16: Circuit-Breaker Closing And Opening Procedures

    7.2. Circuit-breaker closing and opening procedures The operation of the circuit-breaker can be either manual or electrical. a) Manual loading of the closing springs - Make sure that the indicator (3) shows “O” (circuit-breaker open) - Make sure that the indicator (6) is WHITE (springs unloaded) - Repeatedly activate the lever (2) until the indicator (6) changes its color to YELLOW b) Electrical loading of the closing springs...

  • Page 17: Racking-In/Out Operation

    7.3. Racking-in/out operation WARNING: A) Open the circuit-breaker before carrying out any racking-in/out operation. B) The circuit-breaker (moving part) and fi xed part are fi tted with a lock which prevents the fi xed part from being racked into the circuit-breakers with a different rated current: the congruence of the anti-racking-in lock must be checked by the operator before carrying out the racking-in operation to avoid any unnecessary stress.
  • Page 18 a) Positioning the moving part in the fi xed part in the DISCONNECTED position Lift the moving part as shown in the paragraph (3) and insert it in the fi xed part guide, tilting it as shown in fi gure 2. The manual connection must allow the edge (E) of the circuit-breaker guide to slide under the blocks (D) of the fi...

  • Page 19: Maintenance

    WARNING ELECTRICAL SHOCK HAZARD: Shock Hazard or Injury. ABB declines all responsibility for damage to things and injury to people due to failure to comply with the instructions contained in this document. Maintenance tasks must be performed by qualifi ed staff who are thoroughly familiar with the equipment.

  • Page 20: Maintenance Program

    (1) Data referring to standard installation in accordance with product standards. For other applications, consult ABB Sace. (2) Extreme atmospheric conditions, polluted atmosphere or vibrations may shorten the life of the application. Consult ABB Sace. (3) Emax LTT for low temperature enviroment application (-40°C ... +70°C) 8.3.

  • Page 21: Dismantling Tab And Cap

    8.3.4. Dismantling tab and cap - The tab (1) of the release by rotating the screws (2) as shown in fi gure 33. - Remove the front cap (3) by loosening the four screws (4). Fig. 33 - If there is a minimum release, remove the coils support and release the control springs, closing and opening the switch. Fig.

  • Page 22: Electrical And Mechanical Accessories

    8.3.6. Electrical and mechanical accessories - Check that the accessories are fi xed to the switch - Check that the electrical accessories are connected to the switch - Reduction gear: after 10000 operations check brushes for wear and replace the reduction gear if necessary. - Check that the releases (SOR-UVR-SRC) are in good condition (no excessive wear, overheating, breakages) Fig.

  • Page 23: Interlock

    8.3.10. Interlock - Check that the interlock devices have been correctly installed and operate correctly between adjacent and superimposed switches (if present). The operating test cannot be run in the Test or Extracted positions. 8.4. Second level maintenance operations 8.4.1. Preliminary operations: - open the switch and check that the control springs are unloaded - in the case of a circuit breaker, remove the circuit breaker...

  • Page 24: Dismantling The Tab, Cap And Arcing Chambers

    8.4.4. Dismantling the tab, cap and arcing chambers - Remove the fl ange (1) of the release, turning the screws (2) as shown in the fi gures - Remove the front escutcheon plate (3) by removing the four screws (4) - Remove, if present, one or both side guards (5) by removing the front (6) and lateral (7) screws - Remove the arcing chambers (8) by removing the screws (9).

  • Page 25: Mechanical Control

    - Check that the opening and closing shafts are free to rotate. Fig. 43 - In the case of deformed or oxidated springs, missing rings or serious wear to the controls contact ABB Sace (*). (*) Subject to the customer’s approval, ABB can replace “A” type parts.

  • Page 26: Protection Releases

    Fig. 45 6.2) close the circuit-breaker and check the gap A - If the gap A is not correct, contact ABB Sace (*) - If the gap A is correct, open the circuit breaker and refi t the arc chambers.

  • Page 27: Maintenance Operations; Fi Nal Checks

    8.4.10. Maintenance operations; fi nal checks: - Refi t each part and if necessary reconnect the auxiliary supply. - Refi t the cap as indicated in fi gure 46. Fig. 46 - Return the movable part to the position TEST-ISOLATED. - Use the different auxiliaries in turn to run the following 10 operations: - opening (both local and remote as applicable) - closing (both local and remote as applicable)

  • Page 28: Measures To Be Taken For Any Operating Anomalies

    Damaged coil Replace the coil Operate by hand. If the fault persists • • Operating mechanism blocked please contact ABB SACE • • Key locked in open position Unlock by inserting the key Circuit-breaker in intermediate position • • Complete the insertion operation...

  • Page 29: Accessories

    10. Accessories 10.1. Electrical accessories Shunt opening/closing (YO/YC) and second shunt opening release (Y02) This allows remote opening or closing control of the apparatus. Given the characteristics of the circuit-breaker operating mecha- nism, opening (with the circuit-breaker closed) is always possible, whereas closing is only possible when the closing springs are loaded.
  • Page 30 Time delay device for undervoltage release (D) The undervoltage release can be combined with an electronic time-delay device for installing outside the circuit-breaker, which enables a delay in the tripping of the release with preset, adjustable times. The use of the delayed undervoltage release is rec- ommended when the power supply network of the release can be subject to power cuts or short-lived voltage drops, in order to avoid trips.
  • Page 31 Auxiliary contacts Auxiliary contacts installed on the circuit-breaker are available to enable an indication of the circuit-breaker’s status. A special version of the auxiliary contacts is also available (gold plated contacts) for a rated voltage under 24 V (digital signal). In max In max cosφ...

  • Page 32: Mechanical Locks

    10.2. Mechanical locks a-b) Lock in open position Different mechanisms are available which enable the circuit-breaker to be locked in the open position. These devices can be controlled by: - a key (a): a special circular lock with different keys (for a single circuit-breaker) or with the same keys (for several circuit-breakers). In the latter case, up to four different key code numbers are available.

  • Page 33: Notes For Emax Ltt Low Temperature Accessories

    For the change over, the customer can use a suitable electronic relay, whose diagram is supplied by ABB SACE. The mechanical interlocks between two or three circuit-breakers are made by means of cables that can be used for circuit-breakers installed, either side-by-side or one over the other.

  • Page 34: Protection Releases - General Notes

    11. Protection releases - General notes The ABB SACE Emax series of air circuit-breakers can be equipped with electronic relay PR121/P. The available accessories and functions are listed in the table below. Function/Unit PR121 Current protections (L, S, I, G)

  • Page 35: Abbreviations And Notes

    Opening coil Closing coil Circuit-Breaker (for example Emax) Current Sensor (current transformer) Ekip Connect Communication software for PC, for electronic devices installed in ABB SACE CB Emax Series of ABB SACE air circuit-breakers Hardware i-Test "i-Test" button on the front of relay Rated current of the Rating Plug installed in the circuit-breaker Low Temperature Technology.

  • Page 36: Sace Pr121/P Relay

    - Ekip T&P, similarly to BT030-USB, can be used to power and communicate with the relay via a PC. It also allows units like PR010/T to be tested, again via a PC. Communication with ABB SACE devices is facilitated by the Ekip Connect SW supplied with BT030-USB and Ekip T&P modules, or available from the Internet website.

  • Page 37: Compatibility Cb

    fl ow, or in the open circuit-breaker condition) and adds to the accessory functions of the relay allowing HMI030 and Flex Interface external devices to be used. To improve the supply condition, ABB recommends use of the auxiliary supply source when there are low load current values and/or distorted signals.

  • Page 38: User Interface

    12.3. User interface The graphic interface of relay PR121/P allows the protections and general state of the relay itself to be adjusted and displayed. Rifer. Description Alarm indicator LED for protection function L Section dedicated to protection S (not present for models PR121/P LI) Alarm indicator LED for protection function I Alarm indicator LED for protection function G (not present for models PR121/P LSI and PR121/P LI) Dip switch position indications, with reference to the L, S, I, G protection thresholds...

  • Page 39: Rating Plug

    There are 2 to 4 red leds for checking the state of the protections: the number of leds depends on the way the relay has been confi gured and on the protections installed. The led of protection L can also come on in the orange colour, thereby providing further information. All the led combinations and the corresponding information are given in the table below.

  • Page 40: Test Connector

    - when the unit is off, it allows the last event recorded by the relay to be checked (when pressed for about 1 second). The function is available for 48 hours after the relay has been switched off (absence of internal or external poser supply). - with the unit powered by PR030/B alone and with the CB off, it allows the relay to be installed in the CB (see sect.

  • Page 41: Thermal Memory S

    real tripping time is forced to t (t(s)= t NOTES: - t(s)= envisaged tripping time; = fault current; given in [In] (example: 1.7In) = protection S parameters set by the user, given in [In] and [s] 12.4.2.1. Thermal memory S The thermal memory function can be enabled for cable protection when the curve with inverse time is selected.

  • Page 42: Protection Against Instantaneous Short-Circuit "Iinst

    The protection cannot be disabled. It has a single fi xed time protection curve and the threshold level is exclusively at the charge of ABB personnel. 12.4.7. Summary table of protections...

  • Page 43: Trip Curves For Functions L-S(T =K/I )-I

    12.4.8.2. Trip curves for functions L-S(t =k/I 12.4.8.3. Trip curves for functions L-S(t=k)-I t = k Model L6555 Scale Apparatus Emax Doc. No Page No 1SDH000460R0002 43/74...

  • Page 44: Trip Curves For Function G

    12.4.8.4. Trip curves for function G t = k 12.5. Main functions 12.5.1. Measurement The current measuring (ammeter) function is available in all versions of the PR121/P unit. This function is accessible by means of test unit BT030-USB, Ekip T&P (connected to a PC) and PR010/T, or by means of HMI030. The measurement tolerance margins are: Standard operation range Type of measurement...

  • Page 45: Putting Into Service And Recommendations

    ABB SACE will apply the adhesive rating plates of all the variables concerning the CB (e.g. Type of CB, Rating Plug size, etc.) so as to provide the user with all the information he needs to defi ne the parameters.

  • Page 46: Troubleshooting

    Customer Support service. The more the information given to the ABB Customer Support service is complete and accurate, the easier the technical analysis on the problem encountered will be, enabling us to take all action to help the user without delay.

  • Page 47: External Units

    12.9. External units 12.9.1. PR030/B PR030/B is an external unit that allows the relay to be powered in order to perform installation, Autotest and Trip Test, and the verifi cations with the CB open. The unit is connected to the relay by means of the front connector. 12.9.2.

  • Page 48: Flex Interface

    Ekip Connect is a software application for personal computers equipped with the Microsoft Windows® operating system, which allows data to be exchanged with one or more ABB low voltage devices. Ekip Connect can be connected to ABB low voltage circuit-breakers equipped with electronic protection relays for the purpose of: - Putting the CB into service.

  • Page 49: Overall Dimensions

    13. Overall dimensions Fixed circuit-breaker Basic version with horizontal rear terminals 4 POLES 3 POLES 3 POLES 4 POLES E1/E2 Legend View A View A 1 Inside edge of compartment door 4 POLES 4 POLES 2 Segregation (where foreseen) 3 POLES 3 POLES 3 Circuit-breaker M10 fi...
  • Page 50 Fixed circuit-breaker Basic version with horizontal rear terminals View A 3 POLES (E4) 4 POLES (E4) 4 POLES(E4/f) View A 3 POLES (E6) 4 POLES (E6) 4 POLES (E6/f) Fig. 36 Model L6555 Scale Apparatus Emax Doc. no. Page No 1SDH000460R0002 50/74...
  • Page 51 Fixed circuit-breaker Basic version with vertical rear terminals E2/E4 E3/E6 View A View A View A Captive M12 included in the supply E4/f E6/f View A View A View A View A Captive M12 included in the supply Captive M12 included in the supply Fig.
  • Page 52 Fixed circuit-breaker Basic version with front terminals Fig. 37 Model L6555 Scale Apparatus Emax Doc. no. Page No 1SDH000460R0002 52/74...
  • Page 53 Fixed circuit-breaker Basic version with front terminals E4/f E6/f Fig. 38 Model L6555 Scale Apparatus Emax Doc. No Page No 1SDH000460R0002 53/74...
  • Page 54 Fixed circuit-breaker Compartment dimensions Compartment door drilling Depth N° 2 holes for IP54 protection 3 POLES 4 POLES Holes for passing through fl exible cables Tightening torque of the main terminals: Nm 70 for mechanical interlocks Tightening torque of the earthing screw: Nm 70 High resistance M12 screw Quantity per terminal PHASE...
  • Page 55 Withdrawable circuit-breaker Basic version with horizontal rear terminals E2/E3/E4/E6 4 POLES 3 POLES 3 POLES 4 POLES Legend E1/E2 View A View A 1 Inside edge of compartment door 3 POLES 3 POLES 2 Segregation (where foreseen) 3 Fixing fi xed part Ø 10 drilling (use M8 screws) 4 N°...
  • Page 56 Withdrawable circuit-breaker Basic version with horizontal rear terminals View A 3 POLES (E4) 4 POLES (E4) 4 POLES (E4/f) View A 3 POLES (E6) 4 POLES (E6) 4 POLES (E6/f) Fig. 41 Model L6555 Scale Apparatus Emax Doc. no. Page No 1SDH000460R0002 56/74...
  • Page 57 Withdrawable circuit-breaker Basic version with vertical rear terminals E2/E4 E3/E6 View A View A View A Captive M12 included in the supply E4/f E6/f View A View A View A View A Captive M12 included in the supply Captive M12 included in the supply Fig.
  • Page 58 Withdrawable circuit-breaker Version with front terminals Fig. 43 Model L6555 Scale Apparatus Emax Doc. no. Page No 1SDH000460R0002 58/74...
  • Page 59 Withdrawable circuit-breaker Version with front terminals E4/f E6/f Fig. 44 Model L6555 Scale Apparatus Emax Doc. No Page No 1SDH000460R0002 59/74...
  • Page 60 Withdrawable circuit-breaker Version with fl at terminals View A View A View A E4/f E6/f View A View A View A View A Fig. 45 Model L6555 Scale Apparatus Emax Doc. no. Page No 1SDH000460R0002 60/74...
  • Page 61 Withdrawable circuit-breaker Compartment dimensions Compartment door drilling Depth N° 2 holes for IP54 protection 3 POLES 4 POLES Holes for passing through fl exible cables Tightening torque of the fi xing screws: 20 Nm Tightening torque of the main terminals: 70 Nm for mechanical interlocks Tightening torque of the earthing screw: 70 Nm High resistance M12 screw...
  • Page 62 Compartment door mechanical lock Door drilling Minimum distance between the circuit-breaker and the switchgear wall Fixed version Withdrawable version 3 POLES 4 POLES E4/f E6/f Fig. 47 Model L6555 Scale Apparatus Emax Doc. no. Page No 1SDH000460R0002 62/74...

  • Page 63: Circuit Diagrams

    14. Circuit diagrams WARNING: Before installing the circuit-breaker, carefully read notes F and O on the circuit diagrams. Operating status shown The circuit diagram is for the following conditions: - withdrawable circuit-breaker, open and racked-in - circuits de-energised - releases not tripped - motor operating mechanism with springs unloaded.
  • Page 64 S75E/1.4 = Contacts for electrical signalling of circuit-breaker in disconnected position (only with withdrawable circuit- breakers) S75I/1..5 = Contacts for electrical signalling of circuit-breaker in connected position (only with withdrawable circuit-breakers) S75T/1..4 = Contacts for electrical signalling of circuit-breaker in test isolated position (only with withdrawable circuit-breakers) = Pushbutton or contact for closing the circuit-breaker = Pushbutton or contact for opening the circuit-breaker = Pushbutton or contact for opening the circuit-breaker with delayed trip...
  • Page 65 X) T3 and T4 poles of X (or XV) connector are used to measure voltage when U>690V. In this case, they must be connected to the secondary winding of the TU voltage transformer (see fi g. 44). Ask ABB SACE for applications of the residual current protection with voltages higher than 690V.
  • Page 66 Circuit diagram symbols (IEC 60617 and CEI 3-14 ... 3-26 Standards) Shield Terminal Change-over position con- (may be drawn tact with momentary circuit in any shape) breaking (limit contact) Time delay Plug and socket Power isolator with automa- tic breaking action (male and female) Mechanical or electrical Motor...
  • Page 67 Circuit diagram - Operating status Three-pole circuit-breaker with PR121/P, PR122/P or PR123/P Four-pole circuit-breaker with PR121/P, PR122/P or PR123/P electronic release electronic release Terminal not Terminal not connected connected Three-pole circuit-breaker with PR122/P or PR123/P electronic Three-or four-pole switch-disconnector release, residual current protection and U<=690V. Model L6555 Scale...
  • Page 68 Motor operating mechanism, opening, closing and undervoltage releases Signalling contacts Model L6555 Scale Apparatus Emax Doc. no. Page No 1SDH000460R0002 68/74...
  • Page 69 Signalling contacts Model L6555 Scale Apparatus Emax Doc. No Page No 1SDH000460R0002 69/74...
  • Page 70 Auxiliary circuits of the PR121, PR122 and PR123 releases Warning: see note F W2 (LOCAL BUS) W2 (LOCAL BUS) PR120/V measuring module Model L6555 Scale Apparatus Emax Doc. no. Page No 1SDH000460R0002 70/74...
  • Page 71 PR120/D-M communication module W1 (SYSTEM BUS) PR120/K signalling module Model L6555 Scale Apparatus Emax Doc. No Page No 1SDH000460R0002 71/74...
  • Page 72 PR021/K signalling unit Model L6555 Scale Apparatus Emax Doc. no. Page No 1SDH000460R0002 72/74...
  • Page 74 Due to possible developments of standards as well as of materials, the characteristics and dimensions speci- fi ed in the present catalogue may only be considered binding after confi rmation by ABB SACE. ABB S.p.A. ABB SACE Division Via Baioni, 35 - 24123 Bergamo - Italy Tel.: +39 035.395.111 - Telefax: +39 035.395.306-433...

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