ABB SACE Emax 2 Installation, Operation And Maintenance Instructions For The Installer And The User Download

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DOC. N° 1SDH000999R0002 - ECN000058721 - Rev. B

SACE Emax 2

Emax E1.2 low voltage air circuit-breakers

Installation, operation and maintenance instructions for
the installer and the user

Summary of Contents for SACE Emax 2

Page 1: ...DOC N 1SDH000999R0002 ECN000058721 Rev B SACE Emax 2 Emax E1 2 low voltage air circuit breakers Installation operation and maintenance instructions for the installer and the user...

Page 2: ...ABB SACE Emax 2 2 2017 ABB 1SDH000999R0002 ECN000058721 Rev B...

Page 3: ...plates 30 Introduction to Ekip protection trip units 31 1 Presentation 31 Families and functionality 31 Protections 32 Measurements 32 Integrated functions Self diagnosis Test and Power Controller 33...

Page 4: ...osition key lock 86 PLC padlock 86 anti insertion lock 86 MOC Operation counter 86 PLP padlock in connected test disconnected positions 87 KLP key lock for connected test disconnected positions 87 KLP...

Page 5: ...ABB SACE Emax 2 3 2017 ABB 1SDH000999R0002 ECN000058721 Rev B...

Page 6: ...led persons to enable him or her to perceive risks and to avoid danger which electricity can create NOTE This manual specifically indicates what operations can be performed by people trained in the fi...

Page 7: ...ons against certain methods of installation use and maintenance that could cause harm to personnel damage devices or make them unsafe these warnings and alarms do not include all conceivable ways to m...

Page 8: ...ional standards IEC 60947 EN 60947 CEI EN 60947 IEC 61000 UL 1066 They comply with the following EC directives Low Voltage Directives LVD no 2006 95 EC Electromagnetic Compatibility Directive EMC no 2...

Page 9: ...pletely discharged Weight of the circuit breakers with packaging The following table specifies the weights of the circuit breakers with packaging Fixed Moving part of withdrawable device Fixed part of...

Page 10: ...5 Circuit breaker serial number 6 Features of the circuit breaker Packaging checks Examine the state of the material received and verify that The circuit breaker or the fixed part are consistent with...

Page 11: ...ed parts on a horizontal plane not in contact with the floor If the circuit breaker has been removed and reinserted in the package ensure prior to storage that the circuit breaker is in the open posit...

Page 12: ...the circuit breaker safely refer to the instruction sheet in the zipped packaging pouch The following is the procedure for opening the packaging 1 Cut the tape that seals the box See Figure 5 e Figur...

Page 13: ...owing table specifies the weights of the circuit breakers without packaging Fixed Moving part of withdrawable device Fixed part of withdrawable device III IV III IV III IV E1 2 14 Kg 31 lbs 16 Kg 35 l...

Page 14: ...ctive or current limiting circuit breaker The circuit breaker is available in two types fixed version withdrawable The circuit breaker in fixed version see Figure 10 has its own terminals for connecti...

Page 15: ...pening pushbutton 7 Mechanical signalling of tripped TU 8 Springs charged discharged signalling device 9 Electrical data plate Description of electrical data plate IEC 1 2 3 4 5 9 8 7 6 10 11 12 Uimp...

Page 16: ...XXXXX ANSI C37 13 UL1066 50 60 Hz Ra t e d M a x i mum Volt a ge V 254 635 Ra t e d S hor t Ci r c ui t kA 66 42 S hor t Time kA 508 66 Low V ol tage AC Power Ci r cui t Br aker 63FA 42 A Figure 17 Po...

Page 17: ...springs charged signalling device B is yellow CHARGED SPRING as indicated in Figure 19 Figure 18 A B Figure 19 3 Check that the circuit breaker is open open closed signalling device O OPEN and check t...

Page 18: ...E1 2 circuit breakers 4 Description Continued from the previous page 7 Check that the circuit breaker is open open closed indicator O OPEN and check that the springs are discharged spring signalling...

Page 19: ...rcuit breaker open with springs discharged see Figure 25 2 Circuit breaker open with springs charged see Figure 26 3 Circuit breaker closed with springs discharged see Figure 27 4 Circuit breaker clos...

Page 20: ...fore proceeding remove all equipment used during the work and remove processing waste and materials used 1 Make sure that signalling device on the fixed part indicates the DISCONNECT position See Figu...

Page 21: ...ndicator shows that the circuit breaker is in TEST position See Figure 34 Figure 34 6 Press the lock button and then rotate the crank clockwise until the button comes out and the indicator shows that...

Page 22: ...h the test position Discharge the springs before removing the circuit breaker from the fixed part On the UL version the fail safe prevents the removal of the circuit breaker from the fixed part with s...

Page 23: ...aracteristics are guaranteed between 25 C and 70 C 13 F e 158 F Particular weather conditions The circuit breaker is designed to operate in particularly difficult industrial environments It was tested...

Page 24: ...68 Rated current A at 40 C 100 98 93 90 Electromagnetic compatibility The use of specific devices in industrial installations may cause electromagnetic interference in the electrical system The SACE...

Page 25: ...sonnel in charge of handling and lifting must use appropriate safety equipment Mounting of the fixed circuit breaker Fix the circuit breaker to a horizontal surface using four M5 x 25 screws see Figur...

Page 26: ...e fixed part to a horizontal surface using four M8 x 25 screws see Figure 44 Tighten the screws with tightening torque 21 Nm 186 lb in Figure 44 Types of terminal The following are the different types...

Page 27: ...721 Rev B Continued from the previous page Figure 49 F ES Spread front IEC UL Figure 50 F FC Terminals for cables IEC UL Figure 51 W HR Horizontal rear IEC Figure 52 W VR Vertical rear IEC Figure 53 W...

Page 28: ...s 6 Installation Continued from the previous page Figure 55 W ES Spread front IEC UL Figure 56 F FC Terminals for cables IEC UL Figure 57 F HR Horizontal rear UL Listed Figure 58 F VR Vertical rear UL...

Page 29: ...osition of the vertical horizontal terminals If the circuit breaker is supplied equipped with terminals of the horizontal rear type it is possible at any moment to switch from horizontal to vertical a...

Page 30: ...acities for the connections by altering the thickness and number of busbars in parallel The following tables provide some examples of the quantity and the sizes of the connections that can be used for...

Page 31: ...onfigurations is available on the web site http new abb com low voltage products circuit breakers emax2 Dimensions Information on the overall dimensions is available on the web site http www abb com a...

Page 32: ...w indicates the distance for positioning the first anchor plate according to the circuit breaker type and the peak current 100 3 94 150 5 91 200 7 87 250 9 84 300 11 81 350 13 78 400 15 75 450 17 72 5...

Page 33: ...Ekip Hi Touch LSI LSIG Ekip G Touch LSIG Ekip G Hi Touch LSIG The Ekip Touch trip unit can be equipped with the Ekip Measuring module to extend the measurement functions or the protection and measurem...

Page 34: ...Pr Measuring Pro Pr Touch Pr Measuring Pro Pr Hi Touch Pr Touch Pr Measuring Pro Pr G Touch Pr Touch Pr Measuring Pro Pr Hi Touch Pr G Touch Pr G Hi Touch Pr External toroid S G R Rc DIP protections...

Page 35: ...he Emax 2 circuit breakers and Ekip trip units can be equipped as indicated in the combination tables on page 53 Various types of modules are available differing in functionality and the position in w...

Page 36: ...Description A LED L Protection LED alarm and trip B L Protection LED pre alarm C S Protection LED alarm and trip D I Protection LED trip E G Protection LED alarm and trip F Power on LED trip unit powe...

Page 37: ...status of the protection trip unit LED on default configuration fixed or blinking signals trip unit energized LED off signals trip unit de energized NOTE with Ekip T P and Ekip Bluetooth modules and...

Page 38: ...ately 4 seconds the power on LED if the trip unit is off due to an energy drop primary current less than the minimum level of operation removal of auxiliary power supply with circuit breaker open etc...

Page 39: ...reference to the curve it is the part parallel to the y axis IMPORTANT The protection is activated and starts timing for currents between 1 05 and 1 2 of the threshold I1 set 1 The delay is interrupt...

Page 40: ...It defines the current value that if exceeded activates the protection with reference to the curve it is the part parallel to the y axis IMPORTANT The I2 threshold set must be higher than the I1 thre...

Page 41: ...fixed non adjustable time Parameters The user can set the intervention threshold Parameter Description Enable By setting the threshold dip switches to the Off position the protection is disabled Thre...

Page 42: ...the selection NOTE calculation of the tripping time of the inverse time curve is based on a mathematical expression The details are provided in the table on page 43 Threshold I4 It defines the curren...

Page 43: ...ers The user can activate the protection and set the percentage for calculation of the protection thresholds Parameter Description Enable By setting the threshold dip switches to the Off position the...

Page 44: ...ons is to signal that the measured current is near the activation threshold of the protection itself It is possible to set the pre alarm threshold in order to establish the pre alarm activation values...

Page 45: ...th I4 0 8 In t4 0 2 s If 2 In 15 Iinst Defined by ABB Instantaneous 1 See the serigraph for the available combinations 2 t t calculation is valid for If values that have exceeded the trip threshold of...

Page 46: ...n be programmed by the user Every measurement recorded is accompanied by the following information Recording interval Phase and value of maximum and minimum current measured Date and time of the recor...

Page 47: ...rcuit breaker is closed and that there are no primary currents 2 Connect Ekip T P or Ekip Bluetooth to the front test connector 3 Start the communication with Ekip Connect 4 Open the Information page...

Page 48: ...its own operating condition and that of all the devices to which it is connected All the signals are available with the front LEDs The protection LEDs provide information with various combinations of...

Page 49: ...ction delay x C Temperature alarm 1 x C Pre alarm L x C Trip 2 x C Hardware Trip 3 x x B Installation error x E Parameter error x D Circuit breaker state not defined or in error x B Error on Local Bus...

Page 50: ...C Normal operation signalling provided by the trip unit D Error in setting of the dip switches Check and correct the following conditions All the dip switches of L are in the ON position I1 I2 or I2 I...

Page 51: ...Ekip Multimeter or Ekip Signalling 10K modules the Local Bus parameter must be enabled NOTE communication with the modules is active if the auxiliary power supply is present Date and time The Ekip Dip...

Page 52: ...ands 7 and 8 are not valid IMPORTANT in this case remote circuit breaker opening and closing can still be obtained using the programmable YC COMMAND and YO COMMAND functions and the Request circuit br...

Page 53: ...source useful for activating some functions such as communication on the Local Bus or recording of manual operations The auxiliary power can be supplied by the modules of the Ekip Supply range for fur...

Page 54: ...t DIPs protections Frequency Neutral other via front bus Protection Parameter Value L 1 In 144 s S 1 Off 0 1 s I 4 In G 1 Off 0 1 s Frequency 50 Hz IEC 60 Hz UL Neutral Off for three pole circuit brea...

Page 55: ...ng table shows the possible combinations of the electrical and mechanical accessories Type of accessory Accessory Circuit breakers Switch disconnectors Electrical signalling AUX 4Q S R AUX 15Q R R Eki...

Page 56: ...R Ekip Com Redundant R R R R Ekip Com Actuator R R R R R Ekip Link R R R R R Ekip Bluetooth R R R R R Ekip Signalling Modbus TCP R R R R R Signal Ekip Signalling 2K R R R R Ekip Signalling 10K R R R R...

Page 57: ...er and protections After reassembling the accessories the parts previously disassembled must be reassembled as indicated Front cover A and protection F by screwing the fixing screws B and C Lock with...

Page 58: ...14 13 XK1 T11 T12 K51 1 N UI N 15 16 T43 T44 EKIP G HI TOUCH EKIP G TOUCH Q 27 Q 26 YO1 7 8 XK3 XK3 10 9 XK3 6 5 RTC EKIP A1 A T41 T42 8 7 TI N C EKIP DIP EKIP TOUCH EKIP HI TOUCH H Diagram A General...

Page 59: ...ies according to the type of circuit breaker Terminal box for circuit breaker in fixed version Terminal box for circuit breaker in withdrawable version The differences between the two terminal boxes a...

Page 60: ...REDUNDANT RIDONDANTE 61 66 n 58 K51 MEAS 51 48 43 42 41 O ORTA COMUNIC COMMUN O ORT W K51 COM K31 K33 K32 K34 K51 SIGN O 32 H32 H31 HC3 O 31 K51 SIGN K21 K23 K22 K24 K51 SIGN O 22 H22 H21 HC2 O 21 K51...

Page 61: ...d 110 240Vac dc K51 SYNC Synchronization module K51 YC Closing control from the Ekip protection trip unit K51 YO Opening control from the Ekip protection trip unit M Motor for loading closing springs...

Page 62: ...e L2 UI L3 Current sensor phase L3 UI N Current sensor on neutral UI O S G R sensor W2 Serial interface with internal bus Local Bus W9 W13 RJ45 connector for communication modules W9R W11R RJ45 connec...

Page 63: ...he case of presence of any Ekip module L In the presence of diagram 32 up to three applications can be provided between diagrams 41 58 taken only once In addition it is possible to duplicate an Ekip C...

Page 64: ...Ekip Supply 110 240Vac dc Compatibility The modules can be installed in the presence of trip units of Ekip Dip Ekip Touch Ekip Hi Touch Ekip G Touch and Ekip G Hi Touch trip units Electrical characte...

Page 65: ...YO EKIP Supply Trip Unit I O Ge Ge Szc K2 K1 W4 W3 Q4 Q3 Q2 Q1 YC YU YO2 RTC I O TU 44 42 41 34 32 31 24 22 21 14 12 11 C12 C13 C11 C2 C3 C1 D2 D1 48 46 45 Ne Rca Ne Gzi Szo Szi Gzo Rct Vn V1 V2 V3 Mo...

Page 66: ...necessary access authorisations and so on The module cannot be connected to other Ethernet networks for example with the purpose of monitoring the system or the office or to the Internet The module is...

Page 67: ...ock of the E1 2 circuit breakers and the wiring diagram R2 R1 U2 U1 38 36 35 98 96 95 YR M S33 S51 YO EKIP Supply Trip Unit I O Ge Ge Szc K2 K1 W4 W3 Q4 Q3 Q2 Q1 YC YU YO2 RTC I O TU 44 42 41 34 32 31...

Page 68: ...on the trip unit power supply and communication with trip unit present with a trip unit with the Alive LED option enabled On with two quick flashes per second not synchronized with those of the green...

Page 69: ...m abblibrary DownloadCenter in particular with the kit sheet 1SDH000999R0501 Wiring diagram are provided below for the module S43 C13 C13 C13 SO C12 C12 C12 YO C11 C11 C11 76 XB4 1 XB4 2 K51 YO K51 7...

Page 70: ...ted current of the circuit breaker indicated on the rating plate of the circuit breaker The trip unit continuously checks for the presence of the Rating Plug signalling its absence or any errors in as...

Page 71: ...tion to a PC automatically switches the module on and charging in progress is indicated by the flashing green LED with increasing frequency as the level of charging rises Completion of charging is ind...

Page 72: ...Check that the opening mechanism of the circuit breaker functions properly by commanding an opening by means of the test procedure see page 45 Power the trip unit so that you can see which protection...

Page 73: ...0022 type TS 35 x 15 mm Its function is to share via an Ethernet network with Modbus TCP communication protocol information about the state of circuit breakers that may even be without the ability to...

Page 74: ...d with a maximum length of 15 m The screen of the cables must be connected to ground on both sides of the connection Further information on Ekip Multimeter is available on the web site http www abb co...

Page 75: ...IMPORTANT If the closing coil is permanently energized and the opening coil trips after opening the closing coil must be momentarily de energized so that it can be reused for the next closing operati...

Page 76: ...nter where the wiring diagram is available 1SDM000091R0001 A4 X XV X XV A1 A4 SC C2 C2 C2 YC C1 C1 C1 77 1 XB3 2 XB3 A4 X XV X XV A1 A4 75 C11 C11 C11 YO C12 C12 C12 SO XB4 1 XB4 2 SO D2 D2 D2 YO2 D1...

Page 77: ...coil YU is a emergency trip unit For service operations use the opening coil NOTE the power supply of the coil must be drawn on the supply side of the circuit breaker or from an independent source If...

Page 78: ...e available voltages and the electrical characteristics are provided below Available voltages Un 24 V AC DC 110 V AC DC 220 V AC DC General characteristics Operating limits 90 110 Un YR Connections Fu...

Page 79: ...closing springs can in any case be charged manually through the appropriate front control lever The tables listing the available voltages and the electrical characteristics are provided below Availab...

Page 80: ...ing table provides information on the electrical characteristics Characteristics Standard Digital signals Breaking capacity DC 24V 0 1 A 125V 0 5A 0ms 0 3A 10ms 250V 0 3A 0ms 0 15A 10ms AC 250V 3A cos...

Page 81: ...als Breaking capacity DC 24V 0 1 A 125V 0 5A 0ms 0 3A 10ms 250V 0 3A 0ms 0 15A 10ms AC 250V 3A cos 0 3 5A cos 0 7 5A cos 1 400V 3A cos 1 2A cos 0 7 1A cos 0 3 Minimum load 100mA 24V 1mA 5V AUX 15Q ext...

Page 82: ...ristics Characteristics Standard Digital signals Breaking capacity DC 24V 0 1 A 125V 0 5A 0ms 0 3A 10ms 250V 0 3A 0ms 0 15A 10ms AC 250V 3A cos 0 3 5A cos 0 7 5A cos 1 400V 3A cos 1 2A cos 0 7 1A cos...

Page 83: ...set pushbutton on the front panel The RTC is a switching contact type and is available in the standard version or in the versions for digital signals The following table provides information on the el...

Page 84: ...nical signalling The following table provides information on the electrical characteristics Characteristics Standard Digital signals Breaking capacity DC 24V 0 1 A 125V 0 3A 0ms 0 15A 10ms 250V 0 3A 0...

Page 85: ...for the motor The following table provides information on the electrical characteristics Characteristics Standard Digital signals Breaking capacity DC 24V 0 1 A 125V 0 5A 0ms 0 3A 10ms 250V 0 3A 0ms 0...

Page 86: ...that inhibits the use of one or both pushbuttons with the aid of a padlock Information on the assembly is available on the web site http www abb com abblibrary DownloadCenter in particular with the ki...

Page 87: ...nal covers Information on assembly is available on the web site http www abb com abblibrary DownloadCenter in particular with the kit sheets 1SDH000999R0612 for the high terminal covers 1SDH000999R061...

Page 88: ...with pre engineering for Castell locks PLC padlock The PLC locks the circuit breaker in the open position It is available in two types lock usable with a maximum number of three padlocks with a diamet...

Page 89: ...ositions is available with two types of lock lock with different key code numbers for a single circuit breaker lock with the same key code number for more than one circuit breaker The maximum number o...

Page 90: ...ed version opening the switchgear door with the circuit breaker closed and in connected position if the circuit breaker is in fixed version closing of the circuit breaker when the switchgear door is o...

Page 91: ...rlock of type A Two Circuit breakers 1 2 O I O O O I The Type A interlock is applicable to two circuit breakers normal power supply emergency power supply It allows you never to have two circuit break...

Page 92: ...rrect ground connections 4 Maximum distances of separators respected Operations Perform some opening and closing operations See chapter Description of the product circuit breaker opening closing opera...

Page 93: ...reaker Result The circuit breaker closes correctly the signals are normal 2 Turn off the voltage supply to the trip unit The circuit breaker opens 3 Power the undervoltage coil at the relevant rated v...

Page 94: ...gnalling circuits 2 bring the circuit breaker to the connected isolated for test and disconnected position Result the signals due to the relative operations are normal Locking devices for connected te...

Page 95: ...er of the installation If necessary power the protection trip unit with an Ekip TT unit 4 Removal of the Ekip TT If present remove the Ekip TT unit 5 Connecting the voltage Connect the auxiliary volta...

Page 96: ...erson with relevant education and experience to enable him or her to perceive risks and to avoid hazards which electricity can create Indeed it may be necessary to perform insulation and dielectric te...

Page 97: ...the closing coil is powered The trip signal of the protection trip unit has not been reset Press the TU Reset button The power supply voltage of the auxiliary circuits is too low Measure the voltage...

Page 98: ...s Make sure there is continuity between cable and terminal and if necessary reconnect the cables of the gearmotor to the terminals The connections of the power supply circuit are wrong Check the conne...

Page 99: ...g condition Temperature outside range Correct operating condition The display is not backlit if present Current and or voltages below the display switch on limit Correct operating condition Incorrect...

Page 100: ...guration conflicts Internal Error Contact ABB Invalid Date Set the date CB Status Error Check the circuit breaker status signal contacts Rating Plug Installation Warning Install Rating Plug and in the...

Page 101: ...see the indication DISCONNECTED If work must be performed on fixed circuit breakers or on fixed parts disconnect the power supply to the power circuit and auxiliary circuits and visibly ground the te...

Page 102: ...cuit breakers specifies the maintenance frequency for the different types of site conditions We include the table indicating the frequency with which maintenance should be carried out and the relative...

Page 103: ...sibly using mild detergent Use a cleaning product such as Henkel 273471 or Chemma 18 or equivalent if there is a heavy coating of dirt 2 Check that the rating plates with the technical specifications...

Page 104: ...e fixing screws E 3 With circuit breaker in the withdrawable version remove the protection F and the terminal cover G by removing the screws H A D E C B Figure 74 Four pole fixed circuit breaker A F H...

Page 105: ...ndition no excessive wear and tear overheating rupture 4 Make sure that the mechanical operation counter functions correctly if present by operating the circuit breaker 5 Check the wear on the brushes...

Page 106: ...paragraph Disassembly Operations in reverse order and if necessary reconnect the auxiliary power supply 2 Put the movable part breakers in the test position see indication TEST 3 Perform the following...

Page 107: ...electrical field IEV 195 04 02 person adequately advised or supervised by electrically skilled persons to enable him or her to perceive risks and to avoid danger which electricity can create End of l...

Page 108: ...ABB SACE Emax 2 106 2017 ABB 1SDH000999R0002 ECN000058721 Rev B Putting into service and maintenance 5 Decommissioning and treatment at end of life...

Page 109: ...1SDH000999R0002 ECN000058721 Rev B...

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