ABB Sace Emax UL Listed Manual

ABB SACE
Emax UL Listed
Installation, service and maintenance
instructions for low voltage air power circuit
breakers
RH0109002 L2275
Installationandservice
instructions
Courtesy of NationalSwitchgear.com

L2275 Emax UL
ABB SACE N° Doc.
Model
RH0109002
Apparatus
Dis. Title
App.
Uff. Resp.
Uff. Utilizz.
Installation, service and maintenance
instructions for low voltage air power
circuit breakers
Scale
Lingua
en
Courtesy of NationalSwitchgear.com

L2275 Emax UL
1/132
Doc. N°
Mod.
RH0109002
Apparatus Scale
Page N°
Index
1. Description ............................................................. page 4
1.1 General characteristics ............................................... « 4
1.2 External front view of the power circuit breaker......... « 4
1.3 Power circuit breaker rating plate data ....................... « 4
1.4 Moving part construction characteristics ................... « 4
1.5 Cradle construction characteristics............................ « 5
2. Checking on receipt ...........................................« 5
3. Storage, lifting and weights................................ « 5
4. Installation .......................................................... « 6
4.1 Installation room ........................................................... « 6
4.2 Installation of fixed power circuit breaker ................... « 6
4.3 Installation of draw out power circuit breaker cradle .. « 6
4.3.1 Preparation of the cradle . ........................................... « 6
4.3.2 Installation of the cradle ............................................... « 7
4.3.3 Installation of the cradle on board a ship .................... « 7
4.4 Installation of the flange on the compartment door..... « 8
5. Electrical connections ............................................. « 8
5.1 Connections to the power circuit................................. « 8
5.1.1 Shapes of the terminals ............................................... « 8
5.1.2 Examples of positioning of the connection busbars
according to the types of terminals ............................. « 9
5.1.3 Assembly procedures for the connection busbars .... « 10
5.2 Grounding .................................................................... « 10
5.3 Cabling the power circuit breaker auxiliary circuits.... « 10
5.3.1 Interfacing elements for fixed power circuit breaker .. « 10
5.3.2 Draw out power circuit breaker................................... « 11
5.4 Conversion of the auxiliary or position contacts from
normally closed (opening) to normally open (closing)
or vice versa ................................................................ « 12
6. Putting into service ............................................. «13
6.1 General procedures .................................................... « 13
7. Instructions for use ................................................... « 14
7.1 Operating and signaling parts ..................................... « 14
7.2 Closing and opening operations of the
power circuit breaker ................................................... « 15
7.3 Racking-in/out operation.............................................. « 16
8. Maintenance ...................................................... « 17
8.1 Warnings ...................................................................... « 17
8.2 Maintenance program.................................................. « 18
8.3 Maintenance operations .............................................. « 18
8.3.1 Preliminary operations ................................................. « 18
8.3.2 General inspection of the power circuit breaker ........ « 19
8.3.3 Checking contact wear................................................ « 19
8.3.4 Operating mechanism maintenance ........................... « 20
8.3.5 Power circuit breaker maintenance ............................ « 20
9. Measures to be taken for any operating
anomalies........................................................... «21
10. Accessories........................................................ «22
10.1 Electrical accessories ................................................. « 22
10.2 Mechanical accessories.............................................. « 25
10.3 Spare parts .................................................................. « 25
11. Trip units – general notes .................................. « 26
11.1 Safety notes ................................................................. « 27
11.1.1 Notes for dielectric strength tests............................... « 27
11.2 Abbreviations and various notes................................. « 27
11.2.1 Abbreviations ............................................................... « 27
11.2.2 Various notes ............................................................... « 27
12. SACE PR111/P-A trip unit –
Identification........................................................ page 28
12.1 Standard....................................................................... « 28
12.2 Specifications ............................................................... « 28
12.2.1 General......................................................................... « 28
12.2.2 Electrical characteristics ............................................. « 28
12.2.3 Self-supply ................................................................... « 28
12.3 Environmental characteristics..................................... « 28
12.4 Protection functions ..................................................... « 28
12.4.1 Protection “L” ............................................................... « 29
12.4.2 Protection “S ” ............................................................... « 29
12.4.3 Protection “I” ................................................................ « 29
12.4.4 Protection “G ” .............................................................. « 29
12.4.5 Protection against “Iinst” instantaneous short circuit .« 29
12.5 Other functions ............................................................ « 30
12.5.1 Watchdog ..................................................................... « 30
12.5.2 Simple test of the trip unit............................................. « 30
12.5.3 Complex test of the trip unit......................................... « 30
12.6 User interface .............................................................. « 30
12.7 Default settings ............................................................ « 31
12.8 Putting into service ...................................................... « 31
12.8.1 Connections ................................................................. « 31
12.8.2 CT and SA connection check ..................................... « 31
12.8.3 Test .............................................................................. « 31
12.8.4 Initial settings............................................................... « 31
12.9 Operating instructions/Service operation ................... « 32
12.9.1 Modification of basic configuration .............................. « 32
12.9.2 Modification of protection functions ............................. « 32
12.9.3 Signals .......................................................................... « 32
12.10 Troubleshooting ........................................................... « 33
12.10.1 In the case of a fault ................................................... « 33
12.11 Accessories ................................................................. « 33
12.11.1 ABB SACE TT1 simple test unit .................................. « 33
12.11.2 ABB SACE PR010/T complex test unit ....................... « 33
12.12 Trip curves................................................................... « 34
12.12.1 Trip curves of functions L-I ......................................... « 34
12.12.2 Trip curves of functions L-S-I ..................................... « 34
12.12.3 Trip curves of functions L-S-I ..................................... « 35
12.12.4 Trip curves of function G............................................. « 35
13. SACE PR112/P-A trip unit –
Identification.............................................................. « 36
13.1 Standard....................................................................... « 36
13.2 Specifications ............................................................... « 36
13.2.1 General......................................................................... « 36
13.3 Electrical characteristics ............................................. « 36
13.3.1 Self-supply ................................................................... « 36
13.3.2 Auxiliary power supply ................................................ « 36
13.4 Environmental characteristics..................................... « 37
13.5 Inputs / outputs ............................................................ « 37
13.5.1 Binary opto-insulated inputs ........................................ « 37
13.5.2 Binary opto-insulated outputs...................................... « 37
Courtesy of NationalSwitchgear.com

L2275 Emax UL
2/132
Doc. N°
Mod.
RH0109002
Apparatus Scale
Page N°
13.5.3 Output contacts ........................................................... « 37
13.6 Communication bus ..................................................... « 37
13.7 Protection functions ..................................................... « 37
13.7.1 Protection L.................................................................. « 37
13.7.2 Protection S ................................................................. « 38
13.7.3 Protection I ................................................................... « 38
13.7.4 Protection G ................................................................. « 38
13.7.5 Signal of unbalance “U” .. ............................................ «39
13.7.6 Protection against overtemperature inside “OT”
trip unit .......................................................................... «39
13.7.7 Load control “K” . ......................................................... «39
13.7.8 Protection against instantaneous short circuit “Iinst”. « 40
13.8 Warning functions ........................................................ « 40
13.8.1 Warning Threshold ...................................................... « 40
13.8.2 Harmonic distortion ...................................................... «40
13.9 Measurement functions............................................... « 41
13.9.1 Current measurements ............................................... «41
13.10 Information functions ................................................... «41
13.10.1 Software version .......................................................... «41
13.10.2 Opening data storage .................................................. « 41
13.11 Other functions ............................................................ « 41
13.11.1 Contact programming K51/p1 ..................................... « 41
13.11.2 Watchdog ..................................................................... « 42
13.11.3 Self-test ........................................................................ « 42
13.11.4 Complex test of the trip unit ......................................... «42
13.12 User interface .............................................................. « 43
13.12.1 Use of pushbuttons ..................................................... « 44
13.12.2 Read and Edit modes .................................................. « 44
13.13 Default settings ............................................................ « 44
13.14 Putting into service ...................................................... « 45
13.14.1 Connections ................................................................. « 45
13.14.2 Test .............................................................................. « 45
13.14.3 Initial settings................................................................ « 45
13.14.4 Password management............................................... « 45
13.15 Operative/operating instructions during service ........ « 46
13.15.1 Menus........................................................................... « 46
13.15.2 Modification of parameters .......................................... « 47
13.15.3 Signals .......................................................................... « 49
13.16 Troubleshooting ........................................................... « 50
13.17 Warning and error messages ..................................... « 51
13.17.1 In the case of a fault .................................................... « 52
13.18 Accessories ................................................................. « 53
13.18.1 ABB SACE PR010/T complex test unit ....................... « 53
13.18.2 ABB SACE PR020/K signaling unit .............................. « 53
13.18.3 ABB SACE PR120/B power supply unit ...................... « 53
13.19 Trip curves................................................................... « 34
13.19.1 Trip curves of functions L-S-I ..................................... « 54
13.19.2 Trip curves of functions L-S-I ..................................... « 54
13.12.3 Trip curves of function G............................................. « 55
14. SACE PR112/PD-A Trip unit –
Identification.............................................................. « 56
14.1 Standard....................................................................... « 56
14.2 Safety notes ................................................................. « 56
14.3 Various notes ............................................................... « 56
14.4 Specifications ............................................................... « 56
14.4.1 General......................................................................... « 56
14.4.2 Inputs / outputs ............................................................ « 57
14.4.3 Communication bus ..................................................... « 57
14.4.4 Information functions ................................................... « 57
14.4.5 Control functions.......................................................... « 58
14.4.6 User interface .............................................................. « 58
14.4.7 Default settings ............................................................ « 59
14.5 Putting into service ...................................................... « 59
14.5.1 Connections ................................................................. « 59
14.5.2 Test .............................................................................. « 59
14.5.3 Initial settings................................................................ « 59
14.6 Operative/operating instructions during service ........ « 60
14.6.1 Menus........................................................................... « 60
14.6.2 Modification of parameters .......................................... « 61
14.6.3 Signals .......................................................................... « 61
14.7 Troubleshooting ........................................................... « 62
14.8 Warning and error messages ..................................... « 62
14.9 Accessories ................................................................. « 62
15. SACE PR113/P-A Trip unit –
Identification........................................................ page 63
15.1 Standard ....................................................................... « 63
15.2 Specifications ............................................................... « 63
15.2.1 General......................................................................... « 63
15.2.2 Electrical characteristics ............................................. « 64
15.2.3 Environmental characteristics ..................................... «64
15.2.4 Inputs / outputs ............................................................ « 65
15.2.5 Communication bus ..................................................... « 65
15.2.6 Protection functions ..................................................... « 65
15.2.7 Warning functions ........................................................ « 71
15.2.8 Measurement functions............................................... « 72
15.2.9 Information functions ................................................... « 75
15.2.10 Other functions ............................................................ « 75
15.2.11 User interface .............................................................. « 78
15.2.12 Default settings ............................................................ « 80
15.3 Putting into service ...................................................... « 81
15.3.1 Connections ................................................................. « 81
15.3.2 VT Connections ........................................................... « 81
15.3.3 CT and SA connection check ..................................... « 82
15.3.4 Test .............................................................................. « 82
15.3.5 Initial settings................................................................ « 82
15.3.6 Password management............................................... « 82
15.4 Operative/operating instructions during service ........ « 83
15.4.1 Menus........................................................................... « 83
15.4.2 Modification of parameters .......................................... « 85
15.4.3 Signals .......................................................................... « 90
15.5 Troubleshooting ........................................................... « 91
15.6 Warning and error messages ..................................... « 92
15.6.1 In the case of a fault ................................................... « 93
15.7 Accessories ................................................................. « 94
15.7.1 ABB SACE PR010/T complex test unit ....................... « 94
15.7.2 ABB SACE PR020/K signaling unit .............................. « 94
15.7.3 ABB SACE PR120/B power supply unit ...................... « 94
15.8 Trip curves................................................................... « 95
15.8.1 Trip curves of functions L-S-I ..................................... « 95
15.8.2 Trip curves of functions L-S-I ..................................... « 95
15.8.3 Trip curves of function G............................................. « 96
15.8.4 Trip curves of function D ............................................. « 97
15.8.5 Trip curves of function U ............................................. « 97
15.8.6 Trip curves of function UV........................................... « 98
15.8.7 Trip curves of function OV .......................................... « 98
15.8.8 Trip curves of function RV........................................... « 99
15.8.9 Trip curves of function RP........................................... « 99
Courtesy of NationalSwitchgear.com

L2275 Emax UL
3/132
Doc. N°
Mod.
RH0109002
Apparatus Scale
Page N°
16. SACE PR113/PD-A Trip unit –
Identification ..............................................................
« 100
16.1 Standard ....................................................................... «100
16.2 Safety notes ................................................................. «100
16.3 Various notes ............................................................... «100
16.4 Specifications ............................................................... «100
16.4.1 General......................................................................... «100
16.4.2 Inputs / outputs ............................................................ «101
16.4.3 Communication bus ..................................................... « 101
16.4.4 Information functions ................................................... «101
16.4.5 Control functions .......................................................... «102
16.4.6 User interface .............................................................. «102
16.4.7 Default settings ............................................................ «103
16.5 Putting into service ...................................................... «103
16.5.1 Connections ................................................................. «103
16.5.2 Test .............................................................................. «103
16.5.3 Initial settings................................................................ «103
16.6 Operative/operating instructions during service ........ «104
16.6.1 Menus........................................................................... «104
16.6.2 Modification of parameters .......................................... «105
16.6.3 Signals .......................................................................... «105
16.7 Troubleshooting ........................................................... «106
16.8 Warning and error messages ..................................... «106
16.9 Accessories ................................................................. «106
17. Overall dimensions ............................................ «107
18. Electrical circuit diagrams .................................. «122
Courtesy of NationalSwitchgear.com

L2275 Emax UL
4/132
Doc. N°
Mod.
RH0109002
Apparatus Scale
Page N°
Fig. 1 Fig. 2
Fig. 3
3
2
4
5b
5a
6a
6b
1
7
8
15
9
12 13 14
11
12
10
1
2
3
4
1.4 Moving part construction characteristics
1 Supporting structure made of steel sheet
2 Current transformer for trip unit
3 Terminalsupportinsulatingbox
4 Horizontalrearterminals
5a Main fixed contact plates
5b Fixed arcing contact plates
6a Main moving contact plates
6b Moving arcing contact plates
7 Arcingchamber
Fixed power circuit breaker
1.3 Power circuit breaker rating plate data
Selective power circuit breaker
1. Description
1.1 General characteristics
The SACE Emax series of power circuit breakers are made up of a steel sheet structure which houses the operating mechanism, the poles and
the auxiliary parts. Each pole, insulated from the others, contains the interrupting parts and the current transformer of the corresponding phase.
The structure of the poles differs according to whether the power circuit breaker is selective or current limiting.
The fixed version power circuit breaker has its own terminals for connection to the power circuit. In the draw out version, the power circuit breaker
makes up the moving part of the apparatus which is completed with a cradle fitted with the terminals for connection to the power circuit of the
installation. Coupling between moving part and cradle takes place by means of special pliers mounted in the cradle.
1 PR111-A,PR112-Aor
PR113-A electronic trip unit
2 Marchio di fabbrica
3 Operating and control parts
of the operating mechanism
and trip unit tripped signals
4 Rating plate
8 Terminal box for the fixed version – Sliding contacts for the draw out version
9 Tripunit
10 Power circuit breaker closing and opening operating mechanism
11 Closing springs
12 Spring charging geared motor (on request)
13 Lever for manually charging the closing springs
14 Racking-out device (only for draw out power circuit breaker)
15 Service trip units (closing coil, shunt trip, undervoltage), on request
1.2 External front view of the power circuit breaker
Courtesy of NationalSwitchgear.com

L2275 Emax UL
5/132
Doc. N°
Mod.
RH0109002
Apparatus Scale
Page N°
Fig. 4
2b
1
2a
3
4
5
6
7
8
9
Fig. 6 Fig. 7
1 Supporting structure made of steel sheet
2 Groundingpliers(a:forallversions;b:forE4
andE6)
3 Safety shutters (IP20 degree of protection)
4 Insulating terminal support base
5 Terminals
6 Contacts for signaling connected/test con-
nected/disconnected (on request)
7 Sliding contacts
8 Padlock for safety shutters (on request)
9 Anti-racking-in lock for power circuit break-
ers of different size
1.5 Cradle construction characteristics
2. Checking on receipt
Examinethe stateof thematerial received andits correspondencewith whatwas foreseenat thetime ofordering. Should anydamage orirregularity
be found on unpacking, which must be carried carefully, make the relative notification within and not over 5 days from receipt of the material. The
notification must indicated the number of the shipping note.
3. Storage, lifting and weights
The power circuit breaker, protected by an external wooden housing, is fixed by means of screws to the transport plate or to the bottom of the
packing case. If the power circuit breaker has to remain in the warehouse even for a short time before being put into service, after checking it
on receipt, it must be put back in its container, and covered with a waterproof sheet.
Caution
– Use a dry, dust-free room free of aggressive chemical agents as the storage room
– Position the power circuit breaker on a horizontal surface, not in direct contact with the floor, but on a suitable support surface (Fig. 6)
– The maximum number of stackable power circuit breakers is indicated in figure 7.
– Keep the power circuit breaker in the open position and with the closing springs discharged to avoid unnecessary stresses and risk of accidents
to the personnel.
Courtesy of NationalSwitchgear.com

L2275 Emax UL
6/132
Doc. N°
Mod.
RH0109002
Apparatus Scale
Page N°
Fig. 9
Fig. 8
Table of the power circuit breaker weights
Notes
Theweightsindicatedinthetableareintendedfor
powercircuitbreakerscompletewithPR111-A,
PR112-AorPR113-Atripunitsandrelativecur-
renttransformers,withexclusionoftheaccesso-
ries.
Thedrawoutversionincludesthemovingpartin
thesameconditionsasabove,andthecradlewith
horizontalrearterminals.
Selective power fixed 3 poles fixed 4 poles draw out 3 poles draw out 4 poles
circuit breaker kg Lbs kg Lbs kg Lbs kg Lbs
E1 45 99 54 119 70 154 82 181
E2 50 110 61 135 78 172 93 205
E3 66 145 80 176 104 229 125 275
E4 97 213 117 258 147 324 165 363
E6 140 308 160 353 210 463 240 529
With regard to lifting, follow these instructions: the power circuit breakers must be placed on a sturdy resting surface and lifted, preferably by means
of a special fork-lift truck. However, the use of ropes is allowed. In this case, the lifting ropes must be hooked up as shown in the figures (the lifting
plates are always supplied with the power circuit breaker).
4.3 Installation of the draw out power circuit breaker cradle
4.3.1 Preparation of the cradle
Assembly of the anti-racking-in lock
Before installing the cradle, it is necessary to check the presence of the anti-racking-in lock of power circuit breakers with different electrical
characteristics from those of the cradle itself. Should the anti-racking-in lock have been supplied separately, proceed to assemble it as follows:
– On the self-adhesive plate (4), find the assembly position of the stop bolts in relation to the power circuit breaker which has to be housed in the
cradle
– Insert the two hexagonal-head screws (1) in the holes found in the previous point as shown in the figure
– Fix the two screws with the washers (2) and the hexagonal stops (3).
Check that the anti-racking-in lock corresponding to the one installed on the cradle is present on the power circuit breaker (moving part).
– Anti-racking-in plate on the moving part (5).
4. Installation
4.1 Installation room
Install the power 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, use assembly in switchgear with a suitable degree
of protection.
For preparation of the installation room, please refer to the “Overall
dimensions”paragraph,whichgivesinformationonthefollowingpoints:
– minimum installation volumes of the power circuit breakers and
derived versions
– distances to be respected for power circuit breakers in compart-
ments
– overall dimensions of the power circuit breakers
– fixing mounting holes
– compartment door mounting holes.
The operation of installation, put in service and eventually ordinary and
straordinary maintenance have to be done by skilled personel, that has
the detailed knowledge of the apparatus.
4.2 Installation of the fixed power circuit breaker
Fix the power circuit breaker to a horizontal surface using the screws
(M10 x 12 min.) (fig. 9).
Courtesy of NationalSwitchgear.com

L2275 Emax UL
7/132
Doc. N°
Mod.
RH0109002
Apparatus Scale
Page N°
Fig. 10 Fig. 11
5
1
4
2
E1 - E2 - E3
E4 - E6
3
Fig. 12a
Example for E1B 08 according to the plate diagram
4.3.2 Installation of the cradle (Fig. 12b)
Fix the cradle by means of the screws (1), washers (2) and nuts (3) (M8 x 16), supplied by ABB SACE. If other screws are used, check that the
head of the screws does not extend more than 5.5 mm (0.22 inches) from the base of the cradle.
4.3.3 Installation of the cradle on board a ship (Fig. 12a)
Regarding the fixing points of the SACE Emax draw out version air power circuit breakers, for the applications on board a ship, additional fixing
on the sides of the cradle itself is recommended (the M12 screws and the spacers are not provided in the supply).
Spacers
Spacers
Courtesy of NationalSwitchgear.com

L2275 Emax UL
8/132
Doc. N°
Mod.
RH0109002
Apparatus Scale
Page N°
Fig. 14 Fig. 15
Fig. 12b Fig. 13
12
1
2
3
5. Electrical connections
5.1 Connections to the power circuit
5.1.1 Shapes of the terminals
Cradle for draw out power circuit breaker
Terminali posteriori orizzontali
Vertical rear terminals
Note
(*) For the E1-E2 and E3 cradles,
there are four fixing points, whereas
there are six for E4 and E6.
4.4 Installation of the flange on the compartment door (Fig. 9)
– Make the compartment door mounting holes foreseen in the “Overall dimensions” paragraph.
– Apply the flange (1) onto the front of the compartment door, fixing it from the inside by means of the self-threading screws (2).
Fixed power circuit breaker
Horizontal rear terminals
Vertical rear terminals
Note
The drawings are made to show the type of terminal in diagram form. The exact shape of the terminals is given in the “Overall dimensions” chapter.
Courtesy of NationalSwitchgear.com