ABB Tmax T8 L5757 Guide

Tmax T8
Instructions for installation, service and
maintenance of low voltage moulded case
circuit-breakers
Instructions for installation
and service
1SDH000682R0002 L5757

L3692 Tmax T8
ABB SACE Division
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L5757
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Drwg. Title
App.
Resp.Off. LB-DTAT
User Office
Scale
Language
en
1SDH000682R0002
Instructions for installation, service and
maintenance of low voltage moulded
case circuit-breakers

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9. Measures to be taken if operating faults occur ....... 20
10. Accessories.............................................................. 21
10.1 Electrical accessories......................................................... 21
10.2 Mechanical locks................................................................ 23
10.3 Spare parts......................................................................... 23
11. Protection releases - References............................. 24
11.1 Safety notes ....................................................................... 24
11.1.1. Notes for dielectric strength tests ...................................... 24
11.2 General characteristics....................................................... 24
12. Overall dimensions .................................................. 25
13. Circuit diagrams....................................................... 31
Index
1. Description................................................................. 5
1.1 General characteristics......................................................... 5
1.2 External front view of the circuit-breaker ............................. 5
1.3.1 IEC circuit-breaker rating plate data .................................... 5
1.3.2 UL circuit-breaker rating plate data ..................................... 5
2. Checking on receipt................................................... 5
3. Storage, lifting and weights ..................................... 5
4. Installation.................................................................. 6
4.1 Installation conditions .......................................................... 6
4.2 Installation of the flange on the compartment door (Fig. 8) . 6
5. Electrical connections................................................ 7
5.1 Power circuit connections.................................................... 7
5.1.1 Shapes of the terminals........................................................ 7
5.1.2. Examples of connection busbar layouts depending on the
types of terminals ................................................................ 7
5.2.3 Assembly procedures for the connection busbars .............. 8
5.2 Wiring of the auxiliary circuits of the circuit-breaker ............ 8
6. Putting into service .................................................... 9
6.1 General procedures.............................................................. 9
7. Instructions for use .................................................. 10
7.1 Operating and signalling components .............................. 10
7.2 Circuit-breaker closing and opening procedures............... 10
8. Maintenance ............................................................ 12
8.1. Warnings ............................................................................ 12
8.2. Maintenance program ........................................................ 12
8.2.1. Circuit-breaker life .............................................................. 12
8.2.2. Maintenance program ....................................................... 12
8.3. First Level maintenance operations ................................... 13
8.3.1. Preliminary operations:....................................................... 13
8.3.2. General inspections and cleaning: ..................................... 13
8.3.3. Circuit-breaker connections and connections between
circuit-breaker and switchboard ........................................ 13
8.3.4. Flange and escutcheon plate disassembly operations ...... 13
8.3.5. Mechanical operating mechanism ..................................... 14
8.3.6. Electrical and mechanical accessories .............................. 14
8.3.7. Protection releases............................................................. 15
8.3.8.1 Test with SD Testbus2 (optional) ........................................ 15
8.4.8.2 Test with EKIP Connect (optional) ...................................... 15
8.3.9. Maintenance operations; final inspections......................... 15
8.3.10. Interlocks............................................................................ 15
8.4. Second Level maintenance operations.............................. 16
8.4.1. Preliminary operations:....................................................... 16
8.4.2. General inspections and cleaning: ..................................... 16
8.4.3. Circuit-breaker connections and connections between
circuit-breaker and switchboard ........................................ 16
8.4.4. Flange and escutcheon plate disassembly operations ...... 16
8.4.5. Mechanical operating mechanism ..................................... 17
8.4.6. Electrical and mechanical accessories .............................. 18
8.4.7. Protection releases............................................................. 18
8.4.8.1 Test with SD Testbus2 (optional) ........................................ 18
8.4.8.2 Test with EKIP Connect (optional) ...................................... 18
8.4.9. Maintenance operations; final inspections......................... 19
8.4.10. Interlocks............................................................................ 19

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1.3.2 UL circuit-breaker rating plate data
Fixed circuit-breaker
Fig. 2
Fig. 3
1.3.1 IEC circuit-breaker rating plate data
1. Description
1.1 General characteristics
Tmax T8 circuit-breakers and disconnectors consist of a plastic structure which houses the operating mechanism, the poles and the auxiliary
parts. Each pole is insulated from the others and contains the circuit breaking parts and the current sensor of the corresponding phase.
The fixed version circuit-breaker has its own terminals for connection to the power circuit.
1 PR232/P-T8, PR331 or PR332 electronic microprocessor-based release
2 Operating and control parts of the operating mechanism and release-tripped signals
3 Rating plate
1.2 External front view of the circuit-breaker
Fig. 1
Fig. 4 Fig. 5
2. Checking on receipt
Examine the condition of the material received and make sure that it corresponds to what was ordered. Any damage or non-compliance found
when the material has been unpacked, which must be carried out with due care, must be notified within 5 days of receipt and the number of the
shipping notice must be indicated on the notification.
3. Storage, lifting and weights
Protected by an external wooden crate, the circuit-breaker is fastened with screws to the pallet used for transport or to the bottom of the pack-
ing crate.
If the circuit-breaker must be stored for even a short period of time before being put into service, after having been checked on receipt it must
be its back into its container and covered with a waterproof tarpaulin.
Caution
– Store the circuit-breaker in a dry, dust-free room well away from aggressive chemicals.
– Place the circuit-breaker and any fixed part on a horizontal surface, not in direct contact with the floor but on a suitable support (Fig. 4).
– The maximum number of circuit-breakers that can be stacked on top of each other is shown in figure 5.
– Keep the circuit-breaker in the open position with the closing springs unloaded to prevent unwarranted stress and the risk of accidents to the
personnel.

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Fig. 8
Fig.7
Table of circuit-breaker weights (kg)
Note
The weights given in the table refer to circuit-breakers complete with PR232/P-T8, PR331 or PR332 releases and relative current sensors, excluding the accessories.
4. Installation
4.1 Installation conditions
Install the circuit-breaker in a dry, dust-free, non-corrosive place where it
will not be subjected to shocks or vibrations. When this is not possible,
assemble it inside a switchboard with a suitable degree of protection.
For preparation of the installation ambient, refer to the “Overall dimen-
sions” chapter, which provides information about the following points:
– minimum installation volumes of the circuit-breakers and derived
versions
– clearances to be respected for circuit-breakers in compartments
– overall dimensions of the circuit-breakers
– drilling holes for fixing purposes
– drilling holes in the compartment door
The operations required for installation, putting into service, routine and
supplementary maintenance must be performed by skilled personnel
with detailed knowledge of the equipment.
To install a circuit-breaker in the switchboard, just fix it to a vertical
surface with M8 screws. (fig. 7 )
The circuit-breaker must only be installed in a vertical position.
Fig. 6
Comply with the following instructions when lifting the circuit-breaker: the circuit-breakers must be placed on a sturdy surface and preferably lifted
with an appropriate fork-lift truck. The use of ropes is, however, permitted: In this case, the lifting ropes ust be attached as shown in the figure.
4.2 Installation of the flange on the compartment door (Fig. 8)
– Drill the holes in the compartment door indicated in the section entitled “Overall dimensions”.
– Apply the flange (1) to the front of the compartment door and fix it from the inside with the self-tapping screws (2).
Circuit-breaker 3 poles 4 poles
kg lbs kg lbs
T8 1600 (UL) 73 161 95 209
T8 2000 73 161 95 209
T8 2500 73 161 95 209
T8 3000 (UL) 107 236 140 308
T8 3200 (IEC) 107 236 140 308

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VR/HR VR VR
5. Electrical connections
5.1 Power circuit connections
Use insulated bars/ perform specific type tests on the installation.
5.1.1 Shapes of the terminals
Fig. 9
Note
The drawings provide a schematic illustration of the type of terminal. The exact shape of the terminals is given in the chapter entitled “Overall
dimensions". The terminals installed on the upper and lower parts (input and output) can be different from each other.
Front terminals
(IEC/UL)
5.1.2. Examples of connection busbar layouts depending on the types of terminals
The busbars allow connections to be made between the terminals of the circuit-breaker and the busbars of the switchboard. They must be ac-
curately sized by the switchboard design engineer.
This section illustrates examples of possible constructions, depending on the shape and size of the circuit-breaker terminals.
It is normally advisable to use the entire contact surface of the terminal, thus the width of the busbar should be the same as that of the terminal.
Different capacities can be obtained for the connections by adjusting the thickness and number of busbars in parallel. In certain cases, reductions
in the width of the connection in relation to that of the terminal can be allowed, as shown in the examples below.
Front terminals Vertical rear terminals
Circuit-breaker Iu [A] Busbar cross-section Busbar cross-section
[mm2]/[in2] [mm2]/[in2]
T8 V 1600 3x(100x5) / 3x(3.94x0.2) 3x(100x5) / 3x(3.94x0.2)
T8 L-V 2000 3x(100x5) / 3x(3.94x0.2) 3x(100x5) / 3x(3.94x0.2)
T8 L-V 2500 4x(100x5) / 4x(3.94x0.2) 4x(100x5) / 4x(3.94x0.2)
T8 V 3000 - 6x(100x5) / 6x(3.94x0.2)
T8 L-V 3200 - 6x(100x5) / 6x(3.94x0.2)
Fig. 10
Extended front
terminals (IEC)
Adjustable rear termi-
nals for flat bar ( VR for
IEC/UL; HR for IEC)
Vertical rear ter-
minals (IEC)
Vertical rear
terminals (UL)

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Positioning the first anchor plate of the busbars
Anchoring to the switchboard
Fig. 11
5.2.3 Assembly procedures for the connection busbars
Check the state of the contact surfaces of the connections very carefully: they must be very clean and free from burrs, dents and traces of rust
- which must be removed with a fine file or emery cloth to prevent localized increases in temperature. On completion of the operation, remove
any traces of grease or dust with a cloth soaked in a suitable solvent.
When aluminium connections are used, the contact surfaces must be tin-plated.
Make sure that the connections are unable to exert any strain on the terminals in any direction.
Always insert a flat washer with a large diameter (to distribute the tightening pressure over the widest possible area) and a spring washer.
Establish contact between the connection and terminal and fully tighten the fixing screws.
Always use two wrenches (to prevent the insulating parts from being unduly stressed) and apply the tightening torque of the main terminals = 70
Nm/615 lb in for M12 high-strength screws. Check tightness after 24 hours.
5.2 Wiring of the auxiliary circuits of the circuit-breaker
There is a special terminal board fitted with screw terminals for connecting the auxiliary circuits.
The terminals are marked with alphanumerical identification codes as indicated in the electrical circuit diagram.
The terminal board is identified by the letters XV on the electrical circuit diagram.
The terminal board is accessed immediately when the compartment door is opened.
Fig. 12
XV
190
190 190 190
190
190
190
7.48"
7.48"
7.48"
7.48"
7.48"
7.48" 7.48"

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6. Putting into service
6.1 General procedures
– Make sure that the power connections to the circuit-breaker terminals are tight
– Perform al the preparatory operations on the release
– Make sure that the power supply voltage of the auxiliary circuits is between 85% and 110% of the rated voltage of the electrical applications
– To avoid temperature rises, make sure that there is sufficient air exchange in the installation area
– Also perform the inspections indicated in the following table.
Item inspected
1 Manual operating mechanism
2 Gearmotor (if provided)
3 Undervoltage release
(if provided)
4 Shunt closing release (if provided)
5 Shunt closing release (if provided).
6 Lock for circuit-breaker in open position
(key or padlock)
7 Auxiliary circuit-breaker contacts
Procedure
Perform a few opening, closing and release
operations (see chap. 7.2).
WARNING
When there is an undervoltage release, the cir-
cuit-breaker can only be closed after the release
itself has been electrically energized.
Supply the spring loading gearmotor at the
relative rated voltage.
Perform a few closing and opening operations.
Note. Supply the undervoltage release at the
relative rated voltage (if provided).
Supply the undervoltage release at the relative
rated voltage and perform the circuit-breaker
closing operation.
Turn off the voltage supply to the release.
Supply the undervoltage release at the relative
rated voltage and perform the circuit-breaker
closing operation.
Close the circuit-breaker.
Supply the shunt opening release at the relative
rated voltage.
Open the circuit-breaker.
Power the shunt closing release at the its
rated voltage.
Open the circuit-breaker, turn the key and
remove it. Attempt the circuit-breaker closing
operation.
Insert the auxiliary contacts into appropriate
signalling circuits. Perform a few circuit-breaker
closing and opening operations.
Successful check
The spring loading lever moves normally.
The springs are loaded normally.
The signals are normal.
The gearmotor stops when the springs have
been loaded.
The gearmotor reloads the springs after each
closing operation.
The circuit-breaker closes normally. The signals
are normal.
The circuit-breaker opens. The signal changes
over.
The circuit-breaker opens normally. The signals
are normal.
The circuit-breaker closes normally. The signals
are normal.
Both manual and electrical closing are pre-
vented.
Signalling occurs normally.

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Note
On request, a transparent cover that increases the degree of protection to IP54 can be installed on the front of the circuit-breaker. The cover is
equipped with a key lock.
As an alternative to the transparent cover, a protection can be installed on the manual opening and closing controls so that the push-buttons
can only be operated with the relative tool.
Fig. 14
7. Instructions for use
7.1 Operating and signalling components
1 Push-button 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
5 Pushbutton for the manual closing operation
6 Indicator for springs loaded - unloaded
7 Operation counter (to order)
8 Key lock on the closing operation (to order)
Fig.13
2
36
Fig. 15
7.2 Circuit-breaker closing and opening procedures
Circuit-breaker operation can be either manual or electrical.
a) Manual operation for loading the closing springs
– Make sure that “O” (circuit-breaker open) is displayed by the indicator
– Make sure that the indicator (6) is WHITE (springs unloaded)
– Repeatedly operate the lever (2) until the colour of the indicator (6)
changes to YELLOW
b) Electrical operation for loading the closing springs
Electrica operation of the circuit-breaker is possible when the following
accessories are present (supplied to order):
– gearmotor for automatic loading of the closing springs
– shunt closing release
– shunt opening release.
The gearmotor automatically reloads the springs after each closing
operation until the yellow indicator appears (6, Fig. 15). If there is a
power failure during the loading operation, the gearmotor stops and
automatically continues with the spring loading operation once the
power returns. However, it is always possible to complete the reloading
operation in the manual mode.

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Fig. 16
Press
Fig. 17
Press
d) Circuit-breaker opening
Press the push-button “O” (1) to open the circuit-breaker in the manual mode. When there is a shunt opening release, the operation can also
be carried out in the remote mode by means of the special control circuit. The open state is signalled by the appearance of the letter “O” in the
indicator (3).
c) Circuit-breaker closing
This operation can only be carried out when the closing springs are fully loaded.
Press the push-button (5) marked with the letter “I” for closing in the manual mode. When there is a shunt closing release, the operation can also
be carried out in the remote mode by means of the special control circuit. Closing is signalled by the relative indicator (3), which moves to the
“I” position. Moreover, the indicator of the state of the springs (6) moves to the WHITE position. The control has enough energy for the opening
operation even when the closing springs are unloaded. If present, the gearmotor immediately begins the automatic spring loading operation.

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8. Maintenance
8.1. Warnings
WARNING: before proceeding with any maintenance operation, it is obligatory to:
-Oen the circuit-breaker and make sure that the springs of the operating mechanism are unloaded;
-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 earth the terminals on both the supply side and load side;
-Set the equipment to safe conditions as established by the standards and laws in force.
WARNING RISK OF ELECTRIC SHOCK: Risk of electric shock or accident.
ABB declines all liability for damage to persons or property caused by failure to comply with the instructions in this document.
The maintenance operations must be performed by skilled personnel with detailed knowledge of the equipment.
8.2. Maintenance program
8.2.1. Circuit-breaker life
When regular maintenance is performed, SACE Emax circuit-breakers - with or without shunt opening or shunt closing devices
- can withstand the following operating cycles without replacement of parts. (1)
Rated uninterrupted
current Mechanical life (2) Electrical life (2)
Iu (40 °C)
[A]
N° of
operations
x 1000
Frequency
operations/
hour
415 V ~
N° of operations x 1000
Frequency
operations/hour
T8 (UL) 1600 15 60 4,5 30
T8 2000 15 60 4,5 30
T8 2500 15 60 4 30
T8 (UL) 3000 15 60 3 30
T8 (IEC) 3200 15 60 3 30
(1) These data refer to the standard installation in accordance with the product standards. Ask ABB Sace if different applications are involved.
(2) Extreme weather conditions, polluted atmosphere or vibrations can reduce the life of the application. Ask ABB Sace.
8.2.2. Maintenance program
We hereby include the table indicating the frequency with which maintenance should be carried out and the relative routine
maintenance operations required.
Compliance with the following rules is also recommended:
- Even circuit-breakers that are operated infrequently or that remain closed or open for long periods of time must be subjected
to programmed maintenance.
- Installation of the mechanical operation counter (supplied on request) is recommended for circuit-breakers equipped with SACE
PR232 and PR331 releases. The SACE PR232 release with Vaux allows the number of operations performed by the circuit-
breaker in service to be shown at all times on the relative display.
- During service, visually inspect the circuit-breaker from the outside to make sure there is no dust, dirt or damage of any kind.
Maintenance operations
Intervals
Installations in normal places Installations in dusty or polluted places ( 1)/( 2)[
(1) = level of dust measured > 1 mg/m³ ]
First Level One year, or 20% of mechanical life, or 20%
of electrical life
6 months, or 10% of mechanical life, or 10%
of electrical life
Second Level
Three years, or 50% of mechanical life, or
50% of electrical life, or after a trip under
short-circuit
18 months, or 25% of mechanical life, or
25% of electrical life, or after a trip under
short-circuit
(1) These data refer to the standard installation in accordance with the product standards. Ask ABB Sace if different applications are involved.
(2) Extreme weather conditions, polluted atmosphere or vibrations can reduce the life of the application. Ask ABB Sace.

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8.3.2. General inspections and cleaning:
- Check to make sure that the device is clean. Remove any dust and traces of oil or grease with a clean, dry cloth (use a mild
detergent if necessary - A cleaning product such as Henkel’s 273471 or equivalent can be used if there is a heavy coating of dirt).
- Make sure that the rating plates with the technical specifications of the apparatus are affixed.
- The rating plates must be cleaned with a clean, dry cloth.
- Remove all traces of dust, mould, condensation and tarnish
- Make sure that there are no foreign bodies in the circuit-breaker compartment.
8.3.3. Circuit-breaker connections and connections between circuit-breaker and switchboard
- Remove any dust and dirt with a brush and dry cloth - use a mild detergent if necessary. Use a cleaning product such as Hen-
kel’s 273471 or equivalent if there is a heavy coating of dirt.
- Make sure that there are no traces of localized overheating on the terminals. This problem is denoted by the change in the colour
of the parts in contact. These parts are usually silvery in colour.
- Make sure that the bolts of the terminal connections are well tightened (M12 - 70 Nm).
WARNING: if work must be performed on the circuit-breakers, disconnect the power circuit and auxiliary circuits
and earth the terminals in a visible way on both the supply side and load side.
- Make sure that the cable connecting screws are well tightened in the terminal boxes (0.7 Nm).
Fig. 18
8.3.4. Flange and escutcheon plate disassembly operations
– Make sure that the circuit-breaker has been set to safe conditions as described in sect. 8.1
– Remove the flange (1) of the release as shown in figure 19.
– Remove the front escutcheon plate (2) by removing the four screws (3).
– Remove both the side guards (4) by removing the front screws (5).
Fig. 19
4
2
1
4
3
5
T8 III T8 IV
1
3
2
5
8.3. First Level maintenance operations
8.3.1. Preliminary operations:
- open the circuit-breaker and make sure that the springs of the operating mechanism are unloaded.
WARNING: if work must be performed on the circuit-breakers, disconnect the power circuit and auxiliary circuits
and earth the terminals in a visible way on both the supply side and load side.

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- If the undervoltage release is installed, disassemble the coil support and unload the springs of the operating mechanism by
closing and opening the circuit-breaker.
Fig. 20
8.3.5. Mechanical operating mechanism
- Clean the points indicated in figure 21. Use a cleaning product such as Henkel’s 273471 or equivalent if there is a heavy coat-
ing of dirt.
- Lubricate the opening and closing latches and the shafts in the points indicated in figure 21 with MOBILGREASE 28 (EXXON
MOBIL).
- Make sure that the opening and closing shafts are free to turn.
Fig. 21
8.3.6. Electrical and mechanical accessories
- Make sure that the accessories are securely fixed to the circuit-breaker.
- Make sure that the electrical accessories are correctly connected to the circuit-breaker.
- Gearmotor: after every 10000 operations, check the brushes for wear and replace the gearmotor if necessary.
- Make sure that the releases (SOR-UVR-SRC) are in good conditions (absence of excessive wear, overheating, breakages) Fig. 22.
- Make sure that the mechanical operation counter functions correctly (if applicable) by operating the circuit-breaker.
2Nm
Fig. 22

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8.3.7. Protection releases
- -Power the protection release with a PR030/B battery unit.
- Make sure that the protection release functions correctly: release test with the “Trip Test” (PR232, PR331, PR332) and “Autotest”
(PR332)
- With release PR332, make sure that the front leds or display do not indicate the presence of alarms.
- With release PR232 and PR331, make sure that the front leds do not indicate the presence of alarms.
- Make sure that the cables are correctly connected to the release modules and to the release itself (if applicable).
- Check the percentage of wear on the circuit-breaker contacts in PR332.
- Remove the PR030/B battery unit from the relay upon termination.
8.3.8.1 Test with SD Testbus2 (optional)
- Connect unit BT030 or BT030-USB to the relay that needs to be tested.
- Run the SD.TestBus2 program in a PC equipped with Bluetooth or Flash Drive connection, depending on the version of the
BT030 used.
- Once the connection between the relay and PC has been established, make sure that there are no alarm signals from the relay.
If this is the case, consult the ‘error messages’ and/or ‘troubleshooting’ sections of this manual.
- In normal operating conditions, proceed with the trip test and autotest (depending on the type of relay). For future check-outs,
you are advised to enter the current information in the area called User Data and/or Tag Name. These data will remain stored
in the relay itself.
- Remove the BT030 or BT030-USB flash drive from the relay.
8.4.8.2 Test with EKIP Connect (optional)
- Connect unit T&P unit to the relay that needs to be tested.
- Run the Ekip Connect program in a PC with flash drive connection.
- Once the connection between the relay and PC has been established, make sure that there are no alarm signals from the relay.
If this is the case, consult the ‘error messages’ and/or ‘troubleshooting’ sections of this manual.
- In normal operating conditions, proceed with the trip test and autotest (depending on the type of relay). For future check-outs, you are advised
to enter the current information in the area called User Data and/or Tag Name. These data will remain stored in the relay itself.
- Remove the T&P cable from the relay.
1,1 Nm
Fig. 23
8.3.9. Maintenance operations; final inspections
- Fit all the parts back in place and re-connect the auxiliary power supply if necessary.
- Re-assemble the escutcheon plate as shown in figure 23.
- Using the different auxiliaries in succession, perform the operations 10 times:
- Opening (in both the local and remote modes, if applicable)
- Closing (in both the local and remote modes, if applicable)
- Release by means of the trip test via relay
- Check the operations in accordance with the following sequence:
- Open - Springs unloaded
- Open - Springs loaded
- Closed - Springs unloaded
- Closed - Springs loaded
- Make sure that the accessories (if installed) function correctly
- Make sure that the gearmotor (if installed) functions correctly
- Make sure that the undervoltage release functions correctly (if installed)
- Make sure that the shunt opening release functions correctly (if installed)
- Make sure that the shunt closing release functions correctly (if installed)
- Make sure that the circuit-breaker's auxiliary contacts function correctly (if installed)
- Make sure that the lock for circuit-breaker in open position (key or padlock) functions correctly (if installed)
8.3.10. Interlocks
- Make sure that the interlocks between circuit-breakers side by side and on top of each other (if applicable) have been correctly
installed and function correctly.

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8.4. Second Level maintenance operations
8.4.1. Preliminary operations:
- open the circuit-breaker and make sure that the springs of the operating mechanism are discharged.
WARNING: if work must be performed on the circuit-breakers, disconnect the power circuit and auxiliary circuits
and earth the terminals in a visible way on both the supply side and load side.
8.4.2. General inspections and cleaning:
- Check to make sure that the device (interrupting part) is clean. Remove any dust and traces of oil or grease with a clean, dry
cloth (use a mild detergent if necessary - A cleaning product such as Henkel’s 273471 or equivalent can be used if there is a
heavy coating of dirt).
- Make sure that the rating plates with the technical specifications of the apparatus are affixed
- The data plates can be cleaned with a clean, dry cloth.
- Remove all traces of dust, mould, condensation and tarnish
- Make sure that there are no traces of overheating or cracks, which could impair the isolating parts of the circuit-breaker
- Make sure that there are no foreign bodies in the circuit-breaker compartment
- Make sure that the screws that fasten the fixed part to the switchboard are well tightened (M8 - 25 Nm).
8.4.3. Circuit-breaker connections and connections between circuit-breaker and switchboard
- Remove any dust and dirt from the isolating parts with a brush and dry cloth (use a mild cleaning product if necessary - A
cleaning products such as Henkel’s 273471 or equivalent can be used if there is a heavy coating of dirt).
- Make sure that there are no traces of localized overheating on the terminals. This problem is denoted by the change in the
colour of the parts in contact. These parts are usually silvery in colour.
- Make sure that the bolts of the terminal connections are well tightened (M12 - 70 Nm).
WARNING:
if work must be performed on the circuit-breakers, disconnect the power circuit and auxiliary circuits and earth
the terminals in a visible way on both the supply side and load side.
- Make sure that the cable connecting screws are well tightened in the terminal boxes (0.7 Nm).
Fig. 24
8.4.4. Flange and escutcheon plate disassembly operations
– Make sure that the circuit-breaker has been set to safe conditions as described in sect. 8.1
– Remove the flange (1) of the release as shown in figure 25.
– Remove the front escutcheon plate (2) by removing the four screws (3).
– Remove both the side guards (4) by removing the front screws (5).
Fig. 25
4
2
1
4
3
5
T8 III T8 IV
1
3
2
5

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- If the undervoltage release is installed, disassemble the coil support and unload the springs of the operating mechanism by
closing and opening the circuit-breaker.
Fig. 26
8.4.5. Mechanical operating mechanism
- Clean (use a cleaning product such as Henkel’s 273471 or equivalent if there is a heavy coating of dirt) and lubricate (in the
points indicated in figure 27, det. A, as per the First Level) the shafts and opening closing latches with MOBILGREASE 28
(EXXON MOBIL).
- Clean (use a cleaning product such as Henkel’s 273471 or equivalent if there is a heavy coating of dirt) and lubricate the operating
shaft supports, including those on the sides of the circuit-breaker (see figure 27, det. B) with MOBILGREASE 28 (EXXON MOBIL).
- Make sure that the opening and closing shafts are free to turn.
det.A det.B
Fig. 27
- Contact ABB Sace (*) if the springs are deformed or tarnished, if rings are missing or if the control is excessively worn.
(*) ABB may replace spare parts type “A” after having obtained the customer’s approval.

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8.4.6. Electrical and mechanical accessories
- Make sure that the accessories are securely fixed to the circuit-breaker.
- Make sure that the electrical accessories are correctly connected to the circuit-breaker.
- Gearmotor: after every 10000 operations, check the brushes for wear and replace the gearmotor if necessary.
- Make sure that the releases (YO, YU, YC) are in good conditions (absence of excessive wear, overheating, breakages) Fig. 28.
- Make sure that the mechanical operation counter functions correctly (if applicable) by operating the circuit-breaker.
2Nm
Fig. 28
8.4.7. Protection releases
- -Power the protection release with a PR030/B battery unit.
- Make sure that the protection release functions correctly: release test with the “Trip Test” (PR232, PR331, PR332) and “Autotest”
(PR332)
- With release PR332, make sure that the front leds or display do not indicate the presence of alarms.
- With release PR232 and PR331, make sure that the front leds do not indicate the presence of alarms.
- Make sure that the cables are correctly connected to the release modules and to the release itself (if applicable).
- Check the percentage of wear on the circuit-breaker contacts in PR332.
- Remove the PR030/B battery unit from the relay upon termination.
8.4.8.1 Test with SD Testbus2 (optional)
- Connect unit BT030 or BT030-USB to the relay that needs to be tested.
- Run the SD.TestBus2 program in a PC equipped with Bluetooth or Flash Drive connection, depending on the version of the
BT030 used.
- Once the connection between the relay and PC has been established, make sure that there are no alarm signals from the relay.
If this is the case, consult the ‘error messages’ and/or ‘troubleshooting’ sections of this manual.
- In normal operating conditions, proceed with the trip test and autotest (depending on the type of relay). For future check-outs,
you are advised to enter the current information in the area called User Data and/or Tag Name. These data will remain stored
in the relay itself.
- Remove the BT030 or BT030-USB flash drive from the relay.
8.4.8.2 Test with EKIP Connect (optional)
- Connect unit T&P unit to the relay that needs to be tested.
- Run the Ekip Connect program in a PC with flash drive connection.
- Once the connection between the relay and PC has been established, make sure that there are no alarm signals from the relay.
If this is the case, consult the ‘error messages’ and/or ‘troubleshooting’ sections of this manual.
- In normal operating conditions, proceed with the trip test and autotest (depending on the type of relay). For future check-outs,
you are advised to enter the current information in the area called User Data and/or Tag Name. These data will remain stored
in the relay itself.
- Remove the T&P cable from the relay.

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8.4.9. Maintenance operations; final inspections
- Fit all the parts back in place and re-connect the auxiliary power supply if necessary.
- Re-assemble the escutcheon plate as shown in figure 30.
1,1 Nm
Fig. 29
- Using the different auxiliaries in succession, perform the operations 10 times:
- Opening (in both the local and remote modes, if applicable)
- Closing (in both the local and remote modes, if applicable)
- Release by means of the trip test via relay
- Check the operations in accordance with the following sequence:
- Open - Springs unloaded
- Open - Springs loaded
- Closed - Springs unloaded
- Closed - Springs loaded
- Make sure that the accessories (if installed) function correctly
- Make sure that the gearmotor (if installed) functions correctly
- Make sure that the undervoltage release functions correctly (if installed)
- Make sure that the shunt opening release functions correctly (if installed)
- Make sure that the shunt closing release functions correctly (if installed)
- Make sure that the circuit-breaker's auxiliary contacts function correctly (if installed)
- Make sure that the lock for circuit-breaker in open position (key or padlock) functions correctly (if installed)
8.4.10. Interlocks
Make sure that the interlocks between circuit-breakers side by side and on top of each other (if applicable) have been correctly
installed and function correctly.

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9. Measures to be taken if operating faults occur
The circuit-breaker fails to open when the opening pushbutton is pressed
Faults
The circuit-breaker fails to open because service release YO has tripped
The circuit-breaker fails to open because undervoltage release YU has tripped
The circuit-breaker fails to open when the protection relay release test is performed
The circuit-breaker fails to close when the closing pushbutton is pressed
The circuit-breaker fails to close because closing coil YC has tripped
The closing springs cannot be loaded with the manual loading lever
The closing springs cannot be loaded with the spring-loading motor
The circuit-breaker cannot be locked in the open position
Possible causes Checks and solutions
•The opening solenoid of the relay is not
connected properly
Make sure that the opening solenoid is con-
nected correctly
••• Relay tripping signal not reset Press the mechanical pushbutton to reset the
relay tripping signal
••
Supply votage of the auxiliary circuits too
low
Measure the voltage: it must not be less than
85% of the rated voltage of the coil
••
Supply voltage different from the value indi-
cated on the nameplate of these releases
Check the voltage indicated on the nameplate of
the releases
•Faulty switching circuit Check the connections, fuses, interlocks, protec-
tion switches and accept contacts
•••
Loose clamping screws of the wires and
auxiliary circuits
Make sure that the wire clamping screws are
tight
•••
Incorrect electrical connections in the
power supply circuit
Check the connections with the relative func-
tional diagram
••
Coil damaged Replace the coil
•• Operating mechanism locked Operate in the manual mode. Contact ABB SACE
if the fault persists
•• Open position key lock activated Unlock by inserting the key
•• Undervoltage release not energized Check the relative supply circuit and the supply
voltage
•• Shunt opening release remains perma-
nently energized Check the supply circuit
•• • Operating mechanism locked Call ABB SACE
•The fuse that protects the spring loading
motor protection has tripped Replace the fuse
•Faulty gearmotor for automatic spring
loading Replace the gearmotor
•Circuit-breaker closed Press the opening pushbutton and activate the
lock
•Lock in open position defective Call ABB SACE
WARNING: If the fault or failure of the circuit-breaker in your application could cause injuries, material damage
or is highly critical, the circuit-breaker itself must be immediately removed so that it can be inspected or repaired.