Thomas&Betts furse ESP 120 D1 User manual

Technical Help
is available from:
Thomas & Betts Limited
Furse
Wilford Road
Nottingham
NG2 1EB
United Kingdom
Tel: [phone]
Fax: [phone]
www.furse.com
© Copyright Thomas&Betts 2010 (Issue 1)
Installation instructions
for mains wire-in protectors
ESP D1, D1R, D1/LCD and D1R/LCD variants
TNB 1639 ESP D1 Instructions (Final Art) new size 1/4/10 09:50 Page 2

Page |3Page |2
Installation instructions for mains wire-in protectors
Introduction
This document explains how to install Furse Electronic
Systems Protectors for mains power supplies:
Single phase ESP 120 D1 |Single phase ESP 240 D1 |Single
phase ESP 277 D1 |Three phase ESP 208 D1, D1R, D1/LCD
& D1R/LCD |Three phase ESP 415 D1, D1R, D1/LCD &
D1R/LCD |Three phase ESP 480 D1, D1R, D1/LCD & D1R/LCD
These instructions are prefaced by a summary of the
Key points of installation. Each key point is explained in
detail in the section entitled Installation.
WARNING: Incorrect installation will impair the
effectiveness of the ESP units
Contents
Key points of installation 3
Before installation 4
Installation 6
Installation check (LED units) 24
Neutral-earth warning light (LED units) 25
Status indication (LED units) 26
Status indication (LCD units) 26
LCD display settings 30
Remote indication 34
Maintenance 35
Application notes 36
Remote display cut-out template 39
Key points of installation
Install protectors very close to the power supply to be
protected, either within the distribution panel or directly
alongside it.
Mount units within a panel or WBX enclosure.
ESP D1 units can be installed in parallel or, for power
supplies ≤125A, in-line (series) with the power supply.
Connect to phase(s), neutral and earth.
NOTE: Units must have a neutral connection.
Units installed at power distribution boards can be
installed either:
on the load side of the incoming isolator, or
on the closest available outgoing way to the
incoming supply
Provide a means of isolation for the ESP unit.
The connecting leads to phase/live terminals should be
suitably fused (125A maximum) ensuring full
discrimination with the immediate upstream supply fuse.
1
2
3
4
5
6
7
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Installation instructions for mains wire-in protectors
Connecting leads should be 10 mm2multi stranded
cable for parallel/shunt installation. For series installation,
refer to section 6.
For parallel/shunt installation, keep the connecting leads as
short as possible and ideally less than 25 cm (10 inches) in
length. For series installation, keep earth lead as short as
possible.
This may be better achieved with the equivalent D1R or
D1R/LCD unit with remote display mounting flexibility.
Bind the connecting leads tightly over their entire length.
Before installation
Check that the voltage between neutral and earth does
not exceed 10 volts.
If this voltage does exceed 10 volts, the installation
is unsafe.
Find and rectify the cause of this fault before proceeding.
(For delta supplies with no neutral, see page 13).
Make sure that the supply voltage is suitable for the unit.
8
9
10
1
2
Supply Rated Unit Voltage
Voltage Range
(VRMS)(V
RMS)
ESP 120 D1
Phase to
Neutral/Earth 110/120/127 90-150
ESP 208 D1 Series
Phase to Phase 190/208/220 156-260
ESP 240 D1
Phase to
Neutral/Earth 220/230/240 200-280
ESP 415 D1 Series
Phase to Phase 380/400/415 346-484
ESP 277 D1
Phase to
Neutral/Earth 240/254/277 232-350
ESP 480 D1 Series
Phase to Phase 415/440/480 402-600
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Page |7Page |6
Installation instructions for mains wire-in protectors
Installation
Location
Protectors need to be installed very close to the power
supply to be protected. Usually the protector will be
installed at a power distribution panel either inside it
(Figure 1) or right next to it (Figure 2).
ESP D1 protectors have been designed to fit onto a
standard 35mm DIN rail (see 3 - DIN Installation) or within
a Furse WBX D enclosure.
Enclose the ESP unit
The ESP unit has exposed terminals. For electrical safety,
the unit must be installed within a panel or enclosure.
For standard single and three phase units, where possible,
install the unit within the power distribution panel behind
a suitable viewing window.
1
2
Figure 1 -
ESP 415
D1/LCD
installed on
a DIN rail
within a
power
distribution
panel.
Figure 2 - ESP 415 D1/LCD installed next to a power
distribution panel in a suitable WBX D enclosure.
Alternatively, for three phase units, a remote display option
is available. Units can be installed within the power
distribution panel with the remote display mounted on the
front of the panel (see 4 - remote display).
When mounting the units in existing metal panels or
enclosures, ensure that the enclosure is securely bonded
to the earth bar to which the ESP unit will be connected.
If it is not possible to install the unit within the distribution
panel it should be mounted in a separate enclosure,
see Figure 2, as close as possible to the distribution panel
(see 12 & 13 - Length of connecting leads). Gland the
enclosure onto the power distribution panel. Suitable
enclosures are available from Furse.
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Installation instructions for mains wire-in protectors
Page |8
DIN Installation
ESP D1 Series protectors have been designed with an
innovative DIN foot for connection to standard 35mm DIN rails.
This DIN foot, comprising spring loaded steel DIN mounts,
enables rapid positioning of D1 protectors onto the rail.
The spring loaded steel DIN mounts pull down and out
to lock into place ready for siting the protector.
Position the D1 protector at the preferred location on the
DIN rail and press the protector back to release the springs.
The protector locks into place.
3
Figure 3 - Reverse of
3 phase protector
showing innovative
spring loaded
DIN foot.
Figure 4 - Reverse
of 3 phase protector
showing spring
loaded DIN foot
locked onto DIN rail.
Remote display
Three phase ESP D1R and D1R/LCD units include a remote
mounting display to ensure optimum positioning of the
unit along with quick and easy status checking.
The remote display should be mounted in a clearly visible
position, typically on the front of the distribution panel
(see Figure 5).
For remote display connection, ensure the cable is of
sufficient length, and is unimpeded within the cabinet.
Allow a minimum of 60 mm behind the front panel for the
interconnection cable.
ESP D1R and D1R/LCD units are supplied with 1 m
interconnection cable as standard, with a 4 m cable
available as an option (contact Furse).
4
Figure 5 -
ESP 415 D1R/LCD
remote display
installed on the
front of a power
distribution panel.
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Installation instructions for mains wire-in protectors
Care should be taken against static discharge when
handling the remote display unit - avoid contact with the
exposed connector.
Parallel connection
ESP D1 protectors can be connected in parallel with the
supply to be protected, or connected in-line (series), for
power supplies ≤125A (see 6).
For parallel connection, the connecting leads do not carry
the load current of the supply, only the current associated
with suppressing the transient overvoltage.
Figures 6 & 7 show connection diagrams for single
phase and three phase star power supplies.
5
Connecting leads to the unit need to be kept short in
order to minimise additive inductive voltages.
Series connection
The twin terminal design of ESP D1 units enables
installation in-line (series) with the power supply
(for power supplies ≤125A). The supply cables should be
suitably rated for the specific load current. The terminals of
the ESP unit can receive up to 35 mm2stranded cable.
Any type of protector installed in parallel (shunt) with the
supply will have additive inductive voltage on the connecting
leads. This resultant voltage let-through the protector is
hence seen by the equipment to be protected (see 5
and 12). Series installation eliminates the additive voltage
associated with connecting leads on parallel installations.
6
PE
Enhanced
Mains
Protector
EN/IEC 61643
PATENT
APPLIED
FOR
LL' L2 L2' L3 L3' NN'
11
14 12
STATUS
S
URGE
P
R
O
TE
C
TI
ON
AC
TIV
E
Figure 7 - Parallel
connection for
three phase
star (4 wire and
earth) supplies.
L N
T2 C
T1 I
imp
4kA
I
n
20kA
I
max
oc
40kA
U6kV
czac
U280V 47-63H
B
DT3
125 AgL
!
GREEN
FULL PROTECTION
GREEN & RED REDUCED
PROTECTION
(replace unit)
RED NO PROTECTION
WARNING: If lit /
flashing disconnect
unit & check Neutral
to Earth voltage
EN/IEC 61643
PATENT
APPLIED
FOR
STATUS INDICATION
ESP 240D1
LL
1N1
N
11
14 12
STATUS
Figure 6
- Parallel
connection
for single
phase supplies.
TNB 1639 ESP D1 Instructions (Final Art) new size 1/4/10 09:51 Page 10

Page |13Page |12
Installation instructions for mains wire-in protectors
Ensure the power supply does not exceed 125A
for series installations. The connecting leads to
phase/live terminals should be suitably fused (125A
maximum) ensuring full discrimination with the
immediate upstream supply fuse.
Figure 8 shows the connection diagram for three phase
star power supplies.
Figure 8 - Series
connection for
three phase star
(4 wire and
earth) supplies.
PE
LL' L2 L2' L3 L3' NN'
11
14 12
STATUS
Enhanced
Mains
Protector
EN/IEC 61643
PATENT
APPLIED
FOR
ESP 415D1
R
S
UR
G
E
P
ROTECTIO
N
A
CTIV
E
Connection to phase, neutral and earth
Connections are made to each supply conductor including
earth. Terminals marked L, N, (single phase units) or L1,
L2, L3, N, (three phase units) must be connected to
phase/live, neutral and earth respectively.
7
Under no circumstances must the ESP unit be installed
without connection to its neutral.
Where no neutral is present (eg delta supplies) the neutral (N)
terminal on the ESP unit must be connected to earth in
addition to the earth ( ) terminal. This will result in a greatly
increased earth leakage current.
On some delta supplies the voltage between phase and
earth/neutral may exceed the rating of the ESP unit.
Consequently, the supply’s phase to earth voltage must be
checked before installing the ESP unit.
We recommend that you consult Furse ESP before
installing ESP units on delta supplies.
Connection point
(a) Protecting supplies feeding equipment in the building
The ESP unit is typically connected to the power supply
at a power distribution board/panel, either:
(i) on the load side of the incoming isolator (Figure 9).
(ii) on the closest available outgoing way to the incoming
supply (ie the incoming isolator).
8
TNB 1639 ESP D1 Instructions (Final Art) new size 1/4/10 09:51 Page 12

Page |15
Installation instructions for mains wire-in protectors
Page |14
The ESP unit can be connected via one of the distribution
board’s outgoing fuseways or circuit breakers. Ideally, the
ESP unit should be connected to the outgoing way
which is nearest to the incoming supply (or isolator).
See Figure 10.
On small, compact, metal cased distribution boards, (such
as small MCB boards) the first way is preferable, although
any outgoing way is suitable.
On a large board such as a cubicle switchboard, it is better to
install the protector on the load side of the incoming isolator
PE
Enhanced
Mains
Protector
EN/IEC61643
PATENT
APPLIED
FOR
LL' L2 L2' L3 L3' NN'
11
14
12
STATUS
Figure 9 - ESP unit mounted
within a distribution board
connected to the incoming
supply on the load side
(ie downstream) of the
isolator. (Note the additional
earth bond to the metalwork
of the distribution board.)
This technique is
explained in 12(iii)
PE
Enhanced
Mains
Protector
EN/IEC61643
PATENT
APPLIED
FOR
LL' L2 L2' L3 L3' NN'
11
14
12
STATUS
Figure 10 - Three phase ESP protector connected to the nearest
available outgoing (MCB) way to the incoming supply. The MCB
also provides the means of isolation. Since there is insufficient
space within the distribution board the ESP unit has been
mounted within a separate enclosure, directly alongside the board.
Note the double connection to earth, in order to compensate for
the long connecting leads. (See 12 Length of connecting leads -
this also gives an alternative technique in 12(iii).)
(eg in the metering section). Fitting the protector in any other
position could affect the protector’s performance.
(iii) directly to the busbars via suitable HRC fuses, switch
fuses or MCCBs - see Section 10.
TNB 1639 ESP D1 Instructions (Final Art) new size 1/4/10 09:51 Page 14

Page |16
PE
Enhanced
Mains
Protector
EN/IEC 61643
PATENT
APPLIED
FOR
LL' L2 L2' L3 L3' NN'
11
14
12
STATUS
Figure 11 -
Connection for
supplies continuing
external to the
building.
(b) Protecting supplies going out of the building
The connection methods 8a (i to iii) are not suitable for
protecting a power distribution board which provides a
supply to outside the building - either to a separate building
or some other external load (eg site lighting).
To protect the equipment inside the building, from transient
overvoltages entering the board on the outgoing feed,
protection should be installed close to the external load.
See Figure 11.
Isolation
It is good practice to be able to isolate or disconnect the
ESP unit from the supply. The supply to the entire
distribution board should not be switched off on many
computer power supplies and other critical loads.
The means of isolation should therefore be installed in the
connection to the ESP unit. Figures 12 & 13 show example
connection schematics. Where it is also necessary to fuse
the connection to the ESP unit (see 10 - Fuse connecting
leads) this can be achieved through use of a switchfuse,
MCCB or type ’C’ MCB.
9
Incoming
supply
fused FS
HRC switch fuse or MCCB
FSPD, where FSPD <0.5 FS
PE
Enhanced
Mains
Protector
EN/IEC 61643
PATENT
APPLIED
FOR
LL' L2 L2' L3 L3' NN'
11
14 12
STATUS
Figure 12 - ESP unit
installed on incoming side
of distribution board.
Page |17
Installation instructions for mains wire-in protectors
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Page |19Page |18
Installation instructions for mains wire-in protectors
Fuse connecting leads
The connecting leads to the phase/live terminals of the
ESP units should be fused.
This is to protect the connecting leads in the event of a
short circuit.
The fuse to the ESP unit (FSPD) should be lower than the
upstream supply fuse FSby a sufficient enough factor to
ensure fuse discrimination. As a general guide a factor of
at least 2 could be used (FSPD ≤0.5 FS), where the
maximum fuse to the ESP unit required is 125 amps
(if the supply fuse is 250 amps or greater).
10
Incoming
supply
fused FS
HRC switch fuse or MCCB
FSPD, where FSPD <0.5 FS
PE
Enhanced
Mains
Protector
EN/IEC 61643
PATENT
APPLIED
FOR
LL' L2 L2' L3 L3' NN'
11
14
12
STATUS
Figure 13 - Installation of
ESP unit on first outgoing
way of distribution
board, nearest to the
incoming supply.
Refer to the fuse manufacturer’s operating characteristics
to ensure discrimination, particularly where an installation
includes a mixture of types of fuse, or of fuses and
circuit breakers.
Live/phase connecting leads can be fused by either:
(a) installing high rupture capacity (HRC) fuses or switch
fuses in the connecting leads at the supply end of the
lead (See Figure 14), or
(b) installing up to a
125 amp circuit breaker
(MCCB or type ’C’ MCB).
Where the ESP unit is
installed via an outgoing
way (8b earlier) this
should incorporate
up to a 125 amp HRC
fuse or circuit breaker.
L N
T2 C
T1
I
imp
4kA
I
n
20kA
I
max
oc
40kA
U6kV
czac
U280V 47-63H
B
DT3
125 AgL
!
GREEN
FULL PROTECTION
GREEN & RED REDUCED
PROTECTION
(replace unit)
RED NOPROTECTION
WARNING:If lit /
flashing disconnect
unit & check Neutral
to Earth voltage
EN/IEC 61643
PATENT
APPLIED
FOR
STATUS INDICATION
ESP 240D1
LL
1
N
1
N
11
14 12
STATUS
Figure 14 - Busbar
mounted HRC fuse at
the end of the live
connecting lead.
TNB 1639 ESP D1 Instructions (Final Art) new size 1/4/10 09:51 Page 18