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ABB Emax E1 Installation And Service Instructions Manual - Abb Sace

Manual is about: low voltage air circuit-breakers Emax Series

Summary of Emax E1

  • Page 1

    Emax installation, service and maintenance instructions for low voltage air circuit-breakers installation and service instructions 1sdh000460r0002 l6555.

  • Page 2: Abb Sace

    L6555 emax abb sace doc. No. Model apparatus dwg. Title app. Resp. Off. Take over off. Scale language en 1sdh000460r0002 installation, service and maintenance instructions for low voltage air circuit-breakers • read this document and the instruction manual carefully before attempting to install, ope...

  • Page 3

    Index 1. Description . . . . . . . . . . . . . . . . . . . . . . . 4 1.1. General characteristics . . . . . . . . . . . . . . . . . 4 1.2. External front view of the circuit-breaker . . . . . . . . 4 1.3. Rating plate . . . . . . . . . . . . . . . . . . . . . . . 4 1.3.1. Circuit-breaker rating plat...

  • Page 4

    L6555 emax 4/74 doc. No. Model apparatus scale page no 1sdh000460r0002 1. Description 1.1. General characteristics the sace emax series of circuit-breakers and disconnectors consists of a steel sheet structure which houses the operating mechanism, the poles and the auxiliary parts. Each pole, insula...

  • Page 5

    L6555 emax 5/74 doc. No model apparatus scale page no 1sdh000460r0002 1.4. Moving part construction characteristics fig. 3 3 2 4 5b 5a 6a 6b 1 7 8 15 9 9 13 14 19 12 13 14 15 3 20 4 5a 6a 1 8 9 11 12 10 10 11 1 supporting structure made of steel sheet 2 current sensor for protection release 3 termin...

  • Page 6

    L6555 emax 6/74 doc. No. Model apparatus scale page no 1sdh000460r0002 2. Checking on receipt examine the state of the material received and its consistency with the content of the order. Should any damage or errors be found on unpacking, which must be carried out carefully, make the relative notifi...

  • Page 7

    L6555 emax 7/74 doc. No model apparatus scale page no 1sdh000460r0002 4. Installation 4.1. Installation room install the circuit-breaker in a dry, dust-free, non-corrosive room, and in such a way that it is not subject to shocks or vibrations. Where this is not possible, install it inside a switchbo...

  • Page 8

    L6555 emax 8/74 doc. No. Model apparatus scale page no 1sdh000460r0002 4.3.2. Installation of the fi xed part (fig. 12) attach the fi xed part by means of the screws (1), washers (2) and nuts (3) (m8 x 16), supplied by abb sace. If other screws are used, make sure that the head of the screws does no...

  • Page 9

    L6555 emax 9/74 doc. No model apparatus scale page no 1sdh000460r0002 5. Electrical connections 5.1. Connections to the power circuit 5.1.1. Shapes of the terminals hr vr hr vr f f fl fig. 14 fixed part for withdrawable circuit-breaker fig. 15 fixed circuit-breaker note the drawings are provided to ...

  • Page 10

    L6555 emax 10/74 doc. No. Model apparatus scale page no 1sdh000460r0002 vertical terminals horizontal and front terminalsi circuit-breaker iu [a] continuous current-carrying capacity busbar cross-section continuous current-carrying capacity busbar cross-section [a] [mm 2 ] [a] [mm 2 ] 35°c 45°c 55°c...

  • Page 11

    L6555 emax 11/74 doc. No model apparatus scale page no 1sdh000460r0002 5.1.3. Assembly procedure for the connection busbars check the state of the contact surfaces of the connections very carefully: they must be very clean with no burrs, dents or traces of rust which must be eliminated using a fi ne...

  • Page 12

    L6555 emax 12/74 doc. No. Model apparatus scale page no 1sdh000460r0002 5.3.2. Withdrawable circuit-breaker for connection of the moving part to the auxiliary circuits, a connection with sliding contacts is available on the fi xed part (see fi gure), identifi ed by code x on the electrical circuit d...

  • Page 13

    L6555 emax 13/74 doc. No model apparatus scale page no 1sdh000460r0002 5.4. Conversion of the auxiliary contacts or of the signalling contacts (disconnected - test isolated - connected), from normally closed (opening) to normally open (closing) or vice versa the contacts are wired at the factory as ...

  • Page 14

    L6555 emax 14/74 doc. No. Model apparatus scale page no 1sdh000460r0002 6. Putting into service 6.1. General procedures - check tightness of the power connections at the circuit-breaker terminals - carry out all the preparatory operations on the release - make sure that the value of the auxiliary ci...

  • Page 15

    L6555 emax 15/74 doc. No model apparatus scale page no 1sdh000460r0002 7. Instructions for use 7.1. Operating and signalling parts 1 pushbutton for the manual opening operation 2 lever for manual loading of the closing springs 3 mechanical indicator for circuit-breaker open “o” and closed “i” 4 mech...

  • Page 16

    L6555 emax 16/74 doc. No. Model apparatus scale page no 1sdh000460r0002 7.2. Circuit-breaker closing and opening procedures the operation of the circuit-breaker can be either manual or electrical. A) manual loading of the closing springs - make sure that the indicator (3) shows “o” (circuit-breaker ...

  • Page 17

    L6555 emax 17/74 doc. No model apparatus scale page no 1sdh000460r0002 7.3. Racking-in/out operation warning: a) open the circuit-breaker before carrying out any racking-in/out operation. B) the circuit-breaker (moving part) and fi xed part are fi tted with a lock which prevents the fi xed part from...

  • Page 18

    L6555 emax 18/74 doc. No. Model apparatus scale page no 1sdh000460r0002 a) positioning the moving part in the fi xed part in the disconnected position lift the moving part as shown in the paragraph (3) and insert it in the fi xed part guide, tilting it as shown in fi gure 2. The manual connection mu...

  • Page 19

    L6555 emax 19/74 doc. No model apparatus scale page no 1sdh000460r0002 8. Maintenance 8.1. Warning warning: before carrying out any maintenance task, you must: - open the circuit-breaker and check that the operating mechanism springs are unloaded; - in the case of withdrawable circuit-breakers, work...

  • Page 20

    L6555 emax 20/74 doc. No. Model apparatus scale page no 1sdh000460r0002 8.2.2. Maintenance program the table shows the maintenance intervals and the frequency of periodical intervention and routine maintenance tasks. The fol- lowing rules should also be followed: - even circuit-breakers that are lit...

  • Page 21

    L6555 emax 21/74 doc. No model apparatus scale page no 1sdh000460r0002 8.3.4. Dismantling tab and cap - the tab (1) of the release by rotating the screws (2) as shown in fi gure 33. - remove the front cap (3) by loosening the four screws (4). 1 2 3 4 1 2 3 4 fig. 33 - if there is a minimum release, ...

  • Page 22

    L6555 emax 22/74 doc. No. Model apparatus scale page no 1sdh000460r0002 8.3.6. Electrical and mechanical accessories - check that the accessories are fi xed to the switch - check that the electrical accessories are connected to the switch - reduction gear: after 10000 operations check brushes for we...

  • Page 23

    L6555 emax 23/74 doc. No model apparatus scale page no 1sdh000460r0002 8.3.10. Interlock - check that the interlock devices have been correctly installed and operate correctly between adjacent and superimposed switches (if present). The operating test cannot be run in the test or extracted positions...

  • Page 24

    L6555 emax 24/74 doc. No. Model apparatus scale page no 1sdh000460r0002 8.4.4. Dismantling the tab, cap and arcing chambers - remove the fl ange (1) of the release, turning the screws (2) as shown in the fi gures - remove the front escutcheon plate (3) by removing the four screws (4) - remove, if pr...

  • Page 25

    L6555 emax 25/74 doc. No model apparatus scale page no 1sdh000460r0002 8.4.5. Mechanical control - cleaning (for excessive deposits, a laminated dilutant such as henkel 273471 or the equivalent can be used) and lubricate, at the points indicated in fi g. 43, part a, as for first level, the opening a...

  • Page 26

    L6555 emax 26/74 doc. No. Model apparatus scale page no 1sdh000460r0002 6.1) check the blowout magnets distances (distance a fi g 45). Fig. 45 circuit breaker 6.2) close the circuit-breaker and check the gap a - if the gap a is not correct, contact abb sace (*) - if the gap a is correct, open the ci...

  • Page 27

    L6555 emax 27/74 doc. No model apparatus scale page no 1sdh000460r0002 8.4.10. Maintenance operations; fi nal checks: - refi t each part and if necessary reconnect the auxiliary supply. - refi t the cap as indicated in fi gure 46. Fig. 46 - return the movable part to the position test-isolated. - us...

  • Page 28

    L6555 emax 28/74 doc. No. Model apparatus scale page no 1sdh000460r0002 9. Measures to be taken for any operating anomalies the switch does not open when the opening button is pressed anomalies the switch does not open when the yo operating release is tripped the switch does not open when the yu min...

  • Page 29

    L6555 emax 29/74 doc. No model apparatus scale page no 1sdh000460r0002 10. Accessories 10.1. Electrical accessories shunt opening/closing (yo/yc) and second shunt opening release (y02) this allows remote opening or closing control of the apparatus. Given the characteristics of the circuit-breaker op...

  • Page 30

    L6555 emax 30/74 doc. No. Model apparatus scale page no 1sdh000460r0002 time delay device for undervoltage release (d) the undervoltage release can be combined with an electronic time-delay device for installing outside the circuit-breaker, which enables a delay in the tripping of the release with p...

  • Page 31

    L6555 emax 31/74 doc. No model apparatus scale page no 1sdh000460r0002 auxiliary contacts auxiliary contacts installed on the circuit-breaker are available to enable an indication of the circuit-breaker’s status. A special version of the auxiliary contacts is also available (gold plated contacts) fo...

  • Page 32

    L6555 emax 32/74 doc. No. Model apparatus scale page no 1sdh000460r0002 10.2. Mechanical locks a-b) lock in open position different mechanisms are available which enable the circuit-breaker to be locked in the open position. These devices can be controlled by: - a key (a): a special circular lock wi...

  • Page 33

    L6555 emax 33/74 doc. No model apparatus scale page no 1sdh000460r0002 for the change over, the customer can use a suitable electronic relay, whose diagram is supplied by abb sace. The mechanical interlocks between two or three circuit-breakers are made by means of cables that can be used for circui...

  • Page 34

    L6555 emax 34/74 doc. No. Model apparatus scale page no 1sdh000460r0002 11. Protection releases - general notes the abb sace emax series of air circuit-breakers can be equipped with electronic relay pr121/p. The available accessories and functions are listed in the table below. Function/unit pr121 c...

  • Page 35

    L6555 emax 35/74 doc. No model apparatus scale page no 1sdh000460r0002 11.2. Abbreviations and notes 11.2.1. Abbrevations abbreviations meaning yo opening coil yc closing coil cb circuit-breaker (for example emax) cs current sensor (current transformer) ekip connect communication software for pc, fo...

  • Page 36

    L6555 emax 36/74 doc. No. Model apparatus scale page no 1sdh000460r0002 12. Sace pr121/p relay 12.1. Identification the pr121/p units available, in accordance with the iec standards, with the various default and optional protections and mod- ules, are illustrated in the fi gure below: 12.2. Specifi ...

  • Page 37

    L6555 emax 37/74 doc. No model apparatus scale page no 1sdh000460r0002 12.2.2. Compatibility cb pr121/p can be installed on 3-pole cbs with and without an external neutral, or on 4-pole emax cbs of any model. The cb model establishes the rated uninterrupted current the circuit-breaker is able to sup...

  • Page 38

    L6555 emax 38/74 doc. No. Model apparatus scale page no 1sdh000460r0002 12.3. User interface the graphic interface of relay pr121/p allows the protections and general state of the relay itself to be adjusted and displayed. 1 2 4 3 5 6 7 9 10 8 11 12 13 14 rifer. Description 1 alarm indicator led for...

  • Page 39

    L6555 emax 39/74 doc. No model apparatus scale page no 1sdh000460r0002 there are 2 to 4 red leds for checking the state of the protections: the number of leds depends on the way the relay has been confi gured and on the protections installed. The led of protection l can also come on in the orange co...

  • Page 40

    L6555 emax 40/74 doc. No. Model apparatus scale page no 1sdh000460r0002 - when the unit is off, it allows the last event recorded by the relay to be checked (when pressed for about 1 second). The function is available for 48 hours after the relay has been switched off (absence of internal or externa...

  • Page 41

    L6555 emax 41/74 doc. No model apparatus scale page no 1sdh000460r0002 real tripping time is forced to t 2 (t(s)= t 2 .) notes: - t(s)= envisaged tripping time; - i f = fault current; given in [in] (example: 1.7in) - i 2 , t 2 = protection s parameters set by the user, given in [in] and [s] 12.4.2.1...

  • Page 42

    L6555 emax 42/74 doc. No. Model apparatus scale page no 1sdh000460r0002 12.4.6. Protection against instantaneous short-circuit “iinst” the purpose of this protection is to maintain the integrity of the circuit-breaker and installation in the case of particularly high current requiring shorter reacti...

  • Page 43

    L6555 emax 43/74 doc. No model apparatus scale page no 1sdh000460r0002 12.4.8.2. Trip curves for functions l-s(t =k/i 2 )-i t = k i 2 12.4.8.3. Trip curves for functions l-s(t=k)-i t = k.

  • Page 44

    L6555 emax 44/74 doc. No. Model apparatus scale page no 1sdh000460r0002 12.4.8.4. Trip curves for function g t = k i 2 t = k 12.5. Main functions 12.5.1. Measurement the current measuring (ammeter) function is available in all versions of the pr121/p unit. This function is accessible by means of tes...

  • Page 45

    L6555 emax 45/74 doc. No model apparatus scale page no 1sdh000460r0002 12.6. Putting into service and recommendations 12.6.1. Nstallation circuit-breakers purchased with the relay unit assembled do not require this operation which is, however, necessary in the case of replacement. Comply with the fo...

  • Page 46

    L6555 emax 46/74 doc. No. Model apparatus scale page no 1sdh000460r0002 12.8. Troubleshooting 12.8.1. Troubleshooting the following table lists a series of typical service conditions, to help you understand and solve hypothetical faults or malfunctions. N.B.: 1. Before consulting the following table...

  • Page 47

    L6555 emax 47/74 doc. No model apparatus scale page no 1sdh000460r0002 12.9. External units 12.9.1. Pr030/b pr030/b is an external unit that allows the relay to be powered in order to perform installation, autotest and trip test, and the verifi cations with the cb open. The unit is connected to the ...

  • Page 48

    L6555 emax 48/74 doc. No. Model apparatus scale page no 1sdh000460r0002 12.9.6. Flex interface flex interfaces are electronic units that can be installed on din rail, with analog and/or digital inputs and outputs that can be connected to the pr121/p relay via local bus. The flex interface family for...

  • Page 49

    L6555 emax 49/74 doc. No model apparatus scale page no 1sdh000460r0002 13. Overall dimensions fixed circuit-breaker basic version with horizontal rear terminals a b c d e f g e1 386 296 148 148 10 130 117,5 e2 386 296 148 148 26 114 117,5 e3 530 404 202 202 26 114 117,5 e4 656 566 238 328 26 166 91,...

  • Page 50

    L6555 emax 50/74 doc. No. Model apparatus scale page no 1sdh000460r0002 e4 view a e6 view a fixed circuit-breaker basic version with horizontal rear terminals 3 poles (e4) 4 poles (e4) 4 poles(e4/f) 3 poles (e6) 4 poles (e6) 4 poles (e6/f) fig. 36.

  • Page 51

    L6555 emax 51/74 doc. No model apparatus scale page no 1sdh000460r0002 e1 e2/e4 e3/e6 fixed circuit-breaker basic version with vertical rear terminals e1 view a e2 view a e3 view a captive m12 included in the supply e4 view a e6 view a e6/f view a captive m12 included in the supply captive m12 inclu...

  • Page 52

    L6555 emax 52/74 doc. No. Model apparatus scale page no 1sdh000460r0002 e1 e2 e3 fixed circuit-breaker basic version with front terminals fig. 37.

  • Page 53

    L6555 emax 53/74 doc. No model apparatus scale page no 1sdh000460r0002 e4 e4 e4/f e6 e6 e6/f fixed circuit-breaker basic version with front terminals fig. 38.

  • Page 54

    L6555 emax 54/74 doc. No. Model apparatus scale page no 1sdh000460r0002 a b e1 400 490 e2 400 490 e3 500 630 e4 700 790 e4/f - 880 e6 1000 1130 e6/f - 1260 tightening torque of the main terminals: nm 70 tightening torque of the earthing screw: nm 70 compartment dimensions compartment door drilling h...

  • Page 55

    L6555 emax 55/74 doc. No model apparatus scale page no 1sdh000460r0002 e1 e2/e3/e4/e6 e1 414 324 162 162 10 – – e2 414 324 162 162 8 – – e3 558 432 216 216 8 370 490 e4 684 594 252 342 8 530 610 e4/f 774 - - 342 8 – 700 e6/f 1062 - - 468 8 - 1000 e6 936 810 342 468 8 750 870 withdrawable circuit-bre...

  • Page 56

    L6555 emax 56/74 doc. No. Model apparatus scale page no 1sdh000460r0002 withdrawable circuit-breaker basic version with horizontal rear terminals e4 view a e6 view a 3 poles (e4) 4 poles (e4) 4 poles (e4/f) 3 poles (e6) 4 poles (e6) 4 poles (e6/f) fig. 41.

  • Page 57

    L6555 emax 57/74 doc. No model apparatus scale page no 1sdh000460r0002 e1 e2/e4 e3/e6 withdrawable circuit-breaker basic version with vertical rear terminals captive m12 included in the supply e1 viewa e2 viewa e3 viewa e4 viewa e6 viewa e4/f viewa e6/f viewa captive m12 included in the supply capti...

  • Page 58

    L6555 emax 58/74 doc. No. Model apparatus scale page no 1sdh000460r0002 e1 e2 e3 withdrawable circuit-breaker version with front terminals fig. 43.

  • Page 59

    L6555 emax 59/74 doc. No model apparatus scale page no 1sdh000460r0002 e4 e6 e6 e6/f e4 e4/f withdrawable circuit-breaker version with front terminals fig. 44.

  • Page 60

    L6555 emax 60/74 doc. No. Model apparatus scale page no 1sdh000460r0002 e1 e2 fig. 45 withdrawable circuit-breaker version with fl at terminals e1 viewa e2 viewa e3 viewa e4 viewa e6 viewa e4/f viewa e6/f viewa.

  • Page 61

    L6555 emax 61/74 doc. No model apparatus scale page no 1sdh000460r0002 a b e1 400 490 e2 400 490 e3 500 630 e4 700 790 e4/f - 880 e6 1000 1130 e6/f - 1260 withdrawable circuit-breaker tightening torque of the fi xing screws: 20 nm tightening torque of the main terminals: 70 nm tightening torque of t...

  • Page 62

    L6555 emax 62/74 doc. No. Model apparatus scale page no 1sdh000460r0002 e1 180 180 e2 180 180 e3 234 234 e4 270 360 e4/f - 360 e6 360 486 e6/f - 486 fixed version withdrawable version minimum distance between the circuit-breaker and the switchgear wall door drilling compartment door mechanical lock ...

  • Page 63

    L6555 emax 63/74 doc. No model apparatus scale page no 1sdh000460r0002 14. Circuit diagrams warning: before installing the circuit-breaker, carefully read notes f and o on the circuit diagrams. Operating status shown the circuit diagram is for the following conditions: - withdrawable circuit-breaker...

  • Page 64

    L6555 emax 64/74 doc. No. Model apparatus scale page no 1sdh000460r0002 s75e/1.4 = contacts for electrical signalling of circuit-breaker in disconnected position (only with withdrawable circuit- breakers) s75i/1..5 = contacts for electrical signalling of circuit-breaker in connected position (only w...

  • Page 65

    L6555 emax 65/74 doc. No model apparatus scale page no 1sdh000460r0002 fig. 47 = circuits of the indicator module pr120/k of the pr122/p and pr123/p releases - connection 2 (optional) (see note v). Fig. 48 = circuits of the measuring module pr120/v of the pr122/p and pr123/p releases connected insid...

  • Page 66

    L6555 emax 66/74 doc. No. Model apparatus scale page no 1sdh000460r0002 circuit diagram symbols (iec 60617 and cei 3-14 ... 3-26 standards) shield (may be drawn in any shape) time delay mechanical or electrical connection manual mechanical control (general case) rotating control pushbutton control e...

  • Page 67

    L6555 emax 67/74 doc. No model apparatus scale page no 1sdh000460r0002 terminal not connected terminal not connected z) four-pole circuit-breaker with pr121/p, pr122/p or pr123/p electronic release circuit diagram - operating status three-pole circuit-breaker with pr121/p, pr122/p or pr123/p electro...

  • Page 68

    L6555 emax 68/74 doc. No. Model apparatus scale page no 1sdh000460r0002 motor operating mechanism, opening, closing and undervoltage releases signalling contacts.

  • Page 69

    L6555 emax 69/74 doc. No model apparatus scale page no 1sdh000460r0002 signalling contacts.

  • Page 70

    L6555 emax 70/74 doc. No. Model apparatus scale page no 1sdh000460r0002 w2 (local bus) w2 (local bus) auxiliary circuits of the pr121, pr122 and pr123 releases pr120/v measuring module warning: see note f.

  • Page 71

    L6555 emax 71/74 doc. No model apparatus scale page no 1sdh000460r0002 w1 (system bus) (+) (+) (+) (-) (-) (-) pr120/d-m communication module pr120/k signalling module.

  • Page 72

    L6555 emax 72/74 doc. No. Model apparatus scale page no 1sdh000460r0002 pr021/k signalling unit.

  • Page 73

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  • Page 74

    1sdh000460r0002 l6555 abb s.P.A. Abb sace division via baioni, 35 - 24123 bergamo - italy tel.: +39 035.395.111 - telefax: +39 035.395.306-433 http://www.Abb.Com due to possible developments of standards as well as of materials, the characteristics and dimensions speci- fi ed in the present catalogu...