ABB SACE Emax E2.2 Installation, Operation And Maintenance Instructions For The Installer And The User
Low voltage air circuit-breakers
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- Page 1 DOC. N° 1SDH001000R0002 - ECN000109166 - Rev. D SACE Emax 2 Emax low voltage air circuit-breakers Emax E2.2-E4.2-E6.2 Installation, operation and maintenance instructions for the installer and the user...
- Page 2 ABB | SACE Emax 2 2 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D...
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Page 3: Table Of Contents
3 - Maintenance ..............58 4 - First level maintenance ..........60 5 - Second level maintenance ..........64 6 - Decommissioning and treatment at end of life ....73 © 2019 ABB SACE Emax 2 | I 1SDH001000R0002 - ECN000109166 - Rev. D... - Page 4 1SDH001000R0002 - ECN000109166 - Rev. D II | © 2019 ABB SACE Emax 2...
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Page 5: Glossary
CB configuration: four-pole (4P), three-pole (3P) and three-pole with external neutral (3P + N) Fault current measured by Trip unit, useful for calculating the trip time t 3 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Glossary |... -
Page 6: Emax E2.2-E4.2-E6.2 Circuit-Breakers
All the remaining operations described in the handbook must be performed by skilled persons, in the electrical field. ABB declines all liability for damage to persons or property caused by failure to comply with the instructions in this document. -
Page 7: Safety
• these warnings and alarms do not include all conceivable ways to make installation, use and maintenance recommended by ABB or not, that may be made, or possible consequences and complications of each conceivable way, nor shall ABB investigate all those ways. -
Page 8: Regulations
The SACE Emax 2 circuit-breakers also feature a range certified according to these standards: • Russian - GOST (Russia Certificate of Conformity) • Chinese - China CCC (China Compulsory Certification) 6 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Emax E2.2-E4.2-E6.2 circuit-breakers | 3 - Regulations... -
Page 9: Management Operations
Never lift a circuit-breaker and / or a fixed part above other people. IMPORTANT: The trained personnel in charge of handling and lifting must use appropriate safety equipment. 7 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 1 - Transport and checking on receipt... - Page 10 Damage and Discrepancy If there is any damage to the packaging upon receipt and / or inconsistencies between order and product identification label or product please contact ABB. Damage to the packaging must be reported no later than Report seven days from receipt of the material.
- Page 11 (E2.2 - E4.2) (E6.2) Figure 4 Figure 5 9 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 1 - Transport and checking on receipt...
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Page 12: Unpacking And Handling
Remove the packing box by lifting it upwards. See Figure 9. Figure 9 Figure 8 Continued on the next page 10 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 2 - Unpacking and handling... - Page 13 Disposal of packing materials For disposal of the packaging materials see the chapter " 6 - Decommissioning and treatment at end of life " on page 73. 11 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 2 - Unpacking and handling...
- Page 14 IMPORTANT: keep the lifting plates for the circuit breaker, the lifting hooks of the fixed part and the manual of the circuit-breaker until disposal. 12 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 2 - Unpacking and handling...
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Page 15: Description
The coupling between the mobile part and the fixed part is via disconnection contacts mounted on the fixed part. Figure 19 Figure 18 Figure 20 Figure 21 13 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 3 - Description... - Page 16 Admissible rated short-time current Rated duty short-circuit breaking capacity Rated ultimate short-circuit breaking capacity Rated service voltage Standards Circuit-breaker serial number Impulse voltage 14 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 3 - Description...
- Page 17 Type of circuit-breaker Rated current Rated operating frequency Rated voltage of accessories Rated short-circuit breaking capacity Rated service voltage Standards Circuit-breaker serial number 15 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 3 - Description...
- Page 18 Opening - Press the opening pushbutton “O - Push OFF” as indicated in Figure 30. Figure 29 Figure 30 Continued on the next page 16 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 3 - Description...
- Page 19 • The pushbutton for enabling the insertion/extraction crank of a withdrawable circuit-breaker is pressed. Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 17 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 3 - Description...
- Page 20 See Figure 39. Figure 39 Figure 38 Continued on the next page 18 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 3 - Description...
- Page 21 Grip the guide levers of the fixed part and push them until the moving part stops. See Figure 42. Figure 42 Continued on the next page 19 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 3 - Description...
- Page 22 11. Press the lock button and rotate the crank clockwise until it comes out and the indicator shows that the circuit-breaker is in CONNECT position. See Figure 46. Figure 46 Continued on the next page 20 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 3 - Description...
- Page 23 To extract the moving part from the fixed part, perform the same steps indicated for insertion in reverse order. Figure 49 Continued on the next page 21 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 3 - Description...
- Page 24 • circuit-breaker in test position (see Figure 52) • circuit-breaker in CONNECT position (see Figure 53) Figure 51 Figure 52 Figure 53 22 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 3 - Description...
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Page 25: Environmental Conditions
See Figure 55. Information on the assembly is available on the website http://www.abb.com/abblibrary/DownloadCenter/, in particular with the kit sheet 1SDH001000R0701. Figure 55 23 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 4 - Environmental conditions... - Page 26 Fasten the fixed part to a horizontal surface using four M8 x 25 screws for E2.2 and E4.2 fixed parts, and using six M8 x 25 screws for E6.2 fixed parts. The screws are supplied by ABB. See Figure 56. Tighten the withdrawable circuit-breaker screws with tightening torque = 21 Nm - 186 lb.in...
- Page 27 Terminal compatibility The table of terminals available for each circuit-breaker is given below. HR/VR <=690V 800V/900V E2.2 1000/1150V <=600V <=690V 800V/900V E4.2 1000/1150V <=600V (**) <=690V 800V/900V E6.2 1000/1150V <=600V (**) 25 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 4 - Environmental conditions...
- Page 28 The sizing of the busbars is specified by the designer of the electrical switchgear. Figure 69 IEC Figure 70 UL Continued on the next page 26 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 4 - Environmental conditions...
- Page 29 70 Nm - 619.5 lb in. NOTE: the information on the performances of the circuit-breakers in switchboards is available on the website: http://new.abb.com/low-voltage/products/circuit-breakers/emax2. 27 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 4 - Environmental conditions...
- Page 30 - E6.2 III-IV Withdrawable VR UL • 1SDH001060R0312 - E6.2 IV FS Withdrawable VR UL • 1SDH001060R0313 - E6.2 6000 III Withdrawable VR UL 28 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 4 - Environmental conditions...
- Page 31 Positioning anchor plates E4.2-A 3600A The anchor plates for E4.2-A 3600A circuit-breakers must be positioned as indicated in the figure. 30mm max. Figure 72 29 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 4 - Environmental conditions...
- Page 32 After assembly of the conductor, tighten the screw with a torque of 2 Nm - 17.7 lb in. Figure 73 Figure 74 30 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Management operations | 4 - Environmental conditions...
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Page 33: Ekip Dip
All the external connections, including the supply and communication modules, the external sensors and mechanical accessories, are available in the upper terminal box (3) (page 48 for an overview of the electronic accessories). 31 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 1 - General characteristics... -
Page 34: Operating Features
IMPORTANT: if connection is direct, the power supply must be galvanically insulated and provide the insulation characteristics established by standard IEC 60950 (UL 1950) or equivalent. 32 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 2 - Operating features... -
Page 35: Operator Interface
IMPORTANT: the figure above refers to an Ekip Dip, LSIG version. In the case of Ekip Dip LI or LSI versions, LEDs and dip-switches related only to the protections present are available. 33 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 3 - Operator interface... - Page 36 • Neutral allows activation and adjustment of the protections on the neutral pole. • Frequency allows the selection of the installation frequency. 34 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 3 - Operator interface...
- Page 37 • Analysis, supervision and setting of additional parameters through external communication test units (Ekip T&P, Ekip Bluetooth). 35 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 3 - Operator interface...
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Page 38: Protections
With the modules Ekip T&P or Ekip Bluetooth and with the Ekip Connect software, it is possible to activate the function Thermal Memory, and adjust the threshold of Pre-alarm. 36 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 4 - Protections... - Page 39 With the modules Ekip T&P or Ekip Bluetooth and with the Ekip Connect software, it is possible to activate the function Thermal Memory. 37 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 4 - Protections...
- Page 40 Threshold I3 IMPORTANT: The I3 threshold set must be higher than the I2 threshold. An incorrect configuration returns an alarm signal. 38 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 4 - Protections...
- Page 41 With the Ekip T&P or Ekip Bluetooth modules and with the Ekip Connect software, it is possible to adjust the threshold of Pre-alarm. 39 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 4 - Protections...
- Page 42 (example: 1000 A). WARNING! With 200% threshold and measured neutral current exceeding 16In, the Trip unit resets the protection to 100% by itself 40 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 4 - Protections...
- Page 43 The protection activates with a TRIP if the disconnections persist for more than one second; in the case of Trip coil disconnection, the unit merely handles alarm signaling. 41 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 4 - Protections...
- Page 44 Activation for If in the range (1.05...1.2) x I1 ± 20 % ± 10 % ± 20 % ≤ 60 ms ± 15 % ± 15 % ± 20 % 42 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 4 - Protections...
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Page 45: Measurements
Internal earth fault currents 0,08...64 In 0,2...1,2 In the accuracies refer to normal operating ranges, as established by IEC 61557-12 available with LSIG versions 43 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 5 - Measurements... -
Page 46: Test
Start the communication with Ekip Connect. Select the trip test command. Check that the circuit-breaker opens and that the TU Reset button comes out 44 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 6 - Test... -
Page 47: List Of Alarms And Signals
NOTE: for further details refer to the table listing the components of the interface, available on page 33. 45 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 7 - List of alarms and signals... - Page 48 The following are the suggestions for checking with reference to the preceding LED table: HELP note Operation Contact ABB and give details about the state of the LEDs on the unit. Check the connections between trip unit and accessories (Rating Plug, trip coil, sensors, etc).
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Page 49: Additional Functions
Disabled (Power-on LED fixed) Maintenance S Protection available with LSI and LSIG versions of the trip unit. G Protection available with LSIG version. 47 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Ekip Dip | 8 - Additional functions... -
Page 50: Accessories
Ekip AUP and Ekip RTC 48 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Accessories | 1 - Overview... -
Page 51: Rating Plug
It is installed on a dedicated front connector and is accessible to the user for inspections or replacement following a change of model/size. For further details about the available models, operations and reference documents, consult document 1SDH001330R1002. 49 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Accessories | 2 - Rating Plug... -
Page 52: Putting Into Service And Maintenance
NOTE: for safety reasons, ABB strongly advises you to change the password right from the first access and to keep it with care. 50 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D... - Page 53 NOTE: The test can be performed if the trip unit and the coils are energized. if present. (**) withdrawable versions only. Continued on the next page 51 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 1 - Putting into service...
- Page 54 Protections or Advanced menus 4. Make sure there are no alarms if present. (**) withdrawable versions only. 52 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 1 - Putting into service...
- Page 55 - springs discharged O - OPEN and white spring signalling device DISCHARGED SPRING 53 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 1 - Putting into service...
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Page 56: Identification Of Alarms Or Failures
Ekip Touch manual 1SDH001316R0002. 54 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 2 - Identification of alarms or failures... - Page 57 The operating mechanism is blocked Contact ABB opening pushbutton is pressed Continued on the next page 55 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 2 - Identification of alarms or failures...
- Page 58 The busbar current is greater than zero Correct operating condition. Continued on the next page 56 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 2 - Identification of alarms or failures...
- Page 59 The expected trip does not Correct operating condition. Enable Trip excluded occur trip if necessary 57 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 2 - Identification of alarms or failures...
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Page 60: Maintenance
(IEV 195-04-01): person with relevant education and experience to enable him or her to perceive risks and to avoid hazards which electricity can create. ABB declines all liability for damage to persons or property caused by failure to comply with the instructions in this document. - Page 61 • During the service, visually inspect the circuit-breaker from the outside to check for the presence of dust, dirt or damage. 59 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 3 - Maintenance...
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Page 62: First Level Maintenance
60 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 4 - First level maintenance... - Page 63 If there is an undervoltage coil (G), remove it, and discharge the springs of the operating mechanism for closing and opening the circuit breaker. Figure 79 - Removing the undervoltage coil 61 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 4 - First level maintenance...
- Page 64 These data will be stored within the trip unit itself. Remove the Ekip Bluetooth or Ekip T & P unit from the trip unit. 62 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 4 - First level maintenance...
- Page 65 After a trip due to a short-circuit. Figure 81 Use Mobilgrease 28, also available in the ABB greasing kit. 63 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 4 - First level maintenance...
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Page 66: Second Level Maintenance
Make sure that the screws that fasten the fixed part to the switchgear are well tightened (M8 - 25Nm - 221.27 lb in) 64 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 5 - Second level maintenance... - Page 67 65 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 5 - Second level maintenance...
- Page 68 Figure 86 - Removing the undervoltage coil Continued on the next page 66 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 5 - Second level maintenance...
- Page 69 Before cleaning and lubrication of the operating mechanism, you must remove the protection trip unit. For information about removal, see the document 1SDH001000R0523, or request the intervention of a technician ABB. 67 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 5 - Second level maintenance...
- Page 70 Figure 90 - Lubricating the closing hook Figure 91 - Lubricating the shaft and opening hook Continued on the next page 68 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 5 - Second level maintenance...
- Page 71 NOTE: it is advisable to replace the gear motor if it has performed more than 10000 spring charging operations or reached 50% of the declared mechanical life of the circuit-breaker. 69 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 5 - Second level maintenance...
- Page 72 ->OK Figure 94 - Checking the breaking gaps Close the circuit-breaker and check dimension A. Contact ABB Sace (*) if dimension A is incorrect. If dimension A is correct, open the circuit-breaker again and re-assemble the arc chutes. NOTE: (*) After approval from the customer, ABB can proceed with replacement of the worn parts.
- Page 73 • auxiliary contacts of the circuit-breaker, if provided. • lock for circuit-breaker in open position (key or padlock), if provided 71 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 5 - Second level maintenance...
- Page 74 After a trip due to a short-circuit. Figure 95 Use Mobilgrease 28, also available in the ABB greasing kit. 72 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 5 - Second level maintenance...
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Page 75: Decommissioning And Treatment At End Of Life
73 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 6 - Decommissioning and treatment at end of life... - Page 76 ABB | SACE Emax 2 74 | © 2019 ABB | 1SDH001000R0002 - ECN000109166 - Rev. D Putting into service and maintenance | 6 - Decommissioning and treatment at end of life...