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Summary of Contents for NHP TERASAKI TemBreak PRO ZS
- Page 1 ZS Model Circuit Breaker with Integrated Residual Current Protection (CBR) Thermal Magnetic and Residual Current Trip Unit from 125A up to 250A USER MANUAL Version 1.0.1...
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Page 2: Using This Manual
Appropriate use of NHP / Terasaki products NHP / Terasaki products are intended to be used only for the applications described in the catalogue and technical documentation, which is dedicated to them. If products and components from other manufacturers are used, they must be recommended or approved by NHP or Terasaki. -
Page 3: Summary Of Changes
Summary of Changes This section highlights the details of changes made since the previous issue of this document. The versioning convention used to track changes in this document follows the structure Vx.y.z where: x: Major revision, where extensive changes are made which is generally incompatible with the previous version. Such changes may include new products and/or features, or removal of information which is no longer relevant or applicable to the previous version. -
Page 4: Table Of Contents
Table of Contents Using this manual Integrated Residual Current Unit Safety Precautions Residual Current Unit Indication and Function Button Locations Summary of Changes Residual Current Unit Power Indication Table of Contents Residual Current Trip Indication Introduction Residual Current Unit Test Button Who Should Use This Manual? Remote Trip Operation Additional resources... -
Page 5: Introduction
This manual aims to provide users, electricians, panel builders and maintenance personnel, with the technical information required for commissioning and operation of the NHP / Terasaki TemBreak PRO ZS_TF CBR. Users of this document must have at minimum a basic understanding of electrical circuit protection topics including (but not limited to):... -
Page 6: Terminology And Abbreviations
Introduction Terminology and Abbreviations Abbreviation Description Abbreviation Description Maintenance Interface Port: Plug for temporary Auxiliary Communications port: Plug for Smart auxiliary / connection to OCR testing, servicing, and maintenance alarm contact block tools Alarm: An auxiliary contact indicating trip status Neutral ASCII American Standard Code for Information Interchange... -
Page 7: Product Information
Product Information The TemBreak PRO ZS model circuit breakers with integrated residual current protection (CBRs) with trip unit type TF offer protection against overloads and short circuits, with additional functionality for the detection and tripping of earth leakage and earth fault currents. The TF type trip unit features adjustable protection settings via preset rotary switches. -
Page 8: Part Number Break Down
36 kA 25 kA Switch Notice: Not all combinations are possible. Confirm part number combination with NHP for availability. 160AF only For P_SE versions these features are standard and therefore are not added to the end of the part number. -
Page 9: Available Mccbs In The Tembreak Pro Range
Product Information Available MCCBs in the TemBreak PRO range Frame Size Rating Short Circuit Break Capacity 1000 1250 1600 2000 2500 3200 (kA) A160E – TF A160E – FF A250E – TM P400E-TM P630E – TM B160E – FF A160F – TF A250F –... -
Page 10: Available Cbrs In The Tembreak Pro Range
Product Information Available CBRs in the TemBreak PRO range Rating Frame Size Short Circuit Break Capacity 1000 1250 1600 2000 2500 3200 (kA) ZS125M – TF ZS250M – TF TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 11: Label Identification
Identifies the additional localised certifications of the product, in addition to the international product standard, IEC 60947-2 / AS/NZS IEC 60947-2. For additional certifications please contact NHP. TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 12: Zs_Tf Information
Product Information ZS_TF Information Frame / Model Attribute Unit Condition ZS125_TF ZS250_TF Number of Poles 3, 4 3, 4 Nominal current ratings 50°C 20, 32, Trip unit ratings Calibration 50, 63, 100, 125 0.03, 0.1, 0.3, 0.03, 0.1, 0.3, Residual current ampere settings Δn 0.5, 1, 3 0.5, 1, 3... -
Page 13: Neutral Switching Options For 4-Pole Zs_Tf Cbrs
Neutral Switching Options for 4-pole ZS_TF CBRs The 4-pole ZS_TF CBRs are available with Switched Neutral as standard, however Solid (Unswitched) Neutral versions can be selected depending on the electrical requirements of the application. Selecting Switched or Solid Neutral versions of 4-pole ZS_TF CBRs is achieved by modifying the part number when ordering: Switched Neutral versions are standard, and no further action is required when ordering (e.g. -
Page 14: Internal Accessories
Internal Accessories Internal accessories include Auxiliary and Alarm contacts, which may be installed under the front cover of the MCCB in various combinations to provide additional functionality and connection with external control circuits. For information regarding installation of the internal accessories, see Internal Accessory Mounting Locations Auxiliary &... -
Page 15: Auxiliary And Alarm Data
Internal Accessories Auxiliary and Alarm Data General purpose contact AC (V) DC (V) Amperes (A) Amperes (A) Minimum Load Volts (V) Volts (V) Resistive Load Inductive Load Resistive Load Inductive Load ─ ─ ─ ─ 0.05 100 mA @ 15 Vdc Heavy duty contact AC (V) DC (V) -
Page 16: Shunt Trip Or Under Voltage Trip
Internal Accessories Shunt Trip or Under Voltage Trip The ZS_TF CBRs can accept auxiliary and alarm contact accessories as fitted in the left-hand side accessory chamber, however the ZS_TF CBRs cannot accept Shunt Trip nor Under Voltage Trip accessories as the right-hand side area of the CBR is occupied by the integrated residual current unit. ZS125 ZS250 While Shunt Trip and Under Voltage Trip accessories cannot be installed in ZS_TF CBRs, the ZS_TF CBRs come standard with a Remote Trip (RT) -
Page 17: Zs_Tf Cbr Only Accessories
ZS_TF CBR Only Accessories Notice: The following list of accessories are unique to the ZS_TF model CBRs. For other accessories in the TemBreak PRO series, refer to the TemBreak PRO technical catalogues, respective user manuals, and installation instructions. Trip Control Unit (TCU) The Trip Control Unit (TCU) is an optional accessory that mounts on the right-hand side of a ZS_TF CBR, part number T2M1166CBA. -
Page 18: Installation
Installation Precautions WARNING: To prevent electrical shock and damage to equipment, disconnect and isolate power source upstream of the MCCB before installing or servicing the MCCB including its connected accessories. Notice: To ensure correct performance, and integrity of equipment, the installation instructions and recommendations provided herein shall be respected. -
Page 19: Clearances
Installation Clearances WARNING: Exposed conductors including terminals at attached busbars must be insulated to avoid possible short-circuit or earth faults due any foreign matter coming into contact with the conductors. Phase to Phase and Earth Interruption of large currents during fault or normal switching operation produces ionised gases and arcing materials which expelled from the vents at the top of the MCCB for both ZS125 and ZS250. - Page 20 Installation Insulating Distance When earth metal is installed within proximity of the breakers, the correct insulating distance must be maintained, refer to Minimum Clearance for further details. This distance is necessary to allow the exhausted arc gases to disperse. This could include the mounting plate or side panel within a switchboard. Minimum Clearance Below illustrates the minimum clearance that must be maintained.
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Page 21: Internal Accessory Mounting Locations
Installation Internal Accessory Mounting Locations ZS125 and ZS250 frame sizes have different internal mounting locations for auxiliary contacts and alarm contacts. Auxiliary contacts and alarm contacts may be mounted in the left-hand side internal accessory chamber only as the right-hand side is occupied by the integrated residual current unit. -
Page 22: Zs250 Internal Accessories Combination
Installation ZS250 internal accessories combination Legend TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 23: Alarm Switch Installation
Installation Alarm Switch Installation The alarm switch has a trip bar that needs to interact with the MCCBs trip mechanism. As such they must be installed in a specific way. Refer to the supplied Installation Instructions for the respective accessories for further detail. Standard Alarm &... -
Page 24: Protection Settings
Protection Settings Trip Curve The TemBreak PRO ZS_TF thermal magnetic trip unit protects against overcurrent and short circuit faults for many types of electrical distribution systems. The ZS_TF OCR has protective characteristics according to the requirements of the standard AS/NZS IEC 60947-2. The ZS_TF residual current trip unit protects against earth leakage and earth faults in electrical systems, the protective characteristics of which are according to the requirements of AS/NZS IEC 60947-2 Annex B. -
Page 25: Thermal Protection
Protection Settings Thermal protection The thermal protection is designed to protect against current overloads or surges in power distribution or motor control applications. Thermal protection is an inverse-time protection, labelled as I TF – Adjusting I (Current) The thermal protection trip range is: 0.63 – 1.0 x I according to standard AS / NZS / IEC 60947-2. -
Page 26: Magnetic Protection
Protection Settings Magnetic Protection The magnetic protection is designed to protect against fast high current faults such as short circuits, labelled as I TF – Fixed I (Current) The magnetic protection of the TF type Trip Unit is at a fixed value based on a multiple of the nominal current rating of the CBR (I The multiple of the rated current I , and the magnetic trip threshold currents for the respective ZS_TF CBR rated currents are as follows: Magnetic Protection Settings... -
Page 27: Residual Current Protection
Protection Settings Residual Current Protection The residual current protection is designed to provide protection against abnormal current flow to the earth, either due to an insulation fault (Earth Fault) or in the absence of an insulation fault (Earth Leakage). The ZS_TF CBR allows for adjustment of both the residual operating current and non-actuating time delay. Settings can be adjusted to provide specific residual current protection for electrical systems and equipment, or to allow for residual current selectivity in electrical systems where residual current protection devices are connected in series. -
Page 28: R - Adjusting Iδ N (Residual Operating Current)
Protection Settings The residual operating current and non-actuating time delay can be selected from multiple values using the adjustment dials on the ZS_TF CBR. R – Adjusting IΔ (Residual Operating Current) The residual operating current setting can be set to values between 30 mA and 3.0 A according to standard AS / NZS / IEC 60947-2 Annex B. The residual operating current setting is adjusted using the ‘IΔ... -
Page 29: Temperature Ratings
Protection Settings Temperature Ratings The ZS_TF CBRs are fitted with a thermomagnetic trip unit which has its thermal element set for a specific calibration temperature. The ZS_TF CBRs have been calibrated for operation at 50 C for all frame sizes. °... -
Page 30: Integrated Residual Current Unit
Integrated Residual Current Unit The ZS_TF CBR uses an integrated residual current unit which provides the residual current protection functionality. The residual current unit features a power indication LED, residual current Trip indicator, Test button, and Remote Trip functionality as standard. Notice: The integrated residual current unit of the ZS_TF CBR is not a repairable or replaceable component. -
Page 31: Residual Current Trip Indication
Integrated Residual Current Unit Residual Current Trip Indication The yellow pushbutton labelled “E/L trip” indicates that the ZS_TF CBR has tripped due to operation of the residual current protection. The E/L trip button remains in the depressed (“pushed in”) position during normal operation and no residual current trip event has occurred. When a residual current trip event occurs, the CBR main power toggle will switch to the TRIPPED position and the E/L trip indicator will extend outwards (“popped out”). -
Page 32: Remote Trip Operation
Integrated Residual Current Unit Remote Trip Operation Remote Trip (RT) functionality is provided as a standard feature for ZS_TF model CBRs. The residual current unit of the ZS_TF CBRs has two Remote Trip wires, labelled RT1 and RT2, which come out of the front right-hand side of the CBR through a small opening in the front cover. - Page 33 Integrated Residual Current Unit Remote Trip Operation If Remote Trip functionality is not required, the “REMOTE TRIP” wires RT1 and RT2 can be stored or removed in such a manner that there is no continuity between the RT conductors. When storing the Remote Trip wires for future use, the RT1 and RT2 conductors can either be coiled up safely or wired to terminal blocks that are not connected to any other equipment.
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Page 34: Commissioning
Commissioning Thermal Setting (I WARNING: Risk of nuisance tripping. Only qualified personnel are to set the protection levels. Failure to respect these instructions may cause death, serious injuries or equipment damage. WARNING: Setting I dial outside of the calibrated zone (0.63 - 1) may cause unpredictable behaviour of the MCCB. -
Page 35: N ) And Time Delay (Δt) Setting
Commissioning Residual Operating Current (IΔ ) and Time Delay (Δt) Setting WARNING: Risk of nuisance tripping. Only qualified personnel are to set the protection levels. Failure to respect these instructions may cause death, serious injuries or equipment damage. WARNING: The residual operating current threshold (IΔ ) and non-actuating time delay (Δt) can be set to levels that are not suitable for personnel protection against earth leakage or earth fault currents. -
Page 36: Residual Operating Current
Commissioning Dielectric Test Disconnect Plug The ZS_TF CBR features a built-in dielectric disconnection test plug. This plug must be removed prior to performing dielectric testing on the CBR. The dielectric test plug can be found on the front and towards the bottom of the ZS_TF CBR between the 1 and 2 left most main connection terminals. -
Page 37: Dielectric Testing Methodology
Commissioning Dielectric Testing Methodology Please refer to the below table for permissible testing methods for performing dielectric testing on the ZS_TF CBRs. The dielectric test disconnect plug should be removed prior to performing any of the below tests, and reinstated once testing has been completed. Test Measurement points Insulation Resistance Measurement... -
Page 38: Troubleshooting
Troubleshooting In the event of a problem when using the TemBreak PRO system, this section provides advice on how to resolve issues. Problem description Possible cause Remedial advice Abnormal voltage on load side Excessive wear of contacts Replace MCCB Foreign matter interfering with contacts or contact surfaces Failure in ON position Reset operation not conducted... - Page 39 Troubleshooting Problem description Possible cause Remedial advice Residual current unit Power Incorrect power source connection Confirm ZS CBR is connected to power source correctly indication LED not illuminated Annex G – Connection Diagrams Insufficient supply voltage Residual current unit requires at least 200V AC to function correctly Dielectric test plug not present Ensure dielectric test plug has been reinstated after completing dielectric testing Residual current unit has failed...
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Page 40: Annex A - Dimensions
Annex A – Dimensions ZS125 Dimensions TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 41: Zs250 Dimensions
Annex A – Dimensions ZS250 Dimensions TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 42: Annex B - Trip Curves
Annex B – Trip Curves ZS125M TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 43: Zs125M Residual Current Characteristic
Annex B – Trip Curves ZS125M Residual Current Characteristic TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 44: Zs250M 160A
Annex B – Trip Curves ZS250M 160A TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 45: Zs250M 250A
Annex B – Trip Curves ZS250M 250A TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 46: Zs250M Residual Current Characteristic
Annex B – Trip Curves ZS250M Residual Current Characteristic TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 47: Annex C - I 2 T Let Through Curves
Annex C – I t Let Through Curves ZS125M TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 48: Zs250M
Annex C – I t Let Through Curves ZS250M TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 49: Annex D - Peak Let Through Curves
Annex D – Peak Let Through Curves ZS125M TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 50: Zs250M
Annex D – Peak Let Through Curves ZS250M TemBreak ZS Model MCCB with Integrated Residual Current Protection User Manual – V1.0.1... -
Page 51: Annex E - Watts Loss
Annex E – Watts Loss Resistance Watts Loss Rating Resistance per pole Watts Loss per pole Pole Watts Loss per product Frame In (A) (mΩ) Based on Resistance (W) numbers Based on Resistance (W) 18.0 21.6 13.5 ZS125_TF 3/4P 4.68 14.0 24.0 0.73... -
Page 52: Annex F - Temperature Derating
Annex F – Temperature Derating Front & Rear Connect Calibration Temperature: 50℃ Rated Current (A) MCCB Connection Rated I Type type 10°C 15°C 20°C 25°C 30°C 35°C 40°C 45°C 50°C 55°C 60°C 65°C 70°C 23.7 23.2 22.8 22.4 21.9 21.4 21.0 20.5 20.0... -
Page 53: Annex G - Connection Diagrams
Annex G – Connection Diagrams ZS CBR Connection Type Diagram Correct/Incorrect Notes No. Poles Reverse (bottom) connection is permissible for both 3- and 4-pole ZS_TF CBRs. 3-pole When a ZS_TF CBR is reverse Reverse Connection connected, the Power LED located 4-pole on the residual current unit on the front of the CBR will be illuminated... - Page 54 Annex G – Connection Diagrams Connection Type ZS CBR Diagram Correct/Incorrect Notes No. Poles 3-phase 4-wire If a Neutral is present in the system, (3P+N) it must be monitored by the ZS_TF CBR so an imbalance will not occur. The CBR will trip if the Neutral is not 3-pole connected.
- Page 55 Annex G – Connection Diagrams Connection Type ZS CBR Diagram Correct/Incorrect Notes No. Poles 3-pole 2-phase 2-wire (2P) 4-pole When using a 4-pole ZS_TF CBR on a 2P system both P wires must use any of the 3 main power poles and not the 4 Neutral pole.
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Page 56: Annex H - Wiring Diagrams & Terminal Designations
Annex H – Wiring Diagrams & Terminal Designations Internal Accessories Accessory Contact Switching Connection Wiring Diagram Terminal Designation Type Type Arrangement Type 1 – Common Terminal 2 – N/C 3 – N/O General 1 C/O Purpose 11/AXC1 – Common Pre-wired 12/AXB1 –... -
Page 57: Annex I - Internal Harmonics Protection
Annex I – Internal Harmonics Protection ZS_TF CBRs include a harmonics inhibition circuit which limits the CBRs reaction of earth leakage trip unit to high frequency harmonics. This feature makes the ZS_TF CBR suitable for use with AC Drives and other similar equipment known to generate line harmonics. Variable Speed Drives and other similar semiconductor switching products can produce high levels of harmonics that can travel through electrical power systems and can cause other devices to react in different ways to these harmonics.
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