ABB Electronic overload relays Service Manual

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Electronic

Overload relays

Low Voltage Products & Systems 2.19

Description

• Available for starter construction with A Line contactors and separate panel mounting

• Designed for close couple mounting

• Separate base mounting available for all overload relays

• E16DU Class 10, 20, & 30, factory selectable

• E200DU – E800DU Class 10, 20 & 30, field selectable

• Stop button

• Screwdriver guide holes

• All terminal screws are available from the front

Tripping classes of the thermal overload relays

Standard classes in IEC 947-4-1 are classes: 10 A, 10, 20, 30. The tripping class indicates according to IEC 947-4-1 the maximum tripping time in seconds under specified conditions of test at 7.2 times the setting current and specifies tripping and non tripping times for 1.5 and

7.2 times the setting current. Mostly used class is 10 A.

Abstract from IEC 947-4-1

Tripping class 10 A 10 20 30

Max. tripping time at 1.5 x setting current (s) 120 240 480 720 (warm state)

Tripping time at

7.2 x setting current (s) 2 – 10 4 – 10 6 – 20 9 – 30 (cold state)

At 1.05 x setting current no tripping

Electronic overload relays

E16DU – E800DU

• Single phase and phase unbalance protection

• Isolated alarm circuit (N.O.) contact

• Ambient compensation:

-25°C to +70°C (-13oF to +158oF)

• Manual test

• Manual or automatic reset

• Factory calibrated and tested

• Wide adjustment range

• UL File No: E48139

• CSA File No: LR98336

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AC 1030.1 – 12/01

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Nominal current setting

Catalog number explanation

Reset, manual or automatic

Stop button

Frame size

E16DU E200DU E320DU E500DU E800DU

Trip indicator test function

Catalog number explanation

E16DU 1.0 10

Class size

10 20 30

Amp rating

1.0 200 320 500 800

2.20 Low Voltage Products & Systems

AC 1030.1 – 12/01

E16DU – E800DU

for contactors and mini contactors

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E16DU

E200DU

E16DU – Tripping Class 10

For Setting Suffix Catalog List

contactor range code number 1 price

0.1 – 0.32 A1 E16DU0.32-10

B/BC6 – B/BC7 A/AE9 – A/AE16

0.3 – 1.0 B1 E16DU1.0-10

0.9 – 2.7 C1 E16DU2.7-10 $ 96

2.0 – 6.3 D1 E16DU6.3-10

5.7 – 18.9 E1 E16DU18.9-10

E16DU – Tripping class 20

For Setting Suffix Catalog List

contactor range code number 1 price

B/BC6 – B/BC7 A/AE9 – A/AE16

0.1 – 0.32 A2 E16DU0.32-20

0.3 – 1.0 B2 E16DU1.0-20

0.9 – 2.7 C2 E16DU2.7-20 $ 96

2.0 – 6.3 D2 E16DU6.3-20

5.7 – 18.9 E2 E16DU18.9-20

E16DU – Tripping class 30

For Setting Suffix Catalog List

contactor range code number 1 price

B/BC6 – B/BC7

A/AE9 – A/AE16

0.1 – 0.32 A3 E16DU0.32-30

0.3 – 1.0 B3 E16DU1.0-30

0.9 – 2.7 C3 E16DU2.7-30 $ 96

2.0 – 6.3 D3 E16DU6.3-30

5.7 – 18.9 E3 E16DU18.9-30

E200DU – E800DU – Tripping class 10, 20 & 30

For Setting Suffix Catalog List

contactor range code number price

A/AF145 – A/AF185 65 – 200 E2 E200DU200 $ 325 A/AF210 – A/AF300 105 – 320 E3 E320DU320 775

AF400 – AF460 170 – 500 E5 E500DU500 865 AF580 – AF750 270 – 800 E8 E800DU800 950

2

E320DU

E500DU

E800DU

1 Not suitable for single-phase motors and direct current (DC) motors.

Low Voltage Products & Systems 2.21

Discount Schedule TS

AC 1030.1 – 12/01

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Accessories

Mounting kits

for direct mounting on contactors AF400 – AF750

For On Catalog List

overload relays contactor number price

E500DU AF400 – AF460 DT500/AF460 395 E800DU AF580 – AF750 DT800/AF750 415

Separate mounting kits

For Catalog List

overload relays number price

E16DU DB16E $ 50

Lug kits

Wire Electronic Catalog List

range overload number price

6 – 250 MCM E200DU200 ATK185 $ 45 4 – 400 MCM E320DU320 ATK300 68

(2) 4 – 500 MCM E320DU320 ATK300/2 110 (2) 2/0 – 500 MCM E500DU500 ATK580/2 150 (3) 2/0 – 500 MCM E800DU800 ATK750/3 225

2.22 Low Voltage Products & Systems

AC 1030.1 – 12/01

Technical data

E16DU

General technical data

Type E 16 DU

Standards: UL508, IEC 60 947-4-1 / IEC 60 947-5-1

Rated insulation voltage U Rated operational voltage U Impulse withstand voltage U Permissible ambient temperature

- for storage °C - 25 to 70

- with compensated operation °C - 25 to 70 Climatic resistance acc. to IEC 68-2-1, IEC 68-2-2, IEC 68-2-14, IEC 68-2-30 Resistance to shock Shock duration ms 11

Resistance to vibrations (±1 mm, 10 ... 100 Hz) multiple of g 5

Mounting - on contactor Direct to contactor’s

Terminal types and connecting capacity of main conductors (on load side) /and auxiliary contacts.

- Screw terminals (screw size)

- Torque lbin / Nm 7 / 1.0

- connection cross sections

Protection degree to IEC 947-1/EN 60 947-1 All terminals are safe from finger-touch and touch by the

Weight lbs / kg .33 / .15

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- with AB... kit main terminal

- with self-disengaging clamping piece M3.5

- with terminal block –

- with busbar or cable lugs –

- copper stranded AWG / mm

- flexible with connector sleeve AWG / mm

UL / IEC V 600 / 690 UL / IEC V 600 / 690

kV 6

multiple of g 15

2 2

EN 60 947-4-1 / EN 60 947-5-1

10 - 20 / 2X0.75...4 10 - 20 / 2X0.75...4

back of the hand in acc. with VDE 0106, Part 100

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Technical data of the current paths

Type E 16 DU

Number of paths 3 Setting ranges see page 2.21 Tripping class acc. to IEC 947-4-1/EN 60 947-4-1 see page 2.21 Operating frequency Hz 50 and 60 Switching frequency up to 80 ops./h with 40 % continuous duty if starting current not higher

without early tripping than 6 x In and starting time not longer than 1s Resistance per phase q

and heat dissipation per phase in W see page 2.24 acc. to max. setting current

Required fuses for short circuit protection see page 2.24

Low Voltage Products & Systems 2.23

AC 1030.1 – 12/01

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Technical data

Tripping characteristics

120 100

80 60

40

20

10

8 6

2

Tripping time

4

2

Minutes

40

20

10

8 6

Seconds

4

2

1

0.8

from cold state

Class 20

Class 10

1.2

1

2

1.5

Tripping current As multiples of setting current

3

3 phase

4

Class 30

567

Resistance and power dissipation

Setting gL/gG UL/CSA UL/CSA per per phase

range 600V 5kA 480V/50kA phase at upper

A – A A RK5 Class J mΩ q W

0.1 – 0.32 1 2 2 970 0.97 0.1

0.3 – 1.0 4 2 2 113 0.113 0.11

0.9 – 2.7 10 4 4 14 0.014 0.1

2.0 – 6.3 20 15 15 2.4 0.0024 0.1

5.7 – 18.9 50 30 30 0.8 0.0008 0.29

Short circuit protection Resistance Joule losses

current setting

Technical characteristics of auxiliary contacts

Type N.C. N.O.

Rated operational voltage U Conventional free air thermal current I Rated operational current I

10

8

9

Short circuit protection gG (gf) fuses A 6

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on AC-15, 230V A 3 on AC-15, 400V A 1.1 on AC-15, 500V A 0.9 on AC-15, 690V A 0.7

on DC-13, 24V A 1.5

on DC-13, 60V A 0.5 on DC-13, 110V A 0.4 on DC-13, 220V A 0.2

95-96 97-98

V 500 A6

2.24 Low Voltage Products & Systems

AC 1030.1 – 12/01

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Technical data

E200DU – E800DU

Type E200DU E320DU E500DU E800DU

Standards: (major international & European standards IEC 60947-4-1, EN 60947-4-1, IEC 60947-5-1, EN 60947-5-1 Approvals, certificates UL, CSA Rated insulation voltage U

according to IEC 158-1, IEC 60947-4-1 Impulse withstand voltage U

according to IEC 60947-4-1 Permissible ambient temperature

• for storage °C -25 to +70

• with compensated operation °C -25 to +70 Climatic resistance according to: IEC 68-2-1, IEC 68-2-2, IEC 68-2-14, IEC 68-2-30 IEC 68-2-1, IEC 68-2-2, IEC 68-2-30 Mounting positions multiple Resistance to shock (EN 61373) Shock duration ms 30

Resistance to vibrations (EN 61373) Category 1, Class B Mounting

• on contactor

• single mounting 2 x M4 2 x M4 2 x M4 2 x M4 Terminal types and connecting capacity

of auxiliary contacts

• Screw terminals (screw size)

• with self-disengaging clamping piece M3.5

• Torque Nm 1.0 Connection cross sections

– Single core or stranded mm – Flexible with connector sleeve mm

Terminal types and connecting capacity of main conductors

• Screw terminals (screw size)

• with busbar or cable lugs M8 M10 M10 M12

Protection degree to IEC 947-1/EN 60 947-1 All auxiliary contact terminals are safe from finger touch and touch by the back of the hand

Number of current paths 3 Setting ranges A 65 – 200 105 – 320 170 – 500 270 – 800 Tripping class according to IEC 947-4-1/EN 60 947-4-1 10, 20, 30 Operating frequency Hz 50 and 60

Weight lb/kg 1.72 / .78 1.85 / .84 2.60 / 1.18 9.35 / 4.24 NOTE: • Installation and maintenance have to be performed according to the technical rules, codes and relevant standards by skilled electricians only.

• When using the “Auto” setting, remember that this means the overload will automatically reset after tripping and the motor may restart automatically. This automatic restart could cause harm to personnel and material.

• The overload relay mut be exchanged for a new one in case of mechanical and/or electrical damage to prevent harm to personnel and material.

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multiple of g 5

V 690

kV 6

2 2

in accordance with VDE 0106, Part 100. Main contact terminals are safe from finger touch

only with appropriate terminal covers

2 x 0.75...4 2 x 0.75...4

for three phase current only

(bars are accessories) (bars are accessories)

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Low Voltage Products & Systems 2.25

AC 1030.1 – 12/01

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Altitude

Characterizes the place of use. It is expressed in meters above sea level.

Circuits

Auxiliary circuit – all the conductive parts of a contactor designed to be inserted in a different circuit from the main circuit and the contactor

• control circuits.

• Control circuit – all the conductive parts of a contactor (other than the main circuit and the auxiliary circuit) used to control the contactor’s closing operation or opening operation or both.

• Main circuit – all the conductive parts of a contactor designed to be inserted in the circuit that it controls.

Insulation Class according to NFC 20 040 and VDE 0110

Characterizes adaptation of the devices to ambient temperature and operating conditions. For given clearances and creepage distances, a device will have different insulating voltages depending on insulation classes A, B, C & D. Class C corresponds to most industrial applications. The devices in this catalog belong to Class C.

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Coordination of equipment protections during a short circuit

This is the addition upstream of the contactor and thermal overload relay of a short circuit (SCPD) protection device such as a circuit breaker, a fuse with a high breaking capacity or other fuses.

IEC publication 947-4-1 defines coordination Types 1 & 2:

•

Type 1 – Coordination requires that, in the event of a short circuit, the contactor or starter does not endanger persons or installations and will

not be able to operate without being repaired or parts being replaced.

• Type 2 – Coordination requires that, in short circuit conditions, the contactor or starter does not endanger persons or installations and will be able to operate afterwards. The risk of contacts being welded is acceptable. In this case, the manufacturer must stipulate the measures to be taken with respect to maintenance of the equipment.

Rated operational current I

Current rated by the manufacturer. It is mainly based on the rated operational voltage Ue, the rated frequency, the utilization category, the rated duty and the type of protective enclosure, if necessary.

Conventional free air thermal current I

Current that the contactor can withstand in free air for a duty time of 8 hours without the temperature rise of its various parts exceeding the maximum values given by the standard.

Cycle time

Cycle time is the sum of the current flow time and the no-current time for given cycle.

Electrical durability

Number of on-load operations that the contactor is able to carry out; it depends on the utilization category.

Mechanical durability

Number of no-current operations that a contactor is able to carry out.

Load factor

Ratio of the on-load operating time to the total cycle time x 100.

Switching frequency

Number of switching cycles per hour.

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Technical data

Terms and technical definitions

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2.26 Low Voltage Products & Systems

AC 1030.1 – 12/01

Approximate dimensions

E16DU – E200DU

E16DU with A/AE9, A/AE12, A/AE16 E16DU with B/BC6, B/BC7

Electronic

Overload

relays

2

2.15

63.5

2.5

E200DU

54.5

.59

15

.28

1.73

44

1.73

44

2.95

75

47

56

104

4.09

128

5.04

57.5

2.26

7

.71

18

0.67

17

2.95

75

1.87

47.5

47

.708

.59

15

18

7

1.73

44

1.97

50

1.50

38

2.28

58

2

Low Voltage Products & Systems 2.27

AC 1030.1 – 12/01