ABB Electronic overload relays Service Manual

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Low Voltage Products & Systems

Electronic overload relays

E16DU – E800DU

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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

•Single phase and phase unbalance protection

•Isolated alarm circuit (N.O.) contact

•Ambient compensation:

-25°C to +70°C (-13 o F to +158 o F)

•Manual test

•Manual or automatic reset

•Factory calibrated and tested

•Wide adjustment range

•UL File No: E48139

•CSA File No: LR98336

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

2 .19

AC 1030.1 – 12/01

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Catalog number explanation

Reset, manual or automatic

Nominal current setting

Stop button	Trip indicator test function

Catalog number explanation

			E16DU		1.0 10
	Frame size										Class size
	E16DU					10
						20
	E200DU
						30
	E320DU
	E500DU										Amp rating
	E800DU
					1.0
					200
					320
					500
					800

2. 20	Low Voltage Products & Systems
AC 1030.1 – 12/01

E16DU

E200DU

E320DU

E500DU

E800DU

Low Voltage Products & Systems

E

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E16DU – E800DU

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for contactors and mini contactors

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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

0.3 – 1.0

B1

E16DU1.0-10

$ 96

0.9 – 2.7

C1

E16DU2.7-10

A/AE9 – A/AE16

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

2

0.1

–

0.32

A2

E16DU0.32-20

B/BC6 – B/BC7

0.3

–

1.0

B2

E16DU1.0-20

$ 96

0.9

–

2.7

C2

E16DU2.7-20

A/AE9

– A/AE16

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

0.1

–

0.32

A3

E16DU0.32-30

B/BC6 –

B/BC7

0.3

–

1.0

B3

E16DU1.0-30

$ 96

0.9

–

2.7

C3

E16DU2.7-30

A/AE9

–

A/AE16

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

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

Discount Schedule TS

2 .21

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

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Type						E 16 DU
Standards:						UL508, IEC 60 947-4-1 / IEC 60 947-5-1
						EN 60 947-4-1 / EN 60 947-5-1
Rated insulation voltage U		i	UL / IEC	V		600 / 690
Rated operational voltage U		e	UL / IEC	V		600 / 690
Impulse withstand voltage U		imp		kV		6
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		2
Resistance to shock			Shock duration ms			11
			multiple of g			15
Resistance to vibrations
(±1 mm, 10 ... 100 Hz)			multiple of g			5
Mounting	- on contactor					Direct to contactor’s
	- with AB... kit					main terminal
Terminal types and connecting capacity
of main conductors (on load side) /and auxiliary contacts.
	- Screw terminals (screw size)
	- with self-disengaging clamping piece					M3.5
	- with terminal block					–
	- with busbar or cable lugs					–
	- Torque		lbin / Nm			7 / 1.0
	- connection cross sections
	- copper stranded		AWG / mm		2	10 - 20 / 2X0.75...4
	- flexible with connector sleeve		AWG / mm		2	10 - 20 / 2X0.75...4
Protection degree to IEC 947-1/EN 60 947-1						All terminals are safe from finger-touch and touch by the
						back of the hand in acc. with VDE 0106, Part 100
Weight			lbs / kg			.33 / .15
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 I n 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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Tripping characteristics
								120
								100
								80
								60
								40
								20
																					3 phase
								10											from cold state
								8
								6
								4
	<![if ! IE]> <![endif]>timeTripping					<![if ! IE]> <![endif]>Minutes		40															Class 30
								2
									1
								20							Class 20
						<![if ! IE]> <![endif]>Seconds											Class 10
								6
								10
								8
								4
								2
								1
								0.8				1	1.2		1.5		2		3		4		5			6	7		8 9 10

Tripping current

As multiples of setting current

Resistance and power dissipation

			Short circuit protection		Resistance		Joule losses
Setting		gL/gG	UL/CSA	UL/CSA	per		per phase
	range		600V 5kA	480V/50kA	phase		at upper
								current setting
	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

Technical characteristics of auxiliary contacts

Type	N.C.	N.O.
	95-96	97-98

Rated operational voltage U	e		V	500
Conventional free air thermal current I		th	A	6
Rated operational current I	th
	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
Short circuit protection gG (gf) fuses			A	6

2. 24	Low Voltage Products & Systems
AC 1030.1 – 12/01

Technical data

E200DU – E800DU

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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

i

V

690

according to IEC 158-1, IEC 60947-4-1

Impulse withstand voltage U

imp

kV

6

according to IEC 60947-4-1

Permissible ambient temperature

• for storage

°C

-25 to +70

• with compensated operation

°C

-25 to +70

2

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

multiple of g

5

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

2

2 x 0.75...4

– Flexible with connector sleeve

mm

2

2 x 0.75...4

Terminal types and connecting capacity

of main conductors

• Screw terminals (screw size)

• with busbar or cable lugs

M8

M10

M10

M12

(bars are accessories)

(bars are accessories)

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 t

he hand

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

only with appropriate terminal covers

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

for three phase current only

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 ski

lled electricians only.

•

When using the “Auto” setting, remember that this means the overload will automatically reset after tripping and the motor m

ay 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 personne

l and material.

Low Voltage Products & Systems

2 .25

AC 1030.1 – 12/01

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Technical data

Terms and technical definitions

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 circui		t 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 contr		ol 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 dist	ances, a device
		will have different insulating voltages depending on insulation classes A, B, C & D. Class C corresponds to most industrial app	lications. The
	2
		devices in this catalog belong to Class C.

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 ins	tallations 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 install	ations and will be
	able to operate afterwards. The risk of contacts being welded is acceptable. In this case, the manufacturer must stipulate th	e measures to be
	taken with respect to maintenance of the equipment.

Rated operational current I		e
Current rated by the manufacturer. It is mainly based on the rated operational voltage U			e , the rated frequency, the utilization category, the rated
duty and the type of protective enclosure, if necessary.
Conventional	free air thermal current I	th	ts exceeding the
Current that	the contactor can withstand in free air for a duty time of 8 hours without the temperature rise of its various par

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.

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
									2.95					1.87
			1.73						75					47.5
			44
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													15	18
													7
													1.73
														44
			.28 7					0.67
			.59	.71				17	2.95
			15	18					75
			1.73
			44
E200DU

Electronic2 Overload relays

2

1.50

38

2.28

58

Low Voltage Products & Systems

2.27

AC 1030.1 – 12/01