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

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Low Voltage Products & Systems 2.27

AC 1030.1 – 12/01

2

Electronic

Overload

2

E320DU

Approximate dimensions

E320DU – E500DU

relays

E500DU

2.28 Low Voltage Products & Systems

AC 1030.1 – 12/01

E800DU

Approximate dimensions

E800DU

Electronic

Overload

relays

2

Low Voltage Products & Systems 2.29

AC 1030.1 – 12/01

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Thermal

Overload relays

Low Voltage Products & Systems 2.1

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

• Class 10 adjustable overload relays are standard with all ABB Line starters

• Reset can also be adjusted to function as a stop button

• Screwdriver guide holes

• All terminal screws are available from the front

• 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

Thermal overload relays

Type TA Class 10

• Trip indication

• Remote trip and reset option available

• Single phase and phase unbalance protection

• Isolated alarm circuit (N.O.) contact

• Ambient compensation:

-25°C to +55°C (-13oF to +131oF)

• Manual test

• Manual or automatic reset

• Factory calibrated and tested

• Wide adjustment range

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TA thermal overload relays are used with A Line contactors for the protection of motors having a nominal voltage of up to 600VAC max per UL/CSA (690VAC and 800VDC per IEC).

Product range

• Standard relays:

Types: TA25DU, TA42DU, TA75DU, TA80DU, TA110DU, TA200DU and TA450DU

– TA25 to TA110 and TA200 are directly connected in the motor circuit. – TA450DU relays are fed through a linear type transformer

• Special construction

Thermal overload relays with different certifications and approvals. Relays for protection EEx e motors.

Construction and function

2

• General

Thermal O/L relays and their accessories meet UL, CSA and most other important international standards (IEC), European standards (EN) and the most important national standards (DIN-VDE, NFC-UTE, BS, etc.). They meet the certification and approval directives required throughout the world.

Thermal overload relays are 3 pole. The motor current flows through their bimetals (1 per phase) which are indirectly heated. Under the effect of the heating, the bimetals bend, cause the relay to trip and the position of the auxiliary contacts to change.

The relay setting range is graduated in amps. In compliance with international and national standards, the setting current is the motor nominal current and not the tripping current (no tripping at 1.05 x setting current, tripping at 1.2 times setting current).

The tripping curves (cold or warm starting, 3 phases and 2 phases) are shown on page 2.14. The relays are built to be self protecting in the event of an overload until the short circuit protection device is activated.

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Description

Frame size

TA....DU

Amp setting range

Signaling contact, (97, 98)

Terminals L1, L3, L5

Manual test

Manual or auto reset

Trip indication light

Tripping contact, (95, 96)

Terminals T1,T2, T3

Catalog number explanation

TA25DU 0.16

Frame size Amp rating

2.2 Low Voltage Products & Systems

AC 1030.1 – 12/01

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Description

Application Technical data

• All the relays have:

– Free tripping: the resetting button, even if held in, does not prevent tripping of the thermal overload relay in the

event of a fault. – Temperature compensation – Phase failure protection according to IEC 947-4-1: Within the limits of the setting range, a reduced tripping time, and

thus improved motor protection, is obrtained in case of a phase failure. – Tripping class: 10A, for TA relays – Test functions and resetting: see table below.

• Auxiliary contacts

The relays have two built in auxiliary contacts: NC marked 95-96; NO marked 97-98. Both contacts are physically separate and can thus be used for 2 different circuits (control circuit and indication circuit).

Function of TA25DU – TA450DU thermal O/L relays

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TA25DU

Resetting Relay tripped 95-96 Open Relay not tripped 95-96 Closed

Contacts Manual Automatic Both manual and automatic

Effect of blue button indexed

on R (RESET ONLY) button is pressed

Effect of blue button indexed on R/O

(RESET/OFF)

Resetting Yes No No

95-96

97-98

Resetting Yes No No

95-96

97-98

Closed when the

Open when the

button is pressed

Closed when the Open when the button is pressed

button is released

Open when the

button is pressed

97-98 Closed 97-98 Open

No effect No effect

No effect

Closed when the button is released

{{

No effect

Low Voltage Products & Systems 2.3

AC 1030.1 – 12/01

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Types TA25DU TA42DU TA75DU TA80DU Main characteristics

Construction 3 pole with ambient temperature variation compensation.

2

Resetting Convertible: Manual to Automatic Setting ranges Number 18 3 6 4

Mounted with contactors

Mounting kit No kit is required for mounting thermal O/L relays below contactors

Types of contactors A/AE9 BC9 for combined mounting A/AE12

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from 0.1 – 0.16A 18 – 25A 18 – 25A 29 – 42A to 24 – 32A 29 – 42A 60 – 80A 60 – 80A

Selection guide

TA25DU – T A80DU

Protection against single phase operation. Built in auxiliary contacts: 1N.O. + 1N.C.

A/AE16 BC16 A/AE26 BC25

A/AE30 BC30 A/AE30 A/AE40 A/AE40

BC18

A/AE/AF50 A/AE/AF63 A/AE/AF75

A/AE/AF95

A/AE/AF110

Mounted separately (i.e. separate from contactor)

Separate mounting kit DB25 DB80

Accessories

Tripping coil DS25-A Resetting coil DR25-A Terminal shroud Terminals protected against direct contact (without the addition of terminal shrouds) Function markers BA5-50

2.4 Low Voltage Products & Systems

AC 1030.1 – 12/01

Selection guide

TA110DU – TA450DU

Types TA110DU TA200DU TA450DU

Main characteristics

Construction 3 pole with ambient temperature variation compensation.

Resetting Convertible: manual to automatic Setting ranges Number 2 6 3

from A 65 – 90 65 – 90 130 – 185 to A 80 – 110 150 – 200 220 – 310

Mounted with contactors

Mounting kit No kit is required for mounting thermal O/L relays See page 2.7.

Types of contactors for combined mounting

Protection against single phase operation. Built in auxiliary contacts: 1N.O. + 1N.C.

1

2

35

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R

95 97

96 98

A/AE/AF95

A/AE/AF110

A/AF145 A/AF185 A/AF210 + DT450/A300

Mounted separately (i.e. separate from contactor)

Separate mounting kit DB200 No kit required for separate mounting of thermal O/L relays

Accessories

Tripping coil Resetting coil Terminal shroud 1 LT200 – LT450 – Function markers BA5-50

A/AF260 + DT450/A300 A/AF300 + DT450/A300

1 Terminals protected against direct contact (without the addition of terminal shrouds)

Low Voltage Products & Systems 2.5

AC 1030.1 – 12/01

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TA25DU

TA42DU

TA75DU

Type TA, Class 10

for Contactors A9 – A/AF300

For Setting range Suffix Catalog List

contactor A Code number price

A/AE9 – A/AE40 2.2 – 3.1 J TA25DU3.1

BC9 – BC30 2.8 – 4.0 K TA25DU4.0

A/AE30 – A/AE40 22 – 32 B TA42DU32 78

A/AE/AF50 – A/AE/AF75

A/AE/AF95 – A/AE/AF110 60 – 8 0 F TA80DU80

A/AF145 – A/AF185 100 – 135 C TA200DU135

A/AF210 – A/AF300 165 – 235 B TA450DU235 488

0.1 – 0.16 A TA25DU0.16

0.16 – 0.25 B TA25DU0.25

0.25 – 0.4 C TA25DU0.4

0.4 – 0.63 D TA25DU0.63

0.63 – 1.0 E TA25DU1.0

1.0 – 1.4 F TA25DU1.4

1.3 – 1.8 G TA25DU1.8

1.7 – 2.4 H TA25DU2.4

3.5 – 5.0 L TA25DU5.0

4.5 – 6.5 M TA25DU6.5

6.0 – 8.5 N TA25DU8.5

7.5 – 11 P TA25DU11 10 – 14 Q TA25DU14 13 – 19 R TA25DU19 18 – 25 S TA25DU25 24 – 32 T TA25DU32

18 – 25 A TA42DU25 29 – 42 C TA42DU42

18 – 25 A TA75DU25 22 – 32 B TA75DU32 29 – 42 C TA75DU42 36 – 52 D TA75DU52 45 – 63 E TA75DU63 60 – 80 F TA75DU80

29 – 42 C TA80DU42 36 – 52 D TA80DU52 45 – 63 E TA80DU63

65 – 90 A TA110DU90 80 – 110 B TA110DU110

65 – 90 A TA200DU90 80 – 110 B TA200DU110

110 – 150 D TA200DU150 130 – 175 E TA200DU175 150 – 200 F TA200DU200

130 – 185 A TA450DU185 1 220 – 310 C TA450DU310

$ 63

102

135

165

225

AF400 – AF750

TA80DU

TA110DU

1 TA450 overloads require mounting kits for installation.

Discount schedule TAA — TA25

2.6 Low Voltage Products & Systems

AC 1030.1 – 12/01

Discount schedule TBA — TA42, TA75 Discount schedule TCA — TA80, TA110, TA200, TA450

See electronic overloads, pages 2.21

Accessories

Separate mounting kits

For O/L

relays number price

TA25DU 0.1 – 25 DB25/25A $ 30

TA42DU, TA75DU, TA80DU 18 – 80 DB80 45

TA25DU 24 – 32 DB25/32A 38

TA110DU, TA200DU 100 – 200 DB200 60

Amps

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Catalog List

DB25/25A

DB80

DB200

LC26-B1

Flat pin terminal blocks

Mounting on: number price

TA25DU relay LC30-T

DB25/25A or DB25/32A LC26-B1

Catalog List

Terminal block — AWG #8 cable

Mounting on: number price

TA25DU (25A or less) or DB25/25A DX25 $ 15

LC terminal blocks can be used to convert standard connections into Faston connections: 2 x 6.3mm or 4 x 2.8mm per pole. The connections are protected against accidental contact.

The LC30-T has a terminal block for the 3 power terminals and a second for the 4 auxiliary terminals of a TA25DU thermal O/L relay.

The LC26-B1 has two identical terminal blocks each for 3 power terminals. This block allows the power terminals to be mounted with two DB25 kits or a TA25DU thermal O/L relay and DB25 kit assembly.

NOTE: According to DIN 46429 part 1 and NFC 20-120 the max. capacity of a Faston connection is 25 A.

Catalog List

Mounting kit – for TA450 overload relay

For contactor number price

A145 – A185 DT450/A185 A210 – A300 DT450/A300

Catalog List

$ 225

Terminal shrouds – for contactors and overload relays

Contactor

A9 – A16

A26 – A40 A30 – A40 TA42DU Included – A50 – A75 TA75DU Included –

A95 – A110

A145 – A185 TA200DU LT185-AY $ 50 A145 – A185 Load side of TA200DU LT200A185 90

Overload Catalog List

relay number price

TA25DU Included —

TA80DU

TA110DU

Included –

2

$ 6

Terminal lug kits

Wire For Catalog List

range overloads number price

6 – 250MCM TA200DU EHTK210 $ 45 4 – 400MCM TA450DU185 ATK300 68

(2) 4 – 500MCM TA450DU310 ATK300/2 110

Low Voltage Products & Systems 2.7

Discount schedule TAA — TA25

AC 1030.1 – 12/01

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DS25A

Accessories

Remote tripping coils

U voltage at 50/60 Hz Catalog List

DS25-A remote tripping coil

DS25-A remote resetting coil

24V DS25-A-24 48V DS25-A-48 110V DS25-A-110 220/380V DS25-A-220/380 500V DS25-A-500

24V DR25-A-24 48V DR25-A-48 110V DR25-A-110 220/380V DR25-A-220/380 500V DR25-A-500

Application

• The DS25-A coil is used for remote electrical tripping of the TA25 DU thermal O/L relay and is connected to the relay's normally closed 95-96 auxiliary contact.

• The DR 25-A coil is used for remote electrical resetting of the TA25DU thermal O/L relay which is adjusted for “Manual resetting;” it is connected to the relay’s normally open 97-98 auxiliary contact.

The coils are not designed for continuous duty. Impulse duration: 0.2 to 0.35 s.

Set the button to “Man” (Manual resetting). Mounting: clipped on to TA25DU thermal O/L relay.

number 1 price

$ 60

DR25A

Installation diagrams

For connection of DS25-A to TA25DU relay For connection of DR25-A to TA25DU relay

L1 L2/N

STOP

21 22

START

13 14

M

A1 A2

O L

96

95

M

13 14

OVERLOAD

TRIP

E1 E2

OL

TRIPPING

COIL

HAND

OFF

23 24

13 14

AUTO

M

A1 A2

O L

96

95

L1 L2/N

STOP

21 22

START

13 14

M

A1 A2

O L

95

96

M

13 14

OVERLOAD

RESET

HAND

OFF

AUTO

23 24

13 14

L1 L2/N

O L

97

98

M

A1 A2

E1 E2

OL

RESETTING

COIL

O L

96

95

OVERLOAD

TRIP

E1 E2

OL

TRIPPING

COIL

1 Cannot be used with TA42, TA75, or TA200 overload relays.

2.8 Low Voltage Products & Systems

AC 1030.1 – 12/01

Discount schedule TAA — TA25

OVERLOAD

RESET

O L

97

E1 E2

98

RESETTING

OL

COIL

Intermittent duty

(ops/h)

140

120

100

80

60

40

Switching frequency

20

0

0 20 40 60 80 100(%)

in relation to load factor.

[s]

40

20

11

10

6 4 3

2

Tripping time

1

345

Multiple of the setting current

TA thermal O/L relay cold-state

ta = 0.5s

ta = 1s

ta = 1.5s

ta = 3s

ta = 3.5s

Closing time

Switching frequency

ta:

motor starting time.

tripping characteristics

67

7.4

Technical data

TA25DU – TA450DU

Switching frequency:

To avoid untimely tripping, TA and T thermal O/L relays have been designed to withstand roughly 15 switching operations per hour with an approximately equal distribution between working and rest cycles.

In these conditions, the motor starting time must not exceed 1 second and the starting current must be lower than or equal to 6 times the motor I

For intermittent operations, the diagram opposite specifies relay operating limits. Example: Motor starting time: 1 sec.

Load factor: 40 % Switching frequency: 60 ops./h according to diagram

For a higher number of operations and for load variations (e.g. frequent starting and braking), it is advisable to use CUSTORAPID

For motors subject to particularly severe operating conditions (e.g. locked rotor) it is advisable to use protection combined with a thermal O/L relay and the CUSTORAPID

Protection of motors with long starting time

See electronic overload relay section, pages 2.21 - 2.32.

Mounting position

On a support at an angle of ± 30° in relation to the vertical plane (standard position). Other mounting positions possible, except mounting on a horizontal plane (in this case the tripping mechanism would be located above the bimetals).

Special version for EEx e motors

Consult factory.

Tripping limits at ambient temperatures varying by + 20°C

Ambient temperature compensation

Thermal O/L relays are compensated against ambient temperature variations by a compensation bimetal which is sensitive to the ambient temperature.

Thermal O/L relays are designed to operate between –5 °C and +40 °C in compliance with standard IEC 947-4-1. For a wider range of –25° C to +55 °C consult the graph opposite.

Example: tripping at –25 °C. Tripping takes place before 1.5 times the setting current.

8

Resetting: TA25DU – TA450 DU thermal O/L relays have convertible manual/automatic resetting.

Delivery: in manual resetting mode.

®

protection.

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system.

1.5

1.4

1.3

1.2

1.1

1.0

0.9

Multiple of the setting current

-20 -10 0 10 20 30 40 50

Ambient temperature compensation limits according to IEC 947-4-1

Tripping

No tripping

Ambient temperature

Low Voltage Products & Systems 2.9

AC 1030.1 – 12/01

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Technical data

TA25DU – T A80DU

Types TA25DU TA42DU TA75DU TA80DU

Standards: (international, European)

Rated insulation voltage U according to IEC 947-4-1

Rated impulse withstand voltage U according to IEC 947-4-1

Permissible ambient temperature

– for storage °C –40 to +70 – for operation °C –25 to +55 with temperature compensation (maximum values: see page 2.9)

Climatic withstand DIN 50017 Humidity in alternate climate KFW, 30 cycles

2

Mounting positions

Shock withstand shock duration ms 15 at nominal I Critical direction of shocks A1, A2 multiples of g 12

Resistance to vibrations (±1 mm, 50 Hz) multiples of g 8

Mounting – on contactor Latching below the contactor, screw fixing on main terminals

Terminals and cross-sectional areas for main conductors (motor side)

Terminals and cross-sectional area for auxiliary conductors

Degree of protection

e

– separate with DB - kit Using screws: 2 x M4 or 35 mm EN 50022

• screw terminal – with cable clamp M4 – – via tunnel connector – M5 M6 M6 M6 – flat type for lug or bar – – – – –

• conductor cross-sectional area – rigid solid or rigid stranded mm – flexible with cable end mm – recommended bars mm – – – – –

• screw terminal (screw size) – with cable clamp M 3.5

• conductor cross-sectional area – rigid solid or rigid stranded 2 x mm – flexible with cable end 2 x mm

i

imp

A1

V 690

kV 6

On a support at an angle of ±30° in relation to the vertical plane (standard position). Other positions possible

except mounting on a horizontal plane (in this case the tripping mechanism would be located above the bimetals).

TA25DU setting ranges:

from 0.1-0.16A

to 18-25A

A2

2

2 x 1.5 - 6 1 x 10

2

2 x 1.5 - 4 2 x 0.75 - 6

2 2

24-32 A

All the terminals are protected against direct contact according to

VDE 0106/Part. 100. (without additional terminal shrouds)

IEC 947-4-1, EN 60947-4-1

1 x 2.5 - 35 or 2 x 2.5 x 16 1 x 2.5 - 25 or 2 x 2.5 x 10

0.75 - 4

0.75 - 2.5 All the terminals are

protected against direct

direct contact according to

VDE0106/part 100 (with

additional terminal shrouds

for the main terminals

Pole Technical Characteristics

Types TA25 TA42 TA75 TA80 TA10 TA200 T A450

Number of poles 3 Setting ranges see page 2.6 Tripping class according to IEC 947-4-1, EN 60947-1 Rated operational frequencies Hz 0 - 400 50/60 Max. switching frequency Up to 15 starts/h or 60 starts/h with 40 % on-load factor when neither

without untimely tripping the starting current of 6 x In nor the starting time 1 s are exceeded. Resistance per phase in mΩ

and heat dissipation in W see page 2.13

2.10 Low Voltage Products & Systems

AC 1030.1 – 12/01

DU DU DU DU DU DU DU

10 A

Technical data

TA110DU – TA450DU

Types TA110DU TA200DU TA450DU

Standards: (international, European)

Rated insulation voltage U according to IEC 947-4-1

Rated impulse withstand voltage U according to IEC 947-4-1

Permissible ambient temperature

– for storage °C –40 to +70

– for operation °C –25 to +55 with temperature compensation (maximum values: see page 2.9) Climatic withstand DIN 50017 Humidity in alternate climate KFW, 30 cycles Mounting positions

Shock withstand shock duration ms 15 at nominal I Critical direction of shocks A1, A2 multiples of g 12

Resistance to vibrations (±1 mm, 50 Hz) multiples of g 8

Mounting – on contactor

Terminals and cross-sectional areas for main conductors (motor side)

Terminals and cross-sectional area for auxiliary conductors

Degree of protection All the terminals are protected against direct contact according to

e

– separate with DB - kit

• screw terminal – with cable clamp – – – – via tunnel connector HC, M8 – – – flat type for lug or bar – M10 M10

• conductor cross-sectional area – rigid solid or rigid stranded – flexible with cable end – recommended bars mm 12 x 3 20 x 4 20 x 4...5

• screw terminal (screw size) – with cable clamp M 3.5

• conductor cross-sectional area – rigid solid or rigid stranded 2 x – flexible with cable end 2 x mm

i

imp

A1

V 690 1000

kV 6 8

On a support at an angle of ±30° in relation to the vertical plane (standard position). Other positions possible

except mounting on a horizontal plane (in this case the tripping mechanism would be located above the bimetals).

A2

2

mm mm

mm

2

2 2

16 – 35 25 – 120 2 x 240 16 – 35 25 – 95 2 x 240

VDE 0106/Part. 100. (with additional terminal shrouds)

IEC 947-4-1, EN 60947-4-1

4 x M5 screws

0.75 - 4

0.75 - 2.5

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Technical characteristics of auxiliary contacts for thermal O/L relays: TA25DU to TA450DU

Auxiliary contacts normally closed N.C. normally open N.O. Terminal marking 95-96 97-98 Rated operational voltage U Conventional thermal current (in free air) I Rated operational current I

Rated operational current I

Protection against short circuits gG (gl) fuses (according to IEC 269) A 10 6 S 271/S 281circuit-breaker A k3 k1

Maximum potential difference VAC 500 500 between N.C. and N.O. auxiliary contacts VDC 440 440

up to 240 V A 3.0 1.5 up to 440 V A 1.9 0.95 up to 500 V A 1.0 0.75

up to 250 V A 0.12 0.04

e

, AC-15

e

DC-13

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th

Low Voltage Products & Systems 2.11

VAC 500 500

A10 6

AC 1030.1 – 12/01

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Technical data

Motor protection; Choice of protective device

Motor Protection — general

It is very important to choose an adequate protective device for the safety of the motor during operation and for its durability.

The efficiency of protection methods varies according to the application. The overview below will help you to choose. There is no general rule and we are available to advise you for special applications and especially in the case of difficult starting.

Protective devices and efficiency

Protection in relation to current: Protection in relation to temperature:

Fuses

Protective relay with phase fault protection via CUSTORAPID

Motor protection Motor protection thermistor relay

®

via SPEM electronic

2

SPEM

M

3~

M

3~

Causes of dangerous overloads for the motor windings

1 Overload with current ■ ●●●

1.2 times the nominal current

2 S1-S8 nominal duties ■ ■●●

according to IEC 34-I

3 Operation with starting, ■ ■●●

braking, reversal in operating direction

4 Operation with starting ■ ■●●

rate at > 15 cycles/hour

5 Locked rotor ■●■ for motors with ●

6 Overloads due to phase failure ■ ●●● 7 Network undervoltage or overvoltage ■ ●●● 8 Fluctuation of network frequency ■ ●●■ 9 Ambient temperature too high ■ ●●■

10 Overheating due to external ■ ■ ● ■ cause (i.e. overheating of bearings)

11 Motor cooling disturbed ■ ■ ● ■ 12 Undercurrent protection

13 Protection of asymmetry:

14 Earth fault protection 15 Automatic disconnection for

Protection efficiency:

■ unsuitable

■ very average efficiency

● perfectly efficient

2.12 Low Voltage Products & Systems

AC 1030.1 – 12/01

Note: Fuses

Fuses do not protect motors against overloads. They are only used to protect installations and lines against short circuits.

To ensure efficient protection of a motor against short circuits, it is advisable to use aM type fuses in association with thermal OLR relays.

For the selection of fuses or circuit-breakers, refer to the indications given in this catalogue concerning contactors on the one hand and thermal O/L relays on the other.

In general, fuse protection for direct-on-line starting must be sized as follows: – aM fuses: choose the fuse rating immediately above the full load value of the motor current. – gG (gI) fuses: determine the fuse rating immediately above the motor current value and choose the next highest

fuse rating.

M

3~

special rotor

M 3~

on drop in load

wrong phase direction

rotation or asymmetrical load

auxiliary load fault

Technical data

Resistance and Joule losses per phase Short circuit protection

Resistance and Joule losses per phase, short circuit protection

Setting range Resistance per phase at

current per phase max. setting

from – to

AA mΩ W

TA25DU

0.1 – 0.16 85850 2.2

0.16 – 0.25 85150 2.2

0.25 – 0.4 13750 2.2

0.4 – 0.63 5370 2.2

0.63 – 1.0 2190 2.2

1.0 – 1.4 1120 2.2

1.3 – 1.8 670 2.2

1.7 – 2.4 383 2.2

2.2 – 3.1 229 2.2

2.8 – 4.0 137 2.2

3.5 – 5.0 87.5 2.2

4.5 – 6.5 61 2.2

6.0 – 8.5 30.4 2.2

7.5 – 11 18.2 2.2 10 – 14 11.2 2.2 13 – 19 6.3 2.3 18 – 25 4.7 2.9 24 – 32 3.2 3.3

TA42DU

18 – 25 5.5 3.43 22 – 32 2.89 2.91 29 – 42 1.84 3.24

TA75DU

18 – 25 5.5 3.43 22 – 32 2.89 2.91 29 – 42 1.84 3.24 36 – 52 1.3 3.51 45 – 63 0.936 3.72 60 – 80 0.615 3.94

TA80DU

29 – 42 1.84 3.24 36 – 52 1.3 3.51 45 – 63 0.936 3.72 60 – 80 0.615 3.94

Joule losses

Setting range Resistance per phase at

current per phase max. setting

from – to

AA mΩ W

TA110DU

80 – 110 0.378 3.78

TA200DU

100 – 135 0.318 5.79 110 – 150 0.255 5.74 130 – 175 0.214 6.55 150 – 200 0.182 7.28

TA450DU

130 – 185 — 2.5 165 – 235 — 2.5 220 – 310 — 2.5

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AC 1030.1 – 12/01

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Technical data

Tripping curves

2

TA25DU TA75DU TA110DU/SU TA450DU

TA-DU thermal O/L relays are 3-pole with manual or automatic resetting mode selection. The resetting button can also be used for stopping. Built-in auxiliary contacts are physically separate and, consequently, can be used in different circuits (control circuit/indication circuit). Each relay is temperature compensated and ensures phase failure protection. Protective relays up to size TA75DU are protected against direct contact via the front face. Terminal shrouds are available for TA200DU to TA450DU size relays. The connecting terminals are delivered in open position with (+,-) pozidriv screws and screwdriver guidance. It is advisable to tighten unused terminal screws.

Thermal O/L relay tripping curves

TA25DU TA42DU, TA75DU and TA80DU TA110DU

(tripping class 10A) (tripping class 10A) (tripping class 10A)

Minutes

Tripping time

Seconds

120 100

80 60

40

20

10

8

4

2

1

40

20

10

2 Phases

868 6

4

3 Phases

2

from warm state

1

0.8 1 2 3 4 5 6 7 8 9 101.2

1.5

Tripping current in multiples of the setting current

from cold state

2 Phases

3 Phases

Minutes

Tripping time

Seconds

120 100

80 60

40

20

10

8

4

2

1

40

20

2 Phases

10

3 Phases

868 6

4

2

1

from warm state

0.8 1 2 3 4 5 6 7 8 9 101.2 1.5

Tripping current in multiples of the setting current

from cold state

2 Phases

3 Phases

Minutes

Tripping time

Seconds

120 100

80 60

40

20

10

8

4

2

1

40

20

3 Phases

10

868 6

4

2 Phases

2

from warm state

1

0.8 1 2 3 4 5 6 7 8 9 101.2 1.5

Tripping current in multiples of the setting current

from cold state

2 Phases

3 Phases

TA200DU TA450DU

(tripping class 10A) (tripping class 10A)

120 100

80 60

40

20

10

8 6

4

2

Minutes

1

40

Tripping time

20

2 Phases

10

Seconds

8 6

3 Phases

4

2

from warm state

1

0.8 1 1.2 1.5 2 3 4 5 6 7 8 9 10

Tripping current in multiples of the setting current

from cold state

2 Phases

3 Phases

120

100

80 60

40

20

10

8

6 4

2

minutes

1

40

Triping time

20

10

2 Phase

8

seconds

6 4

2

1

0.8 1 1.2 1.5 2 3 4 5 6 7 8 9 10

3 Phase

from warm state

Tripping current as multiple of setting current

from cold state

2 Phase

3 Phase

2.14 Low Voltage Products & Systems

AC 1030.1 – 12/01

00.00

Inches

Millimeters

TA25DU

TA25DU & DB25

Approximate dimensions

T25DU – TA42DU

3.15

80

3.70

94

TA25DU32

3.31

84

1.73

44

only

1.73

44

0.24

6

0.51

13

0.24

4.25

108

6

0.51

13

3.70

94

0.35

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0.17

4.2

1.38

35

1.88

48

TA25DU & DB25/32

TA42DU

TA42DU / TA75DU & DB80

4.41

112

1.73

44

3.54

90

2.13

54

0.24

0.51

4.25

108

6

13

0.51

13

0.24

6

4.35

110.5

0.35

6

1.38

35

0.17

4.2

1.88

48

5.03

127.7

3.86

98

2.36

60

0.24

6

0.51

13

1.97

50

2.95

75

Low Voltage Products & Systems 2.15

AC 1030.1 – 12/01

2

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TA80DU

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Approximate dimensions

TA75DU – T A200DU

0.51

13

3.99

93

0.24

6

2.13

54

2.85

72.3

TOUCH SAFE COVER

4.35

110.5

00.00

Inches

Millimeters

TA110DU

TA200DU

5.44

138.1

3.77

95.7

3.14

80.0

2.12

54.0

0.50

12.5

TOUCH SAFE COVER

0.24

6.0

4.73

120.1

4.37

111.0

0.07

1.7

0.47

12.0

1.18

30.0

2 - M4 Mtg. Slots

1.48

37.5

6 - 0.21 HOLES

1.98

50.2

0.47

12.0

0.24

6.0

2.52

64.0

.61

15.

2.16 Low Voltage Products & Systems

AC 1030.1 – 12/01

00.00

TA450DU

Inches

Millimeters

Approximate dimensions

TA450DU

0.18

4.5

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1.11

28.3

2.28

58.0

0.82

21.0

2.28

58.0

6.62

168.0

0.24

6.0

2.99

76.0

0.96

24.5

642

7.60

193.0

0.2 DIA.

5.0 DIA.

2.17

55.0

2

Low Voltage Products & Systems 2.17

AC 1030.1 – 12/01

ABB Electronic overload relays Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual