Rockwell Automation 140U Q User Manual

Q and M-Frame Circuit Breakers

Instruction Leaflet for Electronic RMS Trip Unit Installation and Operation

Table

Contents

Description Page

General Information Protection

1.1

UL Listed Devices

2.0

Installation

3.0

Preparation (All Trip Units)

3.1

4-Pole Trip Unit Installation

3.2

Ground Fault Trip Unit Installation

3.3

General

3.3.1

Installation

3.3.2

3-Pole (Non-Ground Fault) Trip Unit Installation

3.4

Final Installation Instructions (All Trip Units)

3.5

Principle of Operation

4.0

General

4.1

Overload Trip

4.2

Short Delay/lnstantaneous Trip

4.3

Ground Fault Protection

4.4

Protection Settings

5.0

General

5.1

Short Delay Pick-up Settings

5.2

Short Delay Time Settings

5.3

Instantaneous Pickup Setting

5.4

Ground Fault Pick-up Setting

5.5

Ground Fault Time Settings

5.6

Testing

6.0

Functional Field Testing

6.1

Performance Testing for Ground Fault Trip Units

6.2

6.2.1

Code Requirements Standards Requirements

6.2.2

6.2.3

General Test Instructions

7.0

Rating Plug References

8.0

Q-Frame Molded Case

8.1

Circuit Breakers Internal Accessories

8.2

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12 12

Bul. 140U

PRESENT BEFORE PROCEEDING AND ALWAYS FOLLOW GENERALLY ACCEPTED SAFETY PROCEDURES.

ALLEN

MISAPPLICATION

PRODUCTS.

2 2

The user is cautioned to observe all recommendations,

warnings, and cautions relating to the safety of personnel

and equipment as well as all general and local health and

safety laws, codes, and procedures.

The recommendations and information contained herein

are based on Allen

but should not be considered to be all

ing every application or circumstance which may arise. If

any questions arise, contact Allen-Bradley for further

information or instructions.

7 7 7 7 7 7 7 7

8 8 8 8 8 9 9

Fig.

-BRADLEY

Electronic RMS Trip Unit M Frame Circuit Breaker

GENERAL INFORMATION

NOT LIABLE FOR THE

OR MISINSTALLATION

-Bradley experience and judgement,

for

OF ITS

inclusive or cover

3-Pole Q-Frame &

DEATH, SEVERE PERSONAL INJURY,

SUBSTANTIAL PROPERTY DAMAGE CAN RESULT

FROM CONTACT WITH ENERGIZED EQUIPMENT. DO NOT

AlTEMPTTO INSTALL

MAINTENANCE ON EQUIPMENT WHILE IT ENERGIZED. ALWAYS VERIFY THAT NO VOLTAGE

40752-072(2) Effective

WARNING

6/02

PERFORM

1.1

Protection

The Electronic RMS, illustrated in Figure tronic trip unit that incorporates a microprocessor-based custom application specific integrated circuit design for

use with Q

Circuit Breakers. The Electronic RMS Trip Unit

sensing for proper correlation with thermal characteristics of conductors and equipment. Interchangeable rating plugs

Frame and M Frame Molded Case

provides true RMS current

is an elec

Page

are provided to establish the continuous current rating of each circuit breaker.

The Electronic RMS Trip Unit is completely self tained and when the circuit breaker is closed, requires no external power to operate its protection systems. It operates from current signal levels and control power derived through current sensors integrally mounted in the trip unit.

Electronic applications only. For DC applications, a thermal trip unit should be used.

The Electronic RMS Trip Unit is available in 4 different types, (see Table 1 delay time function (adjusted by changing the rating plug), and may be equipped with a maximum of two phase and two ground (time application requirements. The types of adjustments available for each model include the following:

Adjustment

Short Delay Pick-up

2) Short Delay Pick-up/Short DelayTime

Short Delay Pick-Up/Ground Fault

Pick-up/Ground Fault Time

2.0 UL LISTED DEVICES

The Electronic RMS Trip Unit is listed in accordance with Underwriters Laboratories, Inc. Standard UL489 and satisfies the applicable requirements of the International Electrotechnical Commission (IEC) recommendations for molded case circuit breakers.

Fig.

RMS Trip Units are suitable for 50/60

1). Each trip unit contains a fixed long

current) adjustments to meet specific

Retaining Screw

KPlaces)\

\Trip Unit

Preliminary Alignment Sensor

LSI

LSG

Current

Sensor

Trip Unit and Current

Retaining

Screw

Secondary Winding Connector

con

magnetic

INSTAL LATlO N

3.1 Preparation

The installation procedure consists of inspecting and installing the trip unit and rating plug. To install the trip unit, perform the following steps.

Note: If required, internal accessory installation should be done before the circuit breaker is mounted and connected. Refer to individual accessory instruc tion leaflets.

Make sure that the trip unit is suitable for the intended installation by comparing nameplate data with any existing equipment and system requirements. Inspect the trip unit for completeness, and check for damage before installing it in the circuit breaker frame.

Note:Trip unit center retaining screw is captive in the

trip unit conductor; the remaining retaining screws are supplied with the frame.

Remove circuit breaker pan To continue installation, proceed to the section applicable

to the trip unit being installed:

UnitTvpe Section

Trip

pole Type Trip Unit 3.2

pole Ground Fault Trip Unit

pole Non-Ground Fault Trip Unit

4-PoleTrip Unit Installation

3.2

Remove the three screws for the left fourth pole contact bases (Fig. 3) from the hardware bag.

Place the trip unit and fourth pole current sensor side by side on a flat surface. (See Fig. 2)

Remove the CAUTION tag from the current sensor secondary winding leads.

Note: Secondary winding connector is not polarized.

Plug the current sensor secondary winding connector into the receptacle in the side of the trip unit. Either polarity is acceptable.

Note:The two trip unit outer retaining screws and

fourth pole sensor retaining screw may be placed in the trip unit conductor holes at this time. If preferred, the 5/16 inch hexagonal position the screws when the trip unit is in the base.

Position trip unit and fourth pole current sensor in base. Make sure latch bracket pin is properly seated in slots in side plates (see Fig. 4). If necessary, push circuit breaker handle towards the closed position to help seat trip unit.

(AllTrip Units)

head cover screws, and cover.

head wrench may be used to

3.3

3.4

and right-pole and

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Contact

Base

Load

Copper

Fig.

Contact Bases and Load Copper

LINE

END

Side Plate

Trigger

Trip

Unit and Current Sensor

Retaining Screws

Fourth

Pnh

. -.

Current Sensor

Fig.

Unit

Trip Unit Installed in Circuit Breaker

END

LOAD

CAUTION

DO NOT EXCEED A TORQUE OF 12 LB-FT (16.27 N.M). EXCESSIVE TORQUING WILL SHEAR SCREWS.

FAILURE TO APPLY THE REQUIRED TORQUE

MAY LEAD TO EXCESSIVE HEATING AND CAUSE NUISANCE TRIPPING

OFTHE CIRCUIT BREAKER.

Screw in and tighten three trip unit retaining screws

(center first) and the screw for the fourth pole current

sensor.Torque to 12 Ib-ft (16.27 N.m) (see Fig. 4).

Finish installation of the 4

pole Trip Unit by following the

instructions in Section 3.5.

3.3 Ground

FaultTrip Unit Installation

3.3.1 General Ground fault trip units are supplied from the factory with a

wire harness with pigtail lead connections for a neutral current sensor (white and grey wires) and a ground fault alarm relay (yellow and green wires). A neutral current sensor is provided with each trip unit, and the ground fault alarm relay is ordered and shipped separately if required.

If the alarm relay is not required, the green and yellow leads should be cut off before the trip unit is installed in

the breaker.

Electroni

c RMS

Ground Fault Trip Units detect ground fault currents through Residual Sensing. They are not designed to use source ground or zero sequence ground fault sensing methods. If the system neutral is grounded, but no phase to neutral loads are used, the neutral current sensor is not necessary. In that case, the white and grey

leads on the trip unit should be cut off before installation. If the system neutral is grounded and phase to neutral

loads are used, then the neutral current sensor (see Fig.

must be used. It should be connected to the breaker

according to the diagram in Fig. 6. It has the same turns

ratio as the phase current sensors in the trip unit.

Note: The polarity of the sensor connections is

critical. Always observe the polarity markings on the

installation drawings. The polarity markings are identified as white dots on the

transformer.To insure

correct ground fault equipment performance, conduct field tests to comply with National Electric Code requirements under article

230-95(C). See Section 6.2

for testing instructions.

The optional “Internal Accessories” listed in Section 8.2 are available for installation in a Electronic RMS

Fault Trip

Unit.These items, if required, must be ordered

Ground

separately.

3.3.2 Installation

Plug the wire harness supplied for the neutral current sensor and ground fault alarm relay (white, grey, yellow and green wires) into the connector located in the right pole of the trip unit. With the correct polarity the harness should snap into place. Do not force the harness into the connector with the wrong polarity.

Remove trip unit outer pole screws and red plastic washers from the breaker frame. Discard red plastic washers (fig. 7). For the M

frame, also remove the load

end trip unit mounting screws from the frame

(fig.

7a).

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6/02

Page

Fig.

.Aux~Iiary

switch

shown m the

Breaker

SOURCE

LOAD

Canlacis

Open''

pmilmn

Fig. 7a

M-Frame

Trip

Unit Installation

COVER

TORQUE

SCREWS

20-22

-1b

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Lefl

Contact Base

Right Contact Base

Page

Position trip unit in base. Make sure latch bracket pin is properly seated in slots in side plates (see Fig. 8). If

necessary, move latch toward load end of circuit breaker to seat trip unit.

Screw in and tighten three trip unit retaining screws

(centerfirst).Torque to 12 Ib-ft (16.27 N.m) (see Fig. 8).

DO NOT EXCEED A TORQUE OF 12 LB-FT (16.27 n.m.) EXCESSIVE TORQUING WILL SHEAR SCREWS.

FAILURE TO APPLY THE REQUIRED TORQUE MAY

LEADTO EXCESSIVE HEATING AND CAUSE

NUISANCE TRIPPING OF THE CIRCUIT BREAKER.

For an M-Frame, also screw in and torque the load end screws to 6

8 Ib-ft. (8.14-10.85 N.m.).

CAUTION

Fig.

Left- and Right-Pole Contact Bases

Circuit Latch Breaker

Handle

Side Trip Side

Plate Unit Plate

Fig.

Trip Unit Installed in Circuit Breaker

Note: The two placed preferred, the 5/16 inch hexagonal be used the base.

trip

unit

the trip

unit

position the screws when the

Retaining Screws

outer retaining screws may be

conductor holes at

this

time. If

head wrench may

trip

unit

3.4 3-Pole (Non-Ground FauIt)Trip Unit Installation

Remove trip unit outer pole screws and red plastic washers from the breaker frame. Discard red plastic washers (fig. 7). For the M end trip unit mounting screws from the frame

(fig.

7a).

NOTE: The two

be placed

If preferred, the 5/16 inch hexagonal

be used the base.

Position trip unit in base. Make sure latch bracket pin is properly seated in slots in side plates (see Fig. 8). If

necessary, move latch toward load end of circuit breaker to seat trip unit.

Screw in and tighten three trip unit retaining screws

(centerfirst).Torque to 12 Ib-ft (16.27 N.m) (see Fig. 8).

the trip

position the screws when the

DO NOT EXCEED A TORQUE OF 12 LB (16.27 SCREWS.

FAILURE TO APPLY THE REQUIRED TORQUE MAY

LEADTO EXCESSIVE HEATING AND CAUSE

N.M). EXCESSIVE TORQUING WILL SHEAR

NUISANCE TRIPPING OF THE CIRCUIT BREAKER.

-F

rame, also remove the load

trip

unit

outer retaining screws may

unit

conductor holes at

CAUTION

head wrench may

trip

this

unit

time.

40752-072(2) Effective

6/02

+ 9 hidden pages