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Instruction Leaflet

All possible contingencies which may arise during installation, operation or maintenancvariations of this equipment do not purport to be covered by these instructions. If fdesired by purchaser regarding this particular installation, operation or maintenance oflocal ABB Inc. representative should be contacted.

Printed in U.S.A.

ABB
41-103H
Effective: May 1984

Supersedes I.L. 41-103G, Dated June 1976

( | ) Denotes change from superseded issue

Type CO Circuit OpeningOvercurrent Relay

CONTENTS

This instruction leaflet applies to the followingtypes of circuit opening relays:

Type CO-2 Short Time Relay

Type CO-5 Long Time RelayType CO-6 Definite Minimum Time Relay

Type CO-7 Moderately Inverse Time Relay

Type CO-8 Inverse Time Relay

Type CO-9 Very Inverse Time Relay

Type CO-11 Extremely Inverse Time Relay

CAUTION!Before putting relays into service, remove allblocking which may have been inserted for thepurpose of securing the parts during shipment,make sure that all moving parts operate freely.Inspect the contacts to see that they are cleanand close properly, and operate the relay tocheck the settings and electrical connections.

1.0 APPLICATION

These induction overcurrent relays are used to dis-connect circuits or apparatus when the current inthem exceeds a given value. When no suitable sta-tion battery is available, the circuit opening type relayin conjunction with ac series trip coil is used to trip thecircuit breaker.

2.0 CONSTRUCTION AND OPERATION

The type CO relays consist of an overcurrent unit(CO), a de-ion contactor switch (CS), an operationindicator (OI) and an indicating instantaneous trip(IIT) when required.

2.1 ELECTROMAGNET

The electromagnets for the types CO-5, CO-6, CO-7,CO-8 and CO-9 relays have a main tapped coillocated on the center leg of an “E” type laminatedstructure that produces a flux which divides andreturns through the outer legs. A shading coil causesthe flux through the left leg to lag the main pole flux.The out-of-phase fluxes thus produced in the air gapcause a contact closing torque.

The electromagnets for the types CO-2 and CO-11relays have a main coil consisting of a tapped pri-mary winding and a secondary winding. Two identicalcoils on the outer legs of the lamination structure areconnected to the main coil secondary in a manner sothat the combination of all the fluxes produced by theelectromagnet result in out-of-phase fluxes in the airgap. The out-of phase air gap fluxes produced causea contact closing torque.

2.2 DE-ION CONTACTOR SWITCH (CS)

This switch is a small ac solenoid switch whose coil isenergized from a small transformer connected in themain current circuit. A cylindrical plunger operates aspring leaf arm with a silver contact surface on oneend and rigidly fixed to the frame at the other end.

e, and all details andurther information is this equipment, the

41-41-103H CO Circuit Opening Overcurrent Relay

The overcurrent unit contacts are in the contactorswitch coil circuit and when they close, the solenoidplunger moves upward to open the de-ion contactswhich normally short circuit the trip coil. These con-tacts are able to transfer the heavy current due to ashort circuit and permit this current to energize thebreaker trip coil.

2.3 OPERATION INDICATOR (OI)

The operation indicator is a small clapper typedevice. A magnetic armature is attracted to the mag-netic core upon energization of the switch. When theswitch closed two fingers on the armature deflect aspring located on the front of the switch, which allowsthe operation indicator target to drop.

The front spring, in addition to holding the target, pro-vides restraint for the armature and thus controls thepickup value of the switch.

2.4 INDICATING INSTANTANEOUS TRIP UNIT (IIT)

The instantaneous trip unit s a small ac operatedclapper type device. A magnetic armature, to whichleaf-spring mounted contacts are attached, isattracted to the magnetic core upon energization ofthe switch. When the switch closes, the moving con-tacts bridge two stationary contacts completing thetrip circuit. Also, during the operation, two fingers onthe armature deflect a spring locate on the front ofthe switch which allows the operation indicator targetto drop.

A core screw accessible from the top of the switchprovides the adjustable pickup range.

3.0 CHARACTERISTICS

The relays are available in the following currentrange:

The circuit-opening relay is recommended only in the4 to 12 ampere range. A lower range is not desirablebecause the burden of a low-range trip coil is toheavy on the current transformer. One trip coil isrequired for each relay.

The burden of the auxiliary current transformer at 4amps. s 4.6 VA with contacts IIT or CO closed and5.7 VA with contacts open.

The time vs. current characteristics are shown in Fig-ures 3 to 9. These characteristics give the contactclosing time for the various time dial settings whenthe indicated multiples of the tap value current areapplied to the relay.

4.0 SETTINGS

4.1 CO UNIT

The overcurrent unit settings can be defined either bytap setting and time dial position or by tap setting anda specific time of operation at some current multipleof the tap setting (i.e., 4 tap setting, 2 time dial posi-tion or 4 tap setting, 0.6 seconds at 6 times tap valuecurrent).

To provide selective circuit breaker operation, a mini-mum coordinating time of 0.3 seconds plus circuitbreaker time is recommended between the relaybeing set and the relays with which coordination is tobe effected.

The connector screw on the terminal plate above thetime dial makes connections to various turns on theoperating coil. By placing this screw in the variousterminal plate holes, the relay will respond to multi-ples of tap value currents in accordance with the var-ious typical time-current curves.

CAUTION!Since the tap block connector screw carriesoperating current, be sure that the screw isturned tight. IN ORDER TO AVOID OPENINGCURRENT TRANSFORMER CIRCUITS WHENCHANGING TAPS UNDER LOAD, THE RELAYMUST BE FIRST REMOVED FROM THE CASE.

Chassis operating shorting switches on the casewill short the secondary of the current trans-former. The taps should be changed with therelay outside of the case, then re-inserted intothe case.

4.2 INSTANTANEOUS RECLOSING

The factory adjustment of the CO unit contact pro-

Range Taps

4 - 12 4 5 6 7 8 10 12

2

41-41-103HCO Circuit Opening Overcurrent Relay

vides a contact follow. Where instantaneous circuitbreaker reclosing will be initiated upon the closure ofthe CO contact, this contact follow must be elimi-nated by loosening the stationary contact mountingscrew, removing the contact plate and then replacingthe plate with the bent end resting against the con-tact spring. With this change and the contact mount-ing screw tightened, the stationary contact will restsolidly against its backstop.

4.3 DE-ION CONTACTOR SWITCH (CS)

No setting is required on this unit.

4.4 OPERATION INDICATOR (OI)

NO setting is required on this unit.

4.5 INDICATING INSTANTANEOUS TRIP (IIT)

The core screw must be adjusted to the value of pick-up current desired.

The nameplate data will furnish the actual currentrange that may be obtained from the IIT unit.

5.0 INSTALLATION

The relays should be mounted on switchboard pan-els or their equivalent in a location free from dirt,moisture, excessive vibration and heat. Mount therelay vertically by means of the mounting stud for thetype FT projection case or by means of the fourmounting holes on the flange for the semi-flush typeFT case. Either the stud or the mounting screws maybe utilized for grounding the relay. The electrical con-nections may be made directly to the terminals bymeans of screws for steel panel mounting or to theterminal stud furnished with the relay for thick panelmounting. The terminal stud may be easily removedor inserted by locking two nuts on the stud and thenturning the proper nut with a wrench.

For detail information on the FT case refer to Instruc-tion Leaflet 41-076.

6.0 ADJUSTMENTS AND MAINTENANCE

The proper adjustments to insure correct operation ofthis relay have been made at the factory. Uponreceipt of the relay no customer adjustments, otherthan those covered under “SETTINGS” should berequired.

6.1 PERFORMANCE CHECK

The following check is recommended to insure thatthe relay is in proper working order:

1. Contacts

a. By turning the time dial, move the moving con-tacts until they reflect the stationary contact to aposition where the stationary contact is restingagainst its backstop. The index mark located onthe movement frame should coincide with the “0”mark on the time dial.

b. For relay identified with a “T”, located at lower leftof stationary contact block, the index mark on themovement frame will coincide with the”0” markon the time dial when the stationary contact hasmoved through approximately one-half of its nor-mal deflection. Therefore, with the stationarycontact resting against the backstop, the indexmark is offset to the right of the “0” mark byapproximately.020”. the placement of the varioustime dial positions in line wit the index mark willgive operating times as shown on the respectivetime-current curves.

For type CO-11 relay only, the 1.30 times tap valueoperating time from the number 6 time dial position is53.5 ±5% seconds and should be checked first. It isimportant that the 1.30 times tap value current bemaintained accurately. The maintaining of this cur-rent accurately is necessary because of the steep-ness of the slope of the time-current characteristic(Figure 9). A slight variation, ±1%, in the 1.30 timestap value current (including measuring instrumentdeviation) will change the timing tolerance to ±10%and the effects of different taps can make the totalvariations appear to the ±15%.

2. Minimum Trip Current

Set the time dial to position 6. Alternately apply tapvalue current plus 3% and tap value current minus3%. The moving contact should leave the backstopat tap value current plus 3% and should return to thebackstop at tap value current minus 3%.

3. Time Curve

Table 1 shows the time curve calibration points forthe various types of relays. With the time dial set tothe indicated position, apply the currents specified byTable 1, (i.e., for the CO-2, 3 and 20 times tap valuecurrent) and measure the operating time of the relay.

3


The operating times should equal those of Table 1plus or minus 5 percent.

4. De-Ion Contactor Switch (CS)

The de-ion contactor switch should operate with aminimum of 4 amperes ac applied.

5. Operation Indicator (OI)

The operation indicator should operate with a mini-mum of 3 amperes ac applied. The operation indica-tor target should drop freely.

6. Indicating Instantaneous Trip Unit (IIT)

The core screw which is adjustable from the top ofthe trip unit determines the pickup value. The trip unithas a nominal ratio of adjustment of 1 to 4 and anaccuracy within the limits of 10%.

The making of the contacts and target indicationshould occur at approximately the same instant. Thestationary contact should have a minimum of 1/32”wipe. The bridging moving contact should touch bothstationary contacts simultaneously.

6.2 ROUTINE MAINTENANCE

All relays should be inspected periodically and thetime of operation should be checked at least onceevery year or at such other time intervals as may bedictated by experience to be suitable to the particularapplication. Phantom loads should not be used intesting induction-type relays because of the resultingdistorted current wave form which produces an errorin timing.

All contacts should be periodically cleaned. A contactburnisher number 182A836H01 is recommended forthis purpose. The use of abrasive material for clean-ing contacts is not recommended because of thedanger of embedding small particles in the face ofthe soft silver and thus impairing the contact.

7.0 CALIBRATION

Use of the following procedure for calibrating therelay if the relay has been taken apart for repairs orthe adjustments disturbed. This procedure should beused until it is apparent that the relay is not in properworking order. (See “Performance Check”.)

7.1 CO UNIT

1. Contacts

a. By turning the time dial, move the moving con-tacts until they deflect the stationary contact to aposition where the stationary contact is restingagainst its backstop. The index mark located onthe movement frame should coincide with the “0”mark on the time dial.

b. For relays identified with a “T”, located at thelower left of stationary contact block, the indexmark on the movement frame will coincide withthe “0” mark on the time dial when the stationarycontact has moved through approximately one-half of its normal deflection. Therefore, with thestationary contact resting against the, the indexmark is offset to the right of the “0” mark byapproximately .020”. The placement of the vari-ous time dial positions in line with the index markwill give operating times as shown on the respec-tive time-current curves.

2. Minimum Trip Current

The adjustment of the spring tension is setting theminimum trip current value of the relay.This adjust-ment is most conveniently made with the dampingmagnet removed.

With the time dial set on “0”, wind up the spiral springby means of the spring adjuster until approximately6-3/4 convolutions show.

Set the relay on the minimum tap setting. Set thetime dial to position 6.

Adjust the control spring tension so the moving con-tact will leave the backstop at tap value current +10%and will return to the backstop at tap value current -1.03%.

3. Time Curve Calibration

Install the permanent magnet.

Apply the indicated current per Table 1 for perma-nent magnet adjustment (i.e., CO-8, 2 times tapvalue) and measure the operating time. Adjust thepermanent magnet keeper until the operating timecorresponds to the value of Table 1.

Apply the indicated current per Table 1 for the elec-tromagnet plug adjustment (i.e., 20 times tap value)and measure the operating time. Adjust the proper

4


plug until the operating time corresponds to the valuein Table 1. (Withdrawing the left-hand plug, frontview, increases the operating time and withdrawingthe right-hand plug, front view, decreases the time.)In adjusting the plugs, one plug should be screwed incompletely and the other plug run in or out until theproper operating time has been determined.

For type CO-11 relay only, the 1.30 times tap valueoperating time from the number 6 time dial position of53.5% ±5% seconds. It is important that the 1.30times tap value current be maintained accurately.The maintaining of this current accurately is neces-sary because of the steepness of the slope of thetime-current characteristic (Figure 9). A slight varia-tion, ±1%, in the 1.30 times tap value current (includ-ing measuring instrument deviation) will change thetiming tolerance to ±10% and the effect of differenttaps can make the total variations appear to be±15%. If the operating time at 1.3 times tap value isnot within these limits, a minor adjustment of the con-trol spring will give the correct operating time withoutany undue effect on the minimum pick-up of therelay. This check is to be made after the 2 times tapvalue adjustment has been completed.

Recheck the permanent magnet adjustment. If theoperating time for this calibration point has changed,readjust the permanent magnet and then recheck theelectromagnet plug adjustment.

4. De-ion Contactor Switch (CS)

Adjust the core stop on the top as high as possiblewithout allowing the insulating bushing at the bottomof the plunger to touch the Micarta angle. The con-tact will be separated from the Micarta angle by 1/32”to 1/16”. Adjust the contact gap spacing to slightly

less than 1/16 of an inch. Bend down the contactsprings so that a firm contact is made but not sostrong that the minimum pick-up value cannot beobtained. The spring tension should be about 15grams.

Hold the relay contacts closed and with an auxiliaryrelay coil connected across terminals to simulate thecircuit breaker trip coil, note that the contactor switchpicks up on less than 4 amperes.

5. Operation Indicator (OI)

Pass sufficient current (ac) through the operationindicator to just operate it. This value of currentshould not be greater than 3 amperes. The operationindicator target should drop freely. To change pickup,adjust the core screw.

6. Indicating Instantaneous Trip Unit (IIT)

The making of the contacts and target indicationshould occur at approximately the same instant.Position the stationary contact for a minimum of 1/32”wipe. The bridging moving contact should touch bothstationary contacts simultaneously.

Apply sufficient contact to operate the IIT. The opera-tion indicator target should drop freely.

The nameplate data will furnish the actual currentrange that may be obtained from the IIT unit.

8.0 RENEWAL PARTSRepair work can be done most satisfactorily at thefactory. However, interchangeable parts can be fur-nished to the customers who are equipped for doingrepair work. When ordering parts, always give thecomplete nameplate data.

5


∆ For 50 hertz CO-11 relay 20 times operating time limits are 0.24 + 20%, -5%

Table 1: TIME CURVE CALIBRATION DATA – 50 and 60 Hertz

Permanent Magnet Adjustment Electromagnet Plugs

RelayType

TimeDial

Position

Current(Multiples ofTap Value)

OperatingTime

Seconds

Current(Multiples ofTap Value)

OperatingTime

Seconds

CO-2 6 3 0.57 20 0.22

CO-5 6 2 37.80 10 14.30

CO-6 6 2 2.46 20 1.19

CO-7 6 2 4.27 20 1.11

CO-8 6 2 13.35 20 1.11

CO-9 6 2 8.87 20 0.65

CO-11 6 2 11.27 20 0.24∆

6


ENERGY REQUIREMENTS (Type CO-2 Relay)

* Thermal capacities for short times other than one second may be calculated on the basis of time being inversely pro-portional to the square of the current.

φ Degrees current lags voltage at tap value current.

** Voltages taken with high Impedance type voltmeter.

60 Hertz Volt Amperes** (X∆ for 50 Hz)

AmpereRange Tap

ContinuousRating

(Amperes)

One SecondRating*

(Amperes)

PowerFactor

Angle φ

AtTap ValueCurrent

(∆ = 0.86)

At 3 TimesTap ValueCurrent

(∆ = 0.88)

At 10 TimesTap ValueCurrent(∆ = 0.9)


(∆ = 0.91)

0.5/2/5

0.50.60.81.01.52.02.5

0.910.961.181.371.952.242.50

28282828282828

585753,50503629

4.84.95.05.36.27.27.9

39.639.842.745.454.465.473.6

256270308348435580700

790851

10241220174022802850

2/6

2.02.53.03.54.05.06.0

3.14.04.44.85.25.66.0

110110110110110110110

59555147454137

5.045.135.375.535.725.906.54

38.739.842.842.846.050.354.9

262280312329360420474

800920

10081120121615001800

4/12

4.05.06.07.08.0

10.012.0

7.38.08.89.6

10.411.212.0

230230230230230230230

65504746433734

4.925.205.345.355.86

6.67.00

39.142.044.145.849.955.562.3

268305330364400470528

848102011281260140817202064

7

41-41-103H

8

CO Circuit Opening Overcurrent Relay

ENERGY REQUIREMENTS (Type CO-5 Long time and CO-6 Definite Minimum Time Relays)





AmpereRange Tap

ContinuousRating

(Amperes)

One SecondRating*

(Amperes)

PowerFactor

Angle φ

AtTap ValueCurrent

(∆ = 0.86)


(∆ = 0.88)



(∆ = 0.91)

0.5/2/5

0.50.60.81.01.52.02.5

2.73.13.74.15.76.87.7

88888888888888

69686766626058

3.923.963.964.074.194.304.37

20.620.721.021.423.224.926.0

103106114122147168180

270288325360462548630

2/6

2.02.53.03.54.05.06.0

8.08.89.7

10.411.212.513.7

230230230230230230230

67666463625957

3.883.873.934.094.084.204.38

21.021.622.123.123.524.826.5

110118126136

14162183

308342381417448540624

. 4.05.06.07.08.0

10.012.0

16.018.819.320.822.525.028.0

460460460460460460460

65636159565347

4.004.724.324.354.404.604.92

22.423.725.326.427.830.135.6

126143162183204247288

376450531611699880

1056

41-41-103H

9


ENERGY REQUIREMENTS (Type CO-7 Moderately Inverse Time Relay)





AmpereRange Tap

ContinuousRating

(Amperes)

One SecondRating*

(Amperes)

PowerFactor

Angle φ

AtTap ValueCurrent

(∆ = 0.86)


(∆ = 0.88)



(∆ = 0.91)

0.5/2/5

0.50.60.81.01.52.02.5

2.73.13.74.15.76.87.7

88888888888888

68676664615856

3.883.933.934.004.084.244.38

20.720.921.121.622.924.825.9

103107114122148174185

278288320356459552640

2/6

2.02.53.03.54.05.06.0

8.08.89.7

10.411.212.513.7

230230230230230230230

66636362615958

4.064.074.144.344.344.404.62

21.321.822.523.423.825.227.0

111120129141149163183

306342366413448530624

. 4.05.06.07.08.0

10.012.0

16.018.819.320.822.525.028.0

460460460460460460460

64616058555146

4.244.304.624.694.805.205.40

22.824.225.927.329.833.037.5

129149168187211260308

392460540626688860

1032

41-41-103H

10


ENERGY REQUIREMENTS (Type CO-8 Inverse Time and CO-9 Very Inverse Time Relays)





AmpereRange Tap

ContinuousRating

(Amperes)

One SecondRating*

(Amperes)

PowerFactor

Angle φ

AtTap ValueCurrent

(∆ = 0.86)


(∆ = 0.88)



(∆ = 0.91)

0.5/2/5

0.50.60.81.01.52.02.5

2.73.13.74.15.76.87.7

88888888888888

72716967625753

2.382.382.402.422.512.652.74

21.021.021.121.222.023.524.8

132134142150170200228

350265400440530675800

2/6

2.02.53.03.54.05.06.0

8.08.89.7

10.411.212.513.7

230230230230230230230

70666462605856

2.382.402.422.482.532.642.75

21.021.121.522.022.724.025.2

136142149157164180198

30695430470500580

. 4.05.06.07.08.0

10.012.0

16.018.819.320.822.525.028.0

460460460460460460460

68636057544845

2.382.462.542.622.733.003.46

21.321.822.623.624.827.831.4

146458472192207248292

420480550620700850

1020

41-41-103H

11


ENERGY REQUIREMENTS (Type CO-11 Relay)





AmpereRange Tap

ContinuousRating

(Amperes)

One SecondRating*

(Amperes)

PowerFactor

Angle φ

AtTap ValueCurrent

(∆ = 0.86)


(∆ = 0.88)



(∆ = 0.91)

0.5/2/5

0.50.60.81.01.52.02.5

1.71.92.23.53.03.53.8

56565656565656

36343027221716

0.720.750.810.891.131.301.48

6.546.807.468.30

10.0411.9513.95

71.875.084.093.1

115.5136.3160.0

250267298330411502610

2/6

2.02.53.03.54.05.06.0

7.07.88.39.0

10.011.012.0

230230230230230230230

32302724232020

0.730.780.830.880.961.071.23

6.307.007.748.209.129.80

11.34

74.078.584.089.0

102.0109.0129.0

264285309340372430504

. 4.05.06.07.08.0

10.012.0

14161718202226

460460460460460460460

29252220181716

0.790.891.021.101.231.321.80

7.088.009.18

10.0011.1014.9016.30

78.490.0

101.4440.0124.8131.6180.0

296340378454480600720

41-41-103H

12


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Fig

ure

1:In

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al S

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atic

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ircui

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elay

, with

In

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ting

Inst

anta

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rip, i

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ype

FT

-21

Cas

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igur

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Inte

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Sch

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Circ

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Typ

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*619584Sub 1

Figure 3: Typical Time Curve of the Type CO-2 Relay

13


418245Sub 2


14


418246Sub 1


15


418247Sub 1


16


418248


17


418249Sub 1


18


288B655Sub 2


19


183A214Sub 1

Figure 10: Diagram of Test Connections for the Circuit Opening CO Relay in the Type FT-21 Case

20


183A213Sub 1

Figure 11: External Schematic of the Circuit Opening Type CO Relay for Phase Overcurrent Protection on a Three Phase System

21

41-41-103H

22


This Space Reserved for Notes

ABB Inc.4300 Coral Ridge DriveCoral Springs, Florida 33065Telephone: +1 954-752-6700Fax: +1 954-345-5329www.abb.com/substation automation

IL 4

1-10

3 - R

evis

ion

H

ABB

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