Instruction Manual

1. Product Overview

The ABB Tmax RC222/2 Differential Relay is a crucial component designed to enhance the safety and functionality of Tmax T2 circuit breakers. This residual current release module detects earth fault currents, providing protection against electrical shock and fire hazards by automatically tripping the associated circuit breaker when a fault is detected.

Figure 1: The ABB Tmax RC222/2 Differential Relay. This image displays the compact design of the residual current release, highlighting its integration with the Tmax circuit breaker series. It features clear labeling and robust construction, typical of industrial electrical components.

It is engineered for reliability and precision, ensuring compliance with international safety standards for electrical installations.

2. Safety Information

WARNING: Electrical installation and maintenance should only be performed by qualified and authorized personnel. Failure to follow these instructions can result in serious injury or death, and damage to equipment.

• Always disconnect power before installing, servicing, or removing the device.
• Ensure proper grounding of all electrical systems.
• Verify that the voltage and current ratings of the device match the system requirements.
• Do not operate the device if it appears damaged.
• Adhere to all local and national electrical codes and regulations.

3. Installation and Setup

The RC222/2 Differential Relay is designed for seamless integration with ABB Tmax T2 circuit breakers. Proper installation is critical for its effective operation and safety.

1. Preparation: Ensure the main power supply to the circuit is completely disconnected and locked out. Use appropriate personal protective equipment (PPE).
2. Mounting: Securely attach the RC222/2 module to the designated slot on the Tmax T2 circuit breaker. Refer to the circuit breaker's manual for specific mounting instructions.
3. Wiring: Connect the necessary wiring for the residual current detection as per the wiring diagram provided with your Tmax T2 circuit breaker and the RC222/2 module. Ensure all connections are tight and secure.
4. Testing: After installation, perform a functional test according to the circuit breaker's manual to verify the correct operation of the differential relay. This typically involves a test button on the device.

For detailed wiring diagrams and specific installation procedures, consult the comprehensive technical documentation provided by ABB for the Tmax T2 series and the RC222/2 module.

4. Operation

Once correctly installed and integrated with a Tmax T2 circuit breaker, the RC222/2 Differential Relay operates automatically to monitor for earth fault currents. It continuously compares the current flowing through the live and neutral conductors. In a healthy circuit, these currents should be equal.

• Fault Detection: If an imbalance occurs (indicating a leakage current to earth), the differential relay detects this anomaly.
• Tripping Mechanism: Upon detecting a fault current exceeding its set threshold, the RC222/2 sends a signal to the Tmax T2 circuit breaker, causing it to trip and interrupt the power supply, thereby preventing potential electrical hazards.
• Resetting: After a trip, the cause of the earth fault must be identified and rectified. Once the fault is cleared, the circuit breaker can be manually reset according to its operational instructions.

The device is designed for reliable, maintenance-free operation under normal conditions, acting as a critical safety component in your electrical system.

5. Maintenance

The ABB Tmax RC222/2 Differential Relay is designed for minimal maintenance. However, periodic checks are recommended to ensure continued optimal performance and safety.

• Visual Inspection: Periodically inspect the device for any signs of physical damage, discoloration, or loose connections.
• Test Button Operation: Most residual current devices include a test button. It is recommended to press this button periodically (e.g., monthly or quarterly) to verify that the tripping mechanism is functional. The circuit breaker should trip when the test button is pressed. If it does not, consult a qualified electrician.
• Cleaning: If necessary, gently clean the exterior of the device with a dry, soft cloth. Do not use abrasive cleaners or solvents. Ensure no moisture enters the device.
• Professional Inspection: For critical installations, consider scheduling periodic inspections by a qualified electrician to verify the device's calibration and overall system integrity.

6. Troubleshooting

If the ABB Tmax RC222/2 Differential Relay or the associated circuit breaker is not functioning as expected, consider the following troubleshooting steps:

• Frequent Tripping:
  • Cause: An actual earth fault in the circuit.
  • Solution: Disconnect all loads from the circuit and reset the breaker. Reconnect loads one by one to identify the faulty appliance or wiring. If the tripping persists with no loads, there might be an issue with the wiring itself or the device.
• Device Does Not Trip on Test:
  • Cause: The differential relay or the circuit breaker is faulty, or there is no power to the device.
  • Solution: Verify power supply. If power is present and the device still does not trip when the test button is pressed, the unit may be defective and requires replacement by a qualified electrician.
• No Power to Circuit:
  • Cause: The circuit breaker is tripped, or there is an upstream power issue.
  • Solution: Check the position of the circuit breaker handle. If tripped, attempt to reset it after ensuring no fault exists. Check the main power supply to the distribution board.

If you are unable to resolve an issue, or if you suspect a fault with the device, do not attempt repairs. Contact a qualified electrician or ABB technical support.

7. Specifications

The following specifications are for the ABB Tmax RC222/2 Differential Relay (RC222/2 FOR T2 4p F):

Figure 2: Technical Data Sheet for RC222/2 FOR T2 4p F. This image provides detailed technical specifications, including product type, order number, EAN, dimensions, weight, and compliance information, essential for proper selection and installation.

Note: Some dimensions and weights may refer to the packaging unit or specific components. Always refer to the official ABB documentation for the most precise and up-to-date specifications.

8. Warranty and Support

ABB products are manufactured to high-quality standards and typically come with a manufacturer's warranty against defects in materials and workmanship. The specific terms and duration of the warranty may vary by region and product type.

• Warranty Claims: For warranty-related inquiries or claims, please retain your proof of purchase and contact your authorized ABB distributor or reseller.
• Technical Support: For technical assistance, product information, or troubleshooting beyond the scope of this manual, please visit the official ABB website or contact ABB customer support in your region.
• Official ABB Website: www.abb.com

Always ensure that any service or repair work is carried out by ABB-certified technicians or authorized service centers to maintain product integrity and warranty validity.