ABB Pilot Devices: Installation and Safety Instructions

Safety Instructions

This document contains safety instructions and warnings in multiple languages, including English, Arabic, Bulgarian, Czech, Danish, German, Dutch, Greek, Spanish, Estonian, Finnish, French, Irish, Croatian, Hungarian, Italian, Lithuanian, Latvian, Maltese, Polish, Portuguese, Romanian, Slovak, Slovenian, Swedish, and Chinese. The primary safety message, presented in English, warns of hazardous voltage.

⚠️ Hazardous Voltage! Refer to installation instructions. Disconnect and lock out power before working on this device. Attention! Installation must be performed only by a person with electrotechnical expertise.

ABB shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer's application or use of the product. ABB will provide applicable third-party certification documents identifying ratings and limitations of use at the customer's request. This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product, machine, system, or other application or use. It is the responsibility of the user to ensure the correct overall functionality. While every effort has been taken to ensure the accuracy of the information contained in this manual, ABB cannot accept any responsibility for errors or omissions and reserves the right to make changes and improvements without notice. Performance data given in this document is provided as a guide for the user in determining suitability and does not constitute a warranty.

Product Overview

ABB offers a comprehensive range of pilot devices designed for modular and compact applications. This guide covers various series and configurations, including pushbuttons, selector switches, pilot lights, and emergency stops, along with their associated contact blocks, holders, and accessories.

Installation Guides

General Installation Principles

Installation involves mounting components such as contact blocks, actuators, and holders onto panels or enclosures. Key considerations include:

• Torque Specifications: Various torque values are specified for secure mounting, such as 0.9 Nm (8.0 lb in) for some locking nuts and contact blocks, 2.0-2.3 Nm (17.7-20.4 lb in) for actuators, and 0.7-1 Nm (6.2-8.8 lb in) for adaptors.
• Panel Thickness: Components are designed for specific panel thicknesses, commonly ranging from 1.5 mm to 6 mm (0.06" to 0.24").
• IP Ratings: Many components are rated IP20 for protection against solid objects.

MP, MPD, MPE, MPM, MTS, MJS Series (Modular Plastic Range)

These diagrams illustrate the assembly of modular pilot devices. Components include holders like MCBH-00 and MCBH5-00, contact blocks (MCB, MLBL), and actuators. Some diagrams show incompatible combinations using crosses (❌), such as not using a double MCB in the second layer or an MCB in the middle position. The series supports both non-illuminated and illuminated emergency stops.

M2SS, M3SS, M4SS, M2SSK, M3SSK Series

Installation for these series involves mounting contact blocks and actuators. A drilling plan table is provided, detailing dimensions (X, Y, D, B, C) for panel cutouts for various pushbutton types, including short handles, mushroom pushbuttons, double pushbuttons, and potentiometers. Panel cutout diameters typically range from Ø 22.3 mm to Ø 30.5 mm.

P9ML, P9MP, P9MS, P9MSC, P9MM, P9MC, P9MPS, P9XER4RAW, P9B, P9PL, P9PD Series (Modular Metal Range)

This section details the installation of modular metal pilot devices. It includes diagrams showing assembly steps and component configurations. A table specifies the maximum number of electrical contacts per holder type (e.g., Max 6 for standard momentary pushbuttons, Max 8 for optional). Drilling plans for the P9ML series are also provided, indicating panel cutout dimensions.

CP, C2SS, C3SS, CPM3, CL, CB, CE Series (Compact Range)

Installation for compact range pilot devices is shown, including mounting actuators and contact blocks using holders like MA1-8015 and MA1-8151. Torque and panel thickness specifications are provided. Drilling plan tables detail panel cutout dimensions for various functions like pushbuttons, selector switches, and emergency stops.

MEP, MEM, MEX Series (Plastic Enclosures)

These diagrams illustrate the installation of pilot devices within plastic enclosures. They show assembly with different mounting options, such as 'with back glue' and 'without back glue', using holders like KA1-8045 and MA5-XXXX series accessories. The MEP drilling plan provides dimensions for panel cutouts.

080SP Series (Metal Enclosures)

This section focuses on metal enclosures, detailing their installation with pilot devices. A comprehensive drilling plan table lists various enclosure sizes (1M, 2M, 4M, 6, 8, 12, 18, 24) and their corresponding hole counts, dimensions (A, B, C, D, E, F), and conduit entry types (PG 21, PG 29, PG 36). It also specifies that double level MCBs are only compatible with 1M, 2M, and 4M types.

CEP Series (Compact Plastic Enclosure)

Installation details for the CEP compact plastic enclosure are provided, showing the mounting of pilot devices using holders like MA1-8151, CA1-8053, and MA1-8015, along with associated accessories.

MDB Series (Contact Blocks)

This section illustrates the MDB contact blocks for both AC and DC applications. Simple circuit diagrams show their typical wiring configurations. The MDB-1001 is identified with part number 1SFA611630R1001.

BA9S, P9PDNV0, P9PDTVO, CL-100 (Lamp Replacement)

Instructions are provided for replacing lamps in specific pilot device models, showing the disassembly and reassembly steps.

DIN Rail Installation (MA1-8001, MA1-8131, CA1-8080, MDB-2)

These diagrams demonstrate the process of installing components, including contact blocks and enclosures, onto a standard DIN rail. They show how to attach various modules to the rail for system integration.

KA1-8027, KA1-8028, KA1-8029, KA1-8030 Series

Installation of pilot devices using these specific adaptors and holders is shown. The diagrams highlight the use of gaskets for different panel thicknesses (10 & 12 GA panels, 14 & 16 GA panels) to ensure proper sealing and IP performance.

30mm Adaptors

A step-by-step guide is provided for installing 30mm adaptors. This includes removing and reassembling bezels/adaptors, applying lubricant (silicon grease or motor oil) to the rubber membrane for IP performance, and tightening the locking nut to the specified torque (1.0 Nm / 8.86 lb in). It is noted that a circular hole with a rectangular key recess should not be used to maintain IP performance.

A product-to-adaptor cross-reference table is included:

EU Declaration of Conformity Statement

The product complies with the guidelines and standards given in the EU Declaration of Conformity. This statement is available in multiple languages, including English, Arabic, Bulgarian, Czech, Danish, German, Dutch, Greek, Spanish, Estonian, Finnish, French, Irish, Croatian, Hungarian, Italian, Lithuanian, Latvian, Maltese, Polish, Portuguese, Romanian, Slovak, Slovenian, Swedish, and Chinese.