Beruflich Dokumente
Kultur Dokumente
VD4G
Installation and operating instructions
15 kV - 1250... 3150 A - 25...40 kA
Contents
I. Foreword 2
2. Checking on receipt 4
3. Storage 5
4. Handling 6
5. Description 7
7. Installation 30
9. Maintenance 36
1
I. Foreword II. Environmental protection
program
This publication contains the information required to install VD4G circuit-breakers are manufactured in accordance
VD4G medium voltage circuit-breakers and put them into with ISO 14000 Standards (Guidelines for environmental
service. management).
Please read the manual carefully to ensure that the product is The manufacturing processes are implemented in
used correctly. accordance with the environmental protection standards
Similarly to all the apparatus we manufacture, VD4G circuit- when it comes to reducing both energy consumption and the
breakers are designed for different installation configurations. production of waste. All this is thanks to the environmental
They can therefore undergo further technical-construction management system applied in the medium voltage apparatus
modifications (at the customer's request) so as to adapt them manufacturing facility.
to special installation requirements.
Consequently, the manual may not contain instructions
concerning special customized configurations.
This means that, besides this manual, it is always necessary
to consult the latest technical documentation (circuit and
wiring diagrams, assembly and installation drawings, any
protection coordination studies, etc.), especially regarding any
variants requested in relation to the standard configurations.
Only use original spare parts for maintenance operations.
Please also consult the technical catalog of the circuit-breaker
and the spare parts catalog for further details.
2
1. Packing and transport
3
2. Checking on receipt
Fig. 1
4
3. Storage
5
4. Handling
Before proceeding with any operation, always make sure that When handling the apparatus, take great care to prevent
the spring of the operating mechanism is discharged and that the insulating parts and terminals of the circuit-breaker from
the apparatus is in the open position. being stressed.
Proceed as follows to lift and handle the circuit-breaker (fig. 2):
use suitable lifting equipment (1) (not supplied) with ropes
and safety hooks (2);
insert the hooks (2) into the supports (3) fixed to the frame Do not handle the apparatus by inserting lifting
of the circuit-breaker and lift. Insert hooks (2) into holes in devices directly under it. If this technique is
support (3), depending on the type of apparatus (see table); unavoidable, place the circuit-breaker on a pallet
once the operation has terminated (and in any case before or a sturdy supporting surface (see fig. 3).
putting into service), release the lifting equipment (1) and In any case, it is always advisable to lift the
remove the supports (3) from the frame. apparatus by means of the supports (3).
C B A
3
1
3
Pole center
Versione Rated current Hole
distance
Fixed 150-210 mm 1,250 A A
Fixed 275 mm up to 3150 A A
Fixed 210 mm 2,000 A A
Fixed 275 mm 4,000 A C
Withdrawable 150 mm 1,250 A A
Withdrawable 210 mm 2,000 A B
Withdrawable 275 mm up to 3150 A C
Withdrawable 275 mm 4,000 A C
Fig. 2
Fig. 3
6
5. Description
withdrawable for UniGear ZS1 switchgear. EL1 TWIN 40 kA (up to 2000 A rated current)
EL2 TWIN 40 kA ( 2500 A rated current)
1 4
5
6
11
8
3
7
10
Key
1 Lever for manual loading of closing spring
2 Signaling device for circuit-breaker open/closed
3 Rating plate
4 Opening pushbutton
5 Closing pushbutton
6 Signaling device for closing spring loaded/discharged
7 Operation counter
8 Terminals
9 Earthing screw
10 Delivery terminal box
11 Wiring connection
Fig. 4
7
5.4.1. General characteristics of fixed circuit-breakers
8
VD4G 15 kV fixed circuit-breaker
Ur Isc Rated interrupted current (40C) [A]
H = 461 H = 610 H = 636 H = 636
Type of circuit-breaker
D = 424 D = 459 D = 459 D = 459
kV kA
P = 150 P = 210 P = 275 P = 275
W = 450 W = 600 W = 750 W = 750
25 1250 VD4G-25 15.12.25 p150
40 2000 VD4G-40 15.20.40 p210
15
40 2000 VD4G-40 15.20.40 p275
40 3150 (1) VD4G-40 15.32.40 p275
(1) 4000 A with forced ventilation
9
5.5. Withdrawable circuit-breakers
Withdrawable circuit-breakers up to 15 kV are available for The locks can only be operated by the handles when the
UniGear ZS1 switchgear. truck rests completely against the cross-beam.
They consist of a truck to which the bearing structure of the The operating lever (15) must be inserted to its full extent (see
actual circuit-breaker is fixed. sect. 7.5.). A lock prevents the truck from advancing into the
enclosure or fixed part when the earthing switch is closed.
Circuit-breakers for UniGear ZS1 switchgear (fig. 5a) Another lock prevents racking-in/out when the circuit-breaker
The cord with plug (13) for connecting the electrical is closed. When the truck is in the intermediate position,
accessories of the operating mechanism comes out of the between disconnected and connected, a further lock (both
upper part of connector (14). mechanical and electrical) prevents the circuit-breaker from
Strikers for operating the contacts (connected/disconnected) closing.
in the switchgear are fixed to the upper part of the circuit- The truck is also fitted with a locking magnet which, if de-
breaker. energized, prevents the truck from being racked-in.
Slides (9) for operating the segregation shutters of the An interlock is available on request to prevent the circuit-
medium voltage contacts in the enclosure or switchgear are breaker from being racked-in when the door is open and the
fixed at the sides of the circuit-breaker. Circuit-breakers for door from being opened when the circuit-breaker is closed.
UniSec switchgear have wheels (17) for this purpose. The lever for loading the closing spring (1) in the manual mode
The front part of the circuit-breaker truck has a cross-beam is built into the operating mechanism. The spring is loaded by
with handles (16) which latches onto the circuit-breaker when repeatedly lowering the lever by linear movements until the
this is racked-in/out by means of the operating lever (15). yellow indicator (6) appears to show that loading is complete.
The circuit-breaker is complete with disconnection contacts The spring can only be loaded with the switchgear door
(8). open. Comply with the instructions in the UniGear switchgear
The withdrawable circuit-breaker has locks on the front cross- manual for the operations that can be performed with the
beam allowing it to be latched into the corresponding slot-in door open.
joints of the switchgear.
12
13 17
14
4
1 5
16
6
2
3
7
9
8 11
16 10
Fig. 5a
10
16 19 20 22 21
Fig. 5c
23 30 29
Fig. 5d
11
5.4.2. Types of fixed circuit-breakers available
12
5.4.3. Types of withdrawable circuit-breakers available for UniGear ZS1 switchgear
13
5.6. Characteristics of the electrical accessories
Allows the device to be opened by remote control. This Similarly to shunt opening release -MBO1, this allows the
release is suitable for both instantaneous and permanent duty. opening command of the apparatus to be transmitted by
However, an auxiliary contact -BGB1 de-energizes it after remote control. It can be energized by the same circuit as
the circuit-breaker has opened. In the case of instantaneous main shunt opening release -MBO1 or by a circuit completely
service, the current impulse must last at least 100 ms. separate from release -MBO1.
This release can be controlled by the following devices: coil This release is suitable for both instantaneous and permanent
continuity control (CCC), opening circuit supervision (TCS)(*) duty. However, an auxiliary contact -BGB1 de-energizes it
or the ABB STU functionality control device (see accessory after the circuit-breaker has opened.
21, supplied on request). To guarantee the release action, the current impulse must last at
least 100 ms.
Characteristics Continuity functionality can be checked with a continuity control
Un 48 - 110 ... 125 - 220 ... 250 Vcc device (CCC), opening circuit supervision device (TCS)(*) or the
Un 110 ... 125 - 220 ... 250 VAC STU functionality control device (see accessory 21, supplied on
in accordance with IEC/IEEE 62271-37- request).
Operating limits
013
Power at inrush (Ps) 60...100 W / VA
-MBO2 has the same electrical and operating characteristics as
Holding power (Pc) 1.5 W
release -MBO1.
Electronics self-consumption
(no coil supplied);
1.5 mA
value independent of voltage
applied
Opening time 33...60 ms
Insulation voltage 2000 V 50 Hz (for 1 min)
(*) The minimum current that the relay with TCS function (used for monitoring coil
continuity) detects as a condition denoting that the trip circuit is operating correctly
(specified for each relay in the relative manual), must be sensibly higher than the
current consumption of the actual coil (~1.5 mA).
If this fails to occur, always add, in parallel to the TCS, a circuit able to absorb
sufficient current to compensate the gap while preventing the total current in the TCS
circuit from rising above the maximum threshold (Itcs < 10 mA for High Voltage coils
- from 110V to 250V, and Itcs < 50 mA for Low Voltage coils from 24 V to 60 V).
A simple resistor can be sized for the purpose, depending on the parameters of the
TCS and the auxiliary voltage range used.
14
3 Opening solenoid (-MBO3) 4 Shunt closing release (-MBC)
The opening solenoid (-MBO3) is a special demagnetizing Allows the device to be closed by remote control.
release for use in conjunction with self-supplied overcurrent This release is suitable for both instantaneous and permanent
protection relays. duty. An auxiliary contact to de-energize it after the circuit-
It is situated in the operating mechanism (in the left-hand breaker has closed is not envisaged.
side) and is not an alternative to the additional shunt opening The permanently supplied release provides the electrical anti-
release (-MBO2). pumping function with both electrical opening and re-closing
It is only available for VD4G-25 circuit-breakers. commands maintained. To guarantee the closing action, the
If this accessory is required, it must be specified when current impulse must last at least 100 ms.
ordering since it cannot be installed by the customer at a later If there is the same supply voltage for shunt closing release
date. -MBC and under-voltage release -MBU and the circuit-breaker
Note: ask for document: Data sheet 1VCD600854. must close automatically when auxiliary voltage returns, there
must be a delay of at least 50 ms between under-voltage
The opening solenoid (-MBO3) is available in two versions: release energizing and energizing of the shunt closing release
For D.C. (release by discharging energy stored in protection to allow the closing operation to take place.
relay against overcurrent of the self-supplied type) Continuity functionality can be checked with a continuity control
For A.C. (release by means of energy supplied by an adder device (CCC), opening circuit supervision device (TCS)(*) or the
transformer on the secondaries of the protection current STU functionality control device (see accessory 21, supplied on
transformers) (the adder CT is at the customer's charge) request).
Characteristics
Un 48 - 110 ... 125 - 220 ... 250 Vcc
Un 110 ... 125 - 220 ... 250 VAC
in accordance with IEC/IEEE 62271-37-
Operating limits
013
Power at inrush (Ps) 60...100 W / VA
(*) The minimum current that the relay with TCS function (used for monitoring coil Holding power (Pc) 1.5 W
continuity) detects as a condition denoting that the trip circuit is operating correctly Electronics self-consumption
(specified for each relay in the relative manual), must be sensibly higher than the (no coil supplied);
current consumption of the actual coil (~1.5 mA). 1.5 mA
value independent of voltage
If this fails to occur, always add, in parallel to the TCS, a circuit able to absorb
applied
sufficient current to compensate the gap while preventing the total current in the TCS
circuit from rising above the maximum threshold (Itcs < 10 mA for High Voltage coils Opening time 33...60 ms
- from 110V to 250V, and Itcs < 50 mA for Low Voltage coils from 24 V to 60 V).
Insulation voltage 2000 V 50 Hz (for 1 min)
A simple resistor can be sized for the purpose, depending on the parameters of the
TCS and the auxiliary voltage range used.
15
7a Auxiliary contacts of circuit-breaker (-BGB1) for 15
kV versions
obtained with a group of 10, 16 or 20 auxiliary contacts Insulation voltage 660 V A.C.
to VDE 0110 standards, Group C 800 V D.C.
for the fixed version and 10 or 16 auxiliary contacts for the
withdrawable version. The standard equipment comprises 10 Rated voltage 24 V ... 660 V
The following are available with the standard group of ten Breaking capacity Class 1 (IEC 62271-1)
for fixed circuit-breakers: three closing contacts "a" for Contact travel 90
signaling circuit-breaker open and five opening contacts "b" Actuating force 0.66 Nm
for withdrawable circuit-breakers: three closing contacts "a" Storage temperature -30 C ... +120 C
for signaling circuit-breaker open and four opening contacts Operating temperature -20 C ... +70 C (-30 ref. ANSI 37.09)
"b" for signaling circuit-breaker closed; Contact overtemperature 10 K
Mechanical life 30,000 mechanical operations
Circuit-breakers in the fixed version are available with two Protection class IP20
finishing accessories (to be specified when ordering): Cable section 1 mm2
non-wired auxiliary contacts; wiring to the terminals of the
contacts is at the customer's charge (photo below left; Electrical specifications (according to IEC 60947)
the terminal box to which the other electrical accessories Rated voltage Un Breaking capacity (10000 breaks)
are wired is at the top); ask for instructions 1VCD601204 220 V A.C. Cosj = 0.70 20 A
(available in the main languages) which describe how to 220 V A.C. Cosj = 0.45 10 A
remove, wire the auxiliary contact more easily and fit the 1 ms 12 A
group of auxiliary contacts back in place; 24 V D.C.
15 ms 9A
auxiliary contacts already wired to the terminal box (see 50 ms 6A
photo at top right) 1 ms 10 A
Consult circuit diagrams 1VCD400151 for fixed circuit- 60 V D.C.
15 ms 6A
breakers and 1VCD400155 for withdrawable circuit-breakers. 50 ms 4.6 A
1 ms 7A
Note: The main shunt opening release and/or the additional 110 V D.C. 15 ms 4.5 A
shunt opening release use 1 and/or 2 closing contacts "a", 50 ms 3.5 A
thereby reducing the number of auxiliary contacts available. 1 ms 2A
Always check the maximum number of contacts available with 220 V D.C. 15 ms 1.7 A
non-standard equipment. 50 ms 1.5 A
Auxiliary contacts BGB1 conform to the following standards/ 1 ms 2A
regulations/directives: 250 V D.C. 15 ms 1.4 A
IEC 62271-100 50 ms 1.2 A
IEEE C37.54
EN 61373 cat.1 class B / impact and vibration test Electrical specifications (according to IEC 62271-100 class 1)
Germanish Loyd regulation / vibrations envisaged by the Rated voltage Un Breaking capacity
16
8 Transient contact (-BGB4) 9 Position contact (-BGT3)
This contact closes momentarily (for > 30 ms) upon It is used in conjunction with the locking magnet in the operating
circuit-breaker opening by remote control or by means of a mechanism (-RLE1) to prevent remote closing during movement
shunt opening release. in the cubicle.
The indication is not given when opening is manual and local. It is only supplied for the withdrawable circuit-breaker version for
In this case, a contact (BGB11) is activated by the manual UniGear ZS1 switchgear and PowerCube modules.
pushbutton and cuts out the closing indication of the transient It cannot be supplied when transmitted contacts in the truck are
contact (BGB4). required (-BGT1; -BGT2).
The transient contact is activated by the main operating shaft,
thus the indication is only provided when the main contacts of
the circuit-breaker effectively open.
17
11 Motor operator (-MAS) 12 Closing spring loaded/discharged signaling
contacts (-BGS2)
Automatically loads the closing spring of the circuit-breaker's Consists of a microswitch allowing remote signaling of the
operating mechanism. Once the circuit-breaker has closed, state of the closing spring of the circuit-breaker operating
the motor immediately begins to reload the closing spring. mechanism.
The closing spring can still be loaded in the manual mode The following settings can be obtained:
(using the relative lever built into the operating mechanism) in contact open: spring loaded signal
a power failure or during maintenance work. contact closed: spring discharged signal
The two signals must be used for circuits with the same
energizing voltage.
Characteristics
Un 48 - 110 ... 125 - 220 ... 250 Vcc
Un 110 ... 125 - 220 ... 250 VAC
Operating limits in accordance with IEC/IEEE 62271-37-013
VD4G-25 VD4G-40
Power at inrush (Ps) D.C. = 600 W; D.C. = 900 W;
A.C. = 600 VA A.C. = 900 VA
D.C. = 200 W; D.C. = 350 W;
Rated power (Pn)
A.C. = 200 VA A.C. = 350 VA
Inrush time 0.2 s 0.2 s
Loading time 6-7 s 6-7 s
2000 V 50 Hz 2000 V 50 Hz
Insulation voltage
(for 1 min) (for 1 min)
18
Protections and locks
Various different mechanical and electromechanical protection devices and locks are
available.
15 Locking magnet on truck (-RLE2) 16 Interlock for fixed circuit-breaker
This accessory is mandatory in withdrawable versions for Device for fixed circuit-breakers converted into plug-in by the
UniGear ZS1 switchgear and PowerCube modules to prevent customer. Allows the customer to create a mechanical lock
the circuit-breaker from being racked into the switchgear that inhibits racking-out/racking-in when the circuit-breaker
when the plug of the auxiliary circuits is disconnected. is closed and prevents the circuit-breaker from closing during
The plug also creates an anti-insertion lock against different movement.
rated currents. Striker pins prevent the plug from being NOTE. The device must be requested when the order is
plugged into the socket if the circuit-breaker's rated current is placed since it must be assembled in the factory.
lower than the rated current of the panel.
Note: a specific version for the circuit-breakers of ZS8.4
switchgear is available on request. This accessory
is not available when the motor-operated truck is
required.
Characteristics
Un 48 - 110 ... 125 - 220 ... 250 Vcc
Un 110 ... 125 - 220 ... 250 VAC
in accordance with IEC/IEEE 62271-37-
Operating limits
013
Power at inrush (Ps) D.C. 250 W; A.C. = 250 VA
Continuous power (Pc) D.C. = 5 W; A.C. = 5 VA
Inrush time 150 ms
Insulation voltage 2000 V 50 Hz (for 1 min)
19
17 Mechanical door interlock 18 Motor-operated truck (-MAT)
This device prevents the circuit-breaker from being racked Allows the circuit-breaker to be racked in and out of the
in when the switchgear door is open. It can only be used switchgear by remote control (only for circuit-breakers in the
for circuit-breakers installed in UniGear ZS1 switchgear and withdrawable version for UniGear ZS1 and ZS8.4 switchgear
PowerCube modules equipped with the relative actuator on and PowerCube modules).
the door. The motor-operated version with clutch can be ordered on
request, so that racking-in/out can be performed in an emergency
if the truck motor fails to operate.
Characteristics
Un 24 - 30 - 48 - 60 - 110 - 220 V
Operating limits 85 110% Un
Rated power (Pn) 40 W
20
19 STU Shunt Test Unit
There are two change-over relays on the unit that allow these
Device for monitoring functionality and continuity of shunt two events to be signaled in the remote mode:
opening/closing releases. test failed (resetting occurs automatically once the alarm
Owing to their particular construction, the functionality of the has ceased)
shunt closing (-MBC) and opening releases (-MBO1, -MBO2) failure of three tests (resetting only occurs by means of the
cannot be tested with dedicated relays (e.g. TCS Test Control manual - RESET - on the front of the unit)
Supervision, CCC Control Coil Continuity) or with the REF
monitoring and protection unit. The only device able to test A manual - RESET - key is also installed on the front of the
this functionality is the STU device. Please contact us if this unit.
test must be performed with devices other than STU.
The STU device can be used in conjunction with the shunt Characteristics
opening release (-MBO1; -MBO2) or shunt closing release Un 24 ... 250 V A.C./D.C.
(-MBC) for functionality and continuity tests. Maximum interrupted current 6A
Maximum interrupted voltage 250 V A.C.
The Shunt Test Unit for testing/monitoring is used to test the
21
6. 1Instructions for circuit-breaker operation
4 5
2
6 7
10
9 8
Key
1 K ey lock (if applicable) (*)
2 L ever for manual loading of closing spring
3 Lever seat for racking-out operation (only for withdrawable circuit-breakers)
4 O pening pushbutton
5 C losing pushbutton
6 S ignaling device for circuit-breaker open/closed
7 Signaling device for closing spring loaded/discharged
8 O peration counter
9 H andles for operating truck locks (only for withdrawable circuit-breakers)
10 O perating lever for circuit-breaker racking-in/out
(*) Warning! To activate the key lock: open circuit-breaker, press and hold opening pushbutton, then turn key and remove it from its seat.
Fig. 6a
22
6.2. Operating and signaling b) Electrical spring loading operation
On request, the circuit-breaker can be fitted with the following
components accessories for electrical operation:
VD4G circuit-breakers for UniGear switchgear and PowerCube gearmotor for automatic loading of closing spring
modules (fig. 6a) shunt closing release
shunt opening release.
The gearmotor automatically reloads the spring after each
6.3. Circuit-breaker closing and closing operation until the yellow indicator appears (7).
opening operations If there is a power failure during the loading operation, the
gearmotor stops and automatically continues to load the
The mechanical operating mechanism can be manually or spring once the power returns.
electrically closed, opened and loaded (fig. 6 - fig. 7). However, it is always possible to complete the loading
operation in the manual mode.
a) Manual loading of closing spring for VD4G circuit-
breakers for UniGear switchgear (fig. 7a) c) Circuit-breaker closing
Repeatedly operate the loading lever (2) (the lever's maximum This operation can only be performed when the closing spring
angle of rotation is about 90) until the yellow indicator is fully loaded.
appears (7). Press the pushbutton (5 - fig. 6a) to close the circuit-breaker
Maximum force that can normally be applied to the lever: in the manual mode.
<200 N for operating mechanism EL2. When there is a shunt closing release, the operation can also
Operating mechanisms type EL1 Twin and EL2 Twin are be carried out in the remote mode by means of the special
used for circuit-breakers with 40 kA breaking capacity. Make control circuit. Effective closing is signaled by the indicator
sure the additional lever (1) is fully inserted when loading (6 - fig. 6b).
in the manual mode, as indicated in fig. 7c. In this way, the
maximum force applied is < 200 N. d) Circuit-breaker opening
The type of operating mechanism is indicated on the rating Press the pushbutton (4 - fig. 6a) to open the circuit-breaker
plate of fig. 1 in the manual mode.
When there is a shunt opening release, the operation can also
be carried out in the remote mode by means of the special
control circuit. Effective opening is signalled by the indicator
(6 - fig. 6a).
23
90
Fig. 7a
Fig. 7b
24
7. Installation
7.1. General information
Correct installation is of primary importance. The 7.2.2. Special conditions
manufacturer's instructions must be carefully studied Installations over 1000 m a.s.l.
and followed. It is good practice to use gloves, Possible, within the limits allowed by the reduction in the dielectric
protection for the eyes, head and lower limbs when strength of the air.
handling the components during the installation work. Increase in ambient temperature
Reduction in the rated current.
7.2. Installation and operating Facilitate heat dissipation by use of appropriate additional ventilation.
conditions Climate
To avoid the risk of corrosion or other damage in areas:
It is particularly important to comply with the
with a high level of humidity, and/or
following regulations during installation and operaton: rapid and extensive temperature variations, take appropriate steps
IEC 62271-1/DIN VDE 0101 (for example, by using electric heaters) to prevent condensation from
forming.
VDE 0105: Operation of power installations
DIN VDE 0141: Earthing systems for installations with rated
voltage above 1 kV. Please contact ABB for special installation requirements or
All the accident prevention regulations in force in the other types of operating conditions.
respective countries.
The areas through which power conductors or auxiliary
7.2.1. Normal conditions circuit conductors are routed must be protected
Comply with the recommendations in standards IEC against access by animals, as this could lead to
62271-1 damage or disservice.
and 62271-100, i.e.:
Ambient temperature
Maximum + 40 C
Average maximum over 24 hours + 35 C
Minimum (according to class 5),
5
apparatus for indoor installation
Humidity
The average relative humidity value measured for more than 1 month
must not exceed 95%
The average water vapor pressure value measured for more
24 hours must not exceed 2.2 kPa.
The average relative humidity value measured for more than 1 month
must not exceed 90%
The average water vapor pressure value measured for more
than 1 month must not exceed 1.8 kPa.
Altitude
< 1000 m above sea level.
25
7.3. Preliminary operations When the circuit-breaker has reached the isolated for test/
isolated position, it can be considered to have been racked
Clean insulating parts with clean dry rags. into the switchgear and earthed by means of the truck
Make sure that upper and lower terminals are clean and wheels.
free of any deformation caused by shocks received during Withdrawable circuit-breakers of the same version, thus of the
transport or storage. same size, are interchangeable. However, when, for example,
the electrical accessories are different, the plug of the auxiliary
circuits will have a different code and prevent panels and
7.4. Installation of fixed circuit-breakers circuit-breakers from being wrongly paired.
The technical documentation of the switchgear should also be
The circuit-breaker can be installed straight onto bearing consulted when installing the circuit-breakers.
frames provided by the customer or on special bearing trucks
(available on request). The racking-in/out operations must always be
Circuit-breakers with bearing trucks must be fastened to the performed with the circuit-breaker open.
floor of their compartment at the customer's charge. The When putting into service for the first time,
floor surface where the truck wheels slide must be perfectly always load the circuit-breaker operating
leveled. mechanisms in the manual mode to avoid
A minimum degree of protection (IP2X) must be guaranteed overloading the auxiliary supply circuit.
from the front towards live parts.
7.5.1. Circuit-breakers with motor-operated withdrawable
7.4.1. Assembly of circuit-breakers on trucks provided by trucks
third parties Perform the racking-in/out test for the motor-operated truck
VD4G circuit-breakers that are not installed on ABB trucks in the same way as the manual truck and comply with the
but on trucks provided by the customer must be equipped following instructions:
with one or two additional auxiliary contacts (operated by the Rack the circuit-breaker into the switchgear in the open and
mechanical lock or release device of the circuit-breaker) which isolated position, with the supply circuit of the motor de-
interrupt the circuit of the shunt closing release (-MBC) during energized and the enclosure door closed.
movements to and from the isolated position. Fit the manual racking-in lever (1) into its seat (2) Fig. 9
This function is performed on ABB trucks by auxiliary contacts and move the motor-operated truck to about halfway along
-BGT1 and -BGT2, which shut off the power supplied to the its travel, between the isolated for test and connected
release during and before activation of the mechanical lock of positions. The torque required to move the truck is < 25
the truck's screw insertion device. This means that power can Nm.
only be supplied to the shunt closing release after activation This operation allows you to deal with movements in the
of the mechanical lock. No electrical impulse is therefore able wrong direction without damage should the polarity of the
to activate the shunt closing release when the circuit-breaker truck motor supply accidentally reverse. Verifications:
is in the intermediate position.
a) clockwise motor rotation when circuit-breaker is racked in.
b) counter-clockwise motor rotation when circuit-breaker is
7.5. Installation of withdrawable circuit- racked out.
Remove the manual lever (1) from its seat (2) Fig. 9
breakers Energize the truck motor circuit.
Activate the operating mechanism for electrical racking-in.
The withdrawable circuit-breakers are designed for use in After racking-in, make sure that the relative auxiliary contact
UniGear ZS1 switchgear. has switched correctly.
To rack the circuit-breaker in and out of the switchgear, fully At the end of the sequence, activate the operating
insert the lever (1) (fig. 9) into its seat (2) and turn it clockwise mechanism for electrical racking-out. After racking-out,
to rack-in or counter-clockwise to rack-out until reaching the make sure that the relative auxiliary contact has switched
end of travel positions. The circuit-breaker must be gradually correctly.
racked-in and out to avoid shocks that could deform the If a motor fault occurs during a racking-in or out operation,
mechanical interlocks and limit switches. the truck can be moved to end of travel in an emergency
The torque normally required for racking-in and out is < 25 by first shutting off the voltage supplied to the motor supply
Nm. circuit and then using the manual lever in the same way as
Never exceed this value. If the operations are obstructed in for truck operation in the manual mode.
any way or difficult to perform, do not apply force but check
that the operating sequence is correct. Note
When the manual lever is used to operate the truck, the chain transmission
turns the truck motor which, by acting as a generator, can produce reverse
Note
voltage towards the connection terminals.
To complete the racking-in or out operations, the lever must be turned about 20
Since this can damage the permanent magnet of the motor, all truck racking-in
times for circuit-breakers up to 17.5 kV and about 30 times for 24 kV circuit-
and out operations with the manual lever must be performed with the motor
breakers.
circuit de-energized.
26
Racking-in
Max 25 Nm
Racking-out
Fig. 9
Make sure that the contact surfaces of the connections Clean with a metal brush or emery cloth.
are perfectly flat and without burrs, traces of oxidation or Immediately smear neutral grease over the contact surfaces.
deformities caused by drilling or impact sustained. Insert a bi-metal copper-aluminum strip with dressed surfaces between
the aluminum connection and copper terminal (copper side touching the
The operations indicated in the following table T1 must terminal, aluminum side touching the connection).
be performed on the contact surface of the conductor,
depending on the conductive material used and the surface T2
treatment given. Bolt Recommended tightening torque (1)
Without lubricant With lubricant (2)
Assembly procedures M6 10.5 Nm 4.5 Nm
Put the connections in contact with the circuit-breaker M8 26 Nm 10 Nm
terminals. Take care to avoid mechanical stress (tensile / M10 50 Nm 20 Nm
compressive) exercised, for example, by the busbars on the M12 86 Nm 40 Nm
terminals themselves. M16 200 Nm 80 Nm
Insert a spring washer and flat washer between the bolt
head and connection. (1) The nominal tightening torque is based on 0.14 thread friction coefficient (distributed
value to which the thread is subjected and which, in some cases, is not negligible).
Use of DIN class 8.8 standard bolts is recommended. Refer The nominal tightening torque with lubricant complies with DIN 43673 Standards.
also to the indications in table T2. (2) Oil or grease. Lubricated thread and surfaces in contact with head. Bear in mind
the deviations from the general Standards table (e.g. for systems in contact or
In the case of cable connections, carefully comply with the terminations) as established in the specific technical documentation. The thread and
manufacturer's instructions when making the terminations. surfaces in contact with bolt heads must be slightly oiled or greased, so as to obtain
a correct nominal tightening torque.
27
7.7. Earthing
connection (2) while outside the circuit-breaker, they must be
The fixed version of these circuit-breakers is earthed by screened by an appropriate sort of metallic protection (tube,
means of the dedicated screw identified by the relative duct, ...), which must be earthed.
symbol. Clean and degrease the area around the screw over a
diameter of about 30 mm and, after assembly, cover the joint 7.8.2.Withdrawable circuit-breaker
with Vaseline grease. The auxiliary circuits of the withdrawable circuit-breaker are
Use a conductor (busbar or braid) with a cross-section fully wired in the factory through to the connector (fig. 11).
conforming to the Standards in force. Refer to the circuit diagram of the switchgear for the external
connections.
7.8. Connection of auxiliary circuits
Note: the minimum cross-section of the wires used for the
auxiliary circuits must not be less than the section used for
internal cabling. The wires must also be insulated for 3 kV test
voltage.
Fig. 10a
1 2
28
8. Putting into service
8.1. General procedures Perform the following operations before putting the circuit-
breaker into service:
All the operations for putting into service must be make sure that the power connections to the circuit-breaker
performed by ABB personnel or by the customer's terminals are tight;
adequately qualified personnel with detailed establish the setting of the electronic primary overcurrent
knowledge of the apparatus and installation. release (if applicable);
If the operations are obstructed, do not force the make sure that the value of the voltage supplied to the
mechanical interlocks but check that the operating auxiliary circuits is between 85% and 110% of the rated
sequence is correct. voltage of the electrical applications;
The operating forces to apply when racking-in make sure that there are no foreign bodies, such as bits of
withdrawable circuit-breakers are indicated in packing, between the moving parts;
section 7.5. to avoid overtemperatures, make sure that there is a
sufficient exchange of air in the installation site;
also perform the inspections indicated in table T3.
29
T3
COMPONENT INSPECTED PROCEDURE POSITIVE CHECK
1 Insulation resistance. Medium voltage circuit
Using a 2500 V Megger, measure insulation resistance between The insulation resistance should be at least 50
phases and earth of circuit. Mohm and in any case, constant over time.
Auxiliary circuits
Using a 500 V Megger (installed equipment permitting), measure The insulation resistance should be a few
insulation resistance between auxiliary circuits and earth. Mohm and, in any case, constant over time.
2 Auxiliary circuits. Make sure that connections to control circuit are correct: Operations and signals are normal.
proceed with relative power supply.
3 Manual operating mechanism. Perform a few closing and opening operations (see chap. 6). The operations and relative signals take place
NOTE. Supply undervoltage release and locking magnet on correctly.
operating mechanism at the relative rated voltage (if applicable).
4 Motor operator Supply spring loading gearmotor at the relative rated voltage. Spring is loaded correctly.
(if applicable). Signals are normal.
Gearmotor stops when springs have been
loaded.
Perform a few closing and opening operations. Gearmotor reloads springs after each closing
NOTE. Supply undervoltage release and locking magnet on operation.
operating mechanism at the relative rated voltage (if applicable).
5 Undervoltage release (if Supply undervoltage release at relative rated voltage and Circuit-breaker closes correctly.
provided). perform circuit-breaker closing operation. Signals are normal.
11 Locking electromagnet on Attempt to rack-in circuit-breaker with circuit-breaker open, Racking-in fails to occur.
circuit-breaker truck (-RLE2) (if in isolated for test position and locking electromagnet de-
applicable). energized.
Energize locking electromagnet and perform racking-in Racking-in occurs correctly.
operation.
12 Transmitted auxiliary contacts Connect auxiliary contacts to suitable signaling circuits. Signals due to the operations occur normally.
for signaling circuit-breaker With circuit-breaker racked-in to enclosure, perform a few
connected, disconnected operations from isolated for test position to connected position.
(UniGear switchgear or Move circuit-breaker to withdrawn position.
PowerCube modules).
30
9. Maintenance
The purpose of maintenance is to keep the apparatus in a racking-in/out can be performed up to 1000 times if the
good working condition for as long as possible. operations are carried out correctly (as required by standard
The following operations must be performed in accordance IEC 60271-200);
with the specifications given in standards IEC 61208 / DIN 31 the operating life data are basically applicable to all
051: components that are not directly influenced by the
Inspection: Finding out the actual conditions operator's tasks. The behavior of components operated in
Servicing: Measures to be taken to maintain the specific the manual mode (moving components of disconnectable
conditions parts, etc.) can vary.
Repair: Measures to be taken to restore the specific
conditions. 9.2. Inspections and functionality tests
9.2.1. Pole and conductive parts
9.1. General information Regularly inspect the conditions of the conductive parts.
Inspection at fixed intervals can be avoided when the
Vacuum circuit-breakers are characterized by simple, sturdy apparatus is permanently under the control of qualified
construction and long life. personnel.
The operating mechanism requires functional inspections and Firstly, the assessments must include visual inspection
maintenance if it is to remain operative throughout its forecast to check for any contamination, traces of corrosion or
life cycle (see sect. 9.3.2.). electrical discharge.
The vacuum interrupters are maintenance-free for their whole Perform more frequent inspections when there are unusual
operating life. operating conditions (including severe climatic conditions)
Vacuum interruption does not produce harmful effects even and in the case of environmental pollution (e.g. high level of
when there are frequent interruptions in the rated and short- contamination or an aggressive atmosphere).
circuit current. Visual inspection of the isolating contacts. If there are tulip
Interventions during service and their purpose are determined contacts, remember to turn them alternately in order to
by the ambient conditions, the sequence of operations and keep the internal surface of the conduction areas clean.
shortcircuit interruptions. The contact areas must be cleaned when there are signs of
Note overheating (discolored surface) (also consult the Repairs
Comply with the following regulations for maintenance work: section).
the relative specifications given in the chapter on Standards and
Specifications;
the labor safety regulations in the chapter on Putting into service and
operations;
the standards and specifications in force in the country where the apparatus
is installed.
31
Functional test
Make sure that the electrical and mechanical operation of
Carry out a few opening and closing operations with the the various devices is correct, especially the interlocks.
circuit-breaker disconnected from the load. The screws and nuts are tightened in the factory and
If required, cut off the power supply to the spring loading correct tightening is indicated by a coloured mark. No
motor. Discharge the spring by closing and opening the further tightening operations should be required during the
circuit-breaker by means of the closing and opening operating life of the circuit-breaker. However, if the screws
pushbuttons. or nuts must be retightened after maintenance, always
Visually inspect the tulip isolating contacts, sliding surfaces, replace the screws and nuts and comply with the values
etc., to make sure that they are properly lubricated. indicated in fig. 12.
25 Nm 15 Nm 15 Nm
15 Nm
15 Nm
25 Nm
EL Twin - 40 kA actuator
15 Nm 15 Nm
15 Nm
Fig. 12
32
9.2.3. Circuit-breaker pole 9.3.2. Release devices: actuator and transmission system
No further inspections are necessary beyond those already Circuit-breakers up to 15 kV, 1250 A, 25 kA.
described in sect. 9.2.1. Inspection and maintenance should be performed after every
5,000,000 operations to ensure the circuit-breaker functions
9.2.4. Withdrawable assembly (truck and circuit-breaker) correctly. Contact ABB Service.
Visually inspect the components, especially those which may The damper and other components of the transmission
have been damaged by incorrect operations (also consult system (shaft, main levers, safety rings, etc.) must be totally
chap. 8). replaced after 10,000 operations.
Visually inspect the isolating contacts and clean all contact
parts, especially where signs of overheating are found (also Circuit-breakers up to 15 kV, 40 kA and with Twin actuator
consult sect. 9.4.). Inspection and maintenance must be performed after every
Visually inspect the locks. Perform functional tests to make 5,000,000 operations to ensure the circuit-breaker functions
sure that they operate properly and activate without abnormal correctly. Contact ABB Service.
force - maximum 25 N (also consult the table in chap. 8). The damper and other components of the transmission
system (shaft, main levers, safety rings, etc.) must be totally
replaced after 10,000 operations.
9.3. Servicing
Note
9.3.1. Pole and conductive parts Dismantling and replacement of the operating mechanism (trip box) can only
Comply with the following procedure if the devices had to be be carried out by ABB personnel or by skilled and specially trained personnel,
cleaned during the inspections, as specified in sect. 9.2.1: particularly as regards the necessary adjustments.
isolate the work area and make it safe, following the safety
regulations specified in standards IEC/DIN VDE; Details about servicing
general cleaning of surfaces: When required, cut off the power supply to the spring
dry and remove light deposits of dirt with a soft dry cloth; loading motor and discharge the springs of the operating
more resistant dirt can be removed using slightly alkaline mechanism in the manual mode by closing and opening the
domestic type detergent or Rivolta BWR 210 detergent; circuit-breaker.
clean the insulating surfaces and conductive parts with a Replace parts subject to mechanical stress or stress due
suitable detergent. to particular ambient conditions, (contact an ABB service
After cleaning, thoroughly rinse with clean water and dry center).
carefully.Apply fresh grease if necessary. Refer to maintenance instruction manual 1VCP000558 for
further details.
Note Note
Only use halogen-free detergents and never 1.1.1-trichloroethane, These operations can only be carried out by ABB personnel or by skilled and
trichloroethylene or carbon tetrachloride! specifically trained personnel.
33
9.3.3. Circuit-breaker pole
Replacement of parts and accessories must only be carried
The circuit-breaker pole and relative vacuum interrupter are out by ABB personnel or suitably qualified and specially
maintenance-free until the maximum number of electrical trained personnel.
operations for the type of interrupter is reached. The Always work with the circuit-breaker open and locked so that
operating life of the vacuum interrupter is defined by the sum it cannot be reclosed, with the work area isolated and in safe
of the ultimate currents corresponding to the specific type of conditions.
interrupter in accordance with the indications in the graphs The spring of the operating mechanism must be discharged.
of sect. 7.2.3. Trip curves: the whole pole must be replaced All power supply sources must be disconnected and secured
when the sum of the ultimate currents is reached. against reclosing during the removal and installation work.
The following VIDAR tester test values are valid for the
interrupter vacuum test:
Rated voltage of circuit-breaker D.C. test voltage
15 kV 40 kV
Note
The tester connection cables can produce an indication due to the capacitive
effect. In this case the cables must not be removed.
9.4. Repair
34
10. Application of the X-ray emission Standards
35
11. Spare parts and accessories
36
12. Circuit diagrams
VD4G-25, VD4G-40 K&N Aux.Switches wiring with plug 64 poles 1VCD400152 (2)
VD4G-25, VD4G-40 K&N Aux.Switches wiring with plug 58 poles 1VCD400153 (2)
VD4G-50 1VB2009146P0100
VD4G/P-25, VD4G/P-40 K&N Aux.Switch manual truck for withdr. UniGear 1VCD400155 (2)
VD4G/P-25, VD4G/P-40 K&N Aux.Switch with motorized truck for withdr. UniGear 1VCD400156 (2)
37
13. Overall dimensions
Fixed circuit-breakers
123
VD4G/P-25 121
492
110 150 1 150 1
TN 1VCD000233 233 43
Ur 15 kV
100
10
78
296
Ir 1250 A
25 kA
1
Isc 16/16 kA
205
627
626
619
12,5 kA 64
29
1
260
78
1
23
154
19
341
4
21,5
503 14 25 468
34 492
531 500
302
37
320
382
437
573 1,5 max
610
662
Fixed circuit-breakers
314
VD4G-40 636
123
44,5 220 25 110 16
TN 1VCD000234
Ur 15 kV
10
119
Ir 2000 A
20 kA 20
Isc 25 kA
310
40 kA
698
689
119
281
11 23
165
12,5
19
76
26
605
21,5
19,5
4
4
14 653 14 302
25 320 37
359
382
650
590 52
640
642
626
550
210 210
Powercube
590
359
302
38
Fixed circuit-breakers
600
VD4G-40
323
TN 1VCD000240
210 210 130
Ur 15 kV
Ir 2000 A
119
Isc 50 kA 32
310
30
609
119
475
435
16
56
15
237,5
171
97
77,5
368 28,5
2,5
12 11
24
28,5
48 504 48 172 142 109
424
436 1
20
40
24
Fixed circuit-breakers
750
VD4G-40
396
TN 1VCD000241
275 275 119 99
Ur 15 kV
Ir 2000 A
119
Isc 50 kA
32
310
3
609
30
119
474
435
56
15
238
16
171
97
77,5
28,5
24
49 28,5
429 69 270 84
58 634 424
440 0,8
M10 Deep .18 20 98
24
40
39
13. Overall dimensions
Fixed circuit-breakers
750
VD4G-40
398
TN 1VCD000242 375
275 275 454
Ur 15 kV 240
189 119 69
Ir 3150 A
4000 kA
118
119
Isc 50 kA
32
310
29,5
119
475
16
435
56
237,5
171
116 28,5
24
2,5
77,5
165 28,5 69 270 84
30,5 689 30,5 423
435 0,8
40
4xM12 deep 25 C.B. Type U In Iss O.M
VD4G-40 15 kV 3150/4000 A 50 kA EL2 Twin
12
40
8
20 2xM10 deep 20
Withdrawable circuit-breakers
331
VD4G/P-40 842
313
230 48 110
TN 1VCD000243
Ur 15 kV
Ir 2000 A
Isc 40 kA 20
310
698
689
681
29
280
89
164
19
123
19,5
4
21,5
853 13,5
34 302
880
320
374 359
275 275 416
590 52
144
750
806
836
40
Withdrawable circuit-breakers
842
VD4G/P-40 240 111
10
362 25
95
TN 1VCD000244 130
Ur 15 kV
118
150
3150 A
Ir
4000 A 39
1
20 kA
310
Isc 25 kA
743
733
731
30
678
40 kA
16
478
29
56
1
280
89
213
1
165
19
76
12,5
4
4
19,5
302
21,5
842
853 25 320
880 359 52
34 382
850
836 416
806 553 1,5
750
592
275 275
31
303
4
Withdrawable circuit-breakers
VD4G-25 450
248
52
TN 1VCD003891 95 32
Ur 15 kV
Ir 1250 A
Isc 31,5 kA
205
30
52
475
16
451
435
56
16
217,5
171
96
77,5
56
33 227,5 28,5
49 28,5
24 402 24 45 250 109
406
150 150
417,5 0,8
45
22
22
41
14. Quality of the products and environmental protection
The apparatus is manufactured in accordance with the requirements established by the international standards concerning
quality management and environmental management systems. The level of excellence in these fields is testified by the ISO
9001 and ISO 14001 certificates available.
Disposal methods
The products can be disposed of by means of heat treatments, in incineration systems or by storage in dedicated areas.
42
Notes
43
For further details please contact:
ABB AG
Calor Emag Medium Voltage Products
Oberhausener Strasse 33
D-40472 Ratingen
Phone: +49(0)2102/12-1230
Fax: +49(0)2102/12-1916
E-mail: powertech@de.abb.com
www.abb.com
The data and illustrations are not binding. We reserve the right to
make changes without notice in the course of technical and product
development.