VD4 Vacuum Circuit-breaker

With Embeded Poles 36...40.5 kV, 1250...2500A, 25...31.5kA Instruction Manual

Your safety first

always!

That's why our instruction manual begins with these recommendations: Only install switchgear and/or switchboards in enclosed rooms suitable for electrical equipment. Ensure that installation, operation and maintenance are carried out by specialist electricians only. Comply in full with the legally recognized standards, the connection conditions of the local electrical utility and the applicable safety at work regulations. Observe the relevant information in the instruction manual for all actions involving switchgear and switchboards. Danger! Pay special attention to the hazard notes in the instruction manual marked with this warning symbol. Make sure that under operation condition of the switchgear or switchboard the specified data are not exceeded. Keep the instruction manual accessible to all persons concerned with installation, operation and maintenance. The user's personnel are to act responsibly in all matters affecting safety at work and the correct handling of the switchgear.

WARNING
Always observe the instruction manual and follow the rules of good engineering practice ! Hazardous voltage can cause electrical shock and burns. Disconnect power, then earth and short-circuit before proceeding with any work on this equipment.

If you have any further questions on this instruction manual, the members of our field organization will be pleased to provide the required information.
3

Contents 1 1.1 1.2 Summary General Standards and specifications

Page 5 5 5 5 5 5 5 5 6 6

Contents 4 4.1 4.2 4.3 4.4 4.5 5 6 6.1 6.2 6.3 Despatch and storage Condition on delivery Packaging Transport Delivery Intermediate storage Installation Commissioning/Operation Note on safety at work Preparatory activities Operation of the circuit-breaker storage mechanism 6.3.2 Closing and opening

Page 18 18 18 18 19 19 19 20 20 20 20 20 20 21 24 24 24 24 24 25 25 25 26 26 26 26 27 30

1.2.1 Switchgear manufacture 1.2.2 Installation and operation 1.3 Operating conditions 1.3.1 Normal operating conditions 1.3.2 Special operating conditions 2 2.1 Technical data Technical data Circuit-breakers for fixed installation and on withdrawable part 2.2 2.3 2.4 Technical data Releases and blocking magnet Technical data Motor-operated mechanisms Permissible number of vacuum interrupter switching operations in relation to breaking current 2.5 3 3.1 3.2 Dimensions Structure and function Structure of the breaker poles Structure of the breaker operating mechanism 3.2.1 Releases, blocking magnet and auxiliary switches 3.3 Function

6.3.1 Charging the spring energy 7 7 8

6.3.3 Operating sequence 7 7.1 7.2 Maintenance General Inspection and functional testing

7.2.1 Switching devices in general 9 13 13 13 13 14 14 14 14 14 14 7.2.2 Stored-energy spring mechanism 7.2.3 Checking auxiliary switch settings on withdrawable part 7.2.4 Testing of interlock conditions 7.2.5 Breaker pole 7.3 Servicing 7.3.1 Switching devices in general 7.3.2 Stored-energy spring mechanism 7.3.3 Breaker pole 7.4 8 Repair Application of the X-ray regulations

3.3.1 Charging of the spring energy store 3.3.2 Closing procedure 3.3.3 Opening procedure 3.3.4 Autoreclosing sequence 3.3.5 Quenching principle of the vacuum interrupter

We reserve all rights to this publication. Misuse, particularly including duplication and making available of this manual irdparties is prohibited. The information supplied is without liability. Subject to alteration.
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1
1.1

Summary
General The vacuum circuit-breakers of type VD4 on withdrawable parts for 36 kV or 40.5 kV rated voltage are intended for indoor installation in air-insulated switchgear systems. Their switching capacity is sufficient to handle any conditions arising from switching of equipment and system components under normal operating and fault conditions, particularly short-circuits, within the parameters of their technical data. Vacuum circuit-breakers have particular adswitching frequency in the working current range and/or where a certain number of short-circuit breaking operations are expected. Type VD4 vacuum circuit-breakers are suitable for autoreclosing, and have exceptionally high operating reliability and long life. The vacuum circuit-breakers designed in column form, are supplied as withdrawable modules. Their basic structure is shown in figures 3/1,3/2,3/7 and 3/8.

- Health and Safety at Work Standard VBG 1 - Health and Safety at Work Standard VBG 4 Safety guidelines for auxiliary and operating materials Order related details provided by ABB Xiamen Switchgear Co.,Ltd. 1.3 Operating conditions

1.3.1 Normal operating conditions Design to GB/T 11022, "Common specification for high-voltage switchgear and controlgear standards", IEC publication 60694, VDE 0670 part 100, with the following limit values:

Ambient temperature: - Maximum - Highest mean value measured in 24 hours - Minimum (according to "minus 5 indoor class") -15C +35C +40C

Humidity - Highest mean value of relative humidity measured over 24 hours 95% - Highest mean value of vapour pressure measured over 24 hours 2.2kPa - Highest mean value of relative humidity measured over 1 month measured over 1 month 90% 1.8kPa - Highest mean value of vapour pressure

1.2

Standards and specifications

1.2.1 Switchgear manufacture The switchgear complies with the following specifications in accordance with GB, IEC and the relevant DIN VDE publications respectively.

GB/T 11022, IEC 60694 and DIN VDE 0670 part 100, "Common specifications for highvoltage switchgear and controlgear standards". GB 1984 and IEC 62271-100, "High-voltage alternating-current circuit-breakers".

Maximum site altitude: 1000m above sea level

1.3.2 Special operating conditions Special operating conditions are to be agreed on by the manufacturer and user. The manufacturer must be consulted in advance about each special operating condition:

1.2.2 Installation and operation The relevant specifications are to be taken into account during installation and operation, particularly:

Site altitude over 1000 m: - Allow for the reduction in the dielectric strength of the air.

IEC 61936, Electrical devices with rated voltage above AC 1 kV DIN VDE 0101, Power installations exceeding AC 1 kV DIN VDE 0105, operation of electrical installations DIN VDE 0141, earthing systems for special power installations with rated voltages over 1 kV Accident prevention regulations issued by the appropriate professional bodies or comparable organisations. In Germany, these comprise the following safety regulations:

Increased ambient temperature: - Current carrying capacity is reduced. - Provide additional ventilation for heat dissipation. Climate: - Avoid the risk of corrosion or other damage in areas: with high humidity and/or with major rapid temperature fluctuations. - Implement preventive measures (e.g. electric heaters) to preclude condensation phenomena.
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2
2.1

T echnical data
Technical data circuit-breakers for fixed installation and on withdrawable part Rated voltage kV Rated frequency Hz Rated lightning impulse withstand voltage kV Rated power frequency withstand voltage(1min) kV Rate of rise of transient recovery voltage kV/s Peak of transient recovery voltage kV Rated operating sequence Rated operating sequence with autoreclosing
Breakertype Rated voltage Rated current Rated short-circuit breaking current, symm.1) Rated short-circuit breaking current, asymmetr.1) Rated short-circuit mreaking current, (peak.)1)

36 40.5 50/60 50/60 170 185 70 95 0.57 0.69 62 70 O-3min-CO-3min-CO O-0.3s-CO-3min-CO

Rated short-circuit duration Pole Centres Fixed Withdrawable Weight Fixed Withdrawable

VD4...

kV

A 1250 1600 2000 2500 1250 1600 2000 2500 1250 1600 2000 2500 1250 1600 2000 2500

kA 25

kA 27.3

kA 63

s 4

mm 360 280

approx. kg 320 290 320 290 355 340 355 340

3612-25 36 3616-25 36 3620-25 36 3625-25 36 3612-31 36 3616-31 36 3620-31 36 3625-31 36 4012-25 4016-25 4020-25 4025-25 40.5 40.5 40.5 40.5

31.5

34.3

80

360 280

320 290 320 290 355 340 355 340

25

27.3

63

360 280

290 290 340 340

290 290 340 340

4012-31 40.5 4016-31 40.5 4020-31 40.5 4025-31 40.5

31.5

34.3

80

360 280

290 290 290 290 340 340 340 340

Guideline values for function times at the rated supply voltage: Closing time approx. 55~67 ms approx. 33~45 ms Opening time Arcing time (at 50 Hz) 15 ms Total break time 60 ms Minimum command time on closing 20 ms (120 ms 2) ) Minimum command time on opening 20 ms (80 ms 2) )
1) 2)

When the operating voltage is lower than the rated voltage, the same values apply as for rated voltage. Higher values on request. If the activating relay contact cannot itself interrupt the release coil current

2.2

Technical data Releases and blocking magnet Equipment Power consumption1) AC DC VA W Y23) , Y9 3) Y2 4) , Y9 4) Y3 3) 4) Y3 Y13) 4) Y4 250 310 250 310 10 11 10 Y7 3.5 2) /15 2.0 2) /15 250 310 250 310 10 10 -

Shunt release OFF Shunt release ON Blocking magnet Undervoltage release undelayed delayed Indirect overcurrent release with intermediate current transformer two-phase three-phase
1) 2) 3) 4)

Approximate values With short-circuited intermediate current transformer Auxiliary voltages AC: 110 and 220 V, DC: 24, 48, 60, 110 and 220 V. Auxiliary voltage AC: 240 V, DC: 125 and 240 V.

2.3

Technical data Motor-operated mechanisms Auxiliary voltage V AC 110 220 240 DC 24 30 48 60 110 125 220 240
1) 2)

Power consumption 1) VA/W

Charging time (maximum)2) s

150 150 170

15 15 15

130 130 130 130 140 160 140 150

15 15 15 15 15 15 15 15

Approximate values At the rated auxiliary voltage

2.4

Permissible number of vacuum interrupter switching operations in relation to breaking current See figure 2/1.

10 8 6 4 3 2

10 8 6

Rated current
1250 A 1600 A 2000 A 2500 A

4 3 2

10 8 6 4 3 2

10 8 6 4 3 2

1250 A 1600 A 2000 A 2500 A

Rated current

10 3 8 6 4 3

10 3 8 6 4 3

Number of operations n

Number of operations n
0.1 0.2 0.3 0.4 0.6 0.8 1 2 3 4 6 8 10 20 30 40 60

10 8 6 4 3 2

10 8 6 4 3 2

10 8 6 5 0.05

10 8 6 5 0.05 0.1 0.2 0.3 0.4 0.6 0.8 1 2 3 4 6 8 10 20 30 40 60

Breaking current I a (kA)

a) Circuit-breaker type VD4, 36 kV and 40.5 kV Rated short-circuit breaking current 25 kA

Breaking current I a (kA)

b) Circuit-breaker type VD4, 36 kV and 40.5 kV Rated short-circuit breaking current 31.5 kA

Figure 2/1: Permissible number of vacuum interrupter operating cycles n as a function of the breaking current I a

2.5

Dimensions See figure 2/2,2/3.

892 840 295 390 260

50.2 a 328 b 280 280

25

1294

20

281

40

K 104

80 4

900

TK 36 14 485 510 516 18 8 111

TP 194

204

TP

61 124 100 188 708 760 905 945

35

252 430 400 445 520 535 695

60

85

TK = Transport bracket 147 TP = Transport profile 148 K = Entrance for control cables 50.2 = Front partition plate Note: Transport bracket TK (147) and transport profile TP (148) only fitted for handling. Remove and store prior to commissioning. Fig. 2/2 Dimension of withdrable VD4 40.5kV

Rated current 1250/1600A 2000/2500A

a O 74 O 113

b O 35 O 79

390 260

DETAIL A
40
M 12

360

360

40

85 120

35

10

1575

A 62

1294

2 8

18 8

104

36 4 0

4- 11 40 124 61 139.5 868 920 1065 1105

35

158 185

310 381

516

14

45

36

20

900

535 685

435 445 555

60

75

Fig. 2/3 Dimension of fixed VD4 40.5kV

1575

328

39

Charging motor

Standard arrangement

Type 22

1) Only when Y1 is not fitted 2) External operation

Special arrangement for -S5

Type 19

Type 20

Type 21

Type 23

Type 24

S1 Auxiliary switch on operating mechanism S2 Auxiliary switch on blocking magnet S3 Auxiliary switch on the breaker shaft S4 Auxiliary switch on the breaker shaft S5 Auxiliary switch on the breaker shaft S7 Auxiliary switch for fault annunciation (fleeting contact, time 30 ms)

Y1 Blocking magnet Y2 Shunt release OFF Y3 Shunt release ON Y4 Undervoltage release Y7 Indirect overcurrent release Y9 Second shunt release OFF V1 Series rectifier for Y1 V2 Series rectifier for Y2

V3 Series rectifier for Y3 and K0 V4 Series rectifier for Y4 V7 Series rectifier for Y7 V9 Series rectifier for Y9 M0 Charging motor for stored-energy spring K0 Anti-pumping relay R0 Series resistor

Fig. 2/4 Circuit diagram for motor-charged operation mechanism Note: 1) For DC 24V, 30V, 48V, 60V, 110V, 125V, 220V, 240V; AC 110V, 220V, 240V 2) Spring in the diagram is discharged. Standard configurations and options available for VD4 are contained in the diagram. Also see relative catalogues and order forms for all possible configuration. 3) Releases and blocking magnets are fundamentally wired with rectifiers (e.g. magnet holder 45 with integrated rectifiers V1, V2, V3 and V9). Rectifiers function as free-wheeling diodes with DC supply. Tag. Available auxiliary circuit components 1) Motor charged, fixed version: Y2, Y3, K0, S1, S3, S4 2) Motor charged, withdrwable version: Y1, Y2, Y3, K0, S1, S2, S3, S4, S8, S9 Any requirement exceed mentioned above, should be declared in the contract.

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Circuit diagram for withdrawable VD4

S1 shows the circuit breaker units in the switch position OFF and with the stored-energy spring mechanisms discharged.

Fig. 2/5 Circuit diagram for withdrawable VD4

Auxiliary circuit component in circuit breaker S8 S9 Y0 With S5, connect as dashed showed. Without S5, connect as dashed showed. Limit switch test position Limit switch service position Block magnet on truck

Auxiliary circuit component in truck

X0 Y1 Y2 Y3

Socket with 58 pins Closing block magnet 1st Shunt release OFF Closing release

Y4 Y7

Y9 S1

Undervoltage release Indirect overcurrent release 2nd Shunt release OFF Auxiliary switch on mechanism

S2 Auxiliary switch on block magnet -Y1 S3,S4,S5 Auxiliary switch on switch shaft

Service position

S7

Fleeting contact 30 ms for c.b.

Test position

K0

tripped indication Antipumping relay

V0-V9 M0

Series rectifier Charging motor

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12

Circuit diagram for fixed VD4

Circuit breaker units in the switch position OFF and the stored-energy spring mechanisms is discharged.

Fig. 2/6 Circuit diagram for fixed VD4

Auxiliary circuit component in circuit breaker Note:

X0 Y1

Socket with 58 pins Closing block magnet

S1 shows the storedenergy spring

Y2

1st Shunt release OFF

Y3

Closing release

Y4 Y7

Y9 S1 S2

Undervoltage release Indirect overcurrent release 2nd Shunt release OFF be declared in the contract.

mechanisms discharged. Available auxiliary circuit components: Y2, Y3, K0, S1, S3, S4 Any requirement exceed mentioned above, should

Auxiliary switch on mechanism Auxiliary switch on block magnet -Y1

S3,S4,S5 Auxiliary switch on switch shaft S7 Fleeting contact 30 ms for c.b. tripped indication

K0 V0-V9

Antipumping relay Series rectifier

M0

Charging motor

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3.1

Structure and function

Structure of the breaker poles (Figures 3/1, 3/2 , 3/6, 3/7 and 3/8) The 36 kV and 40.5 kV circuit-breakers of type VD4 are designed as withdrawable units. The poles, which are constructed in column form, are mounted on a torsionally rigid enclosure substructure with rollers. The live parts of the breaker poles are located in the insulating material pole tubes and protected from impacts and other external influences. With the breaker closed, the current path leads from the upper contact arm 57.1 and a chamber holder fixed in the pole tube to the fixed contact 58.2 in the vacuum interrupter 58, then via the moving contact 58.3 and roller contact to the lower contact arm 57.2. The switching motion is effected by means of the insulated coupling rod with internal contact force springs.

Five-pole auxiliary switches S3 and S4 ON-OFF operating shaft 54 Mechanical switch position indicator 55.4 Charging condition indicator 55.8 for the stored energy spring Mechanical operating cycle counter 55.5. Motor charging mechanism Five-pole auxiliary switch S1 to switch the charging motor Anti-pumping relay K0.

The following additional equipment can be installed:

Blocking magnet Y0 on the withdrawable part Second shunt release OFF Y9 Indirect overcurrent release Y7 Auxiliary switch S7 for electrical opening signalling Undervoltage release Y4 Five-pole auxiliary switch S5

3.2

Structure of the breaker operating mechanism (Figures 3/3, 3/4, 3/7, 6/1 to 6/5, 7/5 to 7/8) The operating mechanism located in the housing substructure is of the stored-energy spring type and acts on the three breaker poles. The necessary operating energy is stored ready for activation by charging the spring energy storage mechanism. The stored-energy spring mechanism essentially consists of drum 55.33 containing the spiral spring, the charging system, the latching and operating mechanism and the linkages which transmit the force to the breaker poles. In addition, there are supplementary components such as the charging motor, releases, auxiliary switches and the controls and instruments. The operating mechanism is fundamentally suitable for autoreclosing and, due to the short charging times, also for multi-shot autoreclosing. The operating mechanism is normally fitted with a charging motor. There is also a facility for charging the stored energy spring manually. There is one rating plate 55.7 with the main data of the switch equipment on front cover plate left hand side 50.7, and another on breaker mechanism housing. The basic version of the stored-energy spring mechnism is fitted with the following auxiliary equipment:

3.2.1 Releases, blocking magnet and auxiliary switches (Figures 2/4 to 2/6, 3/3, 6/2, 7/7 and 7/8) The releases and the blocking magnet are mounted at the bottom of the stored-energy spring mechanism. The allocation of the auxiliary switches can be seen in the wiring diagram of figure 2/4. The five-pole auxiliary switch S1 is operated by the charging condition indicator 55.8. It controls the charging motor M1, serves as an electrical interlock for shunt release ON Y3 when the spring energy storage mechanism is not sufficiently charged, and also provides an electrical switching readiness signal. Operation of the five-pole auxiliary switches S3, S4 and S5 is dependent on the switching position of the circuit-breaker. Auxiliary switch S3 interrupts the circuit of the optional additional shunt release OFF Y9 with the circuit-breaker in the open position, and the circuits of shunt release ON Y3 and the optional blocking magnet Y1 with the circuit-breaker in the closed position. There is one further NOC for other purposes. Auxiliary switch S4 interrupts the circuit of shunt release OFF Y2 with the circuit-breaker in the open position. One further NOC and three NCCs are available for annunciation, control and interlock purposes.

Shunt release OFF Y2 Shunt release ON Y3 Blocking magnet Y1 with auxiliary switch S2

13

Auxiliary switch S5 can be optionally designed with any possible combination of contacts from five NOCs to five NCCs. Its contacts are available for any required control, annunciation or interlock functions. The auxiliary switch is normally configured as shown in figure 7/3. The single pole auxiliary switch S7 (fleeting contact time 30 ms) serves to provide a fault signal ("breaker released"). With remote control, the auxiliary switch is necessarily operated via:

Shunt release OFF Y2 or Shunt release OFF Y9 or Undervoltage release Y4 or Indirect overcurrent release Y7.

drive shaft 55.30 to be rotated by the (previously) charged spiral spring. The moving contact 58.3 in vacuum interrupter 58 is moved until the contacts touch by cam disk and further kinematic links. In the further sequence of motion, spring arrangement is tensioned and the appropriate amount of contact force thus applied. The available overtravel is higher than the maximum value of contact erosion during lifetime of the interrupter. During the closing process, opening springs are simultaneously tensioned. 3.3.3 Opening procedure (Figures 3/3, 3/6, 6/3 and 7/7) The opening procedure is initiated manually by the double bit key 145 and the ON-OFF operating shaft 54, or electrically by activation of one of the releases Y2, Y4, Y7 or Y9. Release mechanism then permits drive shaft 55.30 to be turned further by the spring energy storage mechanism, which is still sufficiently charged. The opening spring, which is thus released, moves the contact 58.3 into the open position at a defined speed. 3.3.4 Autoreclosing sequence An OFF-ON or OFF-ON-OFF autoreclosing sequence is activated and checked by the protection system. It is necessary for the spiral spring in the operating mechanism to be in the (re-)charged condition, with the circuitbreaker in the closed position. The (re-)charging process is carried out automatically after closing of the breaker on breakers with motor charging mechanisms, but must be carried out manually on breakers without charging motors (or when the charging motor has broken down). Opening of the breaker is also possible during the (re-)charging process, but sub-sequent closing of the breaker is however blocked until the charging process has been completed. 3.3.5 Quenching principle of the vacuum interrupter Due to the extremely low static interrupter chamber pressure of 10-2 to 10-6 pa, only a relatively small contact gap is required to achieve a high dielectric strength. The arc is extinguished on one of the first natural current zeros. Due to the small contact gap and the high conductivity of the metal vapour plasma, the arc drop voltage, and additionally, due to the short arcing time, the associated arc energy, are extremely low, which has advantageous effects on the life of the contacts and thus on that of the vacuum interrupters.

Note: 1. Shunt releases OFF (Y2) and ON (Y3) are exclusively provided for opening and closing in normal operation. For safety breaking operations, the second shunt release OFF (Y9) must be used, in most cases with a separate control voltage supply. These three releases are of the solenoid type and suitable for a large number of operating cycles. 2. The under voltage release (Y4) and/or indirect over current release (Y7) are pure safety and protection releases and must not be used for switching in normal operation. 3.3 Function (Figures 3/3, 3/10, 6/2, 6/6, 7/7 and 7/8) To provide the necessary motive energy, the spring energy storage mechanism is charged via chain 55.34 fitted with ratchet wheel 55.35, either automatically by a charging motor or by hand in a vertical pumping action with charging lever 128. The current charging condition is shown at charging condition indicator 55.8 As a precondition for an autoreclosing sequence, the operating mechanism is either (re-)charged after a closing operation automatically by the charging motor, or it requires (re-)charging by hand if the operating mechanism is of the manual type. 3.3.2 Closing procedure (Figures 3/4, 3/6, 6/1, 6/3 and 7/7) The closing process is initiated manually by the double bit key 145 and the ON-OFF operating shaft 54, or electrically by activation of shunt release Y3. The release mechanism then permits 3.3.1 Charging of the spring energy store

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50.2

57.1 57.8 57.2

50.1 50.8

Figure 3/1: Withdrawable part with circuit-breaker, type VD4, operator's side

Figure 3/2: Withdrawable part with circuit-breaker, type VD4, pole side 50.1 50.2 50.8 57.1 57.2 57.8 Earthing contact Front partition plate Wheel Upper contact arm Lower contact arm Insulating material pole tube

54 54.1 55.8 55.6 55.5 55.4 55.7

Figure 3/3: Withdrawable part with circuit-breaker, type VD4, controls for the circuit-breaker 54 54.1 55.4 55.5 55.6 55.7 55.8 ON-OFF operating shaft Link rod Switch position indicator Operating cycle counter Socket for charging lever Rating plate Charging condition indicator 15

51.2 51 51.1 147 50.1 50.4 50.3 50.4 50.3 148

50

Figure 3/4: Withdrawable part with circuit-breaker, type VD4, left and operator's side view 50 50.3 50.4 51 51.1 51.2 147 148 Frame of the withdrawable part Actuating pin Guide cam Interlock yoke Catch pin Sliding handle Transport bracket Transport profile

Figure 3/5: Withdrawable part with circuit-breaker, type VD4, (pole side, below) 50.1 50.3 50.4 Earthing contact Actuating pin Guide cam

58.1 58.2 58.3 58.4 58.5 58.7 58.6

Figure 3/6: Partial section of a vacuum interrupter. 58.1 58.2 58.3 58.4 58.5 58.6 58.7 Insulator Fixed contact Moving contact Metal bellows Screen Guide cylinder Lid

16

Figure 3/7: Vacuum circuit-breaker, type VD4, for fixed installation, operating side.

Figure 3/8: Vacuum circuit-breaker, type VD4, for fixed installation, terminal side. 50.8 Rollers 57.1 Upper breaker terminal 57.2 Lower breaker terminal 57.8 Embedded pole

Figure 3/10: Indicators and controls on a circuit-breaker for fixed installation. 50.7 Front plate 54.2 Mechanical ON pushbutton 54.3 Mechanical OFF pushbutton 55.4 Mechanical switch position indicator 55.5 Mechanical operating cycle counter 55.6 Socket (for charging lever) 55.7 Rating plate Figure 3/9: Vacuum circuit-breaker, type VD4, for fixed installation, version with partition, terminal side. 55.8 Charging condition indicator

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4
4.1

Dispatch and storage

Condition on delivery

Notes:

Avoid impact during handling. Do not subject to other damaging mechanical stresses. Lifting gear must not be attached to the breaker poles or parts of the operating mechanism. When moving the withdrawable part only use the sliding handles 51.2 (e.g. for racking in/out the circuit-breaker unit into/out of the switchgear panel or for the transport of the unit in the switchgear room). Do not bring any force on the front partition plate 50.2 of the withdrawable part. Only handle the modules by crane with boltedon transport brackets 147, suitable lifting ropesand crane harness. Ensure that the circuit-breaker unit on the withdrawable part, with its relative high situated centre of gravity, cannot tip over when moving it by crane or fork-lift truck, or when handling it outside the switchgear room.

The factory-assembled circuit-breakers on withdrawable parts are checked at the works for completeness of the equipment installed and simultaneously subjected to a routine test in accordance with GB/T 11022 GB 1984, IEC 60694,DIN VDE 0607 IEC publication 62271-100, thus verifying their correct structure and function.

4.2

Packaging The circuit-breakers on withdrawable parts are mounted individually on wooden pallets and sealed in film and/or packed in cardboard for delivery. Packaging for overseas shipment:

Drying agent bags inserted in the filmsealed packaging.

4.3

Transport Loading of the package units must only be carried out with a

crane, fork-lift truck and/or trolley jack.

CrB

Figure 4/1: VD4 breaker on withdrawable part Only handle by crane when the transport bracket 147 and crane harness are fitted.Always bear in mind that the high situated centre of gravity may induce the breaker to tip over! 50.2 Front partition plate (Do not stress this plate) 147 148 CrB Transport bracket (TK) Transport profile (TP) Crossbar

Figure 4/2: VD4 breaker for fixed installation Only handle by crane when the lifting lugs are fitted. Always bear in mind that the high situated centre of gravity may induce the breaker to tip over!

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4.4

Delivery The duties of the consignee on receipt of the switching devices at site include the following:

Installation
(Figures 3/4, 4/1 and 4/2) Perfect operation of the circuit-breaker depends on careful and professional handling of the withdrawable part.

Checking the delivery for completeness and freedom from damage (e.g. moisture and itsadverse effects). Any short quantities, defects or damage intransit: - Must be precisely documented on the consignment note. - The shipper/carrier is to be notified immediately in accordance with the liability provisions.

Allocate each unit to the appropriate switchgear panel in accordance with the switchgear plan and the rated electrical data. Remove the transport profile 148 and transport brackets 147. Insert the withdrawable part in the switchgear panel checking for unimpeded motion and function sequences, including the closing of primary contacts when the service position is reached. Remove any dirt.

Note: Always take photographs to document any major damage. 4.5 Intermediate storage Intermediate storage of the circuit-breaker unit in the switch position OFF and the storedenergy spring mechanisms discharged (Indicator DISCHARGED: ). Conditions for optimum intermediate storage: 1. Devices with basic packaging or unpacked:

When the switchgears are operated in areas with high humidity and/or major rapid temperature fluctuations, there is a risk of dew deposits which must remain an exception in normal operating conditions Provisions should be taken according to section 1.3.2 (special operating conditions).

A dry and well ventilated storeroom with climate in accordance with GB/T 11022, IEC 60694, DIN VDE 0670. Room temperature which does not fall below -15C. Do not remove or damage the packaging. Unpackaged devices: - Are to be loosely covered with protective sheeting. - Sufficient air circulation must be maintained.

Check regularly for any condensation.

2. Devices with seaworthy or similar packaging with internal protective sheeting:

Store the transport units: protected from the weather, dry, safe from damage.

Check the packaging for damage. Check the drying agent on arrival of the consignment, subsequently at appropriate intervals.

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6
6.1

Commissioning/Operation
(Figures: 3/2, 3/3, 3/10, 6/1 to 6/7) Note on safety at work

Insert charging lever 128 into the socket 55.6 and pump up and down for approx. 25 strokes until the charged condition is displayed. When the charged condition is reached, the charging mechanism automatically disengages, and further strokes of the charging lever have no effect.

The switchgear may only be operated by specially trained personnel who are familiar with the characteristics of the particular device. Operating circuit breaker in normal condition in accordance with relevant regulations in GB/T 11022, IEC 60694,is a pre-condition of faultfree operation.

Note: Charging of the spring energy storage mechanism by hand should only take place when the truck is in the test/disconnected or removed position. Key to the charging condition indications:

6.2

Preparatory activities (Prior to application of primary voltage)

Check the circuit-breaker for damage and restore to the proper conditions where necessary. Remove any contamination (particularly on the insulating materials) which has occurred during transit, storage or installation. Check the primary connections and the earthing contact 50.1. Check the charging motor on circuit-breakers with motor-operated mechanisms by applying auxiliary voltage. On breakers with manual charging mechanisms, charge the stored energy spring by hand (see Section 6.3.1). Perform a trial opening or closing operation of the circuit-breaker using the double bit key 145 at the ON-OFF operating shaft 54 (taking into account any required auxiliary voltage and any relevant interlocks). Observe switch position indicator 55.4 and charging condition indicator 55.8. The further procedure results from the interaction of the truck with the switchgear cubicle. See the Operation Manual for the switchgearts. Ensure that the Instruction Manual is available to the operators at all times.

Discharged

Charged

As a precondition for an autoreclosing sequence, the operating mechanism is either (re-)charged after a closing operation automatically by the charging motor, or it requires (re-)charging by hand if the operating mechanism is of the manual type. 6.3.2 Closing and opening

Operate the local or remote electrical control unit. Observe switch position indicator 55.4.

The mechanical control system facilitates manual operation of the circuit-breaker in the switchgear cubicle even with the door closed:

Fit double bit key 145 on ON-OFF operating shaft 54. Turn the double bit key approx. 15 clockwiese until the stop is reached to close the circuitbreaker, or anti-clockwise to open it.

6.3

Operation of the circuit-breaker (Figures 6/1 to 6/3 and 6/6, 6/7)

The operating cycle counter 55.5 is automatically incremented by one complete figure with each switching cycle. On completion of a switching operation the switch position indicator 55.4 in the window of front cover plate 50.7. shows the appropriate position of the circuit-breaker. The anti-pumping relay K0 (wiring diagram in firgure 2/3) prevents repeated ON-OFF switching operations if, for example, the breaker is tripped by a protection relay in response to a primary side fault while a permanent electrical closing command is simultaneously applied. The circuit-breaker can then only be closed after the closing command has been interrupted.

6.3.1 Charging the spring energy storage mechanism Circuit-breakers with charging motors:

Charging takes place automatically. If the charging motor breaks down, the charging process can be carried out or completed manually.

Circuit-breakers with manual charging mechanisms:

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6.3.3 Operating sequence Circuit-breaker with motorized charging of the stored-energy spring mechanism Operating sequence Result of operation Breaker Position Charging Condition O O and Possible subsequent switching operation On-Off

Switch on charging motor Automatic charging

Close breaker...

I I O

Off Off-On-Off or autoreclosing sequence On-Off Off Off-On-Off or autoreclosing sequence

automatically (re-)charge Open breaker Close breaker... and

I I O I O O

automatically (re-)charge Autoreclosing sequence (Activation via protection system Off On Off Automatic charging completed

(automatic charging starts)

On-Off

Close breaker...

and

I I

Off Off-On-Off or autoreclosing sequence

automatically (re-)charge

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51.1

51.2 51

52

54.1

55.8 55.6 128

50 50.4

50.7 55.7 55.4 55.5 50.6

Figure 6/2: Changing the store-energy spring mechanism manually by moving the inserted charging lever up and down 55.6 55.8 128 Socket for charging lever Charging condition indicator Charging lever

Figure 6/1: Withdrawable part with circuit-breaker, type VD4, control area 50 50.4 50.6 50.7 51 51.1 51.2 52 54.1 55.4 55.5 55.7 Frame of the withdrawable part Guide cam Cover plate, right hand side Cover plate, left hand side Interlock yoke Catch pin, (spring loaded) Sliding handle Spindle Link rod Switch position indicator Operating cycle counter Rating plate

54

145

146 52.1 52

Figure 6/3: Manual operation of the circuit-breaker, by turning the double bit key approx. 15 clockwise (ON), or approx. 15 anti-clockwise (OFF) 54 145 ON-OFF operating shaft Triple bit key (ON-OFF operation)

Figure 6/4: Fitting the hand crank (against spring-loaded intermediate plate) to move the withdrawable part inside the panel clockwise towards the service position, and anti-clockwise from the service position towards the test/ disconnected position 52 52.1 146 Spindle Square spigot Hand crank

22

51

51.2 51.4 51.1

128
Figure 6/5: Interlock yoke with sliding handles which will be moved inwards to release the withdrawable part for withdrawing from the panel. 51 51.1 51.2 51.4 Interlock yoke Catch pin, spring loaded Sliding handle Blocking shaft (interlocking circuit-breaker and withdrawable part)

145

146

Figure 6/6: Operating accessories 128 145 146 Charging lever Triple bit key (ON-OFF operation) Hand crank (for moving of the truck)

54.2 54.3 55.8 55.6 128

Figure 6/7: Vacuum circuit-breaker, type VD4, for fixed installation. Manual charging of the stored-energy spring. 54.2 Mechanical ON push-button 54.3 Mechanical OFF push-button 55.6 Socket 55.8 Charging condition indicator 128 Charging lever

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Maintenance
Maintenance serves to ensure trouble-free operation and achive the longest possible working life of the switchgear. It comprises the following closely related activities: Inspection: Determination of the actual condition Servicing: Measures to maintain the specified condition Repair: Measures to restore the specified condition. 7.2

especially with front cover plates 50.6 and 50.7 removed. The spiral spring in the spring energy strage mechanism, for instance, retains a basic tension which is independent of the charging and discharging processes during switching, so as to ensure correct function. This spring energy can be inadvertently released if work is performed incorrectly on the spring mechanism! Inspection and functional testing

7.1

General (Figure 7/1) Vacuum circuit-breakers are characterized by their simple and robust construction. They have a long life expectancy. Their operating mechanisms have a low maintenance requirement, and the interrupters are maintenance-free during their working life. There is no adverse effect on the vacuum, even from frequent switching of operating and short-circuit currents. The servicing intervals and scope are determined by environmental influences, the switching sequences and number of short-circuit breaking operations. With carefully performed inspections and servicing work, and under normal operating conditions, the circuit-breakers, depending on the type, have a service life of up to 30,000 operating cycles and more. Note: The following must be observed for all maintenance work:

7.2.1 Switching devices in general The proper condition of the switching device is to be verified by regular inspection. Under normal operating conditions, testing by a qualified personnel is to be performed at least every 4 years. In unusual operating conditions (including adverse climatic conditions) and/or special environmental pollutions (e.g. heavy contamination and aggressive atmosphere), inspection may also be necessary at shorter intervals. Inspection at fixed intervals may be waived if the switchgear is permanently monitored by a qualified personnel. The checks first and foremost comprise visual examination for contamination, corrosion, moisture and discharge phenomena. If an incorrect condition is found, appropriate servicing measures are to initiated. 7.2.2 Stored-energy spring mechanism (Figures 7/2 to 7/5) Functional testing of the operating mechanism is to be performed:

The relevant specifications in section 1.2.2 Notes on safety at work in section 6.1 Standards and specifications in the country of installation.

after 5000 operating cycles or during servicing work as set out in 7.2.1. Prior to functional testing, switch the breaker off and isolate the outgoing feeder. Perform several switching operations under no load, above all with circuit-breakers seldom operated in normal service. Switch off the charging motor (if fitted) and discharge the spring mechanism by ON/OFF switching operations. Examine visual the condition of the lubrication on rotary bearings, sliding surfaces, etc. Check the proper mechanical/electrical sequence of the individual functions. Check circuit breaker's appearance.

Maintenance work may only be performed by fully trained personnel, observing all the relevant safety regulations. It is recommended that ABB Xiamen Switchgear Limited Co. after-sales service personnel should be called in, at least during the performance of servicing and repair work. While the work is in progress, all auxiliary voltage sources must also be disconnected and secured to prevent reconnection. Note: In order to prevent accidents (particularly injury to hands!) extreme care should be taken during all repair work on the operating mechanism,

Scope of functional testing:

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7.2.3 Checking auxiliary switch settings on withdrawable part (Figures 6/4, 6/6, 2/5 and 7/2) Compliance with the interlock conditions in the areas of the test/disconnected position and the service position is ensured by auxiliary switches S8 and S9, located in the breaker housing. In test operations, the withdrawable part must be moved by hand with the crank 146 fitted. 1. Settings in the area of the test/disconnected position

service position when the circuit-breaker is open. Check the following conditions individually:

With the circuit-breaker closed, insertion of the withdrawable part towards the service position must be blocked after only half a turn of the crank in the clockwise direction. With the earthing switch closed, insertion of the withdrawable part towards the service position must be blocked after only two clockwise turns of the crank.

Do not use force ! 2. The withdrawable part must only be movable from the service position into the test/ disconnected position with the circuit-breaker open. Check this condition as follows:

Move the withdrawable part out of the test/disconnected position towards the service position with a few turns of the crank 146. Slowly move the withdrawable part back to the stop. Auxiliary switch S8 must then operate when the hand crank has a remaining angle of + 60 of turn to reach the stop. Slowly insert the withdrawable part from the test/disconnected position towards the service position until auxiliary switch S8 just operates. In this position, it must still just be possible to move closing push rod 55.2. For this test, the function of the blocking magnet Y0 (if fitted) must be deactivated manually. This condition ensures that the electrical interlock takes effect before the mechanical interlock in the motion sequence involved.

With the circuit-breaker closed, withdrawal movement of the withdrawable part must be blocked after only half a turn of the crank in anti-clockwise direction.

3. Closing of the circuit-breaker must only be possible when the withdrawable part is in the defined test/disconnected position or service position. The control wiring plug 10.2 must previously have been inserted. Check this condition as follows:

It must not be possible to close the circuit breaker with the withdrawable part in any position between the test/disconnected position and the service position. Enabling of switching when the withdrawable part moves into the service position is effected electrically by operation of auxiliary switch S9 in the breaker housing. For motion into the test/disconnected position, the same enabling conditions apply analogously, in this case by means of auxiliary switch S8 in the breaker housing.

2. Settings in the area of the service position

Move the withdrawable part out of the limit position towards the test/disconnected position with a few turns of the crank 146. Slowly move the withdrawable part forwards again to the stop: Auxiliary switch S9 must then operate when the hand crank has a remaining angle of + 60 of turn to reach the stop.

7.2.4 Testing of interlock conditions (Figures 6/4, 6/6, 2/4, 2/5 and 7/2) The testing procedures for the withdrawable part. 1. The withdrawable part must only be movable from the test/disconnected position into the

4. It must only be possible to open the circuitbreaker (manually) when the withdrawable p a r t i s i n t h e s e r v i c e p o s i t i o n o r test / disconnected position and the control voltage has failed. 7.2.5 Breaker pole No inspection of the breaker pole above and

25

beyond the stipulations of section 7.2.1 is necessary. 7.3 Servicing

service).

7.3.1 Switching devices in general If cleaning is found to be necessary during inspections as set out in 7.2.1, the following procedure is to be adopted:

For replacing highly stressed parts neutralize basic tension of the spiral spring, state the rate. Be careful when carrying out! Relubricate pawls, support shafts, sliding and rotating bearing surfaces. Lubricant: Isoflex Topas NB 52.(Code GCE 0007249P0100) Check the fit of fasteners (e.g. locking pins) in cranks, pins, bolts etc. Check the tightness of fastening bolts. Always replace any spring lock washers, split pins and other fasteners removed during the work with new parts when reassembling the equipment. Perform comprehensive electrical functional tests. mechanical and

Prior to cleaning, the working area is to be isolated and secured against reclosing where necessary in accordance with the safety regulations. Cleaning of surfaces in general: -Dry, lightly adhering dust deposits with a soft, dry cloth. -More strongly adhering contamination with slightly alkaline household cleanser or Rivolta BWR 210.

Note: This work may only be performed by the aftersales service personnel of ABB Xiamen Switchgear Limited Co. or adequately qualified personnel. 7.3.3 Breaker pole The breaker pole with the vacuum interrupter is maintenance-free up to reaching the permissible number of vacuum interrupter operating cycles in accordance with section 2.4. Checking of the vacuum is only necessary when there is good cause to suspect that force applied externally to a pole tube has caused damage to the vacuum interrupter inside. If the pole tube is damaged or destroyed, it may be necessary to replace the complete breaker pole. The working life of the vacuum interrupter is defined by the sum current limit corresponding to the equipment data in individual cases in accordance with section 2.4:

Cleaning of the insulating material surfaces and conductive components: -Light contamination: with Rivolta BWR 210. -Strongly adhering contamination: with cold cleanser 716.

Wipe down after cleaning, using clean water, and dry properly.

Observe the manufacturer's instructions and the special ABB instruction manuals Ba 1002/E or BA 1006/E on safety at work.

Note: Use only halogen free cleansers, and in no case 1.1.1-trichlorethane, trichlorethylene or carbon tetrachloride! 7.3.2 Stored-energy spring mechanism Servicing for 10 years or the spring mechanism is to be performed after 10,000 operating cycles. Prior to servicing, switch the breaker off, and isolate the outgoing feeder. Observe the safety regulations! Details of the servicing:

When the sum current limit is reached, the complete breaker poles are to be replaced. When the permissible number of mechanical operating cycles (i.e. the number corresponding to Ia = 0 on the characteristic curve) of the vacuum interrupters has been reached, t h e b r e a k e r p o l e s m u s t b e replaced. However, it should be investigated before hand as to whether the installation of a new breaker would be more advantageous.

Swich off the charging motor (if fitted), and discharge the spring energy storage mechanism by closing and opening the breaker once. Replace parts subject to high climatic and mechanical stresses after 10,000 operating cycles as a precaution (for details see ABB Xiamen Switchgear Limited Co. after-sales

26

Note: Dismantling and Replacement of the complete breaker poles should only be carried out by ABB Xiame Switchgear Limited Co. after-sales service personnel or by specially trained personnel, particularly as proper adjustment is necessary. 7.4 Repair Replacement of circuit-breaker parts and accessories

Only remove and reassemble circuit-breaker parts and accessories when the breaker has been switched off and the working area is to be isolated and secured against reclosing. The spring energy storage mechanism must be discharged. All auxiliary voltage sources must be disconnected and secured against reclosing during the removal and installation work.

7.5

Spare parts and auxiliary materials Designation Auxiliary switch (with clamp-type terminal) Item no. S1 S3 S4 S5 Auxiliary switch on blocking magnet Auxiliary switch for fault annunciation 1st shunt release OFF 2nd shunt release OFF Shunt release ON Blocking magnet Undervoltage release with spring mechanism Delayed undervoltage release with spring mechanism Indirect overcurrent release with intermediate current transformer and spring mechanism Intermediate current transformer for indirect overcurrent release Magnet holder, complete (with integrated rectifiers V1, V2, V3, V9) Series rectifier Charging motor (with gearing) S2 S7 Y2 Y9 Y3 Y1 Y4 Y4 Y7 DC 24V DC 48V DC 60V DC/AC 110V DC 125V DC/AC 220/240V Rated voltage

V4/V7 M0

Auxiliary materials Lubricant: Isoflex Topas NB 52

Ident no. (order code) GCE0007249P0100

27

51.3 54 51

10.4 10.5 54 51 10 10.1 10.2

54.1 50.6 50.7

Figure 7/1: Before moving the front plate, first disconnect the link rod 54.1 at the lower point and swing it to one side. Turn the hand crank anti-clockwise first to move the interlock yoke 51 an appropriate distance away. 50.6 50.7 51 54 54.1 Cover plate, right hand side Cover plate, left hand side Interlock yoke ON-OFF operating shaft Link rod

Figure 7/2

Auxiliary switches for interlocking withdrawable part and switchgear panel (withdrawable part in service position) 10 10.1 10.2 10.4 10.5 51 51.3 54 Control wiring plug connector, closed Control wiring socket Control wiring plug S8, limit switch for test position indicator S9, limit switch for service position indicator Interlock yoke Guiding rail (panel) ON-OFF operating shaft

55.33 55.8 55.30 55.36 55.6 55.34 55.5 55.4 54.1 55.35 55.3 55.2 45

Figure 7/3: The spring-loaded operating mechanism in the frame of the withdrawable part, front cover plates removed 45 54.1 55.2 55.3 55.4 55.5 28 Magnet holder, complete Link rod ON push rod OFF push rod Switch position indicator Operating cycle counter

55.6 55.8 55.30 55.33 55.34 55.35 55.36

Socket for charging lever Charging condition indicator Drive shaft Drum with spiral spring Chain Ratchet wheel Charging motor

Figure 7/4 Vacuum circuit-breaker, type VD4, for fixed installation, stored-energy spring mechanism, front panel removed. 54.2 Mechanical ON push-button 54.3 55.4 55.5 55.8 60 63 Mechanical OFF push-button Mechanical switch position indicator Mechanical operating cycle counter Charging condition indicator Auxiliary switch block Magnet holder, complete

Figure 7/5 Vacuum circuit-breaker, type VD4, for fixed installation, stored-energy spring mechanism, front panel removed. 55.6 Socket (for charging lever) 55.30 55.33 55.34 55.35 55.36 Drive Shaft Drum with spiral spring Chain Ratchet wheel Charging motor

29

Application of the X-ray regulations

One of the physical properties of vacuum insulations is the possibility of X-ray emissions when the contact gap is open. The specified type test performed by the Physikalisch-Technische Bundesanstalt (PTB) in Brunswick demonstrates that the local dosage output of 1Sv/h at a distance of 10 cm from the touchable surface is not exceeded. The results are as follows:

withstand voltage specified for the switching devices by VDE 0670 and IEC 62271-100: 2001 is also safe. Higher voltages than the rated power frequency withstand voltage or DC test voltage specified in DIN VDE or IEC standards must not be applied! Fulfilment of the above requirement with the vacuum interrupter in the open position is dependent on maintenance of the specified distance between the contacts (which is automatically ensured with correct mechanism function and force transmission).

The use of the vacuum interrupters at rated voltage is completely safe. The application of the rated power frequency

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8279 1133 8279 1236

Publication No: 1YHA000093-en