VD4 Vacuum Circuit-breaker

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.

1 Summary

1.1 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 ad-switching 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.

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 high-voltage switchgear and controlgear standards".
• GB 1984 and IEC 62271-100, "High-voltage alternating-current circuit-breakers".

1.2.2 Installation and operation

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

• 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:
• 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: +40°C
  • Highest mean value measured in 24 hours: +35°C
  • Minimum (according to "minus 5 indoor class"): -15°C
• 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: 90%
  • Highest mean value of vapour pressure measured over 1 month: 1.8kPa
• 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:

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

2 Technical data

2.1 Technical data

Circuit-breakers for fixed installation and on withdrawable part

Guideline values for function times at the rated supply voltage:

• Closing time: approx. 55~67 ms
• Opening time: approx. 33~45 ms
• Arcing time (at 50 Hz): < 15 ms
• Total break time: < 60 ms
• Minimum command time on closing: 20 ms (120 ms²⁾)
• Minimum command time on opening: 20 ms (80 ms²⁾)

¹⁾ When the operating voltage is lower than the rated voltage, the same values apply as for rated voltage. Higher values on request.

²⁾ If the activating relay contact cannot itself interrupt the release coil current

2.2 Technical data Releases and blocking magnet

¹⁾ Approximate values

²⁾ With short-circuited intermediate current transformer

³⁾ Auxiliary voltages AC: 110 and 220 V, DC: 24, 48, 60, 110 and 220 V.

⁴⁾ Auxiliary voltage AC: 240 V, DC: 125 and 240 V.

2.3 Technical data Motor-operated mechanisms

¹⁾ Approximate values

²⁾ At the rated auxiliary voltage

2.4 Permissible number of vacuum interrupter switching operations in relation to breaking current

See figure 2/1.

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

The graphs display the relationship between the number of operations (n) on the y-axis (logarithmic scale) and the breaking current (Ia) in kA on the x-axis (logarithmic scale). Two charts are provided:

• a) Circuit-breaker type VD4, 36 kV and 40.5 kV, Rated short-circuit breaking current 25 kA: Shows curves for rated currents of 1250 A, 1600 A, 2000 A, and 2500 A.
• b) Circuit-breaker type VD4, 36 kV and 40.5 kV, Rated short-circuit breaking current 31.5 kA: Shows curves for rated currents of 1250 A, 1600 A, 2000 A, and 2500 A.

2.5 Dimensions

See figures 2/2 and 2/3.

Figure 2/2: Dimension of withdrawable VD4 40.5kV

This diagram shows the overall dimensions of the withdrawable VD4 circuit-breaker. Key dimensions include:

• Overall width: 892 mm
• Overall height: 1575 mm
• Overall depth: 840 mm
• Pole centers: 360 mm (front) x 280 mm (side)

A table provides specific dimensions 'a' and 'b' for different rated currents:

• 1250/1600A: a = Ø74, b = Ø35
• 2000/2500A: a = Ø113, b = Ø79

Labels indicate:

• 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) are for handling only and must be removed before commissioning.

Figure 2/3: Dimension of fixed VD4 40.5kV

This diagram shows the overall dimensions of the fixed VD4 circuit-breaker, including:

• Overall width: 360 mm
• Overall height: 1294 mm
• Overall depth: 1575 mm

2.6 Circuit Diagrams

Figure 2/4: Circuit diagram for motor-charged operation mechanism

This diagram illustrates the electrical connections for the motor-charged operating mechanism. Key components and their functions are listed:

• Auxiliary circuit component in circuit breaker: S1 (Auxiliary switch on operating mechanism), S2 (Auxiliary switch on blocking magnet), S3, S4, S5 (Auxiliary switch on breaker shaft), S7 (Auxiliary switch for fault annunciation).
• Releases and Blocking Magnets: Y1 (Blocking magnet), Y2 (Shunt release OFF), Y3 (Shunt release ON), Y4 (Undervoltage release), Y7 (Indirect overcurrent release), Y9 (Second shunt release OFF).
• Series Rectifiers: V1, V2, V3, V4, V7, V9.
• Motor and Control: M0 (Charging motor for stored-energy spring), K0 (Anti-pumping relay), R0 (Series resistor).

Note: The diagram supports various DC and AC auxiliary voltages. Spring is shown discharged. Standard configurations are detailed in catalogues.

Figure 2/5: Circuit diagram for withdrawable VD4

This diagram shows the circuit breaker units in the switch position OFF and with the stored-energy spring mechanisms discharged. It details the auxiliary circuit components within the circuit breaker and in the truck, including:

• Auxiliary circuit component in circuit breaker: X0 (Socket with 58 pins), Y1 (Closing block magnet), Y2 (1st Shunt release OFF), Y3 (Closing release), Y4 (Undervoltage release), Y7 (Indirect overcurrent release), Y9 (2nd Shunt release OFF), S1 (Auxiliary switch on mechanism), S2 (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 (Antipumping relay), V0-V9 (Series rectifier), M0 (Charging motor).
• Auxiliary circuit component in truck: S8 (Limit switch test position), S9 (Limit switch service position), Y0 (Block magnet on truck).

Figure 2/6: Circuit diagram for fixed VD4

This diagram shows the circuit breaker units in the switch position OFF and with the stored-energy spring mechanisms discharged for fixed installation. It lists similar auxiliary circuit components as Figure 2/5.

3 Structure and function

3.1 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, constructed in column form, are mounted on a torsionally rigid enclosure substructure with rollers. The live parts are protected within insulating material pole tubes. The current path during closing involves the upper contact arm, chamber holder, fixed contact (58.2) in the vacuum interrupter (58), moving contact (58.3), and roller contact to the lower contact arm (57.2). Switching motion is driven by an insulated coupling rod with internal contact force springs.

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, housed in the substructure, is a stored-energy spring type acting on the three breaker poles. Energy is stored by charging the spring mechanism. This mechanism consists of a drum (55.33) with a spiral spring, a charging system, latching and operating components, and linkages. It is suitable for autoreclosing due to short charging times. The mechanism is typically fitted with a charging motor, but manual charging is also possible. A rating plate (55.7) provides main data.

Basic version auxiliary equipment:

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

Additional equipment that 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

3.2.1 Releases, blocking magnet and auxiliary switches

(Figures 2/4 to 2/6, 3/3, 6/2, 7/7 and 7/8)

Releases and the blocking magnet are mounted at the bottom of the stored-energy spring mechanism. Auxiliary switch allocation is shown in figure 2/4.

• Auxiliary switch S1: Operated by charging condition indicator 55.8. Controls the charging motor (M1), acts as an interlock for shunt release ON Y3 when the spring is not charged, and signals switching readiness.
• Auxiliary switches S3, S4, S5: Operation depends on the circuit-breaker's switching position.
• Auxiliary switch S3: Interrupts circuits for shunt release OFF Y9 (open position) and shunt release ON Y3/blocking magnet Y1 (closed position).
• Auxiliary switch S4: Interrupts circuit for shunt release OFF Y2 (open position).
• Auxiliary switch S5: Can be configured with various contacts for control, annunciation, or interlock functions.
• Auxiliary switch S7: Single pole, fleeting contact (30 ms), provides a fault signal ("breaker released"). Operated via shunt release OFF Y2/Y9, undervoltage release Y4, or indirect overcurrent release Y7 for remote control.

Note on Releases:

• Shunt releases OFF (Y2) and ON (Y3) are for normal operation. Safety breaking uses the second shunt release OFF (Y9). These are solenoid types suitable for many cycles.
• Undervoltage release (Y4) and indirect overcurrent release (Y7) are safety/protection releases, not for normal switching.

3.3 Function

3.3.1 Charging of the spring energy store

(Figures 3/3, 3/10, 6/2, 6/6, 7/7 and 7/8)

The spring energy storage mechanism is charged via chain (55.34) and ratchet wheel (55.35), either automatically by a charging motor or manually using a charging lever (128). The charging condition is shown on indicator 55.8. For autoreclosing, the mechanism must be recharged after a closing operation (automatically by motor or manually).

3.3.2 Closing procedure

(Figures 3/4, 3/6, 6/1, 6/3 and 7/7)

Initiated manually by key (145) and ON-OFF shaft (54), or electrically by shunt release Y3. The release mechanism allows the drive shaft (55.30) to rotate, moving the contacts (58.3) via cam disk and links. This tensions the spring arrangement, applies contact force, and tensions opening springs. Overtravel accommodates contact erosion.

3.3.3 Opening procedure

(Figures 3/3, 3/6, 6/3 and 7/7)

Initiated manually by key (145) and ON-OFF shaft (54), or electrically by releases Y2, Y4, Y7, or Y9. The release mechanism allows the drive shaft (55.30) to turn, driven by the spring energy storage mechanism. The opening spring moves the contact (58.3) to the open position.

3.3.4 Autoreclosing sequence

An OFF-ON or OFF-ON-OFF sequence is activated by the protection system. The spiral spring must be charged, and the breaker closed. Recharging is automatic for motor-charged breakers, manual for others or if the motor fails. Opening during recharging is possible, but subsequent closing is blocked until charging is complete.

3.3.5 Quenching principle of the vacuum interrupter

Due to low vacuum pressure (10^-2 to 10^-6 Pa), a small contact gap provides high dielectric strength. The arc extinguishes at the first natural current zero. The small gap and high plasma conductivity result in low arc drop voltage and energy, extending contact and interrupter life.

Figures 3/1 - 3/10: Visual Descriptions

Figure 3/1: Withdrawable part with circuit-breaker, type VD4, operator's side. Shows the front view of the withdrawable unit, highlighting the operating mechanism housing and connection points.

Figure 3/2: Withdrawable part with circuit-breaker, type VD4, pole side. Shows the side view of the withdrawable unit, displaying the three vacuum interrupter poles. Labeled components include: 50.1 Earthing contact, 50.2 Front partition plate, 50.8 Wheel, 57.1 Upper contact arm, 57.2 Lower contact arm, 57.8 Insulating material pole tube.

Figure 3/3: Withdrawable part with circuit-breaker, type VD4, controls for the circuit-breaker. Shows a close-up of the control panel on the withdrawable unit. Labeled components include: 54 ON-OFF operating shaft, 54.1 Link rod, 55.4 Switch position indicator, 55.5 Operating cycle counter, 55.6 Socket for charging lever, 55.7 Rating plate, 55.8 Charging condition indicator.

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

Figure 3/5: Withdrawable part with circuit-breaker, type VD4, (pole side, below). Shows a lower view of the pole side of the withdrawable unit. Labeled components include: 50.1 Earthing contact, 50.3 Actuating pin, 50.4 Guide cam.

Figure 3/6: Partial section of a vacuum interrupter. A cutaway view of a single vacuum interrupter unit. Labeled components include: 58.1 Insulator, 58.2 Fixed contact, 58.3 Moving contact, 58.4 Metal bellows, 58.5 Screen, 58.6 Guide cylinder, 58.7 Lid.

Figure 3/7: Vacuum circuit-breaker, type VD4, for fixed installation, operating side. Shows the front view of a fixed installation VD4 circuit-breaker.

Figure 3/8: Vacuum circuit-breaker, type VD4, for fixed installation, terminal side. Shows the side view of a fixed installation VD4 circuit-breaker. Labeled components include: 50.8 Rollers, 57.1 Upper breaker terminal, 57.2 Lower breaker terminal, 57.8 Embedded pole.

Figure 3/9: Vacuum circuit-breaker, type VD4, for fixed installation, version with partition, terminal side. Shows another view of the fixed installation unit.

Figure 3/10: Indicators and controls on a circuit-breaker for fixed installation. Close-up of the control panel on a fixed installation unit. Labeled components include: 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, 55.8 Charging condition indicator.

4 Dispatch and storage

4.1 Condition on delivery

Factory-assembled circuit-breakers on withdrawable parts are checked for completeness and subjected to routine tests according to GB/T 11022, GB 1984, IEC 60694, DIN VDE 0607 IEC publication 62271-100 to verify correct structure and function.

4.2 Packaging

Circuit-breakers on withdrawable parts are mounted individually on wooden pallets, sealed in film and/or packed in cardboard. For overseas shipment, drying agent bags are inserted into the film-sealed packaging.

4.3 Transport

Loading of package units must be carried out using a crane, fork-lift truck, and/or trolley jack.

Notes:

• Avoid impact during handling.
• Do not subject to other damaging mechanical stresses.
• Lifting gear must not be attached to breaker poles or operating mechanism parts.
• When moving the withdrawable part, use sliding handles (51.2) for racking in/out of the switchgear panel or transport within the room. Do not apply force to the front partition plate (50.2).
• Handle modules by crane with bolted-on transport brackets (147) and suitable lifting ropes/harness.
• Ensure the circuit-breaker unit on the withdrawable part, with its high center of gravity, cannot tip over during handling.

Figure 4/1: VD4 breaker on withdrawable part

Diagram shows handling of a withdrawable unit. Emphasizes using transport bracket (147) and crane harness. Warns about the high center of gravity inducing tipping. Labels: 50.2 Front partition plate (do not stress), 147 Transport bracket (TK), 148 Transport profile (TP), CrB Crossbar.

Figure 4/2: VD4 breaker for fixed installation

Diagram shows handling of a fixed installation unit. Emphasizes using lifting lugs and warns about the high center of gravity inducing tipping.

4.4 Delivery

Consignee duties on receipt include checking for completeness and freedom from damage (e.g., moisture). Shortages, defects, or damage in transit must be documented on the consignment note and the shipper/carrier notified immediately.

Note: Always take photographs to document major damage.

4.5 Intermediate storage

Circuit-breaker units should be stored in the switch position OFF with stored-energy spring mechanisms discharged (Indicator DISCHARGED: A).

Conditions for optimum intermediate storage:

1. Devices with basic packaging or unpacked:
   • Store in a dry, well-ventilated storeroom compliant with GB/T 11022, IEC 60694, DIN VDE 0670.
   • Room temperature should not fall below -15°C.
   • Do not remove or damage packaging.
   • Unpackaged devices should be loosely covered with protective sheeting, ensuring sufficient air circulation. Check regularly for condensation.
2. Devices with seaworthy or similar packaging with internal protective sheeting:
   • Store transport units protected from weather, dry, and safe from damage.
   • Check packaging for damage.
   • Check drying agent upon arrival and at appropriate intervals.

5 Installation

(Figures 3/4, 4/1 and 4/2)

Perfect operation depends on careful and professional handling of the withdrawable part. Units must be allocated to the appropriate switchgear panel. Remove transport profile (148) and brackets (147). Insert the withdrawable part into the switchgear panel, checking for unimpeded motion and function sequences, including primary contact closing at the service position. Remove any dirt.

When switchgears operate in areas with high humidity and/or rapid temperature fluctuations, there is a risk of dew deposits. Provisions should be taken according to section 1.3.2 (special operating conditions).

6 Commissioning/Operation

(Figures: 3/2, 3/3, 3/10, 6/1 to 6/7)

6.1 Note on safety at work

• Switchgear may only be operated by specially trained personnel familiar with the device characteristics.
• Operating the circuit breaker in normal condition in accordance with GB/T 11022 and IEC 60694 is a prerequisite for fault-free operation.

6.2 Preparatory activities

(Prior to application of primary voltage)

• Check the circuit-breaker for damage and restore to proper conditions if necessary.
• Remove contamination from transit, storage, or installation.
• Check primary connections and earthing contact (50.1).
• For motor-operated mechanisms, check the charging motor by applying auxiliary voltage.
• For manual charging mechanisms, charge the stored energy spring by hand (see Section 6.3.1).
• Perform a trial opening or closing operation using the double bit key (145) on the ON-OFF operating shaft (54), considering auxiliary voltage and interlocks. Observe switch position indicator (55.4) and charging condition indicator (55.8).
• Further procedures depend on the interaction of the truck with the switchgear cubicle. Refer to the Operation Manual for switchgear.
• Ensure the Instruction Manual is available to operators.

6.3 Operation of the circuit-breaker

(Figures 6/1 to 6/3 and 6/6, 6/7)

6.3.1 Charging the spring energy storage mechanism

Circuit-breakers with charging motors: Charging is automatic. If the motor fails, charging can be completed manually.

Circuit-breakers with manual charging mechanisms: Insert charging lever (128) into socket (55.6) and pump up and down for approximately 25 strokes until the charged condition is displayed. The mechanism disengages automatically when charged.

Note: Manual charging should only occur when the truck is in the test/disconnected or removed position.

Key to charging condition indications:

• A [Discharged]
• AIID [Charged]

A precondition for an autoreclosing sequence is that the operating mechanism is recharged (automatically or manually).

6.3.2 Closing and opening

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

Mechanical control allows manual operation even with the cubicle door closed: Fit double bit key (145) onto ON-OFF operating shaft (54) and turn approximately 15° clockwise to close or anti-clockwise to open.

The operating cycle counter (55.5) increments with each switching cycle. The switch position indicator (55.4) shows the breaker's position. The anti-pumping relay (K0) prevents repeated ON-OFF operations if a closing command is active when the breaker trips.

6.3.3 Operating sequence

Circuit-breaker with motorized charging of the stored-energy spring mechanism

Figures 6/1 - 6/7: Visual Descriptions

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

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

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). Shows manual breaker operation using key 145. Labeled components: 54 ON-OFF operating shaft, 145 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. Shows using hand crank 146 for moving the unit. Labeled components: 52 Spindle, 52.1 Square spigot, 146 Hand crank.

Figure 6/5: Interlock yoke with sliding handles which will be moved inwards to release the withdrawable part for withdrawing from the panel. Details the interlock mechanism. Labeled components: 51 Interlock yoke, 51.1 Catch pin, 51.2 Sliding handle, 51.4 Blocking shaft.

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

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

7 Maintenance

Maintenance ensures trouble-free operation and the longest possible working life of the switchgear. It comprises inspection, servicing, and repair.

7.1 General

(Figure 7/1)

VD4 vacuum circuit-breakers are robust and have a long life expectancy. Operating mechanisms require low maintenance, and interrupters are maintenance-free. The vacuum is not adversely affected by frequent switching. Servicing intervals depend on environmental influences, switching sequences, and short-circuit operations. With proper maintenance, service life can exceed 30,000 operating cycles.

Note: For all maintenance work, observe relevant specifications (Section 1.2.2), safety notes (Section 6.1), and country-specific standards. It is recommended to use ABB Xiamen Switchgear Limited Co. after-sales service personnel for servicing and repair.

Note: Extreme care is required during repair work on the operating mechanism, especially with front cover plates removed, to prevent accidents (e.g., injury to hands). The spring energy in the mechanism can be released inadvertently.

7.2 Inspection and functional testing

7.2.1 Switching devices in general

Regular inspection (at least every 4 years under normal conditions, more frequently in unusual conditions) verifies the switching device's condition. Checks include visual examination for contamination, corrosion, moisture, and discharge phenomena. Inspection may be waived if the switchgear is permanently monitored.

7.2.2 Stored-energy spring mechanism

(Figures 7/2 to 7/5)

Functional testing is performed after 5000 operating cycles or during servicing. Before testing, switch off and isolate the outgoing feeder.

Scope of functional testing:

• Perform several switching operations under no load.
• Switch off the charging motor (if fitted) and discharge the spring mechanism by ON/OFF switching.
• Examine lubrication on bearings and sliding surfaces.
• Check mechanical/electrical sequence of functions.
• Check circuit breaker's appearance.

7.2.3 Checking auxiliary switch settings on withdrawable part

(Figures 6/4, 6/6, 2/5 and 7/2)

Auxiliary switches S8 and S9 ensure interlock conditions in test/disconnected and service positions. The withdrawable part is moved by hand with crank 146 for testing.

1. Settings in the test/disconnected position area: Move the part towards service, then back. Auxiliary switch S8 should operate when the crank has a remaining angle of +60° to reach the stop. Slowly insert until S8 operates; closing push rod (55.2) must still be movable. Deactivate blocking magnet Y0 (if fitted) for this test.
2. Settings in the service position area: Move the part towards test/disconnected, then forward. Auxiliary switch S9 should operate when the crank has a remaining angle of +60° to reach the stop.

7.2.4 Testing of interlock conditions

(Figures 6/4, 6/6, 2/4, 2/5 and 7/2)

Testing procedures for the withdrawable part:

1. The withdrawable part moves from test/disconnected to service position only when the circuit-breaker is open. With the breaker closed, insertion towards service is blocked after half a crank turn clockwise. With the earthing switch closed, insertion is blocked after two clockwise turns. Do not use force.
2. The withdrawable part moves from service to test/disconnected position only when the circuit-breaker is open. With the breaker closed, withdrawal is blocked after half a crank turn anti-clockwise.
3. Closing the circuit-breaker is only possible when the withdrawable part is in the test/disconnected or service position (control plug 10.2 inserted). Closing is blocked in intermediate positions. Enabling of switching into service position is electrical via S9; into test/disconnected position is via S8.
4. Opening the circuit-breaker (manually) is only possible when the withdrawable part is in the service or test/disconnected position and control voltage has failed.

7.2.5 Breaker pole

No inspection of the breaker pole is necessary beyond the stipulations of section 7.2.1.

7.3 Servicing

7.3.1 Switching devices in general

If cleaning is necessary, isolate and secure the working area against reclosing. Cleaning surfaces: use a soft, dry cloth for dust; slightly alkaline cleanser or Rivolta BWR 210 for contamination. For insulating material and conductive components: Rivolta BWR 210 for light contamination, cold cleanser 716 for strong contamination. Wipe with clean water and dry. Observe manufacturer's instructions. Use only halogen-free cleansers.

7.3.2 Stored-energy spring mechanism

Servicing is recommended after 10 years or 10,000 operating cycles. Switch off the breaker and isolate the feeder. Discharge the spring mechanism by closing and opening the breaker once. Replace stressed parts after 10,000 cycles. Neutralize spring tension before replacing parts. Relubricate bearings with Isoflex Topas NB 52. Check fasteners and replace removed ones. Perform mechanical and electrical functional tests. This work requires qualified personnel.

7.3.3 Breaker pole

The breaker pole is maintenance-free up to the permissible number of vacuum interrupter operating cycles (Section 2.4). Vacuum checks are only needed if external force might have damaged the pole tube. If damaged, the pole may need replacement. Replacement is required when the sum current limit or the maximum mechanical operating cycles are reached. Consider replacing the entire breaker if advantageous.

Note: Dismantling and replacement of poles should only be done by ABB after-sales service personnel or specially trained personnel.

7.4 Repair

Replacement of circuit-breaker parts and accessories. Ensure the breaker is switched off, the area isolated, and the spring energy storage mechanism discharged. Disconnect all auxiliary voltage sources.

7.5 Spare parts and auxiliary materials

Auxiliary materials

Figures 7/1 - 7/5: Visual Descriptions

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. Shows initial steps for accessing the mechanism. Labeled components: 50.6 Cover plate (right), 50.7 Cover plate (left), 51 Interlock yoke, 54 ON-OFF operating shaft, 54.1 Link rod.

Figure 7/2: Auxiliary switches for interlocking withdrawable part and switchgear panel (withdrawable part in service position). Illustrates interlock switches. Labeled components: 10 Control wiring plug connector, 10.1 Control wiring socket, 10.2 Control wiring plug, 10.4 S8 limit switch (test position), 10.5 S9 limit switch (service position), 51 Interlock yoke, 51.3 Guiding rail (panel), 54 ON-OFF operating shaft.

Figure 7/3: The spring-loaded operating mechanism in the frame of the withdrawable part, front cover plates removed. Detailed view of the mechanism. Labeled components: 45 Magnet holder, 54.1 Link rod, 55.2 ON push rod, 55.3 OFF push rod, 55.4 Switch position indicator, 55.5 Operating cycle counter, 55.6 Socket for charging lever, 55.8 Charging condition indicator, 55.30 Drive shaft, 55.33 Drum with spiral spring, 55.34 Chain, 55.35 Ratchet wheel, 55.36 Charging motor.

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

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

8 Application of the X-ray regulations

Vacuum insulation can emit X-rays when the contact gap is open. Type tests by the Physikalisch-Technische Bundesanstalt (PTB) show that local dosage output does not exceed 1 Sv/h at 10 cm distance.

Results:

• Use of vacuum interrupters at rated voltage is safe.
• Application of rated power frequency withstand voltage (VDE 0670, IEC 62271-100:2001) is safe.
• Higher voltages than specified must not be applied.
• Fulfillment of these requirements depends on maintaining the specified contact distance, ensured by correct mechanism function and force transmission.

Comparison of designations

This table compares VDE-DIN 40719 Part 2 designations with IEC 61346-1/IEC 61346-2 designations for various components.

ABB Contact Information

ABB Xiamen Switchgear Co., Ltd.
ABB Industrial Park,
Torch High-Tech Zone,
Xiamen, Fujian, P.R.China
Tel: 86 592 602 6033
Fax: 86 592 603 0505
Zip Code: 361006
Customer Hot Line: 86 592 603 0523
http://www.abb.com.cn/mv

ABB (Hong Kong) Limited
3 Dai Hei Street
Tai Po Industrial Estate
Tai Po, HongKong
Tel: (852) 2929 3838
Fax: (852) 2929 3553

Regional Sales Organizations (Examples):

• Xi'an Sales Organization: Tel: (029) 8575 8288, Fax: (029) 8575 8299
• Fuzhou Sales Organization: Tel: (0591) 8785 8224, Fax: (0591) 8781 4889
• Chengdu Sales Organization: Tel: (028) 8526 8800, Fax: (028) 8526 8900
• Chongqing Sales Organization: Tel: (023) 6282 6688, Fax: (023) 6280 5369
• Zhengzhou Sales Organization: Tel: (0371) 6771 3588, Fax: (0371) 6771 3873
• Ningbo Sales Organization: Tel: (0574) 8731 5290, Fax: (0574) 8731 8179
• Dongguan Sales Organization: Tel: (0769) 280 6366, Fax: (0769) 280 6367
• Beijing Head Sales Organization: Tel: (010) 8456 6688, Fax: (010) 8456 7613
• Tianjin Sales Organization: Tel: (022) 8319 1801, Fax: (022) 8319 1802
• Shenyang Sales Organization: Tel: (024) 2334 1818, Fax: (024) 2334 1306
• Harbin Sales Organization: Tel: (0451) 8287 6400/6410, Fax: (0451) 8287 6404
• Dalian Sales Organization: Tel: (0411) 8899 3355, Fax: (0411) 8899 3359
• Changchun Sales Organization: Tel: (0431) 892 6825, Fax: (0431) 892 6835
• Hohhot Sales Organization: Tel: (0471) 693 1122, Fax: (0471) 691 6331
• Hefei Sales Organization: Tel: (0551) 384 9700, Fax: (0551) 384 9707
• Shanghai Sales Organization: Tel: (021) 6122 8888, Fax: (021) 6122 8822
• Hangzhou Sales Organization: Tel: (0571) 8790 1355, Fax: (0571) 8790 1151
• Nanjing Sales Organization: Tel: (025) 8664 5645, Fax: (025) 8664 5338
• Jinan Sales Organization: Tel: (0531) 8609 2726, Fax: (0531) 8609 2724
• Qingdao Sales Organization: Tel: (0532) 8502 6396, Fax: (0532) 8502 6395
• Changsha Sales Organization: Tel: (0731) 268 3088, Fax: (0731) 444 5519
• Urumqi Sales Organization: Tel: (0991) 283 4455, Fax: (0991) 281 8240
• Guangzhou Sales Organization: Tel: (020) 3785 0688, Fax: (020) 3785 0608
• Wuhan Sales Organization: Tel: (027) 8725 9222, Fax: (027) 8725 9233
• Shenzhen Sales Organization: Tel: (0755) 8831 3088, Fax: (0755) 8831 3033
• Kunming Sales Organization: Tel: (0871) 315 8188, Fax: (0871) 315 8186
• Nanning Sales Organization: Tel: (0771) 236 8316, Fax: (0771) 236 8308
• Wuxi Sales Organization: Tel: (0510) 8279 1133, Fax: (0510) 8279 1236
• Taiyuan Sales Organization: Tel: (0351) 868 9292, Fax: (0351) 868 9200

We reserve the right to make changes in the course of technical development.