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 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.

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 Contents

1 Summary 5 4.1 Condition on delivery 18

1.1 General 5 4.2 Packaging 18
1.2 Standards and specifications 5 4.3 Transport 18
1.2.1 Switchgear manufacture 5 4.4 Delivery 19
1.2.2 Installation and operation 5 4.5 Intermediate storage 19
1.3 Operating conditions 5
1.3.1 Normal operating conditions 5 5 Installation 20
1.3.2 Special operating conditions 5
6 Commissioning/Operation 21
2 Technical data 6 6.1 Note on safety at work 21
2.1 Technical data 6 6.2 Preparatory activities 21
Circuit-breakers for fixed installation 6.3 Operation of the circuit-breaker 21
and on withdrawable part 6.3.1 Charging the spring energy storage mechanism
2.2 Technical data 7 Circuit-breakers with charging motors 21
Releases and blocking magne 6.3.2 Closing and opening 21
2.3 Technical data 7 6.3.3 Operating sequence 22
Motor-operated mechanisms
2.4 Permissible number of vacuum interrupter 8 7 Maintenance 25
switching operations in relation to breaking 7.1 General 25
current 7.2 Inspection and functional testing 25
2.5 Dimensions 9 7.2.1 Switching devices in general 25
7.2.2 Stored-energy spring mechanism 25
3 Structure and function 13 7.2.3 Checking auxiliary switch settings on
3.1 Structure of the breaker poles 13 withdrawable part 25
3.2 Structure of the breaker operating mechanism 13 7.2.4 Testing of interlock conditions 26
3.2.1 Releases, blocking magnet and auxiliary switches 13 7.2.5 Breaker pole 26
3.3 Function 14 7.3 Servicing 26
3.3.1 Charging of the spring energy store 14 7.3.1 Switching devices in general 26
3.3.2 Closing procedure 14 7.3.2 Stored-energy spring mechanism 27
3.3.3 Opening procedure 14 7.3.3 Breaker pole 27
3.3.4 Autoreclosing sequence 14 7.4 Repair 27
3.3.5 Quenching principle of the vacuum interrupter 14 7.5 Spare parts and auxiliary materials 28

4 Dispatch and storage 18 8 Application of the X-ray regulations 31

4 Contents | VD4 Vacuum Circuit-breaker

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 1 Summary

1.1 General ■ Health and Safety at Work Standard VBG 4

The vacuum circuit-breakers of type VD4 on with-drawable ■ Safety guidelines for auxiliary and operating materials
parts for 36 kV or 40.5 kV rated voltage are intended for ■ Order related details provided by ABB Xiamen Switchgear
indoor installation in air-insulated switchgear systems. Their Co.,Ltd.
switching capacity is sufficient to handle any conditions arising
from switching of equipment and system components under 1.3 Operating conditions
normal operating and fault conditions, particularly short- 1.3.1 Normal operating conditions
circuits, within the parameters of their technical data. Design to GB/T 11022, "Common specification for high-voltage
switchgear and controlgear standards", IEC 62217-1, VDE0670
Vacuum circuit-breakers have particular adswitching frequency part 1000, with the following limit values:
in the working current range and/or where a certain number ■ Ambient temperature:

of short-circuit breaking operations are expected. Type VD4 ■ Maximum +40℃

vacuum circuit-breakers are suitable for auto-reclosing, and ■ Highest mean value measured in 24 hours +35℃
have exceptionally high operating reliability and long life. ■ Minimum (according to "minus 5 indoor class") -15℃

The vacuum circuit-breakers designed in column form, are ■ Humidity

supplied as withdrawable modules. Their basic structure is ■ Highest mean value of relative humidity measured over
shown in figures 3/1,3/2,3/7 and 3/8. 24 hours 95%
■ Highest mean value of vapour pressure measured over
1.2 Standards and specifications 24 hours 2.2kPa
1.2.1 Switchgear manufacture ■ Highest mean value of relative humidity measured over
The switchgear complies with the following specifications in 1 month 90%
accor dance wi th G B, I EC and the rel evant DIN VDE ■ Highest mean value of vapour pressuremeasured over
publications respectively. 1 month 1.8kPa

■ GB/T 11022, IEC 62271-1 and DIN VDE 0670 part 1000, ■ Maximum site altitude:
"Common specifications for highvoltage switchgear and 1000m above sea level
controlgear standards".
1.3.2 Special operating conditions
■ GB 1984 and IEC 62271-100, "High-voltage alternating- Special operating conditions are to be agreed on by the
current circuit-breakers". manufacturer and user. The manufacturer must be consulted
in advance about each special operating condition:
1.2.2 Installation and operation ■ Site altitude over 1000 m:

The relevant specifications are to be taken into account during ■ Allow for the reduction in the dielectric strength of the

installation and operation, particularly: air.

■ IEC 61936-1, Electrical devices with rated voltage above ■ Increased ambient temperature:

AC 1 kV ■ Current carrying capacity is reduced.

■ DIN VDE 0101, Power installations exceeding AC 1 kV ■ Provide additional ventilation for heat dissipation.

■ DIN VDE 0105, operation of electrical installations

■ DIN VDE 0141, earthing systems for special power ■ Climate:

installations with rated voltages over 1 kV ■ Avoid the risk of corrosion or other damage in areas:

■ Accident prevention regulations issued by the appropriate ○ with high humidity and/or
professional bodies or comparable organisations. ○ with major rapid temperature fluctuations.

In Germany, these comprise the following safety regulations: ■ Implement preventive measures (e.g. electric heaters)
■ Health and Safety at Work Standard VBG 1 to preclude condensation phenomena.

VD4 Vacuum Circuit-breaker | Summary 5

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 2 Technical data

2.1 Technical data

circuit-breakers for fixed installation and on withdrawable part
Rated voltage kV 36 40.5
Rated frequency Hz 50/60 50/60
Rated lightning impulse withstand voltage kV 170 185
Rated power frequency withstand voltage(1min) kV 70 95
Rate of rise of transient recovery voltage kV/ s 0.57 0.69
Peak of transient recovery voltage kV 62 70
Rated operating sequence O-3min-CO-3min-CO
Rated operating sequence with autoreclosing O-0.3s-CO-3min-CO

Breaker- Rated Rated Rated Rated Rated Rated Pole Weight

type voltage current short-circuit short-circuit short-circuit short-circuit Centres
breaking breaking mreaking duration Fixed With- Fixed With-
current, current, current, draw- draw-
symm.1) asymmetr. 1) (peak.)1) able able

VD4... kV A kA kA kA s mm approx. kg
3612-25 36 1250 25 27.3 63 4 360 280 320 290
3616-25 36 1600 320 290
3620-25 36 2000 355 340
3625-25 36 2500 355 340

3612-31 36 1250 31.5 34.3 80 4 360 280 320 290

3616-31 36 1600 320 290
3620-31 36 2000 355 340
3625-31 36 2500 355 340

4012-25 40.5 1250 25 27.3 63 4 360 280 290 290

4016-25 40.5 1600 290 290
4020-25 40.5 2000 340 340
4025-25 40.5 2500 340 340

4012-31 40.5 1250 31.5 34.3 80 4 360 280 290 290

4016-31 40.5 1600 290 290
4020-31 40.5 2000 340 340
4025-31 40.5 2500 340 340

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 ms 2 ) )
Minimum command time on opening 2)
20 ms (80 ms )
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

6 Technical data | VD4 Vacuum Circuit-breaker

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 2.2 Technical data
Releases and blocking magnet
Equipment Power consumption 1)
AC DC
VA W
Shunt release OFF Y23) , Y9 3) 250 250
Y24) , Y9 4) 310 310
Shunt release ON Y33) 250 250
Y34) 310 310
Blocking magnet Y13) 4)
10 10
Undervoltage release Y4
undelayed 11 10
delayed 10 -
Indirect overcurrent release Y7
with intermediate current transformer
two-phase 3.5 2) /15 -
three-phase 2.0 2)
/15 -
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 voltages AC: 240 V, DC: 125 and 240 V.

2.3 Technical data

Motor-operated mechanisms
Auxiliary consumption1) Charging time
voltage Power (maximum)2)
V VA/W s
AC
110 200 15
220 200 15
240 200 15
DC
24 180 15
30 180 15
48 180 15
60 180 15
110 190 15
125 190 15
220 190 15
240 190 15
1)
Approximate values
2)
At the rated auxiliary voltage

VD4 Vacuum Circuit-breaker | Technical data 7

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 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 I a
Figure 2/1
10 5 10 5
8 8
6 6

4 Rated 4 Rated
3 current 3 current
1250 A 1250 A
2 2
1600 A 1600 A
2000 A 2000 A
4 4
10
2500 A 10 2500 A
8 8
6 6

4 4
3 3

2 2

3 3
10 10
8 8
6 6

4 4
3 3

2 2

2
10 10 2
8 8
6 6

4 4
3 3

2 2

10 10
8 8
6 6
5 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 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) Breaking current I a (kA)

a) Circuit-breaker type VD4, 36 kV and 40.5 kV b) Circuit-breaker type VD4, 36 kV and 40.5 kV
Rated short-circuit breaking current 25 kA Rated short-circuit breaking current 31.5 kA

8 Technical data | VD4 Vacuum Circuit-breaker

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 2.5 Dimensions
See figure 2/2,2/3.
Fig. 2/2 Dimension of withdrable VD4 40.5kV | Fig. 2/3 Dimension of fixed VD4 40.5kV

Fig. 2/2

TK = Transport bracket 147

TP = Transport profile 148
K = Entrance for control cables
50.2 = Front partition plate

Rated current a b
1250/1600A O 74 O 35
2000/2500A O 113 O79
Note:
Transport bracket TK (147) and transport
profile TP (148) only fitted for handling.
Remove and store prior to commissioning.

Fig. 2/3 390

260
DETAIL A
40

360 360

A
62

36

14
36
Vacuum circuit-breaker for fixed
installation：
35
4- 11 ...1250A = 1×80×10mm
40
124 435 60 ＞1250...2000A = 2×80×10mm
61 139.5 445
555 2500A = 3×80×10mm
868 535 75
920 685
1065
1105

VD4 Vacuum Circuit-breaker | Technical data 9

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 Fig. 2/4 Circuit diagram for motor-charged operation mechanism
Fig. 2/4

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 Y1 Blocking magnet V3 Series rectifier for Y3 and KO
S2 Auxiliary switch on blocking magnet Y2 Shunt release OFF V4 Series rectifier for Y4
S3 Auxiliary switch on the breaker shaft Y3 Shunt release ON V7 Series rectifier for Y7
S4 Auxiliary switch on the breaker shaft Y4 Undervoltage release V9 Series rectifier for Y9
S5 Auxiliary switch on the breaker shaft Y7 Indirect overcurrent release MO Charging motor for stored-energy spring
S7 Auxiliary switch for fault annunciation Y9 Second shunt release OFF KO Anti-pumping relay
(fleeting contact, time≥ 30 ms) V1 Series rectifier for Y1 RO Series resistor
V2 Series rectifier for Y2

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, KO, S1, S3, S4, MO
2) Motor charged, withdrwable version: Y1, Y2, Y3, KO, S1, S2, S3, S4, S8, S9, MO
Any requirement exceed mentioned above, should be declared in the contract.

10 Technical data | VD4 Vacuum Circuit-breaker

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 Fig. 2/5 Circuit diagram for withdrawable VD4
Fig. 2/5

VD4 Vacuum Circuit-breaker | Technical data 11

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 Fig. 2/6 Circuit diagram for fixed VD4
Fig. 2/6

12 Technical data | VD4 Vacuum Circuit-breaker

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 3 Structure and function

3.1 Structure of the breaker poles spring

(Figures 3/1, 3/2 , 3/6, 3/7 and 3/8) ■ Mechanical operating cycle counter 55.5.

The 36 kV and 40.5 kV circuit-breakers of type VD4 are ■ Motor charging mechanism

designed as withdrawable units. The poles, which are ■ Five-pole auxiliary switch S1 to switch the charging motor

constructed in column form, are mounted on a torsionally ■ Anti-pumping relay K0.

rigid enclosure substructure with rollers. The live parts of the

breaker poles are located in the insulating material pole The following additional equipment can be installed:
tubes and protected fr om impacts and other external ■ Blocking magnet Y0 on the withdrawable part

influences. ■ Second shunt release OFF Y9

■ Indirect overcurrent release Y7

With the breaker closed, the current path leads from the ■ Auxiliary switch S7 for electrical opening signalling

upper contact arm 57.1 and a chamber holder fixed in the ■ Undervoltage release Y4

pole tube to the fixed contact 58.2 in the vacuum interrupter ■ Five-pole auxiliary switch S5

58, then via the moving contact 58.3 and roller contact
to the lower contact arm 57.2. The switching motion is 3.2.1 Releases, blocking magnet and auxiliary switches
effected by means of the insulated coupling rod with internal (Figures 2/4 to 2/6, 3/3, 6/2, 7/7 and 7/8)
contact force springs. The releases and the blocking magnet are mounted at the
bottom of the stored-energy spring mechanism.
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 allocation of the auxiliary switches can be seen in the
The operating mechanism located in the housing substructure wiring diagram of figure 2/4.
is of the stored-energy spring type and acts on the three
breaker poles. The necessary operating energy is stored The five-pole auxiliary switch S1 is operated by the charging
ready for activation by charging the spring energy storage condition indicator 55.8. It controls the charging motor M1,
mechanism. serves as an electrical interlock for shunt release ON Y3 when
the spring energy storage mechanism is not sufficiently
The stored-energy spring mechanism essentially consists charged, and also provides an electrical switching readiness
of drum 55.33 containing the spiral spring, the charging signal.
system, the latching and operating mechanism and the
linkages which transmit the force to the breaker poles. In Operation of the five-pole auxiliary switches S3, S4 and S5
addition, there are supplementary components such as the is dependent on the switching position of the circuit-breaker.
charging motor, releases, auxiliary switches and the controls
and instruments. Auxiliary switch S3 interrupts the circuit of the optional
additional shunt release OFF Y9 with the circuit-breaker
The operating mechanism is fundamentally suitable for in the open position, and the circuits of shunt release ON Y3
autoreclosing and, due to the short charging times, also for and the optional blocking magnet Y1 with the circuit-breaker
multi-shot autoreclosing. in the closed position. There is one further NOC for other
purposes.
The operating mechanism is normally fitted with a charging
motor. There is also a facility for charging the stored energy Auxiliary switch S4 interrupts the circuit of shunt release
spring manually. OFF Y2 with the circuit-breaker in the open position. One
further NOC and three NCCs are available for annunciation,
There is one rating plate 55.7 with the main data of the switch control and interlock purposes.
equipment on front cover plate left hand side 50.7, and
another on breaker mechanism housing. Auxiliary switch S5 can be optionally designed with any
possible combination of contacts from five NOCs to five NCCs.
The basic version of the stored-energy spring mechnism Its contacts are available for any required control, annunciation
is fitted with the following auxiliary equipment: or interlock functions. The auxiliary switch is normally configured
■ Shunt release OFF Y2 as shown in figure 7/3.
■ Shunt release ON Y3

■ Blocking magnet Y1 with auxiliary switch S2 The single pole auxiliary switch S7 (fleeting contact time 30
■ Five-pole auxiliary switches S3 and S4 ms) serves to provide a fault signal ("breaker released").
■ ON-OFF operating shaft 54 With remote control, the auxiliary switch is necessarily operated
■ Mechanical switch position indicator 55.4 via:
■ Charging condition indicator 55.8 for the stored energy ■ Shunt release OFF Y2 or

VD4 Vacuum Circuit-breaker | Structure and function 13

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 ■ Shunt release OFF Y9 or spring arrangement is tensioned and the appropriate amount
■ Undervoltage release Y4 or of contact force thus applied. The available overtravel is
■ Indirect overcurrent release Y7. higher than the maximum value of contact erosion during
lifetime of the interrupter. During the closing process,
Note: opening springs are simultaneously tensioned.
1. Shunt releases OFF (Y2) and ON (Y3) are exclusively
provided for opening and closing in normal operation. For 3.3.3 Opening procedure
safety breaking operations, the second shunt release OFF (Figures 3/3, 3/6, 6/3 and 7/7)
(Y9) must be used, in most cases with a separate control The opening procedure is initiated manually by the double
voltage supply. bit key 145 and the ON-OFF operating shaft 54, or electrically
by activation of one of the releases Y2, Y4, Y7 or Y9.
These three releases are of the solenoid type and suitable Release mechanism then permits drive shaft 55.30 to be
for a large number of operating cycles. turned further by the spring energy storage mechanism,
which is still sufficiently charged. The opening spring, which
2. The under voltage release (Y4) and/or indirect over current is thus released, moves the contact 58.3 into the open position
release (Y7) are pure safety and protection releases and at a defined speed.
must not be used for switching in normal operation
3.3.4 Autoreclosing sequence
3.3 Function An OFF-ON or OFF-ON-OFF autoreclosing sequence is
3.3.1 Charging of the spring energy store activated and checked by the protection system. It is necessary
(Figures 3/3, 3/10, 6/2, 6/6, 7/7 and 7/8) for the spiral spring in the operating mechanism to be in
To provide the necessary motive energy, the spring energy the (re-)charged condition, with the circuit-breaker in the
storage mechanism is charged via chain 55.34 fitted with closed position. The (re-)charging process is carried out
ratchet wheel 55.35, either automatically by a charging motor automatically after closing of the breaker on breakers
or by hand in a vertical pumping action with charging lever with motor charging mechanisms, but must be carried out
128. The current charging condition is shown at charging manually on breakers without charging motors (or when the
condition indicator 55.8 charging motor has broken down). Opening of the breaker
is also possible during the (re-)charging process, but sub-
As a precondition for an autoreclosing sequence, the sequent closing of the breaker is however blocked until the
operating mechanism is either (re-)charged after a closing charging process has been completed.
operation automatically by the charging motor, or it requires
(re-)charging by hand if the operating mechanism is of the 3.3.5 Quenching principle of the vacuum interrupter
manual type. Due to the extremely low static interrupter chamber pressure
of 10-2 to 10-6 pa, only a relatively small contact gap is required
3.3.2 Closing procedure to achieve a high dielectric strength. The arc is extinguished
(Figures 3/4, 3/6, 6/1, 6/3 and 7/7) on one of the first natural current zeros.
The closing process is initiated manually by the double
bit key 145 and the ON-OFF operating shaft 54, or electrically Due to the small contact gap and the high conductivity of
by activation of shunt release Y3. The release mechanism the metal vapour plasma, the arc drop voltage, and additionally,
then permits drive shaft 55.30 to be rotated by the (previously) due to the short arcing time, the associated arc energy, are
charged spiral spring. The moving contact 58.3 in vacuum extremely low, which has advantageous effects on the life
interrupter 58 is moved until the contacts touch by cam disk of the contacts and thus on that of the vacuum interrupters.
and further kinematic links. In the further sequence of motion,

14 Structure and function | VD4 Vacuum Circuit-breaker

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 Figure 3/1 Figure 3/2

50.2

57.1

57.8

57.2

50.1

50.8

50.1 Earthing contact 57.1 Upper contact arm

50.2 Front partition plate 57.2 Lower contact arm
50.8 Wheel 57.8 Insulating material
pole tube

Figure 3/3

54

54.1

55.8

55.6

55.5
54 ON-OFF operating shaft
54.1 Link rod
55.4
55.4 Switch position indicator
55.7 55.5 Operating cycle counter
55.6 Socket for charging lever
55.7 Rating plate
55.8 Charging condition indicator

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
Figure 3/3: Withdrawable part with circuit-breaker, type VD4, controls for the circuit-breaker

VD4 Vacuum Circuit-breaker | Structure and function 15

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 Figure 3/4 Figure 3/5
51.2
51

51.1

147 50.1

50.4
50
50.3

50.4

50.3

148

50 Frame of the withdrawable part 51.1 Catch pin 50.1 Earthing contact
50.3 Actuating pin 51.2 Sliding handle 50.3 Actuating pin
50.4 Guide cam 147 Transport bracket 50.4 Guide cam
51 Interlock yoke 148 Transport profile

Figure 3/6

58.1

58.2 58.1 Insulator

58.3 58.2 Fixed contact
58.3 Moving contact
58.4
58.4 Metal bellows
58.5 58.5 Screen
58.6 Guide cylinder
58.7
58.7 Lid
58.6

Figure 3/4: Withdrawable part with circuit-breaker, type VD4, left and operator's side view
Figure 3/5: Withdrawable part with circuit-breaker, type VD4, (pole side, below)
Figure 3/6: Partial section of a vacuum interrupter.

16 Structure and function | VD4 Vacuum Circuit-breaker

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 Figure 3/7 Figure 3/8

50.8 Rollers 57.2 Lower breaker terminal

57.1 Upper breaker terminal 57.8 Embedded pole

Figure 3/9 Figure 3/10

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

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
Figure 3/9: Vacuum circuit-breaker, type VD4, for fixed installation, version with partition, terminal side
Figure 3/10: Indicators and controls on a circuit-breaker for fixed installation

VD4 Vacuum Circuit-breaker | Structure and function 17

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 4 Dispatch and storage

4.1 Condition on delivery Notes:

■ The factory-assembled circuit-breakers on withdrawable ■ Avoid impact during handling.
parts are checked at the works for completeness of the ■ Do not subject to other damaging mechanical
equipment installed and simultaneously subjected to a stresses.
routine test in accordance with GB/T 11022 GB 1984, IEC ■ Lifting gear must not be attached to the breaker
60694,DIN VDE 0607 IEC publication 62271-100, thus poles or parts of the operating mechanism.
verifying their correct structure and function. ■ When moving the withdrawable part only use the
sliding handles 51.2 (e.g. for racking in/out the
4.2 Packaging circuit-breaker unit into/out of the switchgear
The circuit-breakers on withdrawable parts are mounted panel or for the transport of the unit in the
individually on wooden pallets and sealed in film and/or packed switchgear room). Do not bring any force on the front
in cardboard for delivery. partition plate 50.2 of the withdrawable part.

Packaging for overseas shipment: ■ Only handle the modules by crane with boltedon
■ Drying agent bags inserted in the filmsealed packaging. transport brackets 147, suitable lifting ropesand
crane harness.
4.3 Transport ■ E nsur e t ha t t he ci r cu it - b r eak er u ni t on t he
Loading of the package units must only be carried out with a withdrawable part, with its relative high situated
■ crane, centre of gravity, cannot tip over when moving it by
■ fork-lift truck and/or crane or fork-lift truck, or when handling it outside
■ trolley jack. the switchgear room.

Figure 4/1: VD4 breaker on withdrawable part | Figure 4/2: VD4 breaker for fixed installation

Figure 4/1 Figure 4/2

CrB

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 Transport bracket (TK) Only handle by crane when the lifting lugs are fitted.
148 Transport profile (TP) Always bear in mind that the high situated centre of gravity may
CrB Crossbar induce the breaker to tip over!

18 Dispatch and storage | VD4 Vacuum Circuit-breaker

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 4.4 Delivery ■ A dry and well ventilated storeroom with climate in
The duties of the consignee on receipt of the switching accordance with GB/T 11022, IEC 60694, DIN VDE 0670.
devices at site include the following: ■ Room temperature which does not fall below-15℃.
■ Checking the delivery for completeness and freedom ■ Do not remove or damage the packaging.
from damage (e.g. moisture and itsadverse effects). ■ Unpackaged devices:
■ Any short quantities, defects or damage intransit: ■ Are to be loosely covered with protective sheeting.

■ Must be precisely documented on the consignment note. ■ Sufficient air circulation must be maintained.

■ The shipper/carrier is to be notified immediately in ■ Check regularly for any condensation.

accordance with the liability provisions.
2. Devices with seaworthy or similar packaging with internal
Note: protective sheeting:
Always take photographs to document any major damage. ■ Store the transport units:

■ protected from the weather,

4.5 Intermediate storage ■ dry,

Intermediate storage of the circuit-breaker unit in the switch ■ safe from damage.

position OFF and the storedenergy spring mechanisms ■ Check the packaging for damage.

discharged (Indicator DISCHARGED: ). ■ Check the drying agent:

■ on arrival of the consignment,

Conditions for optimum intermediate storage: ■ subsequently at appropriate intervals.

1. Devices with basic packaging or unpacked:

VD4 Vacuum Circuit-breaker | Dispatch and storage 19

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 5 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.

■ 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 bracket s
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.

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).

20 Installation | VD4 Vacuum Circuit-breaker

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 6 Commissioning/Operation

(Figures: 3/2, 3/3, 3/10, 6/1 to 6/7) ■ When the charged condition is reached, the charging
mechanism automatically disengages, and further strokes
6.1 Note on safety at work of the charging lever have no effect.
■ The switchgear may only be operated by specially

tr a i ned p er s onn el who ar e f am i l i ar wi t h t he Note:

characteristics of the particular device. Charging of the spring energy storage mechanism by hand
■ Operating circuit-breaker in normal condition in should only take place when the truck is in the test/disconnected
accordance with relevant regulations in GB/T 11022, or removed position.
IEC 60694, is a precondition of faultfree operation.
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. Discharged Charged

■ Remove any contamination (particularly on the insulating As a precondition for an autoreclosing sequence, the
materials) which has occurred during transit, storage or operating mechanism is either (re-)charged after a closing
installation. operation automatically by the charging motor, or it requires
■ Check the primary connections and the earthing contact 50. (re-)charging by hand if the operating mechanism is of the
1. manual type.
■ Check the charging motor on circuit-breakers with
motor-operated mechanisms by applying auxiliary voltage. 6.3.2 Closing and opening
■ On breakers with manual charging mechanisms, charge the ■ Operate the local or remote electrical control unit.

stored energy spring by hand (see Section 6.3.1). ■ Observe switch position indicator 55.4.

■ Perform a trial opening or closing operation of the circuit-

breaker using the double bit key 145 at the ON-OFF The mechanical control system facilitates manual operation
operating shaft 54 (taking into account any required auxiliary of the circuit-breaker in the switchgear cubicle even with
voltage and any relevant interlocks). Observe switch position the door closed:
indicator 55.4 and charging condition indicator 55.8. ■ Fit double bit key 145 on ON-OFF operating shaft 54.

■ The further procedure results from the interaction of the ■ Turn the double bit key approx. 15 clockwiese until the stop

truck with the switchgear cubicle. is reached to close the circuit-breaker, or anti-clockwise
See the Operation Manual for the switchgearts. to open it.
■ Ensure that the Instruction Manual is available to the

operators at all times. The operating cycle counter 55.5 is automatically incremented
by one complete figure with each switching cycle. On
6.3 Operation of the circuit-breaker completion of a switching operation the switch position
(Figures 6/1 to 6/3 and 6/6, 6/7) indicator 55.4 in the window of front cover plate 50.7.
6.3.1 Charging the spring energy storage mechanism Circuit- shows the appropriate position of the circuit-breaker.
breakers with charging motors:
■ Charging takes place automatically. The anti-pumping relay K0 (wiring diagram in firgure 2/3)
■ If the charging motor breaks down, the charging process prevents repeated ON-OFF switching operations if, for
can be carried out or completed manually. example, the breaker is tripped by a protection relay in response
to a primary side fault while a permanent electrical closing
Circuit-breakers with manual charging mechanisms: command is simultaneously applied. The circuit-breaker can
■ Insert charging lever 128 into the socket 55.6 and pump then only be closed after the closing command has been
up and down for approx. 25 strokes until the charged interrupted.
condition is displayed.

VD4 Vacuum Circuit-breaker | Commissioning/Operation 21

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

Result of operation Possible subsequent

Operating sequence
Breaker Position Charging Condition switching operation

Switch on charging motor O -

Automatic charging O On-Off

Close breaker... and I Off

Off-On-Off or auto-
automatically (re-)charge I
reclosing sequence

Open breaker O On-Off

Close breaker... and I Off

Off-On-Off or auto-
automatically (re-)charge I
reclosing sequence

Autoreclosing Off O
sequence
(Activation via On I (automatic charging starts)
protection system)
Off O

Automatic charging completed O On-Off

Close breaker... and I Off

Off-On-Off or auto-
automatically (re-)charge I
reclosing sequence

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 Figure 6/1 Figure 6/2
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

50 Frame of the withdrawable part 51.2 Sliding handle 55.6 Socket for charging lever
50.4 Guide cam 52 Spindle 55.8 Charging condition indicator
50.6 Cover plate, right hand side 54.1 Link rod 128 Charging lever
50.7 Cover plate, left hand side 55.4 Switch position indicator
51 Interlock yoke 55.5 Operating cycle counter
51.1 Catch pin, (spring loaded) 55.7 Rating plate

Figure 6/3 Figure 6/4

54 145 146 52.1 52

54 ON-OFF operating shaft 52 Spindle

145 Triple bit key (ON-OFF operation) 52.1 Square spigot
146 Hand crank

Figure 6/1: Withdrawable part with circuit-breaker, type VD4, control area
Figure 6/2: Changing the store-energy spring mechanism manually by moving the inserted charging lever up and down
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)
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

VD4 Vacuum Circuit-breaker | Commissioning/Operation 23

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 Figure 6/5 Figure 6/6

51

51.2

51.4

51.1

128 145 146

51 Interlock yoke
128 Charging lever
51.1 Catch pin, spring loaded
145 Triple bit key (ON-OFF operation)
51.2 Sliding handle
146 Hand crank (for moving of the truck)
51.4 Blocking shaft (interlocking circuit-breaker and
withdrawable part)

Figure 6/7

54.2
54.3
55.8

55.6
54.2 Mechanical ON push-button
128
54.3 Mechanical OFF push-button
55.6 Socket
55.8 Charging condition indicator
128 Charging lever

Figure 6/5: Interlock yoke with sliding handles which will be moved inwards to release the withdrawable part for withdrawing from the panel
Figure 6/6: Operating accessories
Figure 6/7: Vacuum circuit-breaker, type VD4, for fixed installation. Manual charging of the stored-energy spring

24 Commissioning/Operation | VD4 Vacuum Circuit-breaker

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 7 Maintenance

Maintenance serves to ensure trouble-free operation and 7.2 Inspection and functional testing
achive the longest possible working life of the switchgear. 7.2.1 Switching devices in general
It comprises the following closely related activities: The proper condition of the switching device is to be verified
Inspection: Determination of the actual condition by regular inspection.
Servicing: Measures to maintain the specified condition
Repair: Measures to restore the specified condition Under normal operating conditions, testing by a qualified
personnel is to be performed at least every 4 years.
7.1 General
(Figure 7/1) In unusual operating conditions (including adverse climatic
Vacuum circuit-breakers are characterized by their simple conditions) and/or special environmental pollutions (e.g.
and robust construction. They have a long life expectancy. heavy contamination and aggressive atmosphere), inspection
Their operating mechanisms have a low maintenance may also be necessary at shorter intervals.
requirement, and the interrupters are maintenance-free during
their working life. There is no adverse effect on the Inspection at fixed intervals may be waived if the switchgear
vacuum, even from frequent switching of operating and short- is permanently monitored by a qualified personnel.
circuit currents.
The checks first and foremost comprise visual examination
The servicing intervals and scope are determined by f or cont am ination, corrosion, moist ur e and dischar ge
environmental influences, the switching sequences and phenomena.
number of short-circuit breaking operations.
If an incorrect condition is found, appropriate servicing
With carefully performed inspections and servicing work, measures are to initiated.
and under normal operating conditions, the circuit-breakers,
depending on the type, have a service life of up to 30,000 7.2.2 Stored-energy spring mechanism
operating cycles and more. (Figures 7/2 to 7/5)
Functional testing of the operating mechanism is to be
Note: The following must be observed for all maintenance work: performed:
■ The relevant specifications in section 1.2.2 ■ after 5000 operating cycles or during servicing work as set

■ Notes on safety at work in section 6.1 out in 7.2.1.

■ Standards and specifications in the country of ■ Prior to functional testing, switch the breaker off and

installation. isolate the outgoing feeder.

Maintenance work may only be performed by fully trained Scope of functional testing:
personnel, observing all the relevant safety regulations. It ■ Perform several switching operations under no load, above
is recommended that ABB Xiamen Switchgear Limited Co. all with circuit-breakers seldom operated in normal service.
after-sales service personnel should be called in, at ■ Switch off the charging motor (if fitted) and discharge

least during the performance of servicing and repair work. the spring mechanism by ON/OFF switching operations.
■ Examine visual the condition of the lubrication on rotary
While the work is in progress, all auxiliary voltage sources bearings, sliding surfaces, etc.
m us t al so b e d is con nect e d a nd sec ur ed t o pr eve nt ■ Check the proper mechanical/electrical sequence of the
reconnection. individual functions.
■ Check circuit-breaker's appearance.

Note: In order to prevent accidents (particularly injury to

hands!) extreme care should be taken during all 7.2.3 Checking auxiliary switch settings on withdrawable part
repair work on the operating mechanism, especially (Figures 6/4, 6/6, 2/5 and 7/2)
with front cover plates 50.6 and 50.7 removed. Compliance with the interlock conditions in the areas of
the test/disconnected position and the service position is
The spiral spring in the spring energy strage mechanism, ensured by auxiliary switches S8 and S9, located in the
for instance, retains a basic tension which is independent breaker housing.
of the charging and discharging processes during
switching, so as to ensure correct function. This spring In test operations, the withdrawable part must be moved by
energy can be inadvertently released if work is performed hand with the crank 146 fitted.
incorrectly on the spring mechanism!
1. Settings in the area of the test/disconnected position

VD4 Vacuum Circuit-breaker | Maintenance 25

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 ■ Move the withdrawable part out of the test/disconnected the withdrawable part is in the defined test/disconnected
position towards the service position with a few turns of position or service position.
the crank 146.
■ Slowly move the withdrawable part back to the stop. The control wiring plug 10.2 must previously have been
■ Auxiliary switch S8 must then operate when the hand crank inserted.
has a remaining angle of + 60 of turn to reach the stop.
■ Slowly insert the withdrawable part from the test/disconnected Check this condition as follows:
position towards the service position until auxiliary switch ■ It must not be possible to close the circuit-breaker with the

S8 just operates. withdrawable part in any position between the test/disconnected

position and the service position.
In this position, it must still just be possible to move closing ■ Enabling of switching when the withdrawable part moves
push rod 55.2. For this test, the function of the blocking into the service position is effected electrically by operation
magnet Y0 (if fitted) must be deactivated manually. of auxiliary switch S9 in the breaker housing.
■ For motion into the test/disconnected position, the same

This condition ensures that the electrical interlock takes effect enabling conditions apply analogously, in this case by means
before the mechanical interlock in the motion sequence of auxiliary switch S8 in the breaker housing.
involved.
4. It must only be possible to open the circuit-breaker
2. Settings in the area of the service position (manually) when the withdrawable part is in the service
■ Move the withdrawable part out of the limit position position or test/disconnected position and the control
towards the test/disconnected position with a few turns of voltage has failed.
the crank 146.
■ Slowly move the withdrawable part forwards again to the 7.2.5 Breaker pole
stop. No inspection of the breaker pole above and beyond the
■ Auxiliary switch S9 must then operate when the hand crank stipulations of section 7.2.1 is necessary.
has a remaining angle of + 60 of turn to reach the stop.
7.3 Servicing
7.2.4 Testing of interlock conditions 7.3.1 Switching devices in general
(Figures 6/4, 6/6, 2/4, 2/5 and 7/2) If cleaning is found to be necessary during inspections as
The testing procedures for the withdrawable part. set out in 7.2.1, the following procedure is to be adopted:
1. The withdrawable part must only be movable from the ■ Prior to cleaning, the working area is to be isolated and
test/disconnected position into the service position when secured against reclosing where necessary in accordance
the circuit-breaker is open. with the safety regulations.

Check the following conditions individually: ■ Cleaning of surfaces in general:

■ With the circuit-breaker closed, insertion of the withdrawable ■ Dry, lightly adhering dust deposits with a soft, dry cloth.

part towards the service position must be blocked after ■ More strongly adhering contamination with slightly
only half a turn of the crank in the clockwise direction. alkaline household cleanser or Rivolta BWR 210.
■ With the earthing switch closed, insertion of the withdrawable

part towards the service position must be blocked after ■ Cleaning of the insulating material surfaces and conductive
only two clockwise turns of the crank. components:
■ Light contamination:

Do not use force ! with Rivolta BWR 210.

■ Strongly adhering contamination:

2. The withdrawable part must only be movable from the with cold cleanser 716.
service position into the test/disconnected position with
the circuit-breaker open. Wipe down after cleaning, using clean water, and dry
properly.
Check this condition as follows:
■ With the circuit-breaker closed, withdrawal movement of ■ Observe the manufacturer's instructions and the special
the withdrawable part must be blocked after only half a ABB instruction manuals Ba 1002/E or BA 1006/E on safety
turn of the crank in anti-clockwise direction. at work.

3. Closing of the circuit-breaker must only be possible when Note: Use only halogen free cleansers, and in no case 1.1.1-

26 Maintenance | VD4 Vacuum Circuit-breaker

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 trichlorethane, trichlorethylene or carbon tetrachloride! free up to reaching the permissible number of vacuum
interrupter operating cycles in accordance with section 2.4.
7.3.2 Stored-energy spring mechanism
Servicing for 10 years or the spring mechanism is to be Checking of the vacuum is only necessary when there is
performed after 10,000 operating cycles. good cause to suspect that force applied externally to a pole
tube has caused damage to the vacuum interrupter inside.
Prior to servicing, switch the breaker off, and isolate the outgoing
feeder. If the pole tube is damaged or destroyed, it may be necessary
to replace the complete breaker pole.
Observe the safety regulations!
The working life of the vacuum interrupter is defined by the
Details of the servicing: sum current limit corresponding to the equipment data in
■ Swich off the charging motor (if fitted), and discharge individual cases in accordance with section 2.4:
the spring energy storage mechanism by closing and ■ When the sum current limit is reached, the complete
opening the breaker once. breaker poles are to be replaced.
■ Replace parts subject to high climatic and mechanical ■ When the permissible number of mechanical operating

stresses after 10,000 operating cycles as a precaution cycles (i.e. the number corresponding to I a = 0 on the
(for details see ABB Xiamen Switchgear Limited Co. characteristic curve) of the vacuum interrupters has been
after-sales service). reached, the breaker poles must be replaced.
■ For replacing highly stressed parts neutralize
basic tension of the spiral spring, state the rate. Be However, it should be investigated before hand as to whether
careful when carrying out! the installation of a new breaker would be more advantageous.
■ Relubricate pawls, support shafts, sliding and

rotating bearing surfaces. Lubricant: Isoflex Topas Note: Dismantling and Replacement of the complete breaker
NB 52.(Code GCE 0007249P0100) poles should only be carried out by ABB Xiame
■ Check the fit of fasteners (e.g. locking pins) in Switchgear Limited Co. after-sales service personnel
cranks, pins, bolts etc. Check the tightness of or by specially trained personnel, particularly as proper
fastening bolts. adjustment is necessary.
■ Always replace any spring lock washers, split pins

and other fasteners removed during the work with new 7.4 Repair
parts when reassembling the equipment. Replacement of circuit-breaker parts and accessories
■ Perform comprehensive mechanical and electrical

functional tests. Only remove and reassemble circuit-breaker parts and

accessories when the breaker has been switched off and the
Note: This work may only be performed by the after-sales working area is to be isolated and secured against reclosing.
service personnel of ABB Xiamen Switchgear Limited The spring energy storage mechanism must be discharged.
Co. or adequately qualified personnel.
All auxiliary voltage sources must be disconnected and
7.3.3 Breaker pole secured against reclosing during the removal and installation
The breaker pole with the vacuum interrupter is maintenance- work.

VD4 Vacuum Circuit-breaker | Maintenance 27

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 7.5 Spare parts and auxiliary materials
Designation Item no. Rated voltage
Auxiliary switch S1
(with clamp-type terminal) S3
S4
S5 DC 24V
Auxiliary switch on blocking magnet S2 DC 48V
Auxiliary switch for fault annunciation S7 DC 60V
1st shunt release OFF Y2 DC/AC 110V
2nd shunt release OFF Y9 DC 125V
Shunt release ON Y3 DC/AC 220/240V
Blocking magnet Y1
Undervoltage release with spring mechanism Y4
Delayed undervoltage release with spring mechanism Y4
Indirect overcurrent release with intermediate Y7
current transformer and spring mechanism
Intermediate current transformer for indirect overcurrent release
Magnet holder, complete (with integrated rectifiers V1, V2, V3, V9)
Series rectifier V4/V7
Charging motor (with gearing) M0

Auxiliary materials Ident no.

(order code)
Lubricant:
Isoflex Topas NB 52 GCE0007249P0100

28 Maintenance | VD4 Vacuum Circuit-breaker

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 Figure 7/1 Figure 7/2
51.3 10.4 10.5

54 54

51
51

10
10.1
54.1 10.2

50.6

50.7

50.6 Cover plate, right hand side 10 Control wiring plug connector, 10.5 S9, limit switch for service
50.7 Cover plate, left hand side closed position indicator
51 Interlock yoke 10.1 Control wiring socket 51 Interlock yoke
54 ON-OFF operating shaft 10.2 Control wiring plug 51.3 Guiding rail (panel)
54.1 Link rod 10.4 S8, limit switch for test position 54 ON-OFF operating shaft
indicator

Figure 7/3

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

45 Magnet holder, complete 55.6 Socket for charging lever

54.1 Link rod 55.8 Charging condition indicator
55.2 ON push rod 55.30 Drive shaft
55.3 OFF push rod 55.33 Drum with spiral spring
55.4 Switch position indicator 55.34 Chain
55.5 Operating cycle counter 55.35 Ratchet wheel
55.36 Charging motor

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
Figure 7/2: Auxiliary switches for interlocking withdrawable part and switchgear panel (withdrawable part in service position)
Figure 7/3: The spring-loaded operating mechanism in the frame of the withdrawable part, front cover plates removed

VD4 Vacuum Circuit-breaker | Maintenance 29

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 Figure 7/4 Figure 7/5

54.2 Mechanical ON push-button 55.6 Socket (for charging lever)

54.3 Mechanical OFF push-button 55.30 Drive Shaft
55.4 Mechanical switch position indicator 55.33 Drum with spiral spring
55.5 Mechanical operating cycle counter 55.34 Chain
55.8 Charging condition indicator 55.35 Ratchet wheel
60 Auxiliary switch block 55.36 Charging motor
63 Magnet holder, complete

Figure 7/4 Vacuum circuit-breaker, type VD4, for fixed installation, stored-energy spring mechanism, front panel removed
Figure 7/5 Vacuum circuit-breaker, type VD4, for fixed installation, stored-energy spring mechanism, front panel removed

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 8 Application of the X-ray regulations

One of the physical properties of vacuum insulations is the voltage specified for the switching devices by VDE 0670
possibility of X-ray emissions when the contact gap is open. and IEC 62271-100: 2001 is also safe.
The specified type test performed by the Physikalisch-
Technische Bundesanstalt (PTB) in Brunswick demonstrates ■ Higher voltages than the rated power frequency withstand
that the local dosage output of 1Sv/h at a distance of 10 cm voltage or DC test voltage specified in DIN VDE or IEC
from the touchable surface is not exceeded. standards must not be applied!

The results are as follows: ■ Fulfilment of the above requirement with the vacuum
■ The use of the vacuum interrupters at rated voltage is interrupter in the open position is dependent on maintenance
completely safe. of the specified distance between the contacts (which is
automatically ensured with correct mechanism function and
■ The application of the rated power frequency withstand force transmission).

VD4 Vacuum Circuit-breaker | Application of the X-ray regulations 31

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