ABB HD4/R User manual

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MEDIUM VOLTAGE PRODUCTS
HD4/R - HD4/R-SEC - HD4/RE-SEC
Installation and operating instructions
Table of Contents
I. Introduction 3
1. Packing and transport 4
2. Inspection on arrival 5
3. Storage 6
4. Handling 7
5. Description 8
6. Instructions for operating
the circuit breaker 15
7. Installation 17
8. Putting into service 25
9. Routine inspections 26
10. Instructions for handling apparatus
containing SF6 gas 28
11. Spare parts and accessories 29
12. Quality of the products and environmental
protection 30
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01 HD4/R series circuit breakers
02 HD4/RE series circuit breakers
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01
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02

HD4/R - HD4/R-SEC - HD4/RE-SEC - INSTALLATION AND OPERATING INSTRUCTIONS2
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For your safety!
• Make sure that the installation room (space,
divisions and environment) is suitable for the
electrical apparatus.
• Make sure that all the installation, putting into
service and maintenance operations are carried
out by skilled personnel with in-depth knowledge
of the equipment.
• Make sure that all the installation, service and
maintenance operations comply with the
standards and laws so as to ensure that the
installations are constructed in accordance with
the rules of good workmanship and safety in the
work place.
• Strictly comply with the instructions in this
manual.
• Make sure that the rated performance of the
apparatus is not exceeded during service.
• Make sure that the personnel are provided with
this manual and are aware of all the relevant
information while operating on the apparatus.
• Pay special attention to the information in the
manual highlighted by the following symbol:
Responsible behaviour safeguards your own
and others’ safety!
Please contact the ABB Assistance Service
for any further requirements.

MEDIUM VOLTAGE PRODUCTS 3
This publication contains the information required
for installing and putting the following medium
voltage circuit breakers into service: HD4/R, HD4/
RE, HD4/R-SEC, HD4/RE-SEC.
Please read the manual carefully to ensure that the
product is used correctly.
Refer to the relative instructions in order to
assemble the accessories and/or spare parts
correctly.
Similarly to all the apparatus we manufacture, the
HD4/R, HD4/RE, HD4/R-SEC, HD4/RE-SEC circuit
breakers are also designed for different
installation configurations.
However, these devices can be subjected to
further technicalconstruction modifications (at
the customer’s request) so as to adapt them to
special installation requirements.
Consequently, the manual may not contain
instructions concerning special customized
configurations.
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I. Introduction
Besides this manual, it is therefore always
necessary to consult the latest technical
documentation (electric circuit and wiring
diagrams, assembly and installation drawings, any
protection coordination studies, etc.), especially
regarding any variants requested in relation to the
standard configurations.
Only use original spare parts for maintenance
operations.
Please also consult the technical catalogue of the
circuit breaker and the spare parts catalogue for
further details.
All the installation, putting into service,
running and maintenance operations must
be carried out by suitably qualified
personnel with in-depth knowledge of the
apparatus.

HD4/R - HD4/R-SEC - HD4/RE-SEC - INSTALLATION AND OPERATING INSTRUCTIONS4
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1. Packing and transport
The circuit breaker is shipped in special packing in
the open position, with the springs discharged
and with the absolute pressure of the pole
corresponding to the service value.
Each piece of apparatus is protected by a plastic
cover to prevent water from infiltrating during the
loading and unloading stages and to keep the
dust off during storage.
Handling and transport must only be carried out
by expert and properly trained personnel.
Do not remove or alter the switch identification
contents and labels.
Switches subject to UN3164 standards for
transportation by air and / or sea.
Safety data sheet: 1VCD850182

MEDIUM VOLTAGE PRODUCTS 5
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2. Inspection on arrival
A
1
3
4
B
5
2
As soon as it arrives, check the condition of the
apparatus, that the packing is undamaged and that
the nameplate data (see fig. 1) correspond to the
information in the order confirmation sent by ABB
and in the shipping note.
Also make sure that the supply includes all the
materials described in the shipping note and the
lever for loading the springs of the operating
mechanism in the manual mode.
Should any damage or irregularity be noted in the
supply on unpacking, notify ABB (directly or
through the agent or supplier) as soon as possible
Before proceeding with any operation,
always make sure that the springs of the
operating mechanism are discharged and
that the apparatus is in the open position.
Figure 1
and in any case within five days of receipt.
The apparatus is only supplied with the accessories
specified at the time of ordering and validated in
the order confirmation sent by ABB.
The following documents accompany the
apparatus when it is shipped:
 Instruction manual (this document)
 Test certificate
 Identification label
 Fiscal copy of the shipping notification
 Wiring diagram.
Other documents, sent prior to shipment of the
apparatus, are:
 Order confirmation
 Original shipping notification
 Any drawings or documents referring to special
configurations/conditions.
Key
A Circuit breaker rating plate
B Operating mechanism rating plate
1 Type of apparatus
2 Symbols indicating compliance with Standards
3 Serial number
4 Circuit breaker specifications
5 Characteristics of the operating mechanism auxiliaries

HD4/R - HD4/R-SEC - HD4/RE-SEC - INSTALLATION AND OPERATING INSTRUCTIONS6
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3. Storage
When the apparatus must be stored for a certain
period of time, our workshops can (on request)
provide suitable packing for the specified storage
conditions.
On arrival, the apparatus must be carefully
unpacked and checked as described in the
Checking on arrival section (chap. 2).
If the apparatus cannot be installed immediately, it
must be repacked in the original packing materials.
Insert at least one standard packet of special
hygroscopic substance per piece of apparatus
inside the packing.
Should the original packing no longer be available
and the apparatus cannot be installed immediately,
it should be stored indoors in a well-ventilated, dry,
dust-free, noncorrosive environment, well away
from any easily flammable materials and at a
temperature between -5 °C and +45 °C.
Avoid any accidental impact or positions which
stress the structure of the apparatus.

MEDIUM VOLTAGE PRODUCTS 7
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4. Handling
Before proceeding with any operation, always
make sure that the springs of the operating
mechanism spring are discharged and that the
apparatus is in the open position.
When handling the apparatus, take great care to
prevent the insulating parts and the terminals of
the circuit breaker from being stressed.
The apparatus must not be handled by
inserting lifting devices directly under the
apparatus itself. If this technique is
unavoidable, place the circuit breaker on a
pallet or a sturdy supporting surface.
Figure 2

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HD4/R - HD4/R-SEC - HD4/RE-SEC - INSTALLATION AND OPERATING INSTRUCTIONS8
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5. Description
5.1 General information
HD4/R circuit breakers made with the separate
pole construction technique. They are sulphur
hexafluoride insulated for indoor installation and
are life-long sealed pressure devices (Standards
IEC 62271-100 and CEI-EN 62271-100).
Refer to the technical catalogue for the electrical
performance.
The following versions are available:
 Fixed, with rh lateral operating mechanism (up
to 36 kV)
 Plug-in, for UniSec switchgear.
Depending on the version (excluding 36 kV), they
can be equipped on request with two or three
current sensors and with a REF601 series device
for protection against overcurrents (only REF601
for HD4/R-SEC, HD4/RE-SEC).
The three poles, the operating mechanism and any
optional accessories used are assembled on a
sturdy bearing frame.
The metal frame is equipped with wheels for 36 kV
circuit breakers and for circuit breakers for
UniSecswitchgear.
Each pole consists of an epoxy resin enclosure
which houses all the active parts, the kinematism
of the moving contacts, the medium voltage
terminals and the arcing chambers, immersed
in SF6 gas.
Reference Standards
 IEC 62271-100
 CEI-EN 62271-100
5.2 Basic configuration
The basic coded versions of the circuit breakers
are always three-pole and comprise the following
equipment (fig. 3 and 4):
1 closing pushbutton
2 opening pushbutton
3 circuit breaker open/closed indicator
4 manual operating mechanism
5 mechanical indicator for closing springs
6 operation counter
moreover:
terminal board for fixed circuit breaker
(connector for plugin circuit breaker), basic
wiring for the connection of electrical
accessories.
NOTE. The basic version is always equipped with shunt opening
release, a set of 5 open/closed auxiliary contacts, key lock and spring
loading lever (spring loading lever for HD4/R series only).
Figure 4 HD4/R series circuit breakers
Figure 3 HD4/RE series circuit breakers

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6
11
2 2
1 1
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3
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11 8
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MEDIUM VOLTAGE PRODUCTS 9
5.3 Operating mechanism
5.3.1 Operating mechanism for HD4/R series
circuit breakers
The ESH operating mechanism with energy stored
by means of preloaded springs is used for fixed or
plu-in HD4/R circuit breakers.
The closing springs of the ESN operating
mechanism are loaded in the manual mode using
the special removable lever.
The opening springs are automatically reloaded
during the closing operation.
If a gearmotor is installed, the closing springs are
automatically loaded after each closing operation.
The shunt closing, shunt opening and
undervoltage releases allow the operations to be
carried out in the remote mode.
5.3.2 Operating mechanism for HD4/RE series
circuit breakers
The EL operating mechanism with energy stored
by means of preloaded springs is used for fixed or
plu-in HD4/RE circuit breakers.
The closing springs of the EL operating
mechanism are loaded in the manual mode using
the special lever.
The opening springs are automatically reloaded
during the closing operation.
If a gearmotor is installed, the closing springs are
automatically loaded after each closing operation.
The shunt closing, shunt opening and
undervoltage releases allow the operations to be
carried out in the remote mode.
Figure 5 Figure 6
Key
1 SF6 gas pressure signalling device (on request - only for
circuit breakers with pressure switch)
2 PR521 or REF 601 overcurrent relay (on request)
3 Closing pushbutton
4 Opening pushbutton
5 Circuit breaker closed indicator
6 Circuit breaker open indicator
7 Undervoltage release
8 Additional shunt opening release
9 Shunt opening release
10 Indicator for closing springs loaded (yellow) / discharged (white)
11 Lever for loading the closing springs in the manual mode
Key
1 SF6 gas pressure signalling device (on request - only for
circuit breakers with pressure switch)
2 PR521 or REF 601 overcurrent relay (on request)
3 Closing pushbutton
4 Opening pushbutton
5 Signalling device for circuit breaker open / closed
6 Undervoltage release
7 Additional shunt opening release
8 Shunt opening release
9 Indicator for closing springs loaded (yellow) / discharged (white)
10 Lever for loading closing springs in manual mode
11 Shunt closing release

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HD4/R - HD4/R-SEC - HD4/RE-SEC - INSTALLATION AND OPERATING INSTRUCTIONS10
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5. Description
5.4 Fixed circuit breakers
The fixed circuit breaker (fig. 7) is the basic
version, previously described in sect. 5.2. There
are two drilled supports in the lower part of the
structure to allow the circuit breaker to be
fixed.
The terminal box (7) is available for the electrical
connections of the circuit breaker’s auxiliary
circuits, in the front protection.
The earthing screw is located at the side of the
circuit breaker.
5.5 Withdrawable circuit breakers
The withdrawable circuit breakers are available for
UniSec switchgears. They are essentially derived
from a fixed circuit breaker to which the wheels,
the disconnecting contacts and the locking lever
are applied. The HD4/R-Sec and HD4/RE-Sec
circuit breakers are used in UniSec switchgears.
The circuit breakers can only be extracted in safe
conditions with open isolation switches open and
earth switches closed. To facilitate the extraction
of the circuit breaker, a special extraction truck is
available.
Figure 7
Legenda
1 REF 601 overcurrent relay (on request)
2 Medium voltage terminals
3 Circuit breaker pole
4 Current sensors (if provided)
5 Key lock
6 Fixing brackets
7 Circuit breaker control circuit supporting terminal box
5.6 Gas pressure monitoring
device (on request)
The device for signalling the state of the SF6 gas
is supplied on request and always has two
intervention thresholds (low pressure
and insufficient pressure).
The following configurations can be obtained:
1) with contacts for remote signalling (normal,
low and insufficient pressure);
2) as in point 1, plus a lock on circuit breaker
closure and a choice between automatic
opening or lock on opening;
3) as in point 2 plus three lamps for local
signalling of the state of the gas.