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

3
4
4
3
1
2
5
6
1
2
5
6
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

7
7
8
10
6
11
2 2
1 1
5
4
5
3
3
9
11 8
4
9
6
10
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

2
3
6
2
1
5
4
7
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.

MEDIUM VOLTAGE PRODUCTS 11
Circuit breaker HD4/R12 HD4/R17 HD4/R24 HD4/R36
Standards     
    
Rated voltage Ur [kV]    
Rated insulation voltage Us [kV]    
     
Impulse withstand voltage Up [kV]    
Rated frequency fr [Hz]    
 Ir [A]            
Rated duty breaking capacity
(symmetrical rated short-circuit current)
Isc [kA]  – –  – –  – –   
           
         – – –
   – –  – – – – – –
 Ik [kA]  – –  – –  – –   
           
         – – –
   – –  – – – – – –
Making capacity Ip [kA]  – –  – –  – –   
           
         – – –
   – –  – – – – – –
Sequence of operations   
Opening time [ms]    
Arcing time [ms]    
Total break-time [ms]    
Closing time [ms]    
Overall dimensions
(maximum)
H [mm]    
W [mm]    
D [mm] ) ())
Pole center-distance [mm]    
Weight [kg] )))
Absolute gas pressure (nominal duty value) [kPa]    
Application protection device  ) ) ) –
Standardized dimensions table ) ) )
)))
Wiring diagram without protection device installed    
    –
Operating temperature [°C]   
Tropicalization     
Electromagnetic compatibility     
5.7 Circuit breaker specifications
5.7.1 General specifications of HD4/R series fixed circuit breakers
with rh lateral operating mechanisms (12 - 17.5 - 24 - 36 kV)
H
WD
(1) 230 mm pole center-distance
(2) 300 mm pole center-distance
(3) increase the indicated weight by 20 kg for circuit breakers with REF 601 devices and 3 current sensors (15 kg only with 2 current sensors)
(4) the REF 601 device and the current sensors are available on request. The rated current of the REF 601 must be set in the relay and must be compatible with the rated current of the
circuit breaker. The rated current that can be set with CEI 0-16 is 80 A or 250 A. With the CEI 0-16 version of REF 601, the circuit breaker is always supplied with 3 phase sensors
(Rogowsky coils) on the circuit breaker itself, one 40/1 A closed-core toroidal TA and a -MU undervoltage release for relay-controlled opening

HD4/R - HD4/R-SEC - HD4/RE-SEC - INSTALLATION AND OPERATING INSTRUCTIONS12
—
5. Description
Circuit breaker HD4/RE12 HD4/RE17 HD4/RE24
Standards    
   
Rated voltage Ur [kV]   
Rated insulation voltage Us [kV]   
    
Impulse withstand voltage Up [kV]   
Rated frequency fr [Hz]   
 Ir [A]   
Rated duty breaking capacity
(symmetrical rated short-circuit current)
Isc [kA]   
  
 Ik [kA]   
  
Making capacity Ip [kA]   
  
Sequence of operations    
Opening time [ms]   
Arcing time [ms]   
Total break-time [ms]   
Closing time [ms]   
Overall dimensions
(maximum)
H [mm]   
W [mm]   
D [mm]   
Pole center-distance [mm]   
Weight [kg]   
Absolute gas pressure (nominal duty value) [kPa]   
Application protection device    
Standardized dimensions table 
Wiring diagram without protection device installed 
 
Operating temperature [°C]  
Tropicalization    
Electromagnetic compatibility    
5.7.2 General specifications of HD4/RE series fixed circuit breakers
with rh lateral operating mechanisms (12 - 17.5 - 24 kV)
H
WD
(1) 230 mm pole center-distance
(2) increase the indicated weight by 20 kg for circuit breakers with REF 601 devices and 3 current sensors (15 kg only with 2 current sensors)
(3) the REF 601 device and the current sensors are available on request. The rated current of the REF 601 must be set in the relay and must be compatible with the rated current of the
circuit breaker. The rated current that can be set with CEI 0-16 is 80 A or 250 A. With the CEI 0-16 version of REF 601, the circuit breaker is always supplied with 3 phase sensors
(Rogowsky coils) on the circuit breaker itself, one 40/1 A closed-core toroidal TA and a -MU undervoltage release for relay-controlled opening

MEDIUM VOLTAGE PRODUCTS 13
Circuit breaker HD4/RSEC12 HD4/RSEC17 HD4/RSEC24
Standards    
   
Rated voltage Ur [kV]   
Rated insulation voltage Us [kV]   
    
Impulse withstand voltage Up [kV]   
Rated frequency fr [Hz]   
 Ir [A]     
Rated duty breaking capacity
(symmetrical rated short-circuit current)
Isc [kA] )  )  )
)  )  )
  ))
  – – –
 Ik [kA]     
    
  )) 
) ) – – –
Making capacity Ip [kA]     
    
    
  – – –
Sequence of operations 





Opening time [ms]   
Arcing time [ms]   
Total break-time [ms]   
Closing time [ms]   
Overall dimensions
(maximum)
H [mm]   
W [mm]   
D [mm]   
Pole center-distance [mm]   
Weight [kg]   
Absolute gas pressure (nominal duty value) [kPa]   
Application protection device  ) ) )
Standardized dimensions table   
Wiring diagram    
Operating temperature [°C]  
Tropicalization    
Electromagnetic compatibility    
5.7.3 General specifications of fixed circuit breakers
with rh lateral operating mechanisms for ABB UniSec switchgear (12 - 17.5 - 24 kV)
H
WD
(1) increase the indicated weight by 20 kg for circuit breakers with REF 601 devices and 3 current sensors (15 kg only with 2 current sensors)
(2) the REF601 device and the current sensors are available on request. The rated current of the REF 601 must be set in the relay and must be compatible with the rated current of the
circuit breaker. The rated current that can be set with CEI 0-16 is 80 A or 250 A. With the CEI 0-16 version of REF 601, the circuit breaker is always supplied with 3 phase sensors
(Rogowsky coils) on the circuit breaker itself, one 40/1 A closed-core toroidal TA and a -MU undervoltage release for relay-controlled opening
(4) at 12, the rated short-time withstand current is 25 kA for 2 seconds
(5) at 17.5 kV, the breaking capacity is 21 kA and the rated short-time withstand current is 21 kA for 3 seconds
(6) at 12 kV, 17.5 kV and 24 kV and at rated current 630 A, the sequence of operations is O - 0.3 s - CO - 15 s - CO

HD4/R - HD4/R-SEC - HD4/RE-SEC - INSTALLATION AND OPERATING INSTRUCTIONS14
—
5. Description
Circuit breaker HD4/RESEC12 HD4/RESEC17 HD4/RESEC24
Standards    
   
Rated voltage Ur [kV]   
Rated insulation voltage Us [kV]   
    
Impulse withstand voltage Up [kV]   
Rated frequency fr [Hz]   
 Ir [A]   
Rated duty breaking capacity
(symmetrical rated short-circuit current)
Isc [kA]   
  
 Ik [kA]   
  
Making capacity Ip [kA]   
  
Sequence of operations    
Opening time [ms]   
Arcing time [ms]   
Total break-time [ms]   
Closing time [ms]   
Overall dimensions
(maximum)
H [mm]     
W [mm]   
D [mm]   
Pole center-distance [mm]   
Weight [kg]   
Absolute gas pressure (nominal duty value) [kPa]   
Application protection device  )))
Standardized dimensions table   
Wiring diagram    
Operating temperature [°C]  
Tropicalization    
Electromagnetic compatibility    
5.7.4 General specifications of fixed circuit breakers
with rh lateral operating mechanisms for ABB UniSec switchgear (12 - 17.5 - 24 kV)
H
WD
(1) increase the indicated weight by 20 kg for circuit breakers with REF 601 devices and 3 current sensors (15 kg only with 2 current sensors)
(2) the REF601 device and the current sensors are available on request. The rated current of the REF 601 must be set in the relay and must be compatible with the rated current of the
circuit breaker. The rated current that can be set with CEI 0-16 is 80 A or 250 A. With the CEI 0-16 version of REF 601, the circuit breaker is always supplied with 3 phase sensors
(Rogowsky coils) on the circuit breaker itself, one 40/1 A closed-core toroidal TA and a -MU undervoltage release for relay-controlled opening

6
5
1
4
8
2
3
7
9
MEDIUM VOLTAGE PRODUCTS 15
—
6. Instructions for operating the circuit breaker
Figure 10
HD4/... circuit breakers guarantee a
minimum IP3X degree of protection when
installed in the following conditions:
fixed version, installed behind a protective
metal net
plug-in version, installed in switchgear.
In these conditions the operator is totally
protected against accidental contact with
moving parts.
Pay the greatest attention to moving parts
if the circuit breaker is subjected to
mechanical operations outside the
switchgear or when the protective nets have
been removed.
If the operations are obstructed, do not
force the mechanical interlocks and check
that the operating sequence is correct.
The circuit breaker must be gradually
racked-in and out of the switchgear to avoid
shocks that could deform the mechanical
interlocks and the isolating contacts.
6.2 HD4/R series operating and
signalling mechanisms
Key
1 Release REF 601 (if provided)
2 Gas state indicator (if provided).
3 Opening pushbutton
4 Closing pushbutton
5 Operation counter (if provided)
6 Circuit breaker open/closed indicator
7 Signalling device for closing springs loaded/discharged
8 Shaft for loading the closing springs in the manual mode
9 Key lock
6.1 Safety indications 6.3 Instructions for HD4/R series
circuit breaker operation
Circuit breaker operation can be either manual or
electrical (see fig. 10).
6.3.1 Loading the closing springs in manually
loaded operating mechanisms
Match the coupling position of the handle
(provided) with the hub (8) on the loading shaft,
fully insert it on the shaft itself and turn in a
clockwise direction until the springs loaded
signal (yellow) appears in the window (7).
The force normally applied to the loading lever
supplied is 130 N. In any case, the maximum force
applied must not exceed 170 N.
6.3.2 Closing spring loading lever
If connected to the electric power supply, the
operating mechanism will automatically load the
springs and will signal when the operation has
been completed with a yellow indicator in
the window (7).
It is advisable to load one mechanism at a time to
prevent excessive current from being absorbed in
installations with several motorized operating
mechanisms.
The first time the equipment is put into service, it
is advisable to load the closing springs in the
manual mode to prevent several operating
mechanisms from starting to load at the same
time and overloading the auxiliary power supply.
6.3.3 Manual loading in operating mechanisms
with automatic loading devices
The automatic loading movement is released
when the handle is inserted: loading can now
proceed as described in sect. 6.3.1.
Remove the handle after loading.
NOTE. If the motor starts during the manual loading operation,
continue regardless with the operation until it has been completed in
the manual mode: the motor will stop as soon as loading terminates.
Neither remove nor insert the handle if the motor is running. If the
motor stops due to the ptotection circuit breaker having tripped,
complete the loading operation in the manual mode before closing the
circuit breaker itself.

4
3 6
10
5
9
7
8
2
1
HD4/R - HD4/R-SEC - HD4/RE-SEC - INSTALLATION AND OPERATING INSTRUCTIONS16
6.3.4 Closing operation
Make sure that the springs of the operating
mechanism are loaded, as indicated by the yellow
signal in the window (7).
Press the closing pushbutton (4). Closing is displayed
by the letter “I” in the red part of the window (6).
If there is a shunt closing release, the closing
operation can be obtained by remote control.
6.3.5 Opening operation
Press the opening pushbutton (3).
Opening is displayed by the letter “O” in the green
part of thewindow (6).
If there is a shunt opening release, the closing
operation can be obtained by remote control.
—
6. Instructions for operating the circuit breaker
6.4 HD4/RE series operating and
signalling mechanisms
Figure 11
Mechanical override of undervoltage
release (on request)
Undervoltage release enabled. The circuit breaker
can only be closed if the undervoltage release is
powered.
Undervoltage release disabled. The circuit
breaker can also be closed if the undervoltage
release is not powered.
Key
1 Relay REF601
2 Key lock
3 Closing spring loading lever
4 Operation counter
5 Housing of undervoltage release’s mechanical override
6 Mechanical indicator for closing springs loaded/unloaded
7 Mechanical indicator for circuit breaker open/closed
8 Closing pushbutton
9 Opening pushbutton
10 Gas state indicator
6.5 Instructions for HD4/RE series
circuit breaker operation
Circuit breaker operation can be either manual or
electrical.
a) Manual loading of the closing springs (fig. 11)
Repeatedly operate the loading lever (3) (the
lever’s maximum angle of rotation is about 90°)
until the yellow indicator appears (6).
Maximum force that can normally be applied to

b) Maximum force that can normally be applied
to the lever
On request, the circuit breaker can be fitted with
the following accessories for electrical operation:
 gearmotor for automatic loading of the closing
springs
 shunt closing release.
When powered, the gearmotor automatically
reloads the springs after every closing operation
until the yellow indicator appears (8).
If a power cut occurs when loading is in progress,
the gearmotor stops and automatically starts
loading the springs again when the power returns.
However, loading can always be completed in the
manual mode.
To avoid excessive power consumption in
installations with several circuit breakers
controlled by a motor operator, it is advisable
to load one operating mechanism at a time during
the starting stage.
c) Circuit breaker closing
This operation can only be performed when the
closing springs are fully loaded.
Press the pushbutton (8 - fig. 11) to close the
circuit breaker in the manual mode.
When there is a shunt closing release, the
operation can also be performed in the remote
mode by means of the special control circuit.
Effective closing is signalled by the indicator (7 -
fig. 11).
d) Circuit breaker opening
Press the pushbutton (9 - fig. 11) to open the
circuit breaker in the manual mode.
When there is a shunt opening release, the
operation can also be carried out in the remote
mode by means of the special control circuit.
Effective opening is signalled by the indicator
(7 - fig. 11).

MEDIUM VOLTAGE PRODUCTS 17
Whatever the method used, the fixing surface
must be welllevelled and all the resting points
must be on the same horizontal plane.
7.5 Installation of plug-in circuit
breakers
Plug-in circuit breakers are designed for use in
UniSec switchgear. Special assembly operations
are not usually required.
However, consult the documentation of the
switchgear in question.
7.6 Power circuit connections
7.6.1 General recommendations
 Make sure that the circuit breaker terminals are
clean and are free from any deformation caused
by shocks received during transport or storage.
 Choose the conductor cross-sections to suit the
service and short-circuit current of the
installation.
 Provide suitable supporting insulators near the
fixed circuitbreaker terminals or the monoblocs
of the cubicles, sized according to the
electrodynamic stress caused by the short-
circuit current of the installation.
Figure 12
Correct installation is of primary
importance.
The manufacturer’s instructions must be
carefully studied and followed. It is good
practice to use gloves for handling the
components during installation.
All the operations required for installation,
putting into service, service and
maintenance must be carried out by
qualified personnel.
—
7. Installation
7.1 General information
7.2 Normal installation conditions
Maximum ambient air temperature 
Minimum ambient air temperature 
Relative humidity 
Altitude 
It must be possible to ventilate the installation
room.
Comply with the indications in the product
standards (IEC 62271-100) if other installation
conditions are involved. Please contact ABB for
special installation requirements.
The areas through which power conductors or
auxiliary circuit conductors are routed must be
protected against the access of animals which
could lead to damage or disservice.
The circuit breaker terminals are always
silver-plated. To clean them, use only dry
rags, soaked in a suitable solvent if
necessary.
NOTE. Never use a file or emery cloth!
7.3 Preliminary operations
 Clean the insulating parts with clean dry rags.
 Make sure that the upper and lower terminals are
clean and free of any deformation caused by
shocks received during transport or storage.
7.4 Installation of fixed circuit
breakers
The circuit breaker can be installed straight on the
floor or on supporting frames provided by the
customer (see fig. 8).
The areas on which the supporting frames or truck
(if provided) rest must be on the same plane to
avoid any risk of distortion in the breaker structure.
A minimum degree of protection (IP2X) must be
guaranteed from the front towards live parts.
The apparatus can be fixed in the following ways:
 by means of special expansion anchoring bolts
with M8 threaded hole if the apparatus is fixed
to a cement floor
 by means of M8 bolts if the apparatus is fixed to
metal structures or to cement floors into which
special steel sections
 have been embedded.

HD4/R - HD4/R-SEC - HD4/RE-SEC - INSTALLATION AND OPERATING INSTRUCTIONS18
—
7. Installation
7.7 Earthing
 Earth fixed version circuit breakers by means of
the special screw marked with the relative
symbol. Clean and degrease the area around the
screw corresponding to a diameter of about
30 mm. Use a conductor (busbar or cord) with a
cross-section conforming to the Standards in
force.
 When the assembly is completed, cover the joint
with vaseline grease.
7.6.2 Maximum dimensions of the connections
For fixed version HD4/R and HD4/RE circuit
breakers, the connections must be shaped and
installed in accordance with the indications given
in figures 14, 15, 16 and 25, and the distances
indicated.
7.6.3 Surface treatment of the connections
The connections can be made of bare copper or
bare aluminium. However, it is always advisable to
silver-plate the contact surfaces.
The thickness of the surface treatment must be
even and regular.
7.6.4 Assembly of the connections
 Make sure that the contact surfaces of the
connections are perfectly flat and without burrs,
traces of oxidation or deformities caused by
drilling or impact sustained.
 Depending on the conductive material used and
the surface treatment given, the operations
indicated in the following table must be carried
out on the surface contact of the conductor.
Bare copper Clean with a fine file or emery cloth

Copper or
silverplated
aluminium
Clean with a rough dry cloth
Only if there are traces of oxidation that are difficult
to shift, clean with ultra-fine grain emergy cloth and
take care not to remove the surface layer
Repeat the surface treatment if necessary
Bare
aluminium
Clean with a metal brush or emery cloth
Immediately smear neutral grease over the contact
surfaces
Insert a bi-metal copper-aluminium strip with
beaded surfaces between the aluminium connection and
the copper terminal (copper side touching the terminal,
aluminium side touching the connection)
Assembly procedures
 Place the connections in contact with the circuit
breaker terminals.
 Insert a spring washer and a flat washer
between the head of the bolt and the
connection.
 The diameter of the flat washers must be able to
distribute the torquing pressure over a wide
area.
 Tighten the bolt, taking care to prevent the
insulating parts from being stressed (consult
the table with the rightening torque values).
 Make sure that the connections do not exert any
force on the terminals.
 Carefully comply with the manufacturer’s
instructions for terminating the cables in cable
connections.
Table of tightening torque values
Screw Tightening torque values
 
 
 
 
Figure 13
Make sure that the circuit breaker is open
and the closing springs discharged before
removing the operating mechanism cover to
access the terminal box.
7.8 Connection of the auxiliary
circuits
The minimum cross-section of the wires used for
the auxiliary circuits must not be less than the one
used for the internal cabling.
They must also be insulated for 3 kV test voltage.
7.8.1 Fixed version circuit breakers
The auxiliary circuits of the circuit breaker must be
connected by means of the terminal box installed in
the circuit breaker’s operating mechanism.
The wires outside the circuit breaker must be
routed inside appropriately earthed metal tubes or
ducts.
7.8.2 Plug-in circuit breaker
The auxiliary circuits of the plug-in or removable
circuit breaker are fully wired in the factory
through to the connector. Please refer to the
wiring diagram of the switchgear for the
connections.

MEDIUM VOLTAGE PRODUCTS 19
7.9 Overall dimensions
7.9.1 Fixed HD4/R, 12 ... 24 kV, 630 ... 1250 A
Figure 14
TN 7237

HD4/R - HD4/R-SEC - HD4/RE-SEC - INSTALLATION AND OPERATING INSTRUCTIONS20
7.9.2 Fixed HD4/R, 12 ... 24 kV, 630 ... 1250 A
—
7. Installation
Figure 15
TN 7234