ABB HD4/R User manual

Power and productivity
for a better worldTM
Medium voltage products
HD4/R - HD4/S - HD4/UniAir - HD4/UniMix - HD4/R-SEC
Installation and operating instructions
I. Introduction 4
1. Packing and transport 5
2. Inspection on arrival 6
3. Storage 7
4. Handling 8
5. Description 9
5.1 General information 9
5.2 Basic configuration 9
5.3 Operating mechanism 10
5.4 Fixed circuit-breakers 10
5.5 Plug-in circuit-breakers 11
5.6 Gas pressure monitoring device (on request) 11
5.7 Circuit-breaker specifications 12
6. Instructions for circuit-breaker operation 17
6.1 Safety indications 17
6.2 Operating and signalling parts 17
6.3 Instructions for circuit-breaker operation 17
7. Installation 19
7.1 General information 19
7.2 Normal installation conditions 19
7.3 Preliminary operations 19
7.4 Installation of fixed circuit-breakers 19
7.5 Installation of plug-in circuit-breakers 19
7.6 Power circuit connections 19
7.7 Earthing 20
7.8 Connection of the auxiliary circuits 20
7.9 Overall dimensions 21
8. Putting into service 31
8.1 General procedures 31
9. Routine inspections 32
9.1 General information 32
9.2 Inspection schedule 32
9.3 Troubleshooting 32
10. Servicing operations 33
11. Instructions for handling apparatus containing
SF6gas 34
12. Spare parts and accessories 35
12.1 List of spare parts 35
13. Quality of the products and environmental
protection 36

3
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 en-
sure that the installations are constructed in accordance with
the rules of good workmanship and safety in the work place.
Responsible behaviour safeguards your own and others’ safety!
Please contact the ABB Assistance Service for any further requirements.
• 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high-
lighted by the following symbol:

4
I. Introduction
All the installation, putting into service, run-
ning and maintenance operations must be
carried out by suitably qualified personnel
with in-depth knowledge of the apparatus.
This publication contains the information required for installing
and putting the following medium voltage circuit-breakers into
service:HD4/R,HD4/S,HD4/UniAir,HD4/UniMix,HD4/R-SEC.
Please read the manual carefully to ensure that the product is
used correctly.
Refer to the relative instructions in order to assemble the ac-
cessories and/or spare parts correctly.
Similarly to all the apparatus we manufacture, the HD4/R,
HD4/S,HD4/UniAir,HD4/UniMix,HD4/R-SECcircuit-breakers
are also designed for different installation configurations.
However,thesedevicescanbesubjectedtofurthertechnical-
construction modifications (at the customer’s request) so as to
adapt them to special installation requirements.
Consequently,themanualmaynotcontaininstructionscon-
cerning special customized configurations.
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.

5
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.

6
Key
ACircuit-breaker rating plate
BOperating mechanism rating plate
1Type of apparatus
2Symbols indicating compliance with Standards
3Serial number
4Circuit-breaker specifications
5Characteristics of the operating mechanism auxiliaries
2. Inspection on arrival
Before proceeding with any operation, al-
ways make sure that the springs of the oper-
ating mechanism are discharged and that the
apparatus is in the open position.
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 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.
Figure 1
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 configura-
tions/conditions.
A
B
3
4
1
5
2

7
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re-
packed 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.

8
4. Handling
The apparatus must not be handled by in-
serting lifting devices directly under the ap-
paratus itself. If this technique is unavoid-
able, place the circuit-breaker on a pallet or
a sturdy supporting surface.
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.
Figure 2

9
1
2
3
4
5
5. Description
5.1 General information
HD4/... circuit-breakers made with the separate pole con-
struction 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UniSwitch,UniAirandUniMixswitchgear.
Depending on the version (excluding 36 kV), they can be
equipped on request with two or three current sensors and
with a PR521 or REF 601 series device for protection against
overcurrents (only REF601 for HD4/R-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UniSwitch,UniAir,UniMix
and UniSec switchgear.
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 SF6gas.
Reference Standards
– IEC 62271-100
– CEI-EN 62271 (dossier 7642).
5.2 Basic configuration
The basic coded versions of the circuit-breakers are always
three-pole and comprise the following equipment (fig. 3):
1closing pushbutton
2opening pushbutton
3circuit-breaker open/closed indicator
4manual operating mechanism
5mechanical indicator for closing springs
6operation counter
moreover:
terminal board for fixed circuit-breaker (connector for plug-
incircuit-breaker),basicwiringfortheconnectionofelectri-
cal accessories.
NOTE. The basic version is always equipped with shunt open-
ingrelease,asetof5open/closedauxiliarycontacts,keylock
and spring loading lever.
Figure 3

10
7
8
9
7
10
11
7
12
13
15
14
1
2
5
6
16
3
4
17
5.3 Operating mechanism
The ESH operating mechanism with energy stored by means
of preloaded springs is used for fixed or plu-in HD/4... circuit-
breakers.
The closing springs of the ESN operating mechanism are load-
ed 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.
5.4 Fixed circuit-breakers
Thefixedcircuit-breaker(fig.4)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 (17) 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.
Key
1SF6gas pressure signalling device (on request - only
for circuit-breakers with pressure switch)
2PR521 or REF 601 overcurrent relay (on request)
3Closing pushbutton
4Opening pushbutton
5Circuit-breaker closed indicator
6Circuit-breaker open indicator
7Medium voltage terminals
8Circuit-breaker pole
9Current sensors (if provided)
10 Key lock
11 Fixing brackets
12 Undervoltage release
13 Additional shunt opening release
14 Shunt opening release
15 Indicator for closing springs loaded (yellow) / discharged (white)
16 Lever for loading the closing springs in the manual mode
17 Circuit-breaker control circuit supporting terminal box
Figure 4