Medium voltage products

VD4G
Installation and operating instructions
15 kV - 1250... 3150 A - 25...40 kA

Contents

For your safety! 1

I. Foreword 2

II. Environmental protection program 2

1. Packing and transport 3

2. Checking on receipt 4

3. Storage 5

4. Handling 6

5. Description 7

6. Instructions for circuit-breaker operation 27

7. Installation 30

8. Putting into service 34

9. Maintenance 36

10. Application of the X-ray emission Standards 40

11. Spare parts and accessories 41

12. Circuit diagrams 42

13. Overall dimensions 43

14. Quality of the products and environmental protection 47

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 regulations
and laws in force 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 behavior safeguards your own

and others' safety!
Please contact the ABB Assistance Service
for any further requirements.

1
I. Foreword II. Environmental protection
program
This publication contains the information required to install VD4G circuit-breakers are manufactured in accordance
VD4G medium voltage circuit-breakers and put them into with ISO 14000 Standards (Guidelines for environmental
service. management).
Please read the manual carefully to ensure that the product is The manufacturing processes are implemented in
used correctly. accordance with the environmental protection standards
Similarly to all the apparatus we manufacture, VD4G circuit- when it comes to reducing both energy consumption and the
breakers are designed for different installation configurations. production of waste. All this is thanks to the environmental
They can therefore undergo further technical-construction management system applied in the medium voltage apparatus
modifications (at the customer's request) so as to adapt them manufacturing facility.
to special installation requirements.
Consequently, the manual may not contain instructions
concerning special customized configurations.
This means that, besides this manual, it is always necessary
to consult the latest technical documentation (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 catalog of the circuit-breaker
and the spare parts catalog 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.

2
1. Packing and transport

The circuit-breaker is shipped in special packing, in the open

position and with the spring discharged.
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.

3
2. Checking on receipt

Before proceeding with any operation, always make A

sure that the springs of the operating mechanism
are discharged and that the switchgear is in the 1 CIRCUIT-BREAKER 2
IEC-IEEE
open position. VD4G ... ... ...
CLASSIFICATION ... ... ... 62271-37-013
3
SN ... ... ... PR. YEAR ......
Upon receipt, check the condition of the apparatus, that the
M WEIGHT ... kV
packing is undamaged and that the nameplate data (see fig. Ur
1) correspond to the information in the order confirmation and
shipping note.
Also make sure that all the materials described in the shipping
note are included in the supply.
Should any damage or irregularity be noted in the supply
on unpacking, notify ABB (directly or through the agent or 4
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 CIRCUIT DIAGRAM ... ... ... ...
FIG. ... ...
sent by ABB.
The following documents accompany the apparatus when it is B
.. ... ... ... OPERATING MECHANISM
shipped:
instruction manual (this document) 5
- MBO1 ... ... ... V
test certificate
Made by ABB
identification label
copy of the shipping documents
circuit diagram.
Other documents, sent prior to shipment of the apparatus,
are: Key
order confirmation A Circuit-breaker rating plate

original shipping notification B Operating mechanism rating plate

1 Type of apparatus
any drawings or documents referring to special
2 Symbols denoting compliance with Standards
configurations/conditions.
3 Serial number
4 Circuit-breaker specifications
5 Characteristics of operating mechanism auxiliaries

Fig. 1

4
3. Storage

When the apparatus must be stored for a certain period of

time, our workshops can (on request) provide packing to suit
the specified storage conditions.
On receipt the apparatus must be carefully unpacked and
checked as described in Checking on receipt (chap. 2).
If the apparatus cannot be installed immediately, it must be
re-packed in its original packing materials.
Insert at least one standard packet of special hygroscopic
substance inside the packing of each piece of apparatus.
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, non-corrosive
environment, well away from any easily flammable materials
and at a temperature between 5 C and + 40 C.
Avoid accidental shocks or positions which stress the
structure of the apparatus.

5
4. Handling

Before proceeding with any operation, always make sure that
the spring of the operating mechanism is discharged and that
the apparatus is in the open position.
Proceed as follows to lift and handle the circuit-breaker (fig. 2):
use suitable lifting equipment (1) (not supplied) with ropes
and safety hooks (2);
insert the hooks (2) into the supports (3) fixed to the frame
of the circuit-breaker and lift. Insert hooks (2) into holes in
support (3), depending on the type of apparatus (see table);
once the operation has terminated (and in any case before
putting into service), release the lifting equipment (1) and
remove the supports (3) from the frame.
When handling the apparatus, take great care to prevent
the insulating parts and terminals of the circuit-breaker from
being stressed.
Do not handle the apparatus by inserting lifting
devices directly under it. If this technique is
unavoidable, place the circuit-breaker on a pallet
or a sturdy supporting surface (see fig. 3).
In any case, it is always advisable to lift the
apparatus by means of the supports (3).

C B A

3
1

Fig. 2a Lifting support

3
Pole center
Versione Rated current Hole
distance
Fixed 150-210 mm 1,250 A A
Fixed 275 mm up to 3150 A A
Fixed 210 mm 2,000 A A
Fixed 275 mm 4,000 A C
Withdrawable 150 mm 1,250 A A
Withdrawable 210 mm 2,000 A B
Withdrawable 275 mm up to 3150 A C
Withdrawable 275 mm 4,000 A C

Fig. 2

Fig. 3

6
5. Description

5.1. General information 5.3. EL operating mechanism

VD4G are vacuum circuit-breakers for indoor installation. VD4G circuit-breakers are equipped with an EL type spring
Refer to technical catalog code 1VCP000661 for the relative operating mechanism. The EL operating mechanism is
electrical performance. designed for the range of circuit-breakers listed in the table.
Please contact ABB for special installation requirements. Type of operating
Breaking capacity
The following versions are available: mechanism
fixed EL2 25 kA

withdrawable for UniGear ZS1 switchgear. EL1 TWIN 40 kA (up to 2000 A rated current)
EL2 TWIN 40 kA ( 2500 A rated current)

5.2. Regulatory framework 5.4. Fixed circuit-breakers

VD4G circuit-breakers conform to standard IEC/IEEE 62271-
37-013. The fixed circuit-breaker (fig. 4) is the basic version complete
with structure and front protection shield. Holes for fixing are
made in the lower part of the structure.
There are two types of connections for connecting the
11 auxiliary circuits (choice at customer's charge when the
purchase order is placed) (see sect. 7.8.1).
The earthing screw is located in the rear part of the circuit-
breaker. See key to figure 4 for further details.

1 4
5
6
11
8
3
7

10

Key
1 Lever for manual loading of closing spring
2 Signaling device for circuit-breaker open/closed
3 Rating plate
4 Opening pushbutton
5 Closing pushbutton
6 Signaling device for closing spring loaded/discharged
7 Operation counter
8 Terminals
9 Earthing screw
10 Delivery terminal box
11 Wiring connection

Fig. 4

7
5.4.1. General characteristics of fixed circuit-breakers

General characteristics of fixed circuit-breakers (15 kV)

Circuit-breaker VD4G-25 VD4G-40

Standards IEC/IEEE 62271-37-013
Rated voltage Ur [kV] 15 15
Rated insulation voltage Us [kV] 15 15
Withstand voltage at 50 Hz
common value Ud (1 min) [kV] 38 38
across insulating distance Ud (1 min) [kV] 45 45
Impulse withstand voltage
common value Up [kV] 95 95
across insulating distance Up [kV] 110 110
Rated frequency fr [Hz] 50-60 50-60
Rated normal current (40 C) Ir [A] 1250 2000 2000 3150 4000 (1)
Rated system-source short-circuit breaking current
Symmetrical short-circuit current IscSFF [kA] 25 40
DC component of rated short circuit breaking %
74 74
current *
Asymmetrical system source short-circuit IascSFF [kA]
36,5 58,5
current
Rated system-source short-circuit breaking current
symmetrical short-circuit current Iscg Class G1 IscGFF [kA] 16 25
DC component of generator-source short-circuit %
110 110
breaking current Class G1
symmetrical short-circuit current Iscg Class G2 IscGFF [kA] 16 25
DC component of generator-source short-circuit %
130 130
breaking current Class G2
Rated breaking current under out-of-phase conditions
symmetrical short-circuit current IscOOP [kA] 12,5 20
DC component of rated short circuit breaking %
74 74
current
Making current
Ip [kA] 68,5 115
Rated operating sequence during short-circuit interruption CO-10 min-CO
Rated short-time withstand current (3s) Ik [kA] 25 40
Opening time [ms]
Arcing time [ms]
Total break-time [ms]
Closing time [ms]
I I H [mm] 461 610 610 636 636
Maximum L [mm] 450 600 750 750 750
overall
H D [mm] 424 459 459 459 459
dimensions
L D Pole center-distance I [mm] 150 210 275 275 275
Weight [kg] 73 146 158 177 177
Standardized dimensions table 1VBM 1VCD003891 1VCD000240 1VCD000241 1VCD000242
Operating temperature [C] - 5 ... + 40
(1) 4000 A with forced ventilation

8
VD4G 15 kV fixed circuit-breaker
Ur Isc Rated interrupted current (40C) [A]
H = 461 H = 610 H = 636 H = 636
Type of circuit-breaker
D = 424 D = 459 D = 459 D = 459
kV kA
P = 150 P = 210 P = 275 P = 275
W = 450 W = 600 W = 750 W = 750
25 1250 VD4G-25 15.12.25 p150
40 2000 VD4G-40 15.20.40 p210
15
40 2000 VD4G-40 15.20.40 p275
40 3150 (1) VD4G-40 15.32.40 p275
(1) 4000 A with forced ventilation

VD4G-25: 15 kV, 25 kA SFF, 16 kA GFF VD4G-40: 15 kV, 40 kA SFF, 25 kA GFF

5.4.3. Standard fittings for fixed circuit-breakers

The basic fixed circuit-breaker versions are three-pole and are

equipped with:
EL manual operating mechanism
mechanical signaling device for closing spring loaded/
discharged
mechanical signaling device for circuit-breaker open/closed
closing pushbutton, opening pushbutton, operation counter
set of ten auxiliary contacts for circuit-breaker open/closed
lever for manual loading of closing spring

9
5.5. Withdrawable circuit-breakers
Withdrawable circuit-breakers up to 15 kV are available for
UniGear ZS1 switchgear.
They consist of a truck to which the bearing structure of the
actual circuit-breaker is fixed.
Circuit-breakers for UniGear ZS1 switchgear (fig. 5a)
The cord with plug (13) for connecting the electrical
accessories of the operating mechanism comes out of the
upper part of connector (14).
Strikers for operating the contacts (connected/disconnected)
in the switchgear are fixed to the upper part of the circuit-
breaker.
Slides (9) for operating the segregation shutters of the
medium voltage contacts in the enclosure or switchgear are
fixed at the sides of the circuit-breaker. Circuit-breakers for
UniSec switchgear have wheels (17) for this purpose.
The front part of the circuit-breaker truck has a cross-beam
with handles (16) which latches onto the circuit-breaker when
this is racked-in/out by means of the operating lever (15).
The circuit-breaker is complete with disconnection contacts
(8).
The withdrawable circuit-breaker has locks on the front cross-
beam allowing it to be latched into the corresponding slot-in
joints of the switchgear.
The locks can only be operated by the handles when the
truck rests completely against the cross-beam.
The operating lever (15) must be inserted to its full extent (see
sect. 7.5.). A lock prevents the truck from advancing into the
enclosure or fixed part when the earthing switch is closed.
Another lock prevents racking-in/out when the circuit-breaker
is closed. When the truck is in the intermediate position,
between disconnected and connected, a further lock (both
mechanical and electrical) prevents the circuit-breaker from
closing.
The truck is also fitted with a locking magnet which, if de-
energized, prevents the truck from being racked-in.
An interlock is available on request to prevent the circuit-
breaker from being racked-in when the door is open and the
door from being opened when the circuit-breaker is closed.
The lever for loading the closing spring (1) in the manual mode
is built into the operating mechanism. The spring is loaded by
repeatedly lowering the lever by linear movements until the
yellow indicator (6) appears to show that loading is complete.
The spring can only be loaded with the switchgear door
open. Comply with the instructions in the UniGear switchgear
manual for the operations that can be performed with the
door open.

12

13 17

14

4
1 5
16
6
2
3
7
9
8 11

16 10

Key 9 Chute for operating shutters of UniGear, PowerCube switchgear

1 Lever for manual loading of closing spring 10 Truck
2 S ignaling device for circuit-breaker open/closed 11 Locks for latching to fixed part
3 R ating plate 12 Strikers for operating contacts in enclosure
4 O pening pushbutton 13 Connector (plug)
5 C losing pushbutton 14 W iring connection
6 S ignaling device for closing spring loaded/discharged 15 Operating lever for circuit-breaker racking-in/out
7 O peration counter 16 Lock operating handles (11)
8 D isconnecting contacts 17 Wheels for moving segregation shutters

Fig. 5a

10
 16 19 20 22 21

Fig. 5c

23 30 29

Fig. 5d

11
5.4.2. Types of fixed circuit-breakers available

General characteristics of withdrawable circuit-breakers

for UniGear ZS1 (15 kV) switchgear

Circuit-breaker VD4G-25 VD4G-40

Standards IEC/IEEE 62271-37-013
Rated voltage Ur [kV] 15 15
Rated insulation voltage Us [kV] 15 15
Withstand voltage at 50 Hz
common value Ud (1 min) [kV] 38 38
across insulating distance Ud (1 min) [kV] 45 45
Impulse withstand voltage
common value Up [kV] 95 95
across insulating distance Up [kV] 110 110
Rated frequency fr [Hz] 50-60 50-60
Rated normal current (40 C) Ir [A] 1250 2000 2000 3150 4000 (1)
Rated system-source short-circuit breaking current
Symmetrical short-circuit current IscSFF [kA] 25 40
DC component of rated short circuit breaking %
74 74
current *
Asymmetrical system source short-circuit IascSFF [kA]
36,5 58,5
current
Rated system-source short-circuit breaking current
symmetrical short-circuit current Iscg Class G1 IscGFF [kA] 16 25
DC component of generator-source short- %
110 110
circuit breaking current Class G1
symmetrical short-circuit current Iscg Class G2 IscGFF [kA] 16 25
DC component of generator-source short- %
130 130
circuit breaking current Class G2
Rated breaking current under out-of-phase conditions
symmetrical short-circuit current IscOOP [kA] 12,5 20
DC component of rated short circuit breaking %
74 74
current
Making current
Ip [kA] 68,5 115
Rated operating sequence during short-circuit interruption CO-10 min-CO
Rated short-time withstand current (3s) Ik [kA] 25 40
Opening time [ms]
Arcing time [ms]
Total break-time [ms]
Closing time [ms]
I I H [mm] 691 730 730 636 636
Maximum L [mm] 853 853 853 750 750
overall
H D [mm] 643 643 643 459 459
dimensions
L D Pole center-distance I [mm] 150 210 275 275 275
Weight [kg] 116 190 205 221 221
Standardized dimensions table 1VBM 1VCD000233 1VCD000234 1VCD000243 1VCD000244
Operating temperature [C] - 5 ... + 40
(1) 4000 A with forced ventilation

12
5.4.3. Types of withdrawable circuit-breakers available for UniGear ZS1 switchgear

VD4G 15 kV withdrawable circuit-breaker

Ur Isc Rated interrupted current (40C) [A]
H = 632 H = 691 H = 730 H = 735
Type of circuit-breaker
D = 664 D = 643 D = 643 D = 650
kV kA
P = 150 P = 210 P = 275 P = 275
W = 503 W = 681 W = 853 W = 851
25 1250 VD4G/P-25 15.12.25 p150
40 2000 VD4G/P-40 15.20.40 p210
15
40 2000 VD4G/P-40 15.20.40 p275
40 3150 (1) VD4G/P-40 15.32.40 p275
(1) 4000 A with forced ventilation

13
5.6. Characteristics of the electrical accessories

Accessories with the same number are alternatives.

1 Shunt opening release (-MBO1) 2 Additional shunt opening release (-MBO2)

Allows the device to be opened by remote control. This Similarly to shunt opening release -MBO1, this allows the
release is suitable for both instantaneous and permanent duty. opening command of the apparatus to be transmitted by
However, an auxiliary contact -BGB1 de-energizes it after remote control. It can be energized by the same circuit as
the circuit-breaker has opened. In the case of instantaneous main shunt opening release -MBO1 or by a circuit completely
service, the current impulse must last at least 100 ms. separate from release -MBO1.
This release can be controlled by the following devices: coil This release is suitable for both instantaneous and permanent
continuity control (CCC), opening circuit supervision (TCS)(*) duty. However, an auxiliary contact -BGB1 de-energizes it
or the ABB STU functionality control device (see accessory after the circuit-breaker has opened.
21, supplied on request). To guarantee the release action, the current impulse must last at
least 100 ms.
Characteristics Continuity functionality can be checked with a continuity control
Un 48 - 110 ... 125 - 220 ... 250 Vcc device (CCC), opening circuit supervision device (TCS)(*) or the
Un 110 ... 125 - 220 ... 250 VAC STU functionality control device (see accessory 21, supplied on
in accordance with IEC/IEEE 62271-37- request).
Operating limits
013
Power at inrush (Ps) 60...100 W / VA
-MBO2 has the same electrical and operating characteristics as
Holding power (Pc) 1.5 W
release -MBO1.
Electronics self-consumption
(no coil supplied);
1.5 mA
value independent of voltage
applied
Opening time 33...60 ms
Insulation voltage 2000 V 50 Hz (for 1 min)

(*) The minimum current that the relay with TCS function (used for monitoring coil
continuity) detects as a condition denoting that the trip circuit is operating correctly
(specified for each relay in the relative manual), must be sensibly higher than the
current consumption of the actual coil (~1.5 mA).
If this fails to occur, always add, in parallel to the TCS, a circuit able to absorb
sufficient current to compensate the gap while preventing the total current in the TCS
circuit from rising above the maximum threshold (Itcs < 10 mA for High Voltage coils
- from 110V to 250V, and Itcs < 50 mA for Low Voltage coils from 24 V to 60 V).
A simple resistor can be sized for the purpose, depending on the parameters of the
TCS and the auxiliary voltage range used.

14
3 Opening solenoid (-MBO3) 4 Shunt closing release (-MBC)

The opening solenoid (-MBO3) is a special demagnetizing
release for use in conjunction with self-supplied overcurrent
protection relays.
It is situated in the operating mechanism (in the left-hand
side) and is not an alternative to the additional shunt opening
release (-MBO2).
It is only available for VD4G-25 circuit-breakers.
If this accessory is required, it must be specified when
ordering since it cannot be installed by the customer at a later
date.
Note: ask for document: Data sheet 1VCD600854.
The opening solenoid (-MBO3) is available in two versions:
For D.C. (release by discharging energy stored in protection
relay against overcurrent of the self-supplied type)
For A.C. (release by means of energy supplied by an adder
transformer on the secondaries of the protection current
transformers) (the adder CT is at the customer's charge)
Allows the device to be closed by remote control.
This release is suitable for both instantaneous and permanent
duty. An auxiliary contact to de-energize it after the circuit-
breaker has closed is not envisaged.
The permanently supplied release provides the electrical anti-
pumping function with both electrical opening and re-closing
commands maintained. To guarantee the closing action, the
current impulse must last at least 100 ms.
If there is the same supply voltage for shunt closing release
-MBC and under-voltage release -MBU and the circuit-breaker
must close automatically when auxiliary voltage returns, there
must be a delay of at least 50 ms between under-voltage
release energizing and energizing of the shunt closing release
to allow the closing operation to take place.
Continuity functionality can be checked with a continuity control
device (CCC), opening circuit supervision device (TCS)(*) or the
STU functionality control device (see accessory 21, supplied on
request).

Characteristics
Un 48 - 110 ... 125 - 220 ... 250 Vcc
Un 110 ... 125 - 220 ... 250 VAC
in accordance with IEC/IEEE 62271-37-
Operating limits
013
Power at inrush (Ps) 60...100 W / VA
(*) The minimum current that the relay with TCS function (used for monitoring coil Holding power (Pc) 1.5 W
continuity) detects as a condition denoting that the trip circuit is operating correctly Electronics self-consumption
(specified for each relay in the relative manual), must be sensibly higher than the (no coil supplied);
current consumption of the actual coil (~1.5 mA). 1.5 mA
value independent of voltage
If this fails to occur, always add, in parallel to the TCS, a circuit able to absorb
applied
sufficient current to compensate the gap while preventing the total current in the TCS
circuit from rising above the maximum threshold (Itcs < 10 mA for High Voltage coils Opening time 33...60 ms
- from 110V to 250V, and Itcs < 50 mA for Low Voltage coils from 24 V to 60 V).
Insulation voltage 2000 V 50 Hz (for 1 min)
A simple resistor can be sized for the purpose, depending on the parameters of the
TCS and the auxiliary voltage range used.

15
7a Auxiliary contacts of circuit-breaker (-BGB1) for 15
kV versions

Electrical signaling of circuit-breaker open/closed can be General characteristics

obtained with a group of 10, 16 or 20 auxiliary contacts Insulation voltage 660 V A.C.
to VDE 0110 standards, Group C 800 V D.C.
for the fixed version and 10 or 16 auxiliary contacts for the
withdrawable version. The standard equipment comprises 10 Rated voltage 24 V ... 660 V

auxiliary contacts. Test Voltage 2 kV for 1 min

Note Maximum rated current 10 A - 50/60 Hz

The following are available with the standard group of ten Breaking capacity Class 1 (IEC 62271-1)

auxiliary contacts and the maximum number of electrical Number of contacts 5

accessories: Quantity of contacts 10 / 16 / 20

for fixed circuit-breakers: three closing contacts "a" for Contact travel 90

signaling circuit-breaker open and five opening contacts "b" Actuating force 0.66 Nm

for signaling circuit-breaker closed; Resistance <6,5 m

for withdrawable circuit-breakers: three closing contacts "a" Storage temperature -30 C ... +120 C

for signaling circuit-breaker open and four opening contacts Operating temperature -20 C ... +70 C (-30 ref. ANSI 37.09)
"b" for signaling circuit-breaker closed; Contact overtemperature 10 K
Mechanical life 30,000 mechanical operations
Circuit-breakers in the fixed version are available with two Protection class IP20
finishing accessories (to be specified when ordering): Cable section 1 mm2
non-wired auxiliary contacts; wiring to the terminals of the
contacts is at the customer's charge (photo below left; Electrical specifications (according to IEC 60947)
the terminal box to which the other electrical accessories Rated voltage Un Breaking capacity (10000 breaks)
are wired is at the top); ask for instructions 1VCD601204 220 V A.C. Cosj = 0.70 20 A
(available in the main languages) which describe how to 220 V A.C. Cosj = 0.45 10 A
remove, wire the auxiliary contact more easily and fit the 1 ms 12 A
group of auxiliary contacts back in place; 24 V D.C.
15 ms 9A
auxiliary contacts already wired to the terminal box (see 50 ms 6A
photo at top right) 1 ms 10 A
Consult circuit diagrams 1VCD400151 for fixed circuit- 60 V D.C.
15 ms 6A
breakers and 1VCD400155 for withdrawable circuit-breakers. 50 ms 4.6 A
1 ms 7A
Note: The main shunt opening release and/or the additional 110 V D.C. 15 ms 4.5 A
shunt opening release use 1 and/or 2 closing contacts "a", 50 ms 3.5 A
thereby reducing the number of auxiliary contacts available. 1 ms 2A
Always check the maximum number of contacts available with 220 V D.C. 15 ms 1.7 A
non-standard equipment. 50 ms 1.5 A
Auxiliary contacts BGB1 conform to the following standards/ 1 ms 2A
regulations/directives: 250 V D.C. 15 ms 1.4 A
IEC 62271-100 50 ms 1.2 A
IEEE C37.54
EN 61373 cat.1 class B / impact and vibration test Electrical specifications (according to IEC 62271-100 class 1)

Germanish Loyd regulation / vibrations envisaged by the Rated voltage Un Breaking capacity

shipping registers 24 VDC 20 ms 18.8 A

UL 508 60 VDC 20 ms 7.4 A

EN 60947 (DC-21A DC-22A DC-23A AC-21A) 110 VDC 20 ms 4.2 A

RoHS Directive 250 VDC 20 ms 1.8 A

16
8 Transient contact (-BGB4)
This contact closes momentarily (for > 30 ms) upon
circuit-breaker opening by remote control or by means of a
shunt opening release.
The indication is not given when opening is manual and local.
In this case, a contact (BGB11) is activated by the manual
pushbutton and cuts out the closing indication of the transient
contact (BGB4).
The transient contact is activated by the main operating shaft,
thus the indication is only provided when the main contacts of
the circuit-breaker effectively open.
9 Position contact (-BGT3)
It is used in conjunction with the locking magnet in the operating
mechanism (-RLE1) to prevent remote closing during movement
in the cubicle.
It is only supplied for the withdrawable circuit-breaker version for
UniGear ZS1 switchgear and PowerCube modules.
It cannot be supplied when transmitted contacts in the truck are
required (-BGT1; -BGT2).
10 Transmitted contacts in truck (-BGT1;-BGT2)
Transmitted contacts of withdrawable circuit-breaker (installed
in circuit-breaker truck - only for withdrawable circuit-breaker
VD4G/P).
These contacts are additional or alternative to the position
contacts (for signaling circuit-breaker withdrawn) in the
cubicle. They also act as position contacts (-BGT3).
Contacts -BGT1 and BGT2 have the same general and
electrical characteristics as auxiliary contacts 7b. -BGB1,
-BGB2, -BGB3.
17
11 Motor operator (-MAS) 12 Closing spring loaded/discharged signaling
contacts (-BGS2)

Automatically loads the closing spring of the circuit-breaker's
operating mechanism. Once the circuit-breaker has closed,
the motor immediately begins to reload the closing spring.
The closing spring can still be loaded in the manual mode
(using the relative lever built into the operating mechanism) in
a power failure or during maintenance work.
Consists of a microswitch allowing remote signaling of the
state of the closing spring of the circuit-breaker operating
mechanism.
The following settings can be obtained:
contact open: spring loaded signal
contact closed: spring discharged signal
The two signals must be used for circuits with the same
energizing voltage.

Characteristics
Un 48 - 110 ... 125 - 220 ... 250 Vcc
Un 110 ... 125 - 220 ... 250 VAC
Operating limits in accordance with IEC/IEEE 62271-37-013
VD4G-25 VD4G-40
Power at inrush (Ps) D.C. = 600 W; D.C. = 900 W;
A.C. = 600 VA A.C. = 900 VA
D.C. = 200 W; D.C. = 350 W;
Rated power (Pn)
A.C. = 200 VA A.C. = 350 VA
Inrush time 0.2 s 0.2 s
Loading time 6-7 s 6-7 s
2000 V 50 Hz 2000 V 50 Hz
Insulation voltage
(for 1 min) (for 1 min)

18
Protections and locks
Various different mechanical and electromechanical protection devices and locks are
available.
15 Locking magnet on truck (-RLE2) 16 Interlock for fixed circuit-breaker

This accessory is mandatory in withdrawable versions for Device for fixed circuit-breakers converted into plug-in by the
UniGear ZS1 switchgear and PowerCube modules to prevent customer. Allows the customer to create a mechanical lock
the circuit-breaker from being racked into the switchgear that inhibits racking-out/racking-in when the circuit-breaker
when the plug of the auxiliary circuits is disconnected. is closed and prevents the circuit-breaker from closing during
The plug also creates an anti-insertion lock against different movement.
rated currents. Striker pins prevent the plug from being NOTE. The device must be requested when the order is
plugged into the socket if the circuit-breaker's rated current is placed since it must be assembled in the factory.
lower than the rated current of the panel.
Note: a specific version for the circuit-breakers of ZS8.4
switchgear is available on request. This accessory
is not available when the motor-operated truck is
required.

Characteristics
Un 48 - 110 ... 125 - 220 ... 250 Vcc
Un 110 ... 125 - 220 ... 250 VAC
in accordance with IEC/IEEE 62271-37-
Operating limits
013
Power at inrush (Ps) D.C. 250 W; A.C. = 250 VA
Continuous power (Pc) D.C. = 5 W; A.C. = 5 VA
Inrush time 150 ms
Insulation voltage 2000 V 50 Hz (for 1 min)

19
17 Mechanical door interlock 18 Motor-operated truck (-MAT)

This device prevents the circuit-breaker from being racked
in when the switchgear door is open. It can only be used
for circuit-breakers installed in UniGear ZS1 switchgear and
PowerCube modules equipped with the relative actuator on
the door.
Allows the circuit-breaker to be racked in and out of the
switchgear by remote control (only for circuit-breakers in the
withdrawable version for UniGear ZS1 and ZS8.4 switchgear
and PowerCube modules).
The motor-operated version with clutch can be ordered on
request, so that racking-in/out can be performed in an emergency
if the truck motor fails to operate.

Characteristics
Un 24 - 30 - 48 - 60 - 110 - 220 V
Operating limits 85 110% Un
Rated power (Pn) 40 W

20
19 STU Shunt Test Unit

continuity of releases with rated operating voltage between 24

V and 250 V (AC and DC), as well as the functionality of the
release's electronic circuit.
The continuity test is performed cyclically with a 20-second
interval between one test and the next.
The unit has optical LED indicators on the front. The following
information is given:
POWER ON: power is being supplied
-MO) TESTING: test is being performed
TEST FAILED: this signal is given after a test has failed or
when there is no auxiliary power being supplied
ALARM: this signal is given after three tests have failed.

There are two change-over relays on the unit that allow these
Device for monitoring functionality and continuity of shunt two events to be signaled in the remote mode:
opening/closing releases. test failed (resetting occurs automatically once the alarm
Owing to their particular construction, the functionality of the has ceased)
shunt closing (-MBC) and opening releases (-MBO1, -MBO2) failure of three tests (resetting only occurs by means of the
cannot be tested with dedicated relays (e.g. TCS Test Control manual - RESET - on the front of the unit)
Supervision, CCC Control Coil Continuity) or with the REF
monitoring and protection unit. The only device able to test A manual - RESET - key is also installed on the front of the
this functionality is the STU device. Please contact us if this unit.
test must be performed with devices other than STU.
The STU device can be used in conjunction with the shunt Characteristics
opening release (-MBO1; -MBO2) or shunt closing release Un 24 ... 250 V A.C./D.C.
(-MBC) for functionality and continuity tests. Maximum interrupted current 6A
Maximum interrupted voltage 250 V A.C.
The Shunt Test Unit for testing/monitoring is used to test the

21
6. 1Instructions for circuit-breaker operation

6.1. Safety indications The circuit-breaker must be gradually racked-in

VD4G circuit-breakers provide at least
IP2X protection class if installed in the
following conditions:
fixed circuit-breaker, installed behind a protective
metal net
withdrawable circuit-breaker, 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.
If the operations are obstructed, do not force the
mechanical interlocks but check that the operating
sequence is correct.
and out of the switchgear to avoid shocks that
could deform the mechanical interlocks.
For safety reasons, if it is impossible to establish
whether the circuit-breaker is open or closed, it
must be considered closed and live to all effects.
In this case, none the high voltage connections
towards the primary side of the circuit-breaker
must be supplied and all must be potential-free.
This condition must be confirmed before any tests,
maintenance work, repairs and successive putting
into service operations are performed.

4 5
2

6 7
10

9 8

Key
1 K ey lock (if applicable) (*)
2 L ever for manual loading of closing spring
3 Lever seat for racking-out operation (only for withdrawable circuit-breakers)
4 O pening pushbutton
5 C losing pushbutton
6 S ignaling device for circuit-breaker open/closed
7 Signaling device for closing spring loaded/discharged
8 O peration counter
9 H andles for operating truck locks (only for withdrawable circuit-breakers)
10 O perating lever for circuit-breaker racking-in/out
(*) Warning! To activate the key lock: open circuit-breaker, press and hold opening pushbutton, then turn key and remove it from its seat.

Fig. 6a

22
6.2. Operating and signaling
components
VD4G circuit-breakers for UniGear switchgear and PowerCube
modules (fig. 6a)
6.3. Circuit-breaker closing and
opening operations
The mechanical operating mechanism can be manually or
electrically closed, opened and loaded (fig. 6 - fig. 7).
a) Manual loading of closing spring for VD4G circuit-
breakers for UniGear switchgear (fig. 7a)
Repeatedly operate the loading lever (2) (the lever's maximum
angle of rotation is about 90) until the yellow indicator
appears (7).
Maximum force that can normally be applied to the lever:
<200 N for operating mechanism EL2.
Operating mechanisms type EL1 Twin and EL2 Twin are
used for circuit-breakers with 40 kA breaking capacity. Make
sure the additional lever (1) is fully inserted when loading
in the manual mode, as indicated in fig. 7c. In this way, the
maximum force applied is < 200 N.
The type of operating mechanism is indicated on the rating
plate of fig. 1
b) Electrical spring loading operation
On request, the circuit-breaker can be fitted with the following
accessories for electrical operation:
gearmotor for automatic loading of closing spring
shunt closing release
shunt opening release.
The gearmotor automatically reloads the spring after each
closing operation until the yellow indicator appears (7).
If there is a power failure during the loading operation, the
gearmotor stops and automatically continues to load the
spring once the power returns.
However, it is always possible to complete the loading
operation in the manual mode.
c) Circuit-breaker closing
This operation can only be performed when the closing spring
is fully loaded.
Press the pushbutton (5 - fig. 6a) to close the circuit-breaker
in the manual mode.
When there is a shunt closing release, the operation can also
be carried out in the remote mode by means of the special
control circuit. Effective closing is signaled by the indicator
(6 - fig. 6b).
d) Circuit-breaker opening
Press the pushbutton (4 - fig. 6a) 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
(6 - fig. 6a).
23
 90

Fig. 7a

Fig. 7b

24
7. Installation
7.1. General information
Correct installation is of primary importance. The
manufacturer's instructions must be carefully studied
and followed. It is good practice to use gloves,
protection for the eyes, head and lower limbs when
handling the components during the installation work.
7.2.2. Special conditions
Installations over 1000 m a.s.l.
Possible, within the limits allowed by the reduction in the dielectric
strength of the air.
Increase in ambient temperature
Reduction in the rated current.

7.2. Installation and operating Facilitate heat dissipation by use of appropriate additional ventilation.

conditions Climate
To avoid the risk of corrosion or other damage in areas:
It is particularly important to comply with the
with a high level of humidity, and/or
following regulations during installation and operaton: rapid and extensive temperature variations, take appropriate steps
IEC 62271-1/DIN VDE 0101 (for example, by using electric heaters) to prevent condensation from
forming.
VDE 0105: Operation of power installations
DIN VDE 0141: Earthing systems for installations with rated
voltage above 1 kV. Please contact ABB for special installation requirements or
All the accident prevention regulations in force in the other types of operating conditions.
respective countries.
The areas through which power conductors or auxiliary
7.2.1. Normal conditions circuit conductors are routed must be protected
Comply with the recommendations in standards IEC against access by animals, as this could lead to
62271-1 damage or disservice.
and 62271-100, i.e.:

Ambient temperature
Maximum + 40 C
Average maximum over 24 hours + 35 C
Minimum (according to class 5),
5
apparatus for indoor installation

Humidity
The average relative humidity value measured for more than 1 month
must not exceed 95%
The average water vapor pressure value measured for more
24 hours must not exceed 2.2 kPa.
The average relative humidity value measured for more than 1 month
must not exceed 90%
The average water vapor pressure value measured for more
than 1 month must not exceed 1.8 kPa.

Altitude
< 1000 m above sea level.

25
7.3. Preliminary operations
Clean insulating parts with clean dry rags.
Make sure that 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 onto bearing
frames provided by the customer or on special bearing trucks
(available on request).
Circuit-breakers with bearing trucks must be fastened to the
floor of their compartment at the customer's charge. The
floor surface where the truck wheels slide must be perfectly
leveled.
A minimum degree of protection (IP2X) must be guaranteed
from the front towards live parts.
7.4.1. Assembly of circuit-breakers on trucks provided by
third parties
VD4G circuit-breakers that are not installed on ABB trucks
but on trucks provided by the customer must be equipped
with one or two additional auxiliary contacts (operated by the
mechanical lock or release device of the circuit-breaker) which
interrupt the circuit of the shunt closing release (-MBC) during
movements to and from the isolated position.
This function is performed on ABB trucks by auxiliary contacts
-BGT1 and -BGT2, which shut off the power supplied to the
release during and before activation of the mechanical lock of
the truck's screw insertion device. This means that power can
only be supplied to the shunt closing release after activation
of the mechanical lock. No electrical impulse is therefore able
to activate the shunt closing release when the circuit-breaker
is in the intermediate position.
7.5. Installation of withdrawable circuit-
breakers
The withdrawable circuit-breakers are designed for use in
UniGear ZS1 switchgear.
To rack the circuit-breaker in and out of the switchgear, fully
insert the lever (1) (fig. 9) into its seat (2) and turn it clockwise
to rack-in or counter-clockwise to rack-out until reaching the
end of travel positions. The circuit-breaker must be gradually
racked-in and out to avoid shocks that could deform the
mechanical interlocks and limit switches.
The torque normally required for racking-in and out is < 25
Nm.
Never exceed this value. If the operations are obstructed in
any way or difficult to perform, do not apply force but check
that the operating sequence is correct.
Note
To complete the racking-in or out operations, the lever must be turned about 20
times for circuit-breakers up to 17.5 kV and about 30 times for 24 kV circuit-
breakers.
26
When the circuit-breaker has reached the isolated for test/
isolated position, it can be considered to have been racked
into the switchgear and earthed by means of the truck
wheels.
Withdrawable circuit-breakers of the same version, thus of the
same size, are interchangeable. However, when, for example,
the electrical accessories are different, the plug of the auxiliary
circuits will have a different code and prevent panels and
circuit-breakers from being wrongly paired.
The technical documentation of the switchgear should also be
consulted when installing the circuit-breakers.
The racking-in/out operations must always be
performed with the circuit-breaker open.
When putting into service for the first time,
always load the circuit-breaker operating
mechanisms in the manual mode to avoid
overloading the auxiliary supply circuit.
7.5.1. Circuit-breakers with motor-operated withdrawable
trucks
Perform the racking-in/out test for the motor-operated truck
in the same way as the manual truck and comply with the
following instructions:
Rack the circuit-breaker into the switchgear in the open and
isolated position, with the supply circuit of the motor de-
energized and the enclosure door closed.
Fit the manual racking-in lever (1) into its seat (2) Fig. 9
and move the motor-operated truck to about halfway along
its travel, between the isolated for test and connected
positions. The torque required to move the truck is < 25
Nm.
This operation allows you to deal with movements in the
wrong direction without damage should the polarity of the
truck motor supply accidentally reverse. Verifications:
a) clockwise motor rotation when circuit-breaker is racked in.
b) counter-clockwise motor rotation when circuit-breaker is
racked out.
Remove the manual lever (1) from its seat (2) Fig. 9
Energize the truck motor circuit.
Activate the operating mechanism for electrical racking-in.
After racking-in, make sure that the relative auxiliary contact
has switched correctly.
At the end of the sequence, activate the operating
mechanism for electrical racking-out. After racking-out,
make sure that the relative auxiliary contact has switched
correctly.
If a motor fault occurs during a racking-in or out operation,
the truck can be moved to end of travel in an emergency
by first shutting off the voltage supplied to the motor supply
circuit and then using the manual lever in the same way as
for truck operation in the manual mode.
Note
When the manual lever is used to operate the truck, the chain transmission
turns the truck motor which, by acting as a generator, can produce reverse
voltage towards the connection terminals.
Since this can damage the permanent magnet of the motor, all truck racking-in
and out operations with the manual lever must be performed with the motor
circuit de-energized.
 Racking-in

Max 25 Nm

Racking-out

Fig. 9

7.6. Power circuit connections of fixed T1

Bare copper
circuit-breakers Clean with a fine file or emery cloth.
7.6.1. General recommendations Fully tighten and smear 5RX Moly grease over the contact surfaces.

Choose the conductor cross-sections to suit the service
Copper or silver-plated aluminium
current and short-circuit current of the installation.
Clean with a rough dry cloth.
Provide suitable supporting insulators near the terminals of
Only if there are traces of oxidation that are difficult to shift, clean with
the fixed circuit-breaker or enclosure, sized according to the ultra-fine grain emergy cloth and take care not to remove the surface
electrodynamic stress caused by the short-circuit current of layer.
the installation. Repeat the surface treatment if necessary.

7.6.2. Assembly of connections Bare aluminum

Make sure that the contact surfaces of the connections Clean with a metal brush or emery cloth.

are perfectly flat and without burrs, traces of oxidation or Immediately smear neutral grease over the contact surfaces.
deformities caused by drilling or impact sustained. Insert a bi-metal copper-aluminum strip with dressed surfaces between
the aluminum connection and copper terminal (copper side touching the
The operations indicated in the following table T1 must terminal, aluminum side touching the connection).
be performed on the contact surface of the conductor,
depending on the conductive material used and the surface T2
treatment given. Bolt Recommended tightening torque (1)
Without lubricant With lubricant (2)
Assembly procedures M6 10.5 Nm 4.5 Nm
Put the connections in contact with the circuit-breaker M8 26 Nm 10 Nm
terminals. Take care to avoid mechanical stress (tensile / M10 50 Nm 20 Nm
compressive) exercised, for example, by the busbars on the M12 86 Nm 40 Nm
terminals themselves. M16 200 Nm 80 Nm
Insert a spring washer and flat washer between the bolt
head and connection. (1) The nominal tightening torque is based on 0.14 thread friction coefficient (distributed
value to which the thread is subjected and which, in some cases, is not negligible).
Use of DIN class 8.8 standard bolts is recommended. Refer The nominal tightening torque with lubricant complies with DIN 43673 Standards.
also to the indications in table T2. (2) Oil or grease. Lubricated thread and surfaces in contact with head. Bear in mind
the deviations from the general Standards table (e.g. for systems in contact or
In the case of cable connections, carefully comply with the terminations) as established in the specific technical documentation. The thread and
manufacturer's instructions when making the terminations. surfaces in contact with bolt heads must be slightly oiled or greased, so as to obtain
a correct nominal tightening torque.

27
7.7. Earthing
connection (2) while outside the circuit-breaker, they must be
The fixed version of these circuit-breakers is earthed by screened by an appropriate sort of metallic protection (tube,
means of the dedicated screw identified by the relative duct, ...), which must be earthed.
symbol. Clean and degrease the area around the screw over a
diameter of about 30 mm and, after assembly, cover the joint 7.8.2.Withdrawable circuit-breaker
with Vaseline grease. The auxiliary circuits of the withdrawable circuit-breaker are
Use a conductor (busbar or braid) with a cross-section fully wired in the factory through to the connector (fig. 11).
conforming to the Standards in force. Refer to the circuit diagram of the switchgear for the external
connections.
7.8. Connection of auxiliary circuits
Note: the minimum cross-section of the wires used for the
auxiliary circuits must not be less than the section used for
internal cabling. The wires must also be insulated for 3 kV test
voltage.

7.8.1. Fixed circuit-breaker

The auxiliary circuit can be connected in two different ways
inside the circuit-breaker, depending on the type chosen by
the customer.
The first type is supplied as the standard version. In this
case, the auxiliary contacts must be disassembled from the
structure of the circuit-breaker, since their terminals cannot be
directly accessed (fig. 10) (consult the installation manual).
The wiring is made during the production phase for the
second type. This means that the customer can directly wire
up to terminal boxes in the front part of the circuit-breaker. In
this case, the wiring operation is much faster and immediate.
To prevent the wires of the cabling inside the circuit-breaker
(made by the customer) from accidentially touching moving
parts (which would damage their insulation), make sure that
they are positioned and fixed as shown in fig. 10a.
In both types of connection, the wires must pass through

Fig. 10a
1 2

Fig. 10 VD4G circuit-breakers for UniGear switchgear

28
8. Putting into service
8.1. General procedures
All the operations for putting into service must be
performed by ABB personnel or by the customer's
adequately qualified personnel with detailed
knowledge of the apparatus and installation.
If the operations are obstructed, do not force the
mechanical interlocks but check that the operating
sequence is correct.
The operating forces to apply when racking-in
withdrawable circuit-breakers are indicated in
section 7.5.
Perform the following operations before putting the circuit-
breaker into service:
make sure that the power connections to the circuit-breaker
terminals are tight;
establish the setting of the electronic primary overcurrent
release (if applicable);
make sure that the value of the voltage supplied to the
auxiliary circuits is between 85% and 110% of the rated
voltage of the electrical applications;
make sure that there are no foreign bodies, such as bits of
packing, between the moving parts;
to avoid overtemperatures, make sure that there is a
sufficient exchange of air in the installation site;
also perform the inspections indicated in table T3.
29
T3
COMPONENT INSPECTED
1 Insulation resistance.
2 Auxiliary circuits.
3 Manual operating mechanism.
4 Motor operator Supply spring loading gearmotor at the relative rated voltage.
(if applicable).
5 Undervoltage release (if
provided).
6 Shunt opening release and
additional shunt opening
release (if provided).
7 Shunt closing release Open circuit-breaker and supply shunt closing release at relative Circuit-breaker closes correctly.
(if provided)
8 Key lock (if applicable)
9 Locking electromagnet (-RLE1) Attempt to close circuit-breaker both manually and electrically
(if applicable). with circuit-breaker open, spring loaded and locking
electromagnet de-energized.
10 Auxiliary contacts in operating
mechanism.
11 Locking electromagnet on
circuit-breaker truck (-RLE2) (if
applicable).
12 Transmitted auxiliary contacts
for signaling circuit-breaker
connected, disconnected
(UniGear switchgear or
PowerCube modules).
30
PROCEDURE POSITIVE CHECK
Medium voltage circuit
Using a 2500 V Megger, measure insulation resistance between The insulation resistance should be at least 50
phases and earth of circuit. Mohm and in any case, constant over time.
Auxiliary circuits
Using a 500 V Megger (installed equipment permitting), measure The insulation resistance should be a few
insulation resistance between auxiliary circuits and earth. Mohm and, in any case, constant over time.
Make sure that connections to control circuit are correct: Operations and signals are normal.
proceed with relative power supply.
Perform a few closing and opening operations (see chap. 6). The operations and relative signals take place
NOTE. Supply undervoltage release and locking magnet on correctly.
operating mechanism at the relative rated voltage (if applicable).
Spring is loaded correctly.
Signals are normal.
Gearmotor stops when springs have been
loaded.
Perform a few closing and opening operations. Gearmotor reloads springs after each closing
NOTE. Supply undervoltage release and locking magnet on operation.
operating mechanism at the relative rated voltage (if applicable).
Supply undervoltage release at relative rated voltage and Circuit-breaker closes correctly.
perform circuit-breaker closing operation. Signals are normal.
Disconnect release from voltage supply. Circuit-breaker opens.
Signal changes over.
Close circuit-breaker and supply shunt opening release at Circuit-breaker opens correctly.
relative rated voltage. Signals are normal.
rated voltage. Signals are normal.
Open circuit-breaker, press and hold opening pushbutton, then Neither manual nor electric closing takes place.
turn key and remove it from its seat.
Attempt circuit-breaker closing operation.
Insert key again and turn it through 90. Both electrical and manual closing take place
Perform closing operation. correctly; in this position the key cannot be
removed.
Closing fails to occur.
Connect auxiliary contacts to suitable signaling circuits. Signaling occurs normally.
Perform a few closing and opening operations.
Attempt to rack-in circuit-breaker with circuit-breaker open, Racking-in fails to occur.
in isolated for test position and locking electromagnet de-
energized.
Energize locking electromagnet and perform racking-in Racking-in occurs correctly.
operation.
Connect auxiliary contacts to suitable signaling circuits. Signals due to the operations occur normally.
With circuit-breaker racked-in to enclosure, perform a few
operations from isolated for test position to connected position.
Move circuit-breaker to withdrawn position.
9. Maintenance
The purpose of maintenance is to keep the apparatus in a
good working condition for as long as possible.
The following operations must be performed in accordance
with the specifications given in standards IEC 61208 / DIN 31
051:
Inspection: Finding out the actual conditions
Servicing: Measures to be taken to maintain the specific
conditions
Repair: Measures to be taken to restore the specific
conditions.
9.1. General information
Vacuum circuit-breakers are characterized by simple, sturdy
construction and long life.
The operating mechanism requires functional inspections and
maintenance if it is to remain operative throughout its forecast
life cycle (see sect. 9.3.2.).
The vacuum interrupters are maintenance-free for their whole
operating life.
Vacuum interruption does not produce harmful effects even
when there are frequent interruptions in the rated and short-
circuit current.
Interventions during service and their purpose are determined
by the ambient conditions, the sequence of operations and
shortcircuit interruptions.
Note
Comply with the following regulations for maintenance work:
the relative specifications given in the chapter on Standards and
Specifications;
the labor safety regulations in the chapter on Putting into service and
operations;
the standards and specifications in force in the country where the apparatus
is installed.
Maintenance operations must only be carried out by
personnel who have been trained and who comply with all
the safety regulations. In addition, it is advisable to have ABB
personnel at least check performance during service and
carry out any repairs required.
Cut off the power supply and ensure the apparatus is in a safe
condition during maintenance.
Before proceeding with any operation, make sure
that the circuit-breaker is open, with the spring
discharged and that it is not powered (medium
voltage circuit and auxiliary circuits).
9.1.1. Operating life
The operating life expectancy of VD4G circuit-breakers is as
follows:
vacuum interrupters: up to 30,000 mechanical operations
actuator and transmission system: up to 30,000 operations,
under normal operating conditions, depending on the type
of circuit-breaker and with regular maintenance (see sect.
9.3.2.);
racking-in/out can be performed up to 1000 times if the
operations are carried out correctly (as required by standard
IEC 60271-200);
the operating life data are basically applicable to all
components that are not directly influenced by the
operator's tasks. The behavior of components operated in
the manual mode (moving components of disconnectable
parts, etc.) can vary.
9.2. Inspections and functionality tests
9.2.1. Pole and conductive parts
Regularly inspect the conditions of the conductive parts.
Inspection at fixed intervals can be avoided when the
apparatus is permanently under the control of qualified
personnel.
Firstly, the assessments must include visual inspection
to check for any contamination, traces of corrosion or
electrical discharge.
Perform more frequent inspections when there are unusual
operating conditions (including severe climatic conditions)
and in the case of environmental pollution (e.g. high level of
contamination or an aggressive atmosphere).
Visual inspection of the isolating contacts. If there are tulip
contacts, remember to turn them alternately in order to
keep the internal surface of the conduction areas clean.
The contact areas must be cleaned when there are signs of
overheating (discolored surface) (also consult the Repairs
section).
Perform servicing if the conditions are abnormal (see
Servicing sect.).
9.2.2. Stored energy spring operating mechanism
Run a functional test on the operating mechanism test at
least every 5,000 operations or 5 years, or as part of the
normal maintenance operations described in sect. 9.2.1.
Perform the following operations before conducting the test:
if the circuit-breaker is withdrawable, it must be brought to
the isolated for test position.
for fixed circuit-breakers: shut off the power supplied to the
medium voltage circuit.
Note
Isolate the work area and make it safe by following the safety regulations
specified in standards IEC/DIN VDE.
31
Functional test
Carry out a few opening and closing operations with the
circuit-breaker disconnected from the load.
If required, cut off the power supply to the spring loading
motor. Discharge the spring by closing and opening the
circuit-breaker by means of the closing and opening
pushbuttons.
Visually inspect the tulip isolating contacts, sliding surfaces,
etc., to make sure that they are properly lubricated.
Make sure that the electrical and mechanical operation of
the various devices is correct, especially the interlocks.
The screws and nuts are tightened in the factory and
correct tightening is indicated by a coloured mark. No
further tightening operations should be required during the
operating life of the circuit-breaker. However, if the screws
or nuts must be retightened after maintenance, always
replace the screws and nuts and comply with the values
indicated in fig. 12.

Inspection of screw tightening torque

25 Nm 15 Nm 15 Nm

15 Nm

15 Nm

25 Nm

EL Twin - 40 kA actuator

15 Nm 15 Nm

15 Nm

Fig. 12

32
9.2.3. Circuit-breaker pole
No further inspections are necessary beyond those already
described in sect. 9.2.1.
9.2.4. Withdrawable assembly (truck and circuit-breaker)
Visually inspect the components, especially those which may
have been damaged by incorrect operations (also consult
chap. 8).
Visually inspect the isolating contacts and clean all contact
parts, especially where signs of overheating are found (also
consult sect. 9.4.).
Visually inspect the locks. Perform functional tests to make
sure that they operate properly and activate without abnormal
force - maximum 25 N (also consult the table in chap. 8).
9.3. Servicing
9.3.1. Pole and conductive parts
Comply with the following procedure if the devices had to be
cleaned during the inspections, as specified in sect. 9.2.1:
isolate the work area and make it safe, following the safety
regulations specified in standards IEC/DIN VDE;
general cleaning of surfaces:
dry and remove light deposits of dirt with a soft dry cloth;
more resistant dirt can be removed using slightly alkaline
domestic type detergent or Rivolta BWR 210 detergent;
clean the insulating surfaces and conductive parts with a
suitable detergent.
After cleaning, thoroughly rinse with clean water and dry
carefully.Apply fresh grease if necessary.
Note
Only use halogen-free detergents and never 1.1.1-trichloroethane,
trichloroethylene or carbon tetrachloride!
9.3.2. Release devices: actuator and transmission system
Circuit-breakers up to 15 kV, 1250 A, 25 kA.
Inspection and maintenance should be performed after every
5,000,000 operations to ensure the circuit-breaker functions
correctly. Contact ABB Service.
The damper and other components of the transmission
system (shaft, main levers, safety rings, etc.) must be totally
replaced after 10,000 operations.
Circuit-breakers up to 15 kV, 40 kA and with Twin actuator
Inspection and maintenance must be performed after every
5,000,000 operations to ensure the circuit-breaker functions
correctly. Contact ABB Service.
The damper and other components of the transmission
system (shaft, main levers, safety rings, etc.) must be totally
replaced after 10,000 operations.
Note
Dismantling and replacement of the operating mechanism (trip box) can only
be carried out by ABB personnel or by skilled and specially trained personnel,
particularly as regards the necessary adjustments.
Details about servicing
When required, cut off the power supply to the spring
loading motor and discharge the springs of the operating
mechanism in the manual mode by closing and opening the
circuit-breaker.
Replace parts subject to mechanical stress or stress due
to particular ambient conditions, (contact an ABB service
center).
Refer to maintenance instruction manual 1VCP000558 for
further details.
Note
These operations can only be carried out by ABB personnel or by skilled and
specifically trained personnel.
33
9.3.3. Circuit-breaker pole
The circuit-breaker pole and relative vacuum interrupter are
maintenance-free until the maximum number of electrical
operations for the type of interrupter is reached. The
operating life of the vacuum interrupter is defined by the sum
of the ultimate currents corresponding to the specific type of
interrupter in accordance with the indications in the graphs
of sect. 7.2.3. Trip curves: the whole pole must be replaced
when the sum of the ultimate currents is reached.
Replacement of parts and accessories must only be carried
out by ABB personnel or suitably qualified and specially
trained personnel.
Always work with the circuit-breaker open and locked so that
it cannot be reclosed, with the work area isolated and in safe
conditions.
The spring of the operating mechanism must be discharged.
All power supply sources must be disconnected and secured
against reclosing during the removal and installation work.

Notes If maintenance is carried out by the customer's

Dismantling and replacement of the pole can only be carried out by ABB personnel, responsibility for the interventions remains
personnel or by skilled and specially trained personnel, particularly as regards with the customer.
the necessary adjustments. Replacement of parts not included in the List of spare
parts/accessories (sect. 11.1.) 11.1) must only be
To perform the interrupter vacuum test, move the circuit- performed by ABB personnel.
breaker to the withdrawn position with the opening and The following parts are not included in the list:
closing springs discharged, and remove from switchgear complete pole with bushings/connections
without dismantling the circuit-breaker pole. Use: actuator and transmission system
a VIDAR vacuum tester, manufactured by Programma closing spring unit
Electric GmbH, Bad Homberg v.d.H. opening spring
damper.

The following VIDAR tester test values are valid for the
interrupter vacuum test:
Rated voltage of circuit-breaker D.C. test voltage
15 kV 40 kV

The test must always be performed with the circuit-breaker

open and the contacts at nominal distance.

How to conduct the vacuum test for the interrupter of

the circuit-breaker poles:
turn off the power supply and ensure safe conditions
in the work area by complying with the safety
regulations specified in the IEC/DIN VDE standards;
open the circuit-breaker;
earth one terminal of each circuit-breaker pole;
connect earth terminal of VIDAR tester to structure of
circuit-breaker;
connect high voltage terminal of VIDAR tester to
terminal of circuit-breaker pole not connected to
earth (L1 phase) and proceed with the test. Repeat
the test for phases L2 and L3.

Note
The tester connection cables can produce an indication due to the capacitive
effect. In this case the cables must not be removed.

9.4. Repair

34
10. Application of the X-ray emission Standards
One of the physical properties of vacuum insulation is that
X-rays could be emitted.
The specific tests performed at the PTB laboratories
(Physikalisch-Technische Bundesanstalt, in Brunswick -
Germany) show that local emission at a distance of 10 cm
from the interrupter or pole surface, does not exceed 1
mSv/h.
This means that:
use of vacuum interrupters is absolutely safe at rated
service voltage;
application of withstand voltage at power frequency
(according to the IEC 62271-100 and VDE 0670
standards) is safe;
voltage higher than the withstand voltage at power
frequency or than a direct current test voltage (specified in
the IEC and VDE standards) cannot be applied;
in interrupters with open contacts, limitation of the above-
mentioned local phenomena depends on maintaining the
specific gap between contacts.
This condition is intrinsically guaranteed by correct
operation of the operating mechanism and by the settings
of the transmission system.
35
11. Spare parts and accessories
All assembly operations of spare parts/accessories
must be carried out in accordance with the instructions
enclosed with the spare parts themselves, by ABB
personnel or by suitably qualified customer personnel
with in-depth knowledge of the apparatus (IEC 62271-
100) and of all the standards aimed at ensuring that
these interventions are carried out in safe conditions.
If maintenance is carried out by the customer's
personnel, responsibility for the interventions remains
with the customer. Before proceeding with any
operation, always make sure that the circuit-breaker
is open, the closing and opening springs discharged
and not energized (medium voltage circuit and auxiliary
circuits).
When ordering spare parts/accessories for the circuit-breaker,
refer to the ordering codes indicated in the technical catalog
and always state the following:
type of circuit-breaker
rated voltage of circuit-breaker
rated thermal current of circuit-breaker
breaking capacity of circuit-breaker
serial number of circuit-breaker
rated voltage of any electrical spare parts.
Please contact our Service office to check on availability and
to order spare parts.
36
11.1. List of spare parts
Shunt opening release
Additional shunt opening release
Spring loading gearmotor with electrical signaling of springs
loaded
Contact for signaling gearmotor protection circuit-breaker
open/closed
Contact for signaling closing spring loaded/discharged
Transient contact with momentary closing during circuit-
breaker opening.
Auxiliary contacts of circuit-breaker
Locking electromagnet on operating mechanism
Position contact of withdrawable truck
Connected/isolated signaling contacts
Door isolating interlock
Locking electromagnet on withdrawable truck
Set of six tulip contacts
Shunt closing release
12. Circuit diagrams

The standard circuit diagrams for VD4G circuit-breakers are:

VD4G-25, VD4G-40 K&N Aux.Switches 1VCD400151 (2)

VD4G-25, VD4G-40 K&N Aux.Switches wiring with plug 64 poles 1VCD400152 (2)

VD4G-25, VD4G-40 K&N Aux.Switches wiring with plug 58 poles 1VCD400153 (2)

VD4G-50 1VB2009146P0100

VD4G/P-25, VD4G/P-40 K&N Aux.Switch manual truck for withdr. UniGear 1VCD400155 (2)

VD4G/P-25, VD4G/P-40 K&N Aux.Switch with motorized truck for withdr. UniGear 1VCD400156 (2)

VD4G/P-50 with manual truck for withdr. UniGear GCE2132701P0102

(1) Electrical diagrams designations according to IEC 61346-1 / IEC 61346-2
(2) Electrical diagrams designations according to IEC 81346-1 / IEC 81346-2
- 1VB2009123: Comparison of designations to VDE-DIN 40719 Part 2, IEC 61346-1 / IEC 61346-2 and IEC 81346-1 / IEC 81346-2

37
13. Overall dimensions

Fixed circuit-breakers
123
VD4G/P-25 121
492
110 150 1 150 1
TN 1VCD000233 233 43

Ur 15 kV

100

10
78
296

Ir 1250 A
25 kA

1
Isc 16/16 kA

205

627
626

619

12,5 kA 64

29

1
260

78
1

23
154
19
341

4
21,5
503 14 25 468
34 492
531 500

302
37
320
382
437
573 1,5 max
610
662

Type U I I System Source I Generator Source I Out-of-Phase O.M Cubible

VD4G/P-25 15 kV 1250A 25 kA 16/ 16 kA 12.5 kA EL UNIGEAR ZS1 W=650

Fixed circuit-breakers
314
VD4G-40 636
123
44,5 220 25 110 16
TN 1VCD000234
Ur 15 kV

10
119

Ir 2000 A
20 kA 20

Isc 25 kA
310

40 kA
698
689

119
281

11 23
165
12,5
19

76

26

605
21,5
19,5
4
4

14 653 14 302
25 320 37
359
382
650
590 52
640
642
626
550
210 210

C.B Type U In Isc/ Iscg/ Id O.M Execution

VD4G-40 15 kV 2000A 40 kA/ 25kA/ 20kA EL1 Twin Unigear
29

Powercube
590
359

302

38
Fixed circuit-breakers
600
VD4G-40
323
TN 1VCD000240
210 210 130
Ur 15 kV
Ir 2000 A

119
Isc 50 kA 32

310
30

609

119

475
435
16

56

15

237,5
171

97

77,5
368 28,5

2,5
12 11

24
28,5
48 504 48 172 142 109
424
436 1
20
40
24

C.B. Type U In Iss O.M Execution

VD4G-40 15 kV 2000 A 50 kA EL1 Twin Unigear
Powercube

2xM10 Deep .18

4xM12 Deep .25

Fixed circuit-breakers
750
VD4G-40
396
TN 1VCD000241
275 275 119 99
Ur 15 kV
Ir 2000 A
119

Isc 50 kA
32
310

3
609
30

119

474
435
56

15

238
16
171

97

77,5

28,5
24

49 28,5
429 69 270 84

58 634 424
440 0,8
M10 Deep .18 20 98
24
40

40 M12 Deep .25

39
13. Overall dimensions

Fixed circuit-breakers
750
VD4G-40
398
TN 1VCD000242 375
275 275 454
Ur 15 kV 240
189 119 69
Ir 3150 A
4000 kA

118
119
Isc 50 kA
32

310
29,5

119

475
16
435

56

237,5
171

116 28,5

24

2,5
77,5
165 28,5 69 270 84
30,5 689 30,5 423
435 0,8

40
4xM12 deep 25 C.B. Type U In Iss O.M
VD4G-40 15 kV 3150/4000 A 50 kA EL2 Twin
12
40
8

20 2xM10 deep 20

Withdrawable circuit-breakers
331
VD4G/P-40 842
313
230 48 110
TN 1VCD000243
Ur 15 kV
Ir 2000 A
Isc 40 kA 20
310
698
689

681

29
280

89
164
19

123
19,5
4
21,5

853 13,5
34 302
880
320
374 359
275 275 416
590 52
144

C.B Type U In Iss O.M Execution

VD4G/P-40 15 kV 2000 A 40kA EL1 Twin Unigear
Powercube
695

750
806
836

40
Withdrawable circuit-breakers
842
VD4G/P-40 240 111

10
362 25
95
TN 1VCD000244 130

Ur 15 kV

118
150
3150 A
Ir
4000 A 39

1
20 kA

310
Isc 25 kA

743

733
731

30

678
40 kA
16

478
29
56

1
280

89
213

1
165
19

76
12,5

4
4

19,5
302

21,5
842
853 25 320
880 359 52
34 382
850
836 416
806 553 1,5
750
592
275 275
31

C.B Type U In I System Source I Generator Source I Out-of-Phase O.M Cubicle

VD4G/P-40 3150A UNIGEAR ZS1

W=1000
591

15 kV 40kA 25kA 20kA EL

VD4G/P-40 4000A UNIGEAR ZS1
W=1000
357

303
4

Withdrawable circuit-breakers

VD4G-25 450
248
52

TN 1VCD003891 95 32

Ur 15 kV
Ir 1250 A
Isc 31,5 kA
205
30

52

475
16

451
435

56

16

217,5
171

96

77,5
56

33 227,5 28,5
49 28,5
24 402 24 45 250 109
406
150 150
417,5 0,8

M10 DEEP.18 M12 DEEP.25

45
22

22

Type U In Isc O.M Version For

VD4G-25 15 kV 1250A 31.5kA EL Fixed
Installation

41
14. Quality of the products and environmental protection
The apparatus is manufactured in accordance with the requirements established by the international standards concerning
quality management and environmental management systems. The level of excellence in these fields is testified by the ISO
9001 and ISO 14001 certificates available.

End of life of the products

ABB undertakes to comply with the environmental protection requirements laid down by law, in accordance with the provisions
established by the ISO 14001 standards.
ABB provides skills and assistance to facilitate the recycling and disposal process for products at the end of their life.
Compliance with the local regulations when disposing of products is always mandatory.

Disposal methods
The products can be disposed of by means of heat treatments, in incineration systems or by storage in dedicated areas.

Material Recommended disposal method

Metals (Fe, Cu, Al, Ag, Zn, W, other) Separation and recycling
Thermoplastics Recycling or disposal, separation of metal parts
Epoxy resin Separation of metal parts, disposal of resin parts
Rubber Disposal
Wood for packaging Recovery, recycling and/or disposal
Sheets of polyethylene or paper for packaging Recycling or disposal

42
Notes

43
For further details please contact:

1VCD601473 - Rev. -, en - Instruction Manual - 2017.03 (VD4G) (gs)

ABB S.p.A.
ABB SACE Division
Medium Voltage Products
Via Friuli, 4
I-24044 Dalmine
Tel.: +39 035 6952 111
Fax: +39 035 6952 874
E-mail: info.mv@it.abb.com

ABB AG
Calor Emag Medium Voltage Products
Oberhausener Strasse 33
D-40472 Ratingen
Phone: +49(0)2102/12-1230
Fax: +49(0)2102/12-1916
E-mail: powertech@de.abb.com

www.abb.com

The data and illustrations are not binding. We reserve the right to
make changes without notice in the course of technical and product
development.

Copyright 2017 ABB. All rights reserved.