Retrofit Solutions, Instruction Manual

For 12/24 kV HKK MOCB with VD4 Circuit Breakers

Sl.No. Title Page No.
I. Introduction 3
II. Retrofitting solutions of ASEA make HKK MOCB with VD4 Breakers 4
1. Packing and transport 5
2. Checking on receipt 5
3. Storage 5
4. Handling 6
5. Description 6
6. Instructions for circuit breaker operation 7
7. Installation 7
8. Putting into service 9
9. Periodical checking 10
9. Maintenance 11
10. Application of the X-ray emission 11
11. Spare parts and accessories 11

2 Retrofit Solutions | Instruction manual

Introduction

Retrofit solutions for medium voltage equipment

Value To Customer
Optimized Maintenance Line

Continuous
upgrade/ Retrofit
Replacement

Maintenance

Overhaul

Aging
Repair

Time
Time
Upgrade and
Warranty Period Modernization Period Replacement & recycle Period

Customer
Project Maintenance Period
Lifecycle

With increasing demand for power, aging equipment are Benefits of retrofitting
subject to stringent loads beyond their rated values at – Life extension
many existing installations. The equipment is also required – Technology upgradation
to perform reliably, meet the necessary standards, combat – Optimized investment
increasing fault levels and be compatible with the latest – Improved safety standards
data communication systems. In many cases, considering – Enhanced reliability
shutdown constraints and cost factors, the value proposition – Re-routing of power / Control cables not required
offered by Retrofit Solutions are far greater than replacing the – Speedy execution
old equipment. – Minimum downtime
– No change of location – foundation not disturbed
The key value proposition of retrofit solutions is the
– Easy availability of spares
optimization of performance and investment

Typically, retrofit constitutes replacement of vital equipment

having similar or advanced features, for life extension,
reduced maintenance and improved functionality. This
includes upgradation & modernization of basic equipment
and allied parts. The retrofitted switchgear offers far greater
system reliability, personnel safety and long term availability of
spares with minimal investment and down time.

Instruction manual | Retrofit Solutions 3

Retrofitting solutions of ASEA make HKK MOCB with VD4 Breakers

The retrofit solution comes with vacuum circuit breaker
type VD4, and is truck-mounted so as to facilitate direct
replacement of the HKK MOCB truck in the cubicle. All
original functionalities are maintained
Salient features
– Designed and tested to meet the requirements of IEC
62271-100
– Vacuum used as insulation and arc quenching medium
– Operationally safe and reliable
– Capable of Interrupting small magnetizing and capacitive
current

Technical specifications
Description Unit Ratings
Type VD4 12.12.25 12.12.40 12.16.40 24.12.25
Rated voltage kV 12 12 12 24
Rated normal current A Upto 1250 1200 1600 1250A
Breaking capacity kA 26.3 40 40 25
STC for 3 sec kA 26.3 40 40 25
Peak withstand current kAp 66 110 110 66
Insulation level kVrms/kVp 28/75 28/75 28/75 50/125
Operating sequence O-3min-CO-3min-CO / 0.03sec-CO-3min-CO
Opening time ms 35-55 35-55 35-55 33-60
Total Breaking time ms 50-70 50-70 50-70 50-70
Closing time ms 60-80 60-80 60-80 50-80

4 Retrofit Solutions | Instruction manual

1 Packing and transport
The circuit breaker is shipped in special packaging in the abb
open position with the springs discharged. 1 IEC. 62271-100
2 SER. NO
Each piece of apparatus is protected by a plastic film to 3 TYPE
prevent any infiltration and ingress of water and dust during RATED VOLTAGE
the loading, transport, unloading and storage phases. RATED IMPULSE VOLTAGE
RATED NORMAL CURRENT
4 RATED SHORT CIRCUIT BREAKING
2 Checking on receipt CURRENT
Before doing anything to the apparatus, always make sure MAKING CAPACITY AT 17.5 kV
that the operating mechanism springs are dis¬charged and SHORT TIME CURRENT FOR 3 SEC
OPENING DEVICE
that the apparatus is in the open position.
5 CLOSING DEVICE
On receipt, check the state of the apparatus, that the packing MOTOR SUPPLY V. HZ
is undamaged and that the nameplate data corresponds (see MASS 180 kg
fig. 1) with that specified in the order acknowledgement and
in the delivery note. Figure 1. Rating Plate

Make sure that all the materials described in the shipping note 1. Symbols and compliance with standards
are included in the supply. 2. Serial number
If any damage or irregularity is discovered on unpacking, 3. Type of apparatus
notify ABB directly, or through the agent or supplier, as soon 4. Circuit breaker characteristics
as possible and within five days of receipt. 5. Characteristics of the operating auxiliaries

The apparatus is supplied with accessories specified at the

time of order and confirmed in the order acknowledgement 3 Storage
sent by ABB. When a period of storage is foreseen, on request our
workshops can provide suitable packing for the specified
Check that the following accompanying documents are storage conditions.
included in the shipping packing:
– Instruction manual (this document). On receipt of the apparatus, it must be carefully unpacked
– Test certificate. and checked as described in point 2. “Checking on receipt.”
– Identification tag. If immediate installation is not possible, the packing must be
– Fiscal copy of shipping note. properly replaced using the original material supplied.
– Electrical diagram.
Additionally, insert hygroscopic substances inside the packing
Other documents that are sent prior to shipment: with at least one standard bag per piece of apparatus.
– Order acknowledgement. Should the original packing not be available and immediate
– Original copy of shipping note. installation is not possible, store the apparatus in a covered,
– Any drawings or documents regarding special well-ventilated, dry, dust-free and non-corrosive atmosphere,
configurations/conditions. away from any flammable materials at a temperature of
between -5°C and +45°C. Avoid any accidental impacts or
positioning that will stress the structure of the apparatus.

Instruction manual | Retrofit Solutions 5

4 Handling
Before carrying out any handling, always check that the
operating mechanism springs are discharged and that the
apparatus is in the open position.

5 Description
5.1 General features
The VD4-HKK retrofit vacuum circuit breakers are for
indoor installation. For electrical performance figures,
please refer to the corresponding technical catalogue VD4
12kv..630A..2500A…44kA.
For special installation conditions please refer to ABB.

5.2 Reference standards

VD4-HKK circuit breakers comply with the following
Standards:
– EC pubbl. 62271
– EC pubbl. 60694

5.3 VD4 HKK circuit breaker

VD4 circuit breakers are available for HKK Switch boards
The VD4 HKK retrofit solution is a exact one to one
replacement for HKK MOCB. It has all identical interlocks
which are as per the standards. The indication lamps (4) are
located on the front door for breaker ON/OFF. These breakers
are tested in a fixture before supply thus ensures highest
standards of Quality and Accuracy. These breakers have a
24 Pin plug arrangement which is identical to the existing
breakers. The charging handle (7) is an integral part of the
basic circuit breaker.

The retrofit Solution is complete with Copper Contacts along

with Power Contacts suitable to Current carrying requirement

There is locking pin (8) at the bottom which prevents the

circuit breakers from coming out of the panel when fully
inserted. To rack-in the breaker, the pull out unit handle is fully
inserted into the Pull out unit. The handle is then rotated to
insert the breaker into service position. The lever into the pull
out unit will come to Lock position.

The Handle (3) for the movement of circuit breakers are

mounted on to the front cover of the circuit breaker. This Fig 2: Part Details
Circuit breaker is manufactured keeping into view the
1. Open push button
requirement of maintenance. The front cover of the basic
2. Close push button
VD4 breakers can be removed without disturbing any other
3. Handle
component. If the circuit breaker is closed in test of service
4. ON / OFF indication lamps
position, then one cannot move the breaker unless it is
5. Isolating contacts
tripped first. While the Circuit breaker is between test &
6. Insulator support
service position in the panel, then the circuit breaker cannot
7. Spring charging handle
be closed.
8. Locking pin
9. Phase barrier

6 Retrofit Solutions | Instruction manual

6 Instructions for circuit breaker operation
6.1 Safety indications
HKK - VD4 circuit breakers ensure a minimum degree
of protection in accordance to IP3X, if installed under
! the following conditions:
The VD4-HKK Retrofit breaker must be installed in a
switchboard to achieve IP3X.
Should any mechanical operations be carried out on the
circuit breaker outside the switchboard, or with the protection
covers removed, be very careful of any moving parts.
If the operations are prevented, do not force the mechanical
interlocks and check that the operation sequence is correct.
The rack-in and rack-out operations of the circuit breaker
must be carried out gradually to prevent any impacts which
might deform the mechanical interlocks.
6.2 Operating and Signalling Parts
1 If the power is cut off during charging, the geared motor
2 stops and automatically starts recharging the springs again
6 when the power returns. It is always possible to complete the
4 5
3 (c) Circuit breaker closing
1. Manual opening push button
2. Manual closing push button
3. Operations counter
4. Manual spring charging handle
5. Signalling device for spring charged/discharges
6. Signalling device for circuit breaker ON/OFF
6.3 Circuit breaker closing and opening operations
Circuit breaker operation can be manual or electrical.
(a) Manual spring charging operation.
To manually charge the closing springs, it is necessary to
repeatedly activate the charging lever (4) to the maximum
rotation angle of the lever at about 90°, until the yellow
signalling device (5) appears, which indicates the completion
of charging.
The maximum force which can normally be applied to the
charging lever is 150N for the EL1 operating mechanism ,
200N for the EL2 operating mechanism and <250N for EL3
operating mechanism
(b) Electrical spring charging operation
The circuit breaker is fitted with the following accessories for
electrical operation:
– Geared motor for automatic charging of the closing
springs.
– Shunt closing release.
– Shunt opening release.
The geared motor automatically recharges the springs after
each closing operation, until the yellow signaling device (5)
appears.
recharging operation manually.
This operation can only be carried out with the closing springs
completely charged.
For manual closing, press the push button (2).
When there is a shunt closing release, the operation can also
be carried out remotely by means of a special control circuit.
Closing having taken place will be indicated by the signaling
device (6).
(d) Circuit breaker opening
For manual opening, press the push button (1).
When there is a shunt opening release, the operation can also
be carried out remotely by means of a special control circuit.
Opening having taken place will be indicated by the signaling
device (6).
7 Installation
7.1 General
Correct installation is of prime importance.
! Instructions given must be carefully studied and
followed. It is good practice to wear gloves during
installation.
Instruction manual | Retrofit Solutions 7
7.2 Normal installation conditions 7.6 Overall dimensions
I. Maximum atmospheric air temperature + 40° C
II Minimum atmospheric air temperature - 5° C
I. Altitude d 1540 m
II. Humidity: The average value of the relative humidity,
measured for a period longer than 24 hours, must not
exceed 95%.
III. The average value of the pressure of water vapour,
measured for a period longer than 24 hours, must not
exceed 2.2 kPa. hi
IV. The average value of the relative humidity, measured for a
period longer than 1 month, must not exceed 90%.
V. The average value of the pressure of water vapour,
measured for a period longer than 1 month, must not
exceed 1.8 kPa.
VI. The installation room must be well ventilated.

Areas affected by the passage of power conductors or

auxiliary circuit conductors must be protected against the
possible access of animals, which could cause damage or TYPE VD4-HKK
abnormal service. Ur 12Kv
Ir 630A/1250A/1600A
7.3. Preliminary operations Isc 40kA
– Clean the insulating parts with clean dry rags.
– Check that the upper and lower terminals are clean
and free of any deformation caused by possible shocks
received during transport or storage.

7.4 Installation of HKK-VD4 circuit breaker

The HKK-VD4 circuit breakers are preset for insertion in the
HKK range of switchboards. Insertion and racking of the
circuit breakers must be gradual to avoid any shocks, which
could deform the mechanical inter-locks.

If the operations are prevented, do not force the interlocks

and check that the operating sequence is correct. The force
normally applicable for insertion or racking is 260 N. The
maximum force applicable must never exceed 400N.Please
refer to the technical documentation of the enclosures and
switchboards for the circuit breaker installation operations.

VIEW FROM SIDE

7.5 Auxiliary circuit connection VIEW FROM FRONT

The minimum cross-section of the wires used for the auxiliary

circuits must not be less than that used for internal wiring. TYPE VD4-HKK
They must also be insulated for a 2kV test voltage. Ur 24Kv
Ir 630A/1250A
Before removing the operating mechanism cover Isc 25kA
! to access the terminals make sure that the circuit
breaker is open and the closing springs discharged.
Figure 3. Overall dimensions

CAUTION !
The insertion and racking operations must always be carried
out with the circuit-breaker in the open position.

8 Retrofit Solutions | Instruction manual

8 Putting into service
8.1 General procedures
All procedures regarding putting into service, must be carried
out by ABB personnel or the customer personnel, who are
suitably qualified and have an in depth knowledge of the
apparatus and its installation. If the operations are prevented,
do not force the mechanical interlocks, but check that the
operation sequence is correct.
For operating forces that can be applied, see paragraph 6.3 (a)
Before putting the circuit breaker into service carry out the
following operations:
– Check the tightness of the power connections on the
circuit breaker terminals.
– Establish the setting of the direct solid-state over-current
release (if provided).
– Check that the value of the supply voltage for the auxiliary
circuits is within 85% and 110% of the rated voltage of the
electrical devices.
– Check that no foreign body, such as packaging, has got
into the moving parts.
– Check that the air circulation in the circuit breaker
installation site is adequate, so that there is no danger of
overheating.
– Carry out the checks indicated in the following table.

Sl. No. Subject of Inspection Procedure Positive Check

1 Insulation resistance
2 Auxiliary Circuits.
3 Manual operating
4 Motor operator (if provided)
5 Under voltage release.
6 Shunt opening release and additional
shunt opening release (if provided)
7 Shunt closing release (if provided)
8 Auxiliary contacts in the operating
mechanism, circuits.
Medium Voltage Circuits
With a 2500V Megger, measure the insulation resistance
between phases & resistance between phases and
exposed Conductive part.
Auxiliary Circuits
With 50 Meager(installed equipment per insulation
measure the insulation resistance between auxiliary
circuits and the exposed conductive part.
Check that the connections to the control circuits are
correct and proceed with relative supply
Carry out a few closing and opening operations
Supply the geared motor for spring charging at the
relative rated voltage
Supply the under voltage release at the relative
rated voltage and carry out the circuit breaker Closing
operation.
Close the circuit breaker.
Supply the shunt opening release at the relative rated
voltage.
Open the circuit breaker .Supply the shunt closing
releases at the relative rated voltage.
Insert the auxiliary contacts into suitable signaling Carry
out a few closing and opening operations.
The insulation resistance should be atleast
50MW resistance should be a few MW and
constant at any time.
Insulation resistance should be a few MW &
constant at any time
Normal switching and signaling.
The operations and relative signals
mechanism. (refer to paragraph 6.3)
occur correctly
The signals are correct.
The geared motor cuts off when the springs
are charged.
Disconnect the power supply to release the
circuit breaker closes correctly.
The signals are correct.
The circuit breaker opens correctly The
signals are correct.
Circuit breaker closes correctly.
The signals are correct.
Signals occur correctly.

Instruction manual | Retrofit Solutions 9

9 Periodical checking
Before carrying out any operation, make sure that the
operating mechanism springs are discharged and that the
apparatus is in the open position.

9.1 General
During normal service the circuit breakers are maintenance
free. The frequency and type of inspections basically depends
on the service conditions. Various factors must be taken into
account. Frequency of operations, interrupted current values,
relative power factor and the installation atmosphere.

The following paragraph gives the checking programme table

showing the relevant checking time intervals.

As far as the time interval between these checks are

concerned, it is advisable to comply with the specifications
given in the table, at least during the first check. On the basis
of the results obtained during the periodic inspections, set the
optimal time limits for carrying out the following operations.

9.2 Typical life span of HKK - VD4 circuit breakers

– Vacuum interrupters: Up to 30,000 operations under
normal service conditions and according to the type of
interrupter
– Activation and transmission system: 10,000 maintenance-
free operation and up to 30,000 operations with
maintenance

9.3 Checking programme

Sl. No. Checking Operation Intervals Criteria
1 Carry out five mechanical opening and closing 1 year The circuit breaker must operate normally without stopping in
operation the intermediate position

2 Visual Inspection of poles(resin parts)
3 Visual and physical inspection of the opening
mechanism and transmission.
4 Visual inspection and lubrication of the isolating
contacts.
5 Measuring of the insulation resistance
6 Checking interlock operation.
1 year or 5000 operations.
1 year, or 5000 operations.
1 year, or 5000 operations.
1 year, or 5000 operations.
1 year.
The resin parts must be free of any accumulation of dust, dirt,
cracks, discharges or traces of surface discharge.
The elements must be free of any deformation. Screws, nuts,
bolts etc., must be tight.
The isolating contacts must be free of any deformation or
erosion. Lubricate the contact elements with grease type NYE
760G.
See paragraph 8.1 inspection point 1.
The interlocks must operate correctly.

After 10,000 operations or 10 years, for installation in polluted

and aggressive atmosphere, it is advisable to contact
your ABB service centre to have the circuit breaker checked.

10 Retrofit Solutions | Instruction manual

10 Maintenance operations apparatus and IEC 60694, CEI EN 60694 paragraph 10.4.2.
Maintenance must only be carried out by ABB personnel, Should any maintenance be carried out by customer
or suitably qualified customer personnel who have in-depth personnel, the responsibility for any interventions lies with the
knowledge of the apparatus and IEC 60694, CEI EN 60694 customer.
paragraph 10.4.2.
Before carrying out any maintenance, check that the circuit
Should any maintenance be done by the customer’s breaker is open, the springs discharged and that there is no
personnel, responsibility for any intervention lies with voltage on the medium voltage circuit or auxiliary circuits.
customer.
To order accessories or spare parts, please refer to the
commercial ordering codes given in the Technical Catalogue
11 Application of the X-ray emission standards
and always indicate :
One of the physical properties of vacuum insulation is the
– Circuit breaker type
possibility of X-ray emission when the interrupter contacts
– Circuit breaker rated voltage
open. The specific tests carried out at the PTB laboratories
– Circuit breaker breaking capacity
(Physicals- Technische Bundesanstalt, in Brunswick -
– Circuit breaker serial number
Germany) shows that local emissions at a distance of 10cm
– Rated voltage of any electrical accessories
from the interrupter or pole surface, does not exceed 1mSv/h.
For the availability of spare parts, please contact our
It therefore follows that:
Service Department.
– At the rated service voltage of the vacuum interrupters, it is
absolutely safe
List of spare parts
– Application of the withstand voltage at industrial frequency
– Shunt opening release
is safe, as per IEC 62271-100 and VDE 0670 standards
– Additional shunt opening release
– Application of a voltage higher than the withstand voltage
– Under voltage release
at industrial frequency or of a direct test voltage in direct
– Contact signalling under voltage release energised/
current, as specified in IEC and VDE standards, cannot be
de-energised
used
– Shunt closing release
– Limitation of the above-mentioned local phenomena of
– Spring charging geared motor with electric signalling of
interrupters with open contacts, depends on keeping the
springs charge
specific distance between the contacts. This condition
– Contact signalling closing springs charged/discharged.
is intrinsically guaranteed by the correct operation of the
– Transient contact with momentary closure during circuit
operating mechanism and adjustments of the transmission
breaker opening
system
– Auxiliary circuit breaker contacts
– Opening solenoid
12 Spare parts and accessories
– Protection for opening push button
All assembly operations of spare parts/accessories regarding
– Protection for closing push button
installation, putting into service, service and maintenance
– Opening/closing buttons
must be carried out by ABB personnel, or suitably qualified
– Set of six power contacts
customer personnel with an in-depth knowledge of the

Instruction manual | Retrofit Solutions 11

Contact us

ABB India Limited Note: We receive the right to make technical changes

© Copyright 2014 ABB. All rights reserved.

Medium Voltage Products
Plot No. 79, Street No 17
MIDC Estate, Satpur, Nashik – 422007
Maharashtra, India
Phone: +91 253 2201200
Fax: +91 253 2351260
South Zone
or modify the contents of this document without prior
notice. with regard to purchase order the agreed
particulars shall prevail. ABB does not accept any
responsibility whatsoever for potential errors or possible
lack of information in this document.
We reserve the rights in this document and in the
subject matter and illustrations contained therein.
Any reproduction, disclosure to third parties or
utilization of its contents in whole or in parts is
forbidden without ABB’s prior written consent

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