ABB DCBreak Series Instructions For Installation & Operation Download

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Contents
For your safety!

1. Foreword

2. General description

3. Operating principle

4. Identification and designation

5. Factory test and accompanying

documentation

6. Characteristics

7. Installation

8. Putting into service

9. DCBreak version installed in a functional

enclosure

10. Disposal

11. Customer Service

12. Maintenance

—

For your safety!

• Make sure that the installation room (spaces,

divisions and ambient) is suitable for the
electrical apparatus.

• Check that all the installation, putting into service

and maintenance operations are carried out by
qualified personnel with suitable knowledge of
the apparatus.

• To ensure that the installations are built in

accordance with the rules of good working
practice and safety in the work place, make sure
that the regulatory and legal requirements are
complied with during installation, putting into
service and maintenance.

• Strictly follow the information given in this

instruction manual.

• Check that the rated performance of the

apparatus is not exceeded during service.

• Check that the personnel operating the apparatus

have this instruction manual to hand as well as the
necessary information for correct intervention.

• Pay special attention to the notes highlighted in

the manual by the following symbol:

Responsible behavior safeguards your
own and others' safety!
Please contact the ABB Assistance
Service for any further requirements.

—

DISTR IBUTION SOLUTIONS

DCBreak

Rolling Stock High Speed Direct Current circuit breaker

Instructions for installation, service and maintenance
900 V - 1500 A - 30 kA; 1800 V - 1500 A - 30 kA
Free standing and in box application

Summary of Contents for DCBreak Series

Page 1: ...f good working practice and safety in the work place make sure that the regulatory and legal requirements are complied with during installation putting into service and maintenance Strictly follow the information given in this instruction manual Check that the rated performance of the apparatus is not exceeded during service Check that the personnel operating the apparatus have this instruction ma...

Page 2: ...h in depth knowledge of the apparatus 1 1 Environmental protection program DCBreak circuit breakers are manufactured in accordance with ISO 14000 Standards Guidelines for environmental management Fully recyclable materials are used since particular care is paid to EoL management of the product Qualified personnel All installation putting into service operation and maintenance work must be carried ...

Page 3: ...taneous release for bidirectional overcurrent that 2 General description 1 Insulating structure 2 Arc quenching chute 3 Main circuit connections 4 Overcurrent detecting system 5 Auxiliary contacts 6 Electromagnetic actuator continuously adjusts to the trip value required by the specific application DCBreak circuit breakers feature long mechanical and electrical life and comprise various subassembl...

Page 4: ...e circuit breaker shows the settings of the release device in relation to the position of the adjustable screw 2 The range of values is established during the routine factory tests to which each circuit breaker produced is subjected and cannot be used for any other circuit breaker 3 Operating principle When the value of the current through the circuit breaker exceeds the trip threshold setting in ...

Page 5: ... the protective enclosure on versions supplied in boxes The data are given in the language requested when the order was placed The relative denomination may vary from one DCBreak to the next To find out the exact version of the product refer to the Serial number which must also be given in any query concerning technical or commercial issues or requests for spare parts When ordering the customer mu...

Page 6: ...embled every circuit breaker produced is subjected to routine tests according to procedures derived from the ABB quality standards and type tests These tests are reported in a test certificate of which a hard copy is attached to each apparatus shipped along with a copy of this manual and the circuit diagram 5 Factory test and accompanying documentation ...

Page 7: ... T3 30 kA 50 ms 30 kA 40 ms Time constant T4 Iss T 30 kA 150 ms 30 kA 100 ms Direct overcurrent release possible setting ranges on request 0 9 1 3 kA 1 3 1 8 kA 1 8 2 5 kA 2 5 3 6 kA 0 9 1 3 kA 1 3 1 8 kA 1 8 2 5 kA 2 5 3 6 kA Maximum arc voltage Ûarc 2 5 x Ue 2 5 x Ue Class of functional operations C3 C3 6 2 Auxiliary control circuit Rated voltage Un 24 36 48 72 110 V DC Supply voltage limits 25 ...

Page 8: ...ary switches KFA1 and KFA3 Closing contacts KFA1 feeds the MBC electromagnet and the main contacts of the high speed circuit breaker QAB Hold After about approximately 500 ms the delayed contact KFA3 closes and feeds the contactor KFA2 The contacts KFA2 open by inserting the RAR resistor the current decreases to a proper value to maintain the circuit breaker in closed position Opening Opening of t...

Page 9: ... 8 9 37 1 Coil temperature 20 C 2 Coil temperature 70 C and Umin 3 Coil temperature 25 C and Umax 4 R1 holding resistor should be 200 W 6 5 Auxiliary contacts Designation Name Unit Value Remarks conditions Terminals Screw with spring washer Rated insulation voltage Ui V 400 Rated impulse withstand voltage Uimp kV 4 Thermal current Ith A 10 Minimum current Imin mA 5 If 5 mA gold alloy on request Co...

Page 10: ... 10 6 6 Operating sequences and durations A Coil current B Main contact C Auxiliary contact a NO D Auxiliary contact b NC Duration min 0 3 s max 1 s Opening closing sequence Closing Holding Opening Closing time Opening time Time in ms Time in ms Ue of the nominal battery voltage Ue of the nominal battery voltage Main contact Main contact 6 Characteristics ...

Page 11: ...he tasks described above must be qualified in accordance with the regulations concerning this type of equipment in force in the country in which the equipment itself is installed and must be familiar with similar types of apparatus They must also be able to understand and comply with the indications in the corresponding circuit diagram and cable specifications during work A working knowledge of th...

Page 12: ...ions 2 Fixing points 3 Earthing point 4 Actuator supply point 5 Auxiliary contacts 6 Adhesive rating plate 7 Aluminum rating plate on request Designation Weight kg DCBreak 915 Free Standing 28 DCBreak 1815 Free Standing 38 Minimum distances from A B C Insulating panel 90 50 30 Earth solid or slatted metal panel 300 100 150 7 Installation ...

Page 13: ...Key 1 Main connections 2 Fixing points 3 Earthing point 4 Actuator supply point 5 Auxiliary contacts 6 Adhesive rating plate 7 Aluminum rating plate on request Minimum distances from A B C Insulating panel 90 50 30 Earth solid or slatted metal panel 300 100 150 ...

Page 14: ...ion numbers and the quantity of components supplied If the apparatus is to be stored for a long period of time seal it in its original packing so as to protect it against environmental influences 7 5 2 Storage IMPORTANT The apparatus accessories and spare parts must remain in their respective original packaging during the storage period Make sure that the apparatus accessories and spare parts are ...

Page 15: ...chute assembled and protected against moisture dust and shocks Make sure that it is fastened to its support so as to prevent it from falling during transport 7 5 5 Transport The apparatus and components can only be transported in their original packaging and by adequate means of transport Avoid shocs and jolts Prevent dust liquids and moisture from penetrating as they would damage the apparatus Th...

Page 16: ...circuit breaker by means of its screws Failure to tighten the screws properly will impair the electrical connection of the arc quenching chute and lead to serious failure of the circuit breaker 8 1 Special requirements DCBreak circuit breakers have been designed by ABB for the standard uses defined by the IEC standards Special requirements concerning the environment in which the circuit breaker mu...

Page 17: ...position the cable terminals correctly so as to maintain the required dielectric clearance between the upper and lower terminals Use screws long enough to project 3 4 threads from their nuts but make sure that the screws are not too long otherwise the clearance will be unnecesarily reduced IMPORTANT In the case of busbar connections and to avoid excessive mechanical stress on the terminals due to ...

Page 18: ...least 2 5 mm2 and is fastened by M4 screws The actuator functions correctly regardless of the polarity of its power supply The section of the supply cables must be chosen to suit the power consumption during the circuit breaker closing operation and the voltage drop this causes must not be excessive see 7 5 Circuit breaker commands 1 Remove the four screws 15 and extract the auxiliary contact box ...

Page 19: ...er body and the arc quenching chute must be guaranteed Make sure that the arc quenching chute has been correctly fastened to the circuit breaker and that this latter is fastened to its support Check that the earth connection has been assembled properly and screwed down in position Check that the auxiliary connections are tight and that the cables are properly fixed Make sure that the release setti...

Page 20: ...cture of the vehicle Protection against shocks and impact for under floor applications and from the penetration of water and polluting dust The dimensions of the enclosure have been optimized and checked during dedicated type tests to which the circuit breaker and enclosure assembly have been subjected The enclosure is certified as able to withstand jets of water and dust IP 65 protection class an...

Page 21: ...thing connection point 4 Harting type auxiliary circuit connector feeding socket 5 Aluminum nameplate 6 Lifting handles 7 Fixing points X Minimum clearance for arc chute removal 30 mm Caption 1 Main cable connection cable glands 2 Harting type auxiliary circuit connector plug supplied loose 3 Earthing connection point 4 Harting type auxiliary circuit connector feeding socket 5 Aluminum nameplate 6...

Page 22: ...e enclosure so as to facilitate the final assembly operations 9 4 1 Removal of upper shell Remove the six screws 27 to separate the upper shell 25 of the enclosure from the lower shell at the base 26 Raise the upper shell 25 using both handgrips 24 and set it down overturned so that the arc quenching chute inside is visible 9 4 2 Assembly of lower base Lift the lower shell 26 and place it on its s...

Page 23: ...e crimping make sure that the 9 4 4 Auxiliary circuit connection Each enclosure is equipped with a Harting type connector standard version The enclosure can be equipped with circular shaped connectors on request size of the chosen terminals allows these latter to pass through the holes in the enclosure First connect the lower cables to the busbar 31 and tighten them with M12 screws 32 and 84 Nm ti...

Page 24: ...t be screwed onto a bolt M12 to 84 Nm tightening torque The section of the earth connection must be at least 35 mm2 9 4 6 Re assembly of the upper shell Place the upper shell on the lower shell in the correct direction Insert six screws 27 and tighten them to 48 Nm tightening torque 9 DCBreak version installed in a box ...

Page 25: ...Electrical components Glass polyester Ceramic guides All materials and components must be dismantled or recycled in accordance with the laws and regulations in force in the place of installation To ensure a high quality Customer Service compliance with the following ABB SpA provisions and directives and thus the Quality Control regulations is mandatory This requirement applies to all cases of dama...

Page 26: ...ate Signature Acknowledgement of receipt of your feedback Thank you for your help We acknowledge receipt of your remarks and suggestions and will forward them to the people concerned After careful assessment we will inform you about the actions that have been taken Name Date Signature 11 Customer Service 11 1 Procedure Before shipping materials for repair please contact ABB SpA in order to establi...

Page 27: ...The event that occurs first among those listed below Every 18 months 25000 operations without load 400 operations up to rated load 6 current interruptions due to overload Visual inspection Check safety rings Tighten screws Clean insulating parts Inspect kinematic chain Check main contacts and arc chute for wear Frequency in normal conditions Operation The event that occurs first among those listed...

Page 28: ...sary If wear has noticeably reduced the thickness of the pads proceed with the inspection described in the next point Connect the ohmmeter to terminals 1 2 and set it to the sound mode Close the circuit breaker If there is no continuity fully tighten an M8 x 60 screw 3 behind the actuator then unscrew it by one turn If the ohmmeter fails to indicate electri cal continuity it means that the contact...

Page 29: ... Spare parts kits 12 5 6 Flexible connection kit 12 5 1 DCBreak 915 arc chute kit 12 5 7 Set of bolts screws and nuts 12 5 3 Ceramic guides kit 12 5 5 Main contacts kit 12 5 4 Auxiliary contacts kit 12 5 2 DCBreak 1815 arc chute kit ...

Page 30: ...Rubber gaskets etc Sintered material Cables Ceramic guides Glass polyester All materials and components must be dismantled or recycled in accordance with the laws and regulations in force in the place of installation 12 5 8 Cable gland kit 12 5 9 Closing cap kit 12 5 10 Handle kit 12 5 11 Plug kit 24pins 28pins 36pins for auxiliary circuits 12 5 12 Socket kit 24pins 28pins 36pins for auxiliary cir...

Page 31: ...DISTRIBUTION SOLUTIONS 31 Notes ...

Page 32: ...com service The data and illustrations are not binding We reserve the right to modify the contents of this document without prior notice following technical and product developments Copyright 2019 ABB All rights reserved 1VCD601427 Rev B en Instruction Manual 2019 03 HSDC Circuit Breaker DCBreak gs For further details please contact ...

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