Download R-MAG®Medium Voltage Tank Vacuum Magnetic

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R-MAG®Medium Voltage Outdoor Dead
Tank Vacuum Magnetic Circuit Breaker
Instruction Manual
38kV 1250/2000A
Table of Contents
1.
2.
3.
SAFETY NOTICES.......................................................................................................... 4
INTRODUCTION ............................................................................................................. 5
RECEIVING, HANDLING AND STORAGE...................................................................... 5
3.1
Receiving Inspection .................................................................................................... 5
3.2
Handling ...................................................................................................................... 5
3.3
Storage ........................................................................................................................ 6
4.
GENERAL DESCRIPTION .............................................................................................. 6
4.1
High-Voltage Assembly ................................................................................................ 6
4.2
Housing ....................................................................................................................... 7
4.3
Magnetic Actuator ........................................................................................................ 7
4.4
Actuator Controller ....................................................................................................... 7
5.
STANDARD PRODUCTION TESTS................................................................................ 7
6.
OPERATION ................................................................................................................... 8
6.1
Closing......................................................................................................................... 8
6.2
Opening ....................................................................................................................... 8
6.3
Manual Trip Handle Operation ..................................................................................... 8
7.
OPERATIONAL CHECK PRIOR TO INSTALLATION (ELECTRICAL CLOSE/OPEN) .... 9
8.
INSTALLATION ............................................................................................................... 9
8.1
Mounting ...................................................................................................................... 9
8.2
Grounding .................................................................................................................... 9
8.3
Arrester Protection ......................................................................................................10
8.4
Control Power .............................................................................................................10
8.5
Final Inspection...........................................................................................................10
9.
INSPECTION, MAINTENANCE AND ADJUSTMENT .................................................... 11
9.1
Maintenance Steps .....................................................................................................11
9.2
High-Pot Test ..............................................................................................................12
9.3
Measuring Contact Travel ...........................................................................................12
10.
38 kV R-MAG ELECTRICAL SPECIFICATIONS ........................................................... 24
10.1
Typical Current Transformer Connections ...............................................................26
10.2
Auxiliary Switch Current Specifications ....................................................................27
10.3
Control Board Voltage Requirements ......................................................................27
10.4
Breaker Nameplate .................................................................................................28
11.
RENEWAL PARTS ........................................................................................................ 28
12.
PRODUCT RECYCLING ............................................................................................... 28
APPENDIX A ............................................................................................................................ 29
2
Table
of Figures

Figure 1 Hazardous Voltage Nameplate .................................................................................... 4
Figure 2 Lifting Detail ................................................................................................................. 6
Figure 3 Trip Handle Position Sticker ......................................................................................... 8
Figure 4 Interrupter Assembly 38 kV, 1250 A ............................................................................15
Figure 5 Interrupter Assembly 38 kV, 2000 A ............................................................................16
Figure 6 Trip Handle .................................................................................................................17
Figure 7 ABB RMAG  Vacuum Interrupter Electrical Switching Life Curves (31.5 kA) .............18
Figure 8 ABB RMAG  Vacuum Interrupter Electrical Switching Life Curves (40 kA) ................19
Figure 9 High Voltage Cabinet Layout .......................................................................................20
Figure 10 Typical Schematic Diagram.......................................................................................21
Figure 11 Typical Outline, 1250 A .............................................................................................22
Figure 12 typical Outline, 2000 A ..............................................................................................23
Figure 13 Breaker Nameplate .................................................................................................. 28

List of Tables
Table 1 RMAG 38 kV, 31.5 kA Ratings ....................................................................................24
Table 2 RMAG 38 kV, 40 kA Ratings ......................................................................................25
Table 3 Typical Current Transformer Connections ....................................................................26
Table 4 Auxiliary Switch Current Specifications.........................................................................27
Table 5 Control Board Voltage Requirements ..........................................................................27
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All sales are subject to ABB INC. General Terms and Conditions of Sale.
While every effort has been made to assure accuracy, the information in
this document is subject to change without notice
© Copyright 2012 ABB INC. All rights reserved.
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
 
Install the RMAG® breaker within the design limitations as described on its nameplate and in
these instructions.
Follow your company’s safety procedures and all applicable laws, regulations and standards
whenever the equipment is being installed, operated, maintained and/or repaired.



This breaker should not be used as the sole means of isolating a high voltage circuit. For the
safety of personnel performing maintenance operations on the breaker or connecting equip
ment, all components should be electrically disconnected by means of a visible break and
should be securely grounded prior to working in the high voltage or low voltage compartment.
This product is intended to be operated and maintained by qualified persons, thoroughly trained
and knowledgeable of the hazards involved. This publication is written only for such qualified
persons and is not intended to be a substitute for adequate training and experience in the safety
procedures for this device.

Detailed descriptions of standard repair procedures, safety principles and service operations are
not included. It is important to note this document contains some warnings and cautions against
some specific service methods that could cause personal injury to service personnel, damage
equipment, or render it unsafe. These warnings do not cover all conceivable ways in which serv
ice, whether or not recommended by ABB, might be performed or the possible hazardous
consequences of each conceivable way, nor could ABB investigate all such ways. Anyone using
service procedures or tools, whether or not recommended by ABB, must satisfy himself

thoroughly that neither personal safety nor equipment safety will be jeopardized by the service
method or tools selected.
All information contained in this manual is based on the latest product information available at
the time of printing. The right is reserved to make changes at any time without notice.
 
These instructions do not attempt to provide the user of this equipment with every possible diffi
culty that may occur in the application, operation and maintenance of the product. Also, as
improvement in parts and assemblies are made, some parts may differ in appearance as depict
ed in the illustrations; however, functionality will be equivalent.
The Type RMAG breaker is a highvoltage, threephase device incorporating three vacuum
interrupters, gang operated by a magnetic actuator. Together with the optional relaying and
current transformers, the breaker will sense an overload and automatically open.
Satisfactory performance of the breaker is contingent upon correct installation of the breaker,
and adequate maintenance and service of the breaker. Careful study of these instructions will
permit the user to obtain maximum benefit from this device.
 
Each breaker is assembled and tested at the factory prior to shipment.
This equipment was packed and shipped in factory new condition. If damage is noted, call the
carrier at once for inspection and request an inspection report. File a formal claim with the carri
er, supported with paid freight bill, inspection report and invoice. The local ABB Sales Office
must be notified. This must be done within 10 days of receipt or receiver assumes all
responsibility for damage.

Upon receipt, it is important to inspect promptly to be certain that the correct material has been
received. In case of shortage, immediately notify the local ABB Sales Office.
Check all parts against the shipping list as they are unpacked. Instructions and literature packed
with the breaker should be kept with the unit. The cabinet provides a convenient place to keep
this instruction book, a copy of the schematic, connection diagram and the breaker test report.
Additional copies of these documents may be obtained upon request from the local ABB Sales
Office.
If the breaker is not to be placed in service immediately, it is essential that proper care be exer
cised in the handling and storage to ensure good operating conditions in the future. (see section
)

The RMAG breaker comes with two brackets attached to the sides of the cabinet which provide
for lifting the breaker. A twopoint lift is recommended using these brackets. (see 
)
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
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
For prolonged storage, indoor storage is recommended. 
 The mechanism and control
compartment is equipped with heaters to reduce condensation.
 

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

The highvoltage section of the RMAG breaker consists of three individual phase assemblies.
Each phase of the RMAG consists of a single vacuum interrupter, flexible shunt and operating
rod.

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
The doors of the breaker housing are removable and retained by hinge pins. The position
indicator is visible through the rear door. The breaker nameplate showing rating information,
serial number and shop order number is mounted on the side of the housing.

The magnetic actuator incorporates a very powerful permanent magnet assembly. When the
armature is in contact with the upper plate, the magnet produces a holding force in excess of
2700 lbs. The actuator connects to the crankshaft through a coupling connected to the upper
end of the actuator shaft. The manual trip is decoupled from the actuator shaft and is controlled
by its own stored spring energy being released against a dedicated lobe on the crankshaft.
The magnetic actuator has no user serviceable parts and therefore no lubrication or mainte
nance is required. Should an actuator fail to operate, please immediately contact ABB for
service. The permanent magnets inside the actuator are extremely powerful, with the potential
to trap fingers.

The actuator control board in the RMAG breaker consists of a power supply, position indication,
switching assembly and capacitor charging system. Refer to Appendix A for an overview of the
actuator controller.
 
Standard production tests include:
1. Verification of all wiring per connection diagrams.
2. Electrical Operation: Close and trip. Overcurrent response and automatic closing, with
relaying control option.
3. Functional check of all manual controls: Local/remote, nonreclosing, ground fault bypass,
etc.
4. Current Path Resistance Test: Three readings are made on each phase of the breaker using
a Biddle “Ductor”. Typical values do not exceed 150 micro ohms.
5. Voltage Withstand: The complete breaker is tested between live parts and tank, across
open contacts and between phases. In compliance with ANSI C37.09 and IEC, an AC
dielectric withstand test at 80 kV is performed. Test duration is one minute.
6. Wiring Insulation: The terminal block connections are given an overpotential test of 1800
volts AC to ground (for 1 sec).
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



In the open position, the magnetic actuator’s armature rests against the bottom plate in the
actuator assembly. The armature is held there by the force developed by the magnet. When the
top coil is energized, the magnetic flux generated is in the same direction as the magnet
assembly. The armature is drawn into the coil and brought into contact with the upper plate. In
this position, the coil is deenergized and the armature is held in position by the magnets alone.
As the armature is drawn into the coil, the operating rod, which is attached to the top guide rod,
moves the moving contact of the vacuum interrupter towards the closed position. The actuator
has more stroke than the vacuum interrupter and the interrupter contacts make contact before
the actuator has completed the stroke. The additional movement of the operating rod after the
contact closing causes the contact pressure spring to compress at the top of the operating rod.
This wipe allows for contact wear in service.

When the bottom coil is energized, the magnetic flux opposes the force generated by the
magnet assembly. This reduces the holding force, the armature is released and the coil attracts
the armature to the bottom plate. Once there, it is held open by the magnet.
 
The trip handle for the 38 kV RMAG has two states: Normal and Trip/Close Block, which are
described below in further detail.
 
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
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
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 

The breaker should be tested for mechanical and electrical operation before delivery to the
installation site. Make the necessary control power connections. Open the door of the low
voltage compartment to observe the mechanical operations. A manual trip handle is provided on
the outside of the cabinet. (see 
Observe the positionindicator located on the front of the actuator cover plate. If the panel is
green, the breaker is open, and if the panel is red, the breaker is closed (on breakers configured
per IEEE standard). To perform a close or open, ensure the “Ready” light is illuminated above
the Close (1) and Open (0) buttons. Press the appropriate button firmly; keeping hands and
loose clothing clear of operating linkages. If the breaker is already open, nothing will happen
when the open button is pressed. If the breaker is already closed, nothing will happen when the
close button is pressed.
 In the event of a malfunction or loss of source voltage, the “Ready” light will not be
illuminated.
 
The breaker must be vertical, level and securely fastened. Follow your company guidelines and
codes for setting the height of the breaker, securing the frame to the pole or foundation, and
making connections.

The breaker is normally shipped suitable for substation mounting. The following is the recom
mended installation procedure.
Substation Mounting:
1. With the lifting brackets mounted to the breaker roof, lift the breaker off the pallet and move
into desired position.
2. Bolt the legs to the pad and raise the upper portion to the desired height.
3. Bolt the legs to the sides of the breaker.
4. Install “X” braces on all sides of breaker.(see 
5. Make sure all hardware is securely tightened.

The breaker cabinet includes a standard NEMA twohole stainless steel pad on both side
sheets, legs, and on the roof (optional) for grounding. To ensure proper operation of the
actuator controller, the side sheet where the actuator controller is mounted must be grounded to
the ground grid. For personnel safety it is recommended that the opposite side sheet is also

grounded. Ground connections should be made using #6 or larger. If there is ground pad is on
the roof, it should also be grounded to the side sheet.

ABB recommends that surge arresters be properly applied in the substation.

Supply the control power as indicated on the wiring diagram. Verify connections for the heaters
before applying power. For breakers not equipped with DINRail style connectors, check all
terminal block connections for proper tightness. For details of the overall control circuit, refer to
the specific wiring diagrams supplied with the breaker.




After installation has been completed and prior to energizing the breaker, the following points of
inspection are recommended:
1. Ensure the breaker is properly leveled and securely anchored.
2. Make a final check of tightness of all hardware.
3. Check that the heaters work.
4. Verify that all barriers in high voltage compartment are in place (if removed during
inspection)
5. Securely tighten terminal and ground connections.
6. An A/C HiPot test should be performed to verify the vacuum integrity. A successful
withstand indicates satisfactory vacuum integrity. Replace interrupters that fail to maintain
voltage across the open contacts. Please contact the factory for interrupter replacement.
Refer to section  for procedure.
7. Make a continuity check, preferably one measuring contact resistance. Measure contact
resistance with suitable equipment rated not less than 100 A. The resistance value should
not exceed 150 micro ohms.
8. Check control cable entrance fittings for tightness.
9. Operate the breaker from the control box to verify normal operation.
10. Secure all doors and ensure proper gasketing for weather, if supplied.

11. Ensure that all tools are removed.

12. Confirm that all high voltage test connections have been removed.
 
The RMAG breaker is an extremely simple device and requires minimal maintenance,
depending on the frequency of operation and local environmental conditions.
The safety and successful functioning of any apparatus or system connected with the breaker
largely depends on the proper and reliable operation of the unit.

To provide long reliable service, the breaker must have systematic inspections at regular inter
vals. Operating experience based on environmental conditions, the number of operations, mag
nitude of current and any unusual operation, will establish a maintenance schedule that gives
assurance of proper breaker reliability. The following check list is a minimum guide:
1. Check the phase assemblies for external damage and clean if contamination is evident.
2. Lubricate wear points and all pins in linkage assemblies with grease (Use only Dow Corning
55 silicone lubricants).
3. Verify that the breaker operates correctly using the electrical controls.
4. An AC HiPot test can be performed to verify the vacuum integrityRefer to section
for procedure. A successful withstand indicates satisfactory vacuum integrity.
Replace interrupters that fail to maintain voltage across the open contacts. Please contact
the factory for interrupter replacement.
5. 

6. Check heaters to verify proper operation.
7. When inspecting breaker, verify torque on current carrying parts are within tolerances: .500
13 (or 12mm) threaded bus connections. 6580 ftlbs









1. With the breaker in the open position, jumper both sets of three top terminals (bushings 13
5 together and bushings 246 together). Ground one set of terminals and the housing.
Connect the high voltage to the other set of terminals. See Figure 11
 and Figure 12 A for positioning.
2. Stand clear more than one meter from the breaker before energizing the high voltage
source.
3. Do not exceed 64 kV. Test duration is one minute.
4. If internal flashover occurs, isolate the phases and test each one independently to identify
the defective interrupter. Any defective pole assembly must be replaced prior to the breaker
being placed in service.
 
The desired overtravel (wipe) for 38 kV RMAG breakers should be within 0.157 in – 0.177 in
(4.0 mm – 4.5 mm). The following steps must be performed to measure the contact travel.
1. The faceplate from the mechanism covers one of the rod’s ends. Remove the front panel to
access the rod.


2. Connect the transducer to the rod’s end as shown below:
3. Connect the transducer to the motion analyzer. ABB utilizes a Kocos – ACTAS P14:
4. Connect the AMP meter to the actuator coil cables:

5. Connect the Kocos to the breaker contacts/bus:

5. If the result is different from the suggested range of 0.157 in – 0.177 in (4.0 mm – 4.5 mm),
turn the pushrod’s end clockwise to increase wipe, or counterclockwise to decrease wipe,
depending on the adjustment needed to achieve a measurement within the specified range.
































100000
10000
1000
100
10
0.1
1
10
100





100000
10000
1000
100
10
0.1
1
10
100












































Parameter
Rated Maximum Voltage
Voltage Range Factor, K
Rated Continuous Current
Temperature Range
Dielectric Strength
Dry 60Hz 1 minute
Wet 60Hz 10 sec
Full Wave Withstand
Chopped Wave Withstand
Minimum Creep to Ground
ANSI Operating Duty
Interrupting Time
Permissible Tripping Delay (Y)
Reclosing Time
Interrupting Ratings
Symmetrical RMS
Asymmetrical RMS
Short
Timefor
Current
TRV Peak
100% Terminal Faults
TRV
Peak to
forPeak
100%(T2)
Terminal Faults
TRV Time
TRV
Time
to
Peak
(T2)
Peak Withstand Current (Same as Close and Latch)
Peak
Withstand Current
(Same
asconstant
Close and
Latch)
D.C. Component
(referred
to time
= 45ms
D.C.
Component
(referred
to
time
constant
=
45ms
Short Line Fault
Short
Fault
Out ofLine
Phase
Switching Current
Out of Phase
Switching
Double
Earth Fault
(IEC)Current
Double
Earth
Fault
(IEC)
Load Current Switching
Load
RatedCurrent
Back toSwitching
Back Switching (Class C1)
Rated
Back to Back
Switching
Rated Transient
Inrush
Current(Class
peak C1)
Rated
Transient Inrush
Inrush Current
peak
Rated Transient
Frequency
Rated
Transient
Inrush
Frequency
Rated Isolated Capacitor Bank Current (Class C1)
Rated
Isolated Capacitor
Bank Current
C1)
Rated Overhead
Line Switching
Current(Class
– ANSI
(Class C1)
Rated
Overhead
Line
Switching
Current
–
ANSI
Rated Cable Switching Current (Class C1) (IEC) (Class C1)
Rated
CableLife
Switching Current (Class C1) (IEC)
Mechanical
Mechanical
Life
NoLoad Mechanical
(IEC M2)
No-Load
Mechanical
Between Servicing (IEC M2)
Between
Servicing
Continuous
Current Switching
Continuous
Current
Switching
Inrush
Current
Switching
Inrush
Current
Switching
Seismic Rating (per IEEE 6931997; exceeds previous zone 4 category)
Seismic Rating (per IEEE 693-1997; exceeds previous zone 4 category)

Rating
38kV
1.0
1250A/2000A*
40C to +40C
-40C
80kV
75kV
200kV
258kV
33"
O0.3sCO3MinCO****
O-0.3s-CO-3Min-CO
3.0 Cycles
2 seconds
0.3 seconds
31.5kA
36.2kA
31.5kA
71.1kV
71.1kV
63sec
63µsec
81.9kA
81.9kA
40%
40%
28.35kA
28.35kA
7.88kA
7.88kA
27.4kA
27.4kA
1250A/2000A
1250A/2000A
630A
630A
20kA
20kA
4240Hz
4240Hz
630A
630A
100A
100A
50A
50A
10,000
10,000
2000
2000
10,000
10,000
200
200
High
High
*Continuous current tested at +40C ambient
** Operating duty conforms to old ANSI Standard (actual time can be CO15SecCO)








Rated Maximum Voltage
Voltage Range Factor, K
Rated Continuous Current
Temperature Range
Dielectric Strength
Dry 60Hz 1 minute
Wet 60Hz 10 sec
Full Wave Withstand
Minimum Creep to Ground
ANSI Operating Duty
Interrupting Time
Permissible Tripping Delay (Y)
Reclosing Time
Interrupting Ratings
Symmetrical RMS
Short Time Current
TRV Peak for 100% Terminal Faults
TRV Time to Peak (T3)
Peak Withstand Current (Same as Close and Latch)
D.C. Component (referred to time constant = 45ms
Short Line Fault
Out of Phase Switching Current
Load Current Switching
Rated Overhead Line Switching Current – ANSI (Class C1)
Rated Cable Switching Current (Class C1) (IEC)
Mechanical Life
NoLoad Mechanical (IEC M2)
Between Servicing
Continuous Current Switching
Inrush Current Switching
Seismic Rating (per IEEE 6931997; exceeds previous zone 4 category)

38kV
1.0
1250A/2000A
40C to +40C*
80kV
75kV
200kV
33"
O0.3sCO3MinCO**
3.5 Cycles
2 seconds
0.3 seconds
40 kA
40 kA
71.7kV
59sec
104kA
40%
36.1kA
10.5kA
1250A/2000A
100A
100A
10,000
2000
10,000
200
High
*Continuous current tested at +40C ambient
** Operating duty conforms to old ANSI Standard (actual time can be CO15SecCO)








 








X2X3
505
X2X3
1005
X1X2
1005
X1X1
2005
X1X3
1505
X1X3
3005
X4X5
2005
X4X5
4005
X3X4
2505
X3X4
5005
X2X4
3005
X2X4
6005
X1X4
4005
X1X4
8005
X3X5
4505
X3X5
9005
X2X5
5005
X2X5
10005
X1X5
6005
X1X5
12005








X3X4
3005
X3X4
3005
X1X2
4005
X4X5
5005
X4X5
5005
X3X5
8005
X2X3
8005
X1X2
10005
X2X4
11005
X2X3
12005
X1X3
12005
X2X4
15005
X1X4
15005
X2X5
20005
X2X5
16005
X1X3
22005
X1X5
20005
X1X4
25005
X1X5
30005




 
•
•
•
Tested per UL Document 1054. AC tests specs with one set of contacts. DC tests specs
with two sets of contacts in series.
Contacts will carry 140 A for 3 seconds.
Overload test – 50 operations at 90 A and 120 VAC.







24/48 VDC
16
16
20
125 VDC
10
10
20
250 VDC
5
5
20
115 VAC
15
15
20
230 VAC
10
10
20

 



BINARY INPUTS AC 
KM10051, 2 (INCLUDES
TRIP AND CLOSE)
20.4 VOLTS TO 264 VOLTS
OPENING COMMANDS CAN
GO AS LOW AS 16.8 VAC
20.4 VOLTS TO 264 VOLTS
OPENING COMMANDS CAN
GO AS LOW AS 16.8 VAC
BINARY INPUTS DC –
KM10051 (INCLUDES TRIP
AND CLOSE)
20.4 VOLTS TO 264 VOLTS
OPENING COMMANDS CAN
GO AS LOW AS 16.8 VDC
**20.4 VOLTS TO 264 VOLTS
OPENING COMMANDS CAN
GO AS LOW AS 16.8 VDC
AUXILIARY POWER AC 
KM10031
20.4 VOLTS TO 52.8 VOLTS
85 VOLTS TO 264 VOLTS
AUXILIARY POWER DC 
KM10031
16.8 VOLTS TO 75 VOLTS
77 VOLTS TO 280 VOLTS


The threshold for the binary inputs occurs at approximately 18 VDC or 19 VAC. The threshold for the
protection relay input is approximately 7 VDC.
2
Binary input thresholds depend on filter card jumpers. (see Appendix A section 






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
 
Renewal parts are available exclusively from ABB. Contact your local ABB field sales office for
the latest RMAG Spare Parts List.
 
Definitions and regulations of hazardous materials are countryspecific and change when
knowledge of materials increases. The materials used in this product are typical for electric and
electronic devices.
All parts used in this product are recyclable. When disposing of a RMAG or its parts contact a
local waste handler who is authorized and specialized in disposing electronic waste including
leadacid batteries. These handlers can sort the material by using dedicated sorting processes
and dispose of the product according to the local requirements.

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






Table
of Contents

1.
OVERVIEW ................................................................................................................... 32
2.
CONTROL BOARDS AVAILABLE/MAGNETIC ACTUATOR COIL ENERGIZING
CAPACITOR ............................................................................................................................. 33
3.
BINARY INPUTS ........................................................................................................... 33
3.1
Remote Close (KM1005, CH 1, Pins 1 and 2) .............................................................33
3.2
Remote Open (KM1005, CH 2, Pins 3 and 4) .............................................................33
3.3
Auxiliary Open / Safe Open (KM1005, CH 3, Pins 5 and 6).........................................33
3.4
Protection Trip / Second Trip (KM1005, CH 4, Pins 7 and 8) ......................................34
3.5
Circuit Breaker Close Blocking (KM1005, CH 6, Pins 11 and 12) ................................34
3.6
Under Voltage Trip (KM1005, CH 7, Pins 13 and 14) ..................................................34
4.
BINARY OUTPUTS ....................................................................................................... 35
4.1
Circuit Breaker Opened (KM1004 Pins 1 and 2) .........................................................35
4.2
Circuit Breaker Closed (KM1004 Pins 3 and 4) ...........................................................35
4.3
Circuit Breaker Auxiliary Open (KM1004 Pins 5 and 6) ...............................................35
4.4
Circuit Breaker Auxiliary Closed (KM1004 Pins 7 and 8) .............................................35
4.5
Unit Ready (KM1004 Pins 9 and 10) ...........................................................................35
4.6
Unit Not Ready (KM1004 Pins 11 and 12) ..................................................................35
4.7
Circuit Breaker Remote Open (KM1004 Pins 13 and 14) ............................................35
5.
FEATURES ................................................................................................................... 37
5.1
Temperature Protection ..............................................................................................37
5.2
Actuator Close and Trip Coil Continuity Monitor ..........................................................37
5.3
Wrong Position Auto Trip ............................................................................................37
5.4
Energy Failure Auto Trip .............................................................................................37
5.5
Reduced Power Consumption ....................................................................................38
5.6
RS232 Port / JTAG Communication Port ...................................................................38
6.
POWER CONSIDERATIONS ........................................................................................ 38
6.1
Discharging Storage Unit Capacitors ..........................................................................39
6.2
Capacitor Life..............................................................................................................39
6.3
Breaker Ready / Not Ready Binary Output Contacts and Ready Light Status .............40
7.
STANDARD ACTUATOR CIRCUIT BOARD AND CONNECTION DIAGRAM ............... 41
8.
CONTROL BOARD CONNECTORS ............................................................................. 42
9.
DEFAULT JUMPER AND DIP SWITCH SETTINGS...................................................... 43
10.
TROUBLESHOOTING FLOWCHARTS ......................................................................... 44
11.
INSTRUCTIONS FOR TROUBLESHOOTING A CONTROL BOARD............................ 47
11.1
READY LIGHT IS OFF ............................................................................................48
11.2
SPECIFIC LINE ITEM CHECK IS SHOWN BELOW ...............................................49
12.
INSTRUCTIONS FOR CHANGING OUT A CONTROL BOARD.................................... 52



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






List
of Illustrations

Apx Figure 1 Electrical System Block Diagram..........................................................................32
Apx Figure 2 Electrical Load Curves .........................................................................................37
Apx Figure 3 Standard Actuator Circuit Board and Connection Diagram ...................................41
Apx Figure 4 Standard Actuator Circuit Board and DIP Switch Settings ....................................43
Apx Figure 5 Ready LED Continually Flashing ..........................................................................44
Apx Figure 6 Ready LED Off .....................................................................................................45
Apx Figure 7 Conditions for CB Not Opening/Closing ...............................................................46
Apx Figure 8 Standard Actuator Control Board and Pin Assignments .......................................47
Apx Figure 9 Control Board with Terminal Numbering...............................................................54
Apx Figure 10 Control Board, Simplified....................................................................................54
Apx Figure 11 ED2.0 Control Board Parts and Mounting ..........................................................55




List of Tables
Apx Table 1 DIP Switch Thresholds ..........................................................................................34
Apx Table 2 Output Contact Specifications ...............................................................................36
Apx Table 3 CB Operation vs. Available Capacitor Charge .......................................................38
Apx Table 4 Circuit Breaker Condition vs. Position ...................................................................40
Apx Table 5 KM1001  Breaker Position (CB Position) ..............................................................42
Apx Table 6 KM1002  Power Output and Capacitor Link .........................................................42
Apx Table 7 Breaker Troubleshooting Guide.............................................................................52
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
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 

The actuator control board is comprised of a Power Supply Recharge Unit, Control Unit, and
FET Switching circuit which connects the Storage Unit Capacitors to the Magnetic Actuator
coils.
The power supply recharge circuitry adapts whatever input voltage, within the specified range
(see 

is supplied to maintain an 80 V charge voltage across the capacitors. The Control Unit monitors
binary inputs and outputs, hardware and software configurations, auxiliary contacts, capacitor
charge, and switches the FET circuit to connect the capacitor voltage to the Magnetic Actuator
coils following an open or close command. 
The Capacitor Storage Unit consists of four 0.1 farad aluminum electrolytic capacitors
connected in parallel to provide a total capacitance of 0.4 farads. When called to energize the
Magnetic Actuator coils, the capacitors will deliver a peak current of up to 100A and a pulse
width of 45 milliseconds for opening operations and 60 milliseconds for closing operations.
The actuator control board system Block Diagram is given in









 


1. Low voltage full optional board (17 – 75 VDC or 20 – 52 VAC).
2. High voltage full optional board (77 – 280 VDC or 85 – 264 VAC).
3. 0.1 farad aluminum electrolytic capacitors.
 
There is a removable filter card plugged into the control board. This filter card has five metal
jumpers on the board. When these jumpers are cut the binary input threshold is raised by 20
Volts. It is recommended that these jumpers are cut for 125VDC applications.
Binary input channels work properly with a voltage range of 24 to 264 VAC/DC regardless of
which board is used. All inputs have a low threshold at about 18 VDC and 19 VAC with the
exception of the Protection Relay input, which has a low threshold of 7 VDC. To avoid false
triggering by noise, the inputs must be active for at least 6 milliseconds. The current draw for
most inputs is < 2 milliamperes. The exception is the Remote Open and Remote Close inputs,
which draw up to approximately 20 milliamperes. The input impedance (Z) is 300k except for
binary inputs 1 and 2 (Remote Open and Remote Close) which are around 14 k input Z.
There are seven different input channels. Only six of them are used for the RMAG breaker
(channel 5 is not used).
 
The Remote Close input is used to close the breaker remotely. The input impedance is approxi
mately 15 k.
 
The Remote Open input is used to trip the breaker remotely. The input impedance is
approximately 15 k. When tripping with electromechanical relays, an additional resistor will be
required to drop the trip flags.
 
This input can be configured as either an Auxiliary Open function or a Safe Open function. The
position of dip switch I10021 determines which is selected. If it is Off, it is used as Auxiliary. If
the dip switch is On, it is used as Safe Open.
The Auxiliary Open functions the same as the Remote Open function, with the exception of the
input impedance which is approximately 300 k.
The Safe Open function allows the user to open the circuit breaker when the onboard
microcontroller is faulty. During normal conditions, all opening inputs work, but if the
microcontroller is damaged, only the Safe Open input can perform the opening command. When
the microcontroller is damaged, capacitor monitoring is not active so other inputs will be

ignored. In order for the breaker to open correctly, there must be sufficient energy in the
capacitors.
 
This input can be configured as either a Protection Trip or Second Trip function. It is
programmed via Jumper JP1001 pins 1 and 2 or as a normal input by jumpering JP1001 pins 2
and 3.
The Protection Trip input is designed to work at a lower threshold of 7 VDC. This input is provid
ed to use with special protection relay requirements. It can also be used as a normal trip input.
The Second Trip is often referred to as “Shunt Trip.” It functions the same as the Remote Input
with the exception of the input impedance which is 300 k.
 
The circuit breaker Close Blocking feature functions like the familiar 69 switch. The circuit is de
energized when the external trip handle is moved from its normal position (i.e., to the trip
position). In this position the breaker cannot be either locally or remotely closed.
When the circuit breaker is tripped by operating the manual trip handle, the breaker will go into
the Close Block mode. This prevents any future closings until the trip handle is returned to the
normal position. The manual trip handle must be left in the down position for the switch to
remain open (i.e., locked open).
There is a padlock provision for locking the manual trip handle in the locked open position.
There is a padlock provision for locking the manual trip handle in the locked open
position. (see

 
The Under Voltage Trip input will perform an auto trip in the event the voltage source being
monitored by this input falls between 35% to 70% of nominal. It is enabled through DIP Switch
I1004/234. The response of this input also has a programmable time delay from 50 millisec
onds to 5 seconds. The delay is set by the various combinations of DIP Switch I1004/234 (see
section ).The Under Voltage Threshold is
set by I1001. (see Thresholds


1
100 – 127 VAC/DC
2
48 – 60 VDC
3
24 – 30 VDC
NONE
220 – 240 VAC/DC





Binary outputs are simply pairs of mechanical wipe relay contacts. They can be employed to
switch in other circuitry or to an alarm indicator. See 
and for the power limitations of the contacts. Notice the flat
curve for AC voltage in . On the inside of the low voltage
cabinet there is a membrane style button plate that contains a “Ready” LED. The Ready light
will either flash or turn off depending on the state of the capacitor voltage and coil continuity.
The “Unit Ready” output contact can be used to alarm for the more serious of the three types of
problems, but will not signal for all levels of the above problems. (see 

 
The Circuit Breaker Opened contacts are normally open. They close only when the circuit
breaker is in the Open position.
 
The Circuit Breaker Closed contacts are normally open. They close only when the circuit
breaker is in the Closed position.
 
The Circuit Breaker Auxiliary Open contacts close whenever the breaker is in the Open position.
 
An additional set of normally open contacts close whenever the breaker is in the Close position.
 
These contacts are normally open. They close when the breaker is ready. They are used to
monitor capacitor charge (OCO operation ready), valid circuit breaker position and coil
continuity.
 
The Unit Not Ready contacts are normally closed. They open when the Unit is Ready. These
contacts are the inverse (negative) of the Unit Ready contacts.
When using the Not Ready contacts to provide an alarm to SCADA, an 8 second delay is
recommended since the unit will go to Not Ready when the capacitors are below 49 V. The 8
second delay allows the capacitors to charge prior to alarming.
 
The Circuit Breaker Remote Open contacts are referred to as the “Fleeting Output Contacts.”
This means that they only close for 100 milliseconds after a Remote Operation is performed.





Maximum Switching Power
1500 VA on Resistive load
Maximum Switching Voltage
400 VAC, 300 VDC
Maximum Switching Current
6A
Maximum Rated Current
6A

Maximum On Resistance (Ron)
100 m (measured by voltage drop 6
VDC 1 A)
Maximum Capacitance
1.5 pF

Maximum Actuating Time
5.0 milliseconds
Maximum Releasing Time
3.0 milliseconds

Between Contacts and Coil
4000 Vrms (50 Hz/1 min.)
Between Open Contact
1000 Vrms (50 Hz/1 min.)
Resistance (Roff)
>1000 M at 500 VDC

Operating Temperature Range
50 to +55 Degrees C
Storing Temperature Range
40 to +55 Degrees C
Expected contacts life (min. operations)



Mechanical (at 180 cpm)
5 million
Electrical (6 A / 277 VAC/resistive load)
30,000
*See for specific loads and voltages.







 
 
The Temperature Protection circuit monitors the average temperature of a critical area on the
CONTROL BOARD power supply. The output power will be linearly reduced to zero as the
component temperature increases from 78 degrees C to 95 degrees C.
 
See.
 
An Auto Trip command will be issued in the event the breaker does not perform a successful
close operation within 95 milliseconds after the close command is issued.
 




The Energy Failure Auto Trip function is selected by Dip Switch I10041 and will cause the
breaker to auto trip in the event the capacitor voltage falls below 49 volts. Necessary
precautions must be taken when power is removed (e.g., power removed for maintenance) as
the breaker will automatically trip if I10041 is in the “On” position.


 
The Reduced Power Consumption setting will lower the power output of the power supply
recharge unit on the control board, from 75 W to 33 W. This enables the control board to be
supplied with the energy delivered by a voltage transformer if necessary. The Power Supply
Recharge Unit is 80% efficient. This means that the Auxiliary Power supply input must be at
least 93.75 W for the 75 W setting or 41.3 W for the 33 W setting. The 33 W option is hardware
selectable with Jumper JP1019. (see
.
 
Used by ABB factory only.
 
The control board power supply recharge unit adapts any voltage within the specified range of
the board to maintain 80 V across the capacitors. The following voltage thresholds must be
reached to complete the specified operations:
1. The capacitor voltage threshold for an Open operation is 49 volts.
2. The capacitor voltage threshold for a CloseOpen operation is 72.5 volts.
3. The capacitor voltage threshold for an OpenCloseOpen operation is 78 volts.
Note: Contact an ABB sales representative for a replacement. Apx Figure 5 Ready LED
Continually Flashing and Figure 6 Ready LED Off are provided to indicate the states of the
Ready LED, Ready and Not Ready output contacts.





Energy sufficient for OCO operations
Open allowed
Close allowed
Energy sufficient for CO operations
Open allowed
Close allowed
Energy sufficient for O operations
Open allowed
Blocked in open position
Energy insufficient for any operation
Blocked in closed position
or CB opened (depending
on dip switch setting 
I1004)
Blocked in open position








The actuator control board provides access through KM1003 for discharging the Storage Unit
capacitors. Make sure the control board power is removed before attempting to discharge the
capacitors.

A 10 k capacitor discharge resistor is mounted on the circuit board. Discharging is done by
jumpering KM1003 pins 4 and 5. The time constant is 66 minutes. An external resistor can be
used for quicker discharging, but the discharge current should be restricted to 10A maximum.
This means that no lower than 10  external resistances should be used to perform capacitor
discharging. In this case an external 10 , 25 watt resistor can be connected to KM1003 Pins 4
and 6. Approximately 20 seconds is needed to discharge the capacitors using the 10  external
resistor.

 
The standard 0.1 farad electrolytic capacitors are designed to be operated in the temperature
range of 40°F to 185°F (40°C to 85°C). The endoflife corresponds to the point at which the
capacitance decreases by 20% or more.
It is recommended that replacement of capacitors be performed every 15 years for tropical cli
mates and 20 years for an average yearly temperature (in the outdoor breaker enclosure) of
less than 122°F. Extreme temperature capacitors are available as an option. These optional
capacitors are rated for operation between 67°F and 221°F. (55°C to 105°C)









Capacitor Energy sufficient For O
CO operations
Ready LED: on
Ready contact: closed
Not ready contact: opened
Ready LED: on
Ready contact: closed
Not ready contact: opened
Capacitor Energy sufficient for CO
operations
Ready LED: blinking
Ready contact: closed
Not ready contact: opened
Ready LED: blinking
Ready contact: closed
Not ready contact: opened
Capacitor Energy sufficient for O
operations
Ready LED: blinking
Ready contact: closed
Not ready contact: opened
Ready LED: off
Ready contact: opened
Not ready contact: closed
Capacitor Energy insufficient for
any operations
Ready LED: off Ready
contact: opened Not ready
contact: closed
Ready LED: off
Ready contact: opened
Not ready contact: closed
Close Coil continuity not right
Ready LED: blinking Ready
contact: closed Not ready
contact: opened
Ready LED: off
Ready contact: opened
Not ready contact: closed
Open Coil continuity not right
Ready LED: off
Ready contact: opened
Not ready contact: closed
Ready LED: off
Ready contact: opened
Not ready contact: closed
























 
KM10011
ELECTRONIC GRD (0 VDC)
KM10012
ELECTRONIC GRD (0 VDC)
KM10013
+18 VDC
KM10014
+18 VDC
KM10015
ON SIGNAL (0 VDC)
KM10016
OFF SIGNAL (0 VDC)


KM10021
CAPACITOR PLUS (+80 VDC)
KM10022
CAPACITOR PLUS (+80 VDC)
KM10023
CAPACITOR MINUS (0 VDC)
KM10024
CAPACITOR MINUS (0 VDC)
KM10025
+ CLOSE COIL (+80 VDC)
KM10026
+ CLOSE COIL (+80 VDC)
KM10027
+ TRIP COIL (+80 VDC)
KM10028
+ TRIP COIL (+80 VDC)
KM10029
 CLOSE COIL
KM100210
 CLOSE COIL
KM100211
 TRIP COIL
KM100212
 TRIP COIL















Unless specified by the customer, the Low Energy and Under Voltage trip functions are
disabled. Input three is set for Auxiliary trip mode as opposed to the Protection Relay trip mode.
The Protection Relay mode has a lower switching threshold (7 VDC). See section 3.0 
 for the switch and jumper locations. The following represents the functional jumper and
dip switch settings which are the shipped configuration.








READY LED
FLASHING
CIRCUIT
BREAKER
POSITION
OPEN
NOTE: ENERGY
SUFFICIENT
ONLY FOR
CLOSE OPEN
OPERATION
CLOSED
NOTE: ENERGY
SUFFICIENT
ONLY FOR OPEN
CLOSE
OPERATION
<15 SEC
SINCE ANY
OPERATION OR
<30 SEC SINCE
POWER UP
YES
NO ISSUE
NO
CHECK CLOSE
COIL
CONNECTIONS &
CONTINUITY
POSSIBLE ISSUES:
1) ED2.0 BOARD BAD*
2) AUX SUPPLY LOW
3) FAULTY CAPACITORS*


























 

The Power Supply recharge circuitry either reduces (high voltage board) or increases (low volt
age board) input voltage within the specified range supplied to maintain an 80 V charge voltage
across the capacitors.
The Control Unit monitors binary inputs and outputs, hardware and software configurations,
position sensors, capacitor charge, and switches the FET circuit to connect the capacitor
voltage to the magnetic actuator coils following an open or close command.
Because of the risk of death or serious bodily injury, capacitors must be fully
discharged prior to troubleshooting.




1. Use diagram on the previous page for references to troubleshooting the actuator control
board.
2. Disconnect source power to outdoor breaker.
3. Warning: removing cover exposes live voltage.
4. Remove the two #4 screws holding on the Push button plate and let it hang down.
5. Remove the four .250 X 20 screws from the corners of the control board cover.
Follow these instructions for a quick setup check on a breaker that has operated previously:
 

1. Check pins 2 and 3 on KM1003 to confirm proper input voltage is applied.
2. Verify that there is 18 VDC on terminals 1 () to 3 (+) on KM1001.
3. Verify there is 80 VDC from KM1002 1 () to 3 (+).
4. If correct voltage is applied and DC is not reading, then the board needs to be replaced.




























The auxiliary supply
voltage is absent.
Check pins 2 and 3 on KM1003 to confirm proper
input voltage is applied.
The magnetic
actuator is damaged
or not connected.
Check the magnetic actuator circuit. Unplug the
magnetic actuator from the plug to the left of the
mechanism (MA). There are two Phillips head
screws that keep the plug held together. The top
two wires are red and the bottom two wires are
blue. The top red (43) and top blue (45) wire go
to the "On" (close) coil. The other two wires go to
the off (open) coil. Each of these coils should
read approximately 0.3 ohms.
The breaker position
is not being read
correctly.
When breaker is  verify I1001 shows
18Volts from terminal 1 to terminal 5 and
approximately 0 volts from terminal 2 to terminal
6. Reverse this procedure if breaker is open, 0V
terminal 1 to 5, 18V terminal 2 to 6.
The Under Voltage
(UV) function is
enabled and input is
open.
Inspect dip switch I1004. Ensure switches 2, 3, 4
and 5 are in the off (down) position (disables UV),
or apply correct input voltage to pins 13 and 14
on KM1005.
Ready LED is off
(unit not ready)
Ready LED is off
(unit not ready)



The UV function is
enabled and the
monitored voltage is
connected to the UV
input, but the voltage
is lower than the
threshold.
The auxiliary supply
voltage has been
turned off and the
voltage on the
capacitor is under the
OCO levels.
Set the correct UV threshold level via DIP switch
I1001 or disable UV by putting switches 2, 3, 4
and 5 in the off (down) position on I1004.
Check pins 2 and 3 on KM1003 to confirm proper
source input voltage is applied.
The control panel is
damaged or not con
nected correctly.
Verify the control panel 6pin plug is plugged into
KM1007.











The circuit breaker is
closed and the close
coil is disconnected or
broken.
In this case, only the opening operation is avail
able; open the circuit breaker (the ready LED will
be turned off) and check the closing coil circuit.
Unplug the magnetic actuator from the plug to the
left of the mechanism (MA). There are two
Phillips head screws that keep the plug held
together. The top two wires are red and the
bottom two wires are blue. The top red (43) and
top blue (45) wire go to the "On" (close) coil. The
coil should read approximately 0.3 ohms.
The auxiliary supply
voltage has been
turned off.
If the circuit breaker is closed you can perform a
COoperation; connect the auxiliary supply.
Check pins 2 and 3 on KM1003 to confirm proper
input voltage is applied.
The capacitor bank is
charging during start
up or after an opera
tion.
Wait a few seconds.
The opening coil is
broken or damaged.
In this case, only the closing operation is avail
able; open the circuit breaker (the ready LED will
be turned off) and check the closing So circuit.
Disconnect the magnetic actuator from the plug
to the left of the mechanism. There are two
Phillips head screws that keep the plug held
together. The top two wires are red and the
bottom two wires are blue. The top red (43) and
top blue (45) wire go to the "On" (close) coil. The
coil should approximately 0.3 ohms.
The capacitor bank is
not connected.
Check the capacitor bank circuit. Verify the
capacitors are connected to the control board.
Ensure that there is 80 VDC across KM1002 ter
minals 1 and 3.
No external opening
input is connected.
Verify opening input is wired.
The control panel is
either damaged or not
connected correctly.
Verify the control panel 6pin plug is plugged into
KM1007.
Ready LED is
blinking
The opening
command is not
performed
The opening
command is not
performed

The voltage on the
All indication output
capacitor bank is
contacts are open
under 46 VDC.
Connect the auxiliary power supply voltage.



The closing
command is
not performed
Capacitor bank is not
connected.
If it happens immediately when the supply
voltage is switched off and the ready LED is
immediately turned off, check the capacitor bank
circuit.



The closing coil is
broken or damaged.
Check the closing coil circuit. Disconnect the
magnetic actuator from the plug to the left of the
mechanism. There are two Phillips head screws
that keep the plug held together. The top two
wires are red and the bottom two wires are blue.
The top red (43) and top blue (45) wire go to the
"On" (close) coil. The coil should approximately
0.3 ohms.
One open input is
active.
Verify there is not a held trip signal on the
CONTROL BOARD board. Verify the voltage
across TB18 and TB13 is "0" (KM1005 3, 4),
and also across KM1005 5, 6 Safe open (if used),
and KM1005 7, 8 second trip (if used).
The block in open
input is open (manual
trip lever).
Check the manual trip lever to verify it is in the up
(normal) position. If it is, verify the microswitch
(mounted on the mechanism side) has continuity
across the wires.
The capacitor bank is
not connected.
Check the capacitor bank circuit. Verify the
capacitors are connected to the control board.
Ensure that there is 80 VDC across KM1002 ter
minals 1 and 3.
The ready LED on
control panel is off.
See conditions under "Ready LED is off (unit not
ready)".
The control panel is
damaged or not con
nected properly.
The energy in the
capacitor bank is not
enough for a CO
operation.
The closing
command is
not performed
The circuit breaker
closes and then
opens during a
close operation
Verify the control panel 6pin plug is plugged into
KM1007.
Ensure the auxiliary supply voltage is connected.
See "ready light blinking" section.
The external close
input is not supplied.
Verify close command is wired to input.
The auxiliary contacts
are not operating
properly.
Verify the close position auxiliary contact.
The circuit breaker
doesn't reach the cor
rect close position.
Verify the presence of unwanted objects under
the magnetic actuator plunger.


The circuit breaker
opens if the
auxiliary supply is
switched off
The UV function is
active and the
auxiliary supply is
parallel to this input.
Either disable the UV function or connect to a dif
ferent voltage source.
The energy failure
auto trip function is
enabled.
If possible, disable the function via I10041.
Switch 1 should be in the off position.

 



1. Disconnect the source power to the RMAG.
2. Remove the two #4 screws holding on the push button plate and let it hang down.
3. Remove the four .250 X 20 screws from the corners of the CONTROL BOARD cover.
4. With the cover removed, verify the voltage input to the board is off by measuring the voltage
atKM1003 terminals 2 and 3. It should be zero.
5. Before proceeding, discharge the capacitors by placing jumpers on KM1003 pins 4 and 5.
The time constant is 66 minutes. A smaller external resistor can be used for a quicker
discharge, but the discharge current should be restricted to 10 amperes maximum. This
means that no lower than 10  25 watt external resistance should be used to perform
capacitor discharging. When discharging with an external capacitor, connect to pins 2 and 3
on KM1002.
6. After the capacitors are discharged, take a small screwdriver and remove the capacitor
wires from KM1002 pins 1, 2, 3 and 4. Note how they are connected since they will be
reinstalled on the new board.
7. Remove five plugs: KM1001, KM1002, KM1003, KM1004 and KM1005. To remove, loosen
holddown screws from each plug.
8. Remove plug for push button plate. This is not held by retainers.
9. Remove four .25020 nut, lock and flat washer from the four corners. Keep the three rubber
washers behind each screw.












The following basic rules need to be observed:
1. Handling of MABS1 CONTROL BOARD cards during assembly or replacement operation
must be limited to the minimum time.
2. Always hold a card by its edges.
3. Avoid touching the components assembled on the module.
4. Take care when connecting or disconnecting cables.
5. Avoid bending the card during wiring connectors insertion.
6. First, fix the control board to the panel. Then insert the filter card (if required) and wire
harness connections.
7. Prevent damage to the connectors by aligning connector pins before you connect the cable.
8. Remove and replace the board.

9. Perform this process in reverse order to reinstall the board.






Apx Figure 11 ED2.0 Control Board Parts and Mounting
55
All sales are subject to ABB Inc. General Terms and
Conditions of Sale. While every effort has been made
to assure accuracy, the information in this document
is subject to change without notice.
1VAL255104-MB Rev D, March 2013
For more information, please contact:
ABB Inc.
655 Century Point
Lake Mary, FL 32746
Phone: +1 407-732-2000 ext. 2510
+1 800-929-7947 ext. 5
[email protected]
www.abb.com/mediumvoltage