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ABB K-Line 225A Installation & Maintenance Instructions Manual

Low voltage air-magnetic power circuit breakers
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IB 6.1.12.1-1C
I N S T A L L A T I O N / M A I N T E N A N C E I N S T R U C T I O N S
Low Voltage
Air-Magnetic Power Circuit Breakers
K-Line 225A through 2000A
Stationary and Draw-out Frames
Manually and Electrically Operated Mechanisms
Courtesy of NationalSwitchgear.com

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Summary of Contents for ABB K-Line 225A

  • Page 1 I N S T A L L A T I O N / M A I N T E N A N C E I N S T R U C T I O N S Low Voltage Air-Magnetic Power Circuit Breakers K-Line 225A through 2000A Stationary and Draw-out Frames Manually and Electrically Operated Mechanisms...

  • Page 2: Table Of Contents

    IB 6.1.12.1-1C TABLE OF CONTENTS INTRODUCTION ......................5 Application ................................5 Designation ................................5 Safety Issues ................................5 Receiving, Handling, and Storage ..........................5 OPERATING FEATURES AND FUNCTION ..............7 Anti-pump Lockout Relay (EO) ..........................7 Automatic Spring Discharge (EO) .........................7 Automatic Trip Indicator............................7 Automatic Trip Alarm Contacts (Optional)......................7 Automatic Trip Lockout (Optional)........................7 Close Button (EO)..............................7 Close Handle (MO)..............................7...
  • Page 3 IB 6.1.12.1-1C Charging Operation ..............................11 Electrically Operated Mechanism........................11 Manually Operated Mechanism...........................12 Closing Operation..............................12 Electrically Operated Mechanism........................12 Manually Operated Mechanism...........................12 Opening Operation ..............................12 Slow-close Procedure.............................12 Electrically Operated Mechanism........................12 Manually Operated Mechanism...........................13 INSTALLATION AND REMOVAL................. 14 Stationary Type..............................14 Draw-out Type ...............................14 MAINTENANCE ......................15 Inspection ................................15 Arc Chutes ................................15 Contact Structure ..............................16...
  • Page 4 IB 6.1.12.1-1C Renewal Parts ................................24 These instructions do not purport to cover all details or variations or to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser's purpose, the matter should be referred to the nearest District Office.

  • Page 5: Introduction

    Accompany a claim Shield), or microelectronic (MPSC-2000) trip system. with purchase order number, carton number, and a ABB trip systems are direct acting; actuating power is description of damaged or missing parts. Keep the obtained from the protected power system rather than circuit breaker upright on a flat surface to avoid relying on an external source.
  • Page 6 IB 6.1.12.1-1C Accessory Lifting Yoke Trip Device (Electronic) Auxilliary Switch Bank Skirt Draw-out Arm Figure 1b. Accessory Racking Escutcheon and Maintenance Handles. Interference Panel Blocking Positioning Pins Control Relay Primary Device Disconnect Arc Chute Closing Spring (underneath) Charging Motor Figure 1a. Type K-1600M Circuit Breaker with Electrically Operated Mechanism and Draw-out Frame Construction.

  • Page 7: Operating Features And Function

    IB 6.1.12.1-1C Automatic Trip Lockout (Optional) Following a fault, the lockout places the circuit breaker OPERATING FEATURES AND FUNCTION trip-free by holding the tripper bar paddle in the trip position. The circuit breaker cannot be closed until the The escutcheon panel is the local interface with the indicator is manually reset on the breaker.

  • Page 8: Maintenance Handle (Eo)

    IB 6.1.12.1-1C attempted closure will only discharge the closing number. Provide the serial number when contacting springs. With MO breakers, the closing handle action ABB for information. will not engage the closing springs. Racking Mechanism Maintenance Handle (EO) Utilize a racking handle, as shown in Figure 1b, to...

  • Page 9: Operating Devices

    The "b" contacts are arranged current curve references. For non-standard trip oppositely (closed when the breaker is open). If devices not listed, consult ABB. desired, an “a” contact can be made into a “b” contact (and vice versa) by opening the switch and rotating Electromechanical Overcurrent Trip the contact element 90°.

  • Page 10: Undervoltage Trip Device (Optional)

    IB 6.1.12.1-1C current signal for fault monitoring. Systems with on and off the breaker. Tested on the breaker, the communications ability also offer voltage, current, BTSB can also operate the magnetic latch as part of and power imbalance information. the fault simulation. When testing the MPS-C, the BTSB interactively guides the user through the test MPS (Discontinued) sequence.

  • Page 11: Circuit Breaker Operation

    IB 6.1.12.1-1C CIRCUIT BREAKER OPERATION the charged closing springs within the last few turns of the handle. In principle, all K-Line circuit breakers cycle through Charging Operation three stages of operation: charging, closing, and The potential energy of charged closing springs close opening.

  • Page 12: Manually Operated Mechanism

    IB 6.1.12.1-1C motor is unavailable. Engage the handle with the drive Opening Operation carrier as demonstrated in Figure 2. Charge springs The loaded contact springs and two charged opening by ratcheting the carrier with a smooth, deliberate springs provide the energy for opening the circuit motion.

  • Page 13: Manually Operated Mechanism

    IB 6.1.12.1-1C 6. Open the breaker with the manual trip button. 7. Resume slow closing with steps #2, #3, and #4. Referring to the previous warning, reset the charging cranks for normal electrical operation as follows: 8. Repeat previous steps #5 and #6. 9.

  • Page 14: Installation And Removal

    IB 6.1.12.1-1C INSTALLATION AND REMOVAL circuit breaker to move into the DISCONNECTED position. The draw-out arm of both sides will make initial cradle engagement. NOTE: If a breaker with OD devices has been 5. Lift the racking shutter, insert the racking handle, shipped or stored on its back, then oil in the dashpot and crank CW.

  • Page 15: Maintenance

    Where unusual service DANGER conditions exist, ABB presumes that these conditions were considered at the time of order, the equipment Beware of electrical hazards. Remove a circuit breaker from supplied was designed for the special application, and service (CONNECTED) before attempting any maintenance activities.

  • Page 16: Contact Structure

    Replace a main contact member if it endurance testing, use only the greases approved by has erosion that cannot be dressed sufficiently to re- ABB for use in K-Line circuit breakers. The approved establish a smooth surface. Likewise, inspect the greases and application are as follows: condition of the stationary contacts for erosion.

  • Page 17: Structural Insulation

    IB 6.1.12.1-1C 3. Mobil 28 grease as an alternative to Anderol 757 Structural Insulation (for refurbishment only). strongly Insulated parts should be checked for damage. Glass- recommends using only one type of grease polyester insulation may be cleaned with a clean cloth throughout the breaker.
  • Page 18 IB 6.1.12.1-1C 600 and 800 Ampere Frames If for any reason the contact structure is removed from the breaker, upon assembly, reapply clean NO-OX-ID (K-600, K-800, K-600S, K-800S, and K-800M) “A-Special” to the ends of the contact bushing. Torque 1. The hex portion of the adjustment stud must be the nut of the hinge joint between 15 and 25 lb-ft to centered within 1/16”...
  • Page 19 IB 6.1.12.1-1C Arc Runner Assy Contact Pressure Adjustment Gap Moving Arc Contact Member Upper Terminal Current Studs Moving Main (Upper & Lower Contact Member Halves) Yoke Pushrod Insulator Adjustment Stud Torque Contact Pressure Transfer Contact Torque Hinge Joint Adjustment Gap Member Hinge Joint Figure 6a.

  • Page 20: Control Relay Device

    1-1/2 revolutions CW. Proceed as follows to adjust the tripper bar latch To ensure a properly matched style of latches, ABB engagement: recommends replacing both the secondary and primary close latches as a set.

  • Page 21: Shunt Trip Device

    IB 6.1.12.1-1C Tripper Bar Travel Mechanism Housing Adjustment Screw (Right-hand) Trip Latch Engagement Adjustment Screw 1.06 Secondary Trip Latch Tripper Bar Primary Trip Latch drag Figure 8. Trip Latch Adjustments. Right-hand view shown. Drawn in the latched closed position. K-225 through K-2000, K1600S, K-2000S, K-1600M, Shunt Trip Device and K-2000M Adjustment establishes sufficient range of trip rod...

  • Page 22: Magnetic Latch Device

    IB 6.1.12.1-1C Magnetic Latch Device Shunt Trip Tripped Position Tripper Bar Device Armature 5/16 Adjustment Latched Position Hex Screw Figure 10. Shunt and Magnetic Latch Device Figure 11. Magnetic Latch System. Left-hand view Assemblies. Left-hand view shown. These integrated shown. System is typical of large frame breakers with devices are typical of small frame breakers with an an electronic trip system (shown with a type “S”...

  • Page 23: Solid-State Overcurrent Trip Device

    IB 6.1.12.1-1C The overcurrent trip device trip travel is set at the See Tables B3 and B4 of Appendix B for applicable factory; however, if trip travel readjustment is required time-current curves and reference to complete device due to replacement of the device or affected parts, instruction and testing.

  • Page 24: Trip Latch Drag Force

    Testing a Power Shield trip unit: A Renewal Parts Bulletin is available from the nearest 1. Connect all sixteen terminals of the Power Shield ABB District Sales Office. Verify the part number and trip unit together. proper application prior to ordering.
  • Page 25 IB 6.1.12.1-1C Courtesy of NationalSwitchgear.com...
  • Page 26 Courtesy of NationalSwitchgear.com...
  • Page 27 IB 6.1.12.1-1C Appendix A General Circuit Breaker Information Table A1 – Test Voltages for AC Dielectric Withstand-Voltage Test Secondary (Control) Circuit Primary Circuit Circuit Breaker Motor Disconnected Motor Connected Condition 2200 1500 1000 In-Service 1500 1125 (75% of New) After Short-Circuit 1320 (60% of New) Table A2 - Control Circuit Requirements at Standard Voltages...
  • Page 28 IB 6.1.12.1-1C Schematic Symbol Legend M = Closing Spring Charging Motor X = Close Coil Y = Anti-pump Lockout Coil TC = Shunt Trip Coil LS = Limit Switch CE = Coil Lead x1, x2 = Sensor terminal markers H1 = Sensor orientation marker L = Left end mounted auxiliary switch bank a = Auxiliary Switch Contact: normally open when breaker is open...
  • Page 29 IB 6.1.12.1-1C Table A4 - Nameplate Ratings Available for Standard OD Devices (Calibrated pickup points are based on nameplate rating.) Standard Electromechanical Overcurrent Device Nameplate Rating OD-3 OD-4 OD-5 OD-6 OD-7 OD-8 AC & DC AC & DC 1000 1200 1600 2000 2500...
  • Page 30 IB 6.1.12.1-1B Table A5 - OD Coil Assembly Resistance Based on Device Rating and Circuit Breaker Frame Size Grouped ratings all use the same coil assembly. Standard OD Device Ratings Available by Circuit Breaker Frame Size OD Coil Assembly Allowable Maximum Test K-225 K-600...
  • Page 31 IB 6.1.12.1-1C Table A6 - Maximum Allowable Current Path Resistance for K-Line Circuit Breakers as Non-Automatic or With Solid-state or Microelectronic Trip Systems Circuit breakers with an OD trip system must add the applicable coil assembly resistance (Table A5) to the non- OD resistance in Table A6 below.
  • Page 32 IB 6.1.12.1-1B Appendix B Overcurrent Trip Devices Table B1 - Standard Electro-Mechanical Overcurrent Trip Devices Reference IB 8203 for OD Operating Instructions and Testing Procedure Device Elements Overcurrent Time-Current Curve Range of Pickup as a Percentage of Designation Device Device’s Coil Rating Type INST OD-3...
  • Page 33 IB 6.1.12.1-1C Table B3 - Standard Microelectronic Trip Devices Reference IB 6.1.1.7-4 for MPS Operating Instructions and Testing Procedure Device Elements Device Time-Current Curve Type INST MPS-3 TD-9601 TD-9602 [ST I t OUT] MPS-4 TD-9604 [ST I t IN] TD-9602 [ST I t OUT] MPS-5 TD-9604 [ST I...
  • Page 34 IB 6.1.12.1-1B Appendix C Abbreviated Renewal Parts List Maintenance Items: Maintenance Accessory Kit (Universal): 709770-T01 Lifting Yoke 709770-T05 Racking Handle 711706-K03 Maintenance Handle (EO) 716664-T01 Greases: NO-OX-ID “A-Special” 713222-A00 (1 pint can) Anderol 757 Synthetic 712994-C00 (1 lb can) Charging and Closing Items: Spring Charging Motor Control Relay Device Standard Control...
  • Page 35 IB 6.1.12.1-1C Notes Courtesy of NationalSwitchgear.com...
  • Page 36 Florence, S.C. 29501-0524 Phone: (843) 413-4700 Fax: (843) 413-4850 Marketing and Sales: (800) 338-1585 Post Order Service and Warranty: (800) 634-7643 Component Sales: (800) 929-7947 Email: dsinfo@us.abb.com ABB Corporate Help Desk: (800) 626-4999 US Corp. Web Site: www.abb.com/usa/ Courtesy of NationalSwitchgear.com...

This manual is also suitable for:

K-line 2000aK-line 600aK-line 800aK-line 1600a

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