The ABB FSK II+ apparatus is a medium voltage circuit breaker designed for outdoor installations in 50/60Hz railway traction power supply networks. It is distinguished by its fast breaking times and utilizes a modern magnetically actuated mechanism, replacing conventional mechanical spring-charged mechanisms. The main insulators and the orientation of the HV terminals are configurable to meet specific customer requirements.
Function Description
The FSK II+ apparatus operates through an electronic MABS control card, which manages the magnetic actuator. This system allows for precise control of opening and closing operations, with the current injection being supplied by a capacitor bank. The MABS card continuously monitors the apparatus's state, including the position of the magnetic actuator, capacitor charge, and breaker logic, to ensure safe and reliable operation. Any malfunctions are detected and signaled automatically. The system also incorporates an error-free state indicator ("READY" signal) and allows for configuration via DIP switches to adapt to various customer requirements.
The MABS control card is central to the apparatus's operation, receiving binary inputs for remote close/open commands, auxiliary open, hardware-driven safe open, and standard open/protective trip functions. It also supports local/remote and local/global switchover functions, as well as lock-in-open and undervoltage functions. Binary outputs provide status indications such as "OPEN," "CLOSE," "Aux. OPEN," "Aux. CLOSE," "Unit Ready," "WD Ready," and "Undervoltage detection."
For bi-pole applications, an "Add-on" card synchronizes and handles position information from two poles, ensuring consistency. The position sensors of both poles connect to the MABS card via this add-on board.
Important Technical Specifications
The FSK II+ apparatus is available in two types: FSK1025 (Load break switch & Circuit breaker) and FSK1025 (Circuit breaker).
- Rated Voltage: 27.5 kV (according to EN 50124-1 and EN 60694).
- Rated Frequency: 50 Hz-60 Hz.
- Operating Voltage: 25 kV.
- Number of Phases: 1 or 2.
- Rated Power Frequency Withstand Voltage: Phase to earth: 105 kV; Across open contacts: 105 kV; Electromagnet, electronics, and wiring to earth: 2 kV.
- Rated Lightning Impulse Withstand Voltage (1.2/50 µs): Phase to earth: 250 kV; Across open contacts: 250 kV.
- Rated Current (Normal): ≤1250 A (FSK1025 LBS/CB) or ≤2500 A (FSK1025 CB).
- Short-Circuit Breaking Current: 8/25 kA (FSK1025 LBS/CB) or 25 kA (FSK1025 CB).
- Rated Peak Withstand Current: 50/63 kA (FSK1025 LBS/CB) or 63 kA (FSK1025 CB).
- Short-Circuit Making Current: 50/63 kA (FSK1025 LBS/CB) or 63 kA (FSK1025 CB).
- Short-Time Withstand Current (3 s): 25 kA.
- Operating Sequence: O-0.3s-CO-60s-CO.
- Closing Time: ≤ 65 ms.
- Opening Time: ≤ 45 ms.
- Operating Cycles (Mechanical): 10,000 (class M2=) or 20,000.
- Operating Cycles (with maintenance): 30,000.
- Electric Power at Rated Current (Vacuum Interrupter): 20,000.
- Electric Power at Rated Short-Circuit Break Current (Vacuum Interrupter): 50.
MABS Control Card Supply Voltages:
- Low Voltage: 24-60 VDC (-30% to +25% tolerance), 24-48 VAC (-15% to +10% tolerance) at 50/60 Hz.
- High Voltage: 110-250 VDC (-30% to +12% tolerance), 100-240 VAC (-15% to +10% tolerance) at 50/60 Hz.
- Insulation: Galvanic, 2.5 kVrms.
- Power Consumption: 5-10 W (static mode), approx. 75 W (during capacitor charging).
Usage Features
- Control Panel: Local control is provided via two pushbuttons (ON/OFF) and a "READY" indicator LED. The color scheme of the pushbuttons can be customized.
- Manual Opening: An optional manual opening mechanism can be fitted for ground-level operation using an isolating hook stick. Additionally, manual tripping from pole level is possible by removing a threaded plug and using a hand crank.
- Electrical Pole Interlocking: An optional feature on the control box allows blocking of pole operation in either the "open" or "closed" position, with normal operation activated in the "service" position.
- Mechanical Position Indication: A visual indicator (green for open, red for closed) is located under the breaker for ground-level status checks.
- Portable Power Supply Connector: A specific connector on the front cover panel allows for connection of a portable auxiliary power supply.
- High-Voltage Connections: Designed to accommodate forces from thermal expansion or line weight, requiring flexible connections or cable supports. Maximum force on HV terminals is <30Kg. For 100% copper supply lines, an Al-Cu bimetal is used to prevent corrosion of Al high-voltage terminals.
- Dip Switches: DIP switches on the MABS control card (I1001, I1002, I1004) allow configuration of undervoltage trip thresholds, auxiliary/HW driven safe-OFF behavior, delay times for undervoltage trips, operating modes (LOCAL/GLOBAL/REMOTE), and behavior under energy failure conditions.
- Jumpers: Jumpers (JP1001, JP1019) allow setting the BI Y4 input to "Standard Open" or "Protection Trip" and reducing power consumption during capacitor charging (extending charging time).
Maintenance Features
- Storage: The apparatus, accessories, and spare parts must be stored in their original packaging in a dry, clean place, protected from dust, direct sunlight, humidity, condensation, and vibrations. Storage temperature should be -25 °C to +50 °C. For long storage durations or significant temperature variations, heating resistances (in pole and control box) must be supplied to prevent condensation.
- MABS Control Card and Capacitors Storage: Period of storage without inspection is 2 years. Capacitors require supply with Un for ~30 min. over a 1 kΩ resistance, then discharge, every 2 years. MABS Control Card requires supply with Un for ~30 min., then discharge, every 2 years.
- Visual Inspection: Upon delivery, a visual inspection is recommended to check for damages, conformity with the order, identification plates, and quantity of components.
- Periodic Inspections:
- General: Isolate the work area, inspect the apparatus for soiling, corrosion, moisture, increased temperatures, partial discharges on insulators, and firm seating of HV/LV terminals.
- Drive Unit: Check screw connections in the drive unit and connector pins of the multiple plug connection.
- Operations Counter: Record the number of switching operations from the apparatus logbook.
- Gas Pressure: Check the pole's internal gas pressure every 5 years (0.2-0.8 bar overpressure at 20 °C is OK). A specific pressure gauge is required.
- Vacuum Interrupter: Inspect the vacuum interrupter using a vacuum tester every 10 years (recommended, not compulsory).
- Manual Opening Device: Periodically check the pin and safety rings of the manual tripping device from ground level.
- Cleaning: Dry dust can be removed with a soft dry cloth. Strongly adhering dirt can be cleaned with slightly alkaline household cleaning agents or Rivolta BWR 210. Insulating parts and conductive components can be cleaned with halogen-free cleaning agents or Rivolta BWR 210. Heavy dirt on insulation material parts requires a cold cleaner. Always wipe with clean water and dry carefully after cleaning.
- Repair of Surface Defects: Immediately address white rust on aluminum/zinc surfaces with a wire brush or scouring pad, followed by zinc spray or zinc-dust paint and aluminum spray. For chromated functional parts and phosphated parts, use a wire brush or wire-free scouring pad.
- Disposal: The apparatus components (stainless steel, copper, aluminum, rubber, synthetic materials, cables, magnets, electronic components) are environmentally friendly and can be disposed of separately according to local regulations. Vacuum interrupter elements contain no toxic or environmentally harmful products and can be disposed of without special precautionary measures after contacts have worn away.
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