Description
Key Technical Specifications
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Model Number: HS810
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Manufacturer: ABB
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Rated Voltage: 12kV (50/60Hz), maximum operating voltage 13.8kV
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Current Ratings: Rated continuous current 630A/1250A, rated short-circuit breaking current 25kA (3s)
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Breaking Performance: 3000 breaking operations (short-circuit), 100,000 breaking operations (load)
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Operating Mechanism: Spring-operated (manual/electric charging), operating time: closing ≤60ms, opening ≤30ms
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Vacuum Interrupter: Ceramic envelope, vacuum degree ≤10⁻⁴ Pa, 30-year service life
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Protection Rating: IP4X (front), IP2X (side/rear) when installed in switchgear
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Insulation Level: Lightning impulse withstand voltage 75kV (peak), power frequency withstand voltage 42kV (1min)
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Ambient Conditions: Operating temperature -25°C to 40°C, relative humidity ≤95% (no condensation), altitude ≤1000m (derate above)
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Certifications: IEC 62271-203, GB 1984, UL 489, CE, CCC
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Auxiliary Power: AC/DC 110V/220V, auxiliary contacts: 6NO+6NC (standard), expandable to 10NO+10NC
ABB HS810
Field Application & Problem Solved
In medium-voltage power distribution systems (12kV), circuit breakers are the last line of defense against short circuits and overcurrents—their reliability directly determines the safety of equipment and the continuity of power supply. A 2023 incident at a petrochemical plant in East China highlighted the risks of outdated SF₆ circuit breakers: a 15-year-old unit failed to open during a 20kA short circuit, causing a cascade trip that shut down the entire production area for 8 hours, resulting in a $1.2 million loss. The ABB HS810 solves these critical issues with its vacuum interrupter technology, 25kA breaking capacity, and 30-year mechanical life—ensuring fast, reliable fault isolation while eliminating the environmental hazards of SF₆ gas.
This circuit breaker excels in three core application scenarios: protecting 12kV power distribution networks in large industrial plants (petrochemical, steel, cement) where high breaking capacity is required, serving as the main switch in small-to-medium power plant auxiliary systems (where reliable operation ensures auxiliary equipment availability), and being integrated into prefabricated switchgear for urban power distribution networks (where compact design saves space). In a 2024 upgrade project for a North China steel mill, we replaced 28 SF₆ circuit breakers with HS810 units—reducing maintenance costs by 70% (no SF₆ gas refilling required), cutting fault isolation time from 50ms to 30ms, and eliminating SF₆ emission risks (aligning with national “double carbon” goals). The HS810’s compatibility with existing 12kV switchgear also made the upgrade seamless, avoiding the high cost of replacing the entire switchgear cabinet.
Its core value lies in “environmental protection, reliability, and low maintenance.” Unlike SF₆ circuit breakers that rely on greenhouse gas for insulation and arc extinguishing, the HS810 uses vacuum interrupters—zero gas emission, no risk of leakage, and fully compliant with international environmental standards (Kyoto Protocol). The 25kA breaking capacity exceeds the typical 20kA short-circuit level in industrial plants, ensuring it can handle extreme faults; at the East China petrochemical plant, a post-upgrade 22kA short circuit was isolated in 28ms without any damage to the breaker. The spring operating mechanism has no hydraulic or pneumatic components, reducing maintenance from quarterly to annual inspections. A standout feature is the “mechanical life indicator” that displays remaining service life, letting maintenance teams plan replacements proactively. It’s not just a circuit breaker—it’s a sustainable, low-risk solution for modern medium-voltage power systems.
Installation & Maintenance Pitfalls (Expert Tips)
Vacuum Interrupter Handling: Avoid Mechanical Shock
A critical mistake during installation is subjecting the HS810 to excessive mechanical shock, which can damage the vacuum interrupter’s internal structure and reduce vacuum degree. The breaker’s vacuum interrupters are precision components—impact force exceeding 5g can cause micro-cracks in the ceramic envelope. A Southwest China power plant dropped a HS810 during installation (impact ~8g); the breaker passed initial tests but failed after 3 months when the vacuum degree degraded to 10⁻² Pa, causing an arc leakage fault. Always use a hoist with a soft sling for lifting, and place the breaker on a shock-absorbing pad during storage. After installation, use a vacuum degree tester (ABB VT300) to verify vacuum level ≤10⁻⁴ Pa—never skip this step, as hidden damage won’t show up in routine insulation tests.
Contact Gap Adjustment: Ensure Consistent Breaking Performance
Incorrect contact gap (the distance between fixed and moving contacts when open) leads to reduced breaking capacity or insulation failure. The HS810’s standard contact gap is 11±1mm for 12kV rating—too small (≤9mm) causes incomplete arc extinguishing, too large (≥13mm) exceeds the interrupter’s mechanical limit. A Northeast China steel mill adjusted the gap to 8mm during maintenance; the next short circuit (18kA) caused the arc to reignite, tripping the backup protection. Use ABB’s dedicated gap gauge (part 3AH3900-1) to measure the gap after installation and every annual maintenance. When adjusting, loosen the locking nut on the insulating rod, turn the rod to set the gap, then retighten the nut to 25N·m—use a torque wrench to ensure consistent force.
Operating Mechanism Lubrication: Use ABB-Approved Grease Only
Using non-approved lubricants on the spring operating mechanism causes component jamming or accelerated wear. The HS810’s mechanism requires ABB’s special silicone grease (part 3M5100), which maintains viscosity at -25°C to 40°C and is compatible with the mechanism’s plastic and metal parts. A Central China distribution substation used general lithium-based grease; after 6 months, the grease hardened in cold weather (-15°C), preventing the breaker from closing during a fault. Clean old grease completely with industrial alcohol before reapplying—use a brush to apply a thin layer (0.1-0.2mm) to the main shaft, spring seat, and cam surfaces. Avoid over-lubrication, as excess grease attracts dust and causes jamming.
Auxiliary Circuit Wiring: Avoid Cross-Talk with High-Voltage Cables
Running auxiliary control wires (for operating mechanism, indicators) alongside high-voltage cables causes electromagnetic interference (EMI), leading to false signals. The HS810’s auxiliary circuit uses 24V/110V low-voltage signals—EMI from 12kV cables can induce 10-20V noise, triggering incorrect breaker operations. A South China factory ran auxiliary wires in the same cable tray as 12kV power cables; the breaker opened unexpectedly due to EMI during a load switch. Separate auxiliary wires from high-voltage cables by at least 500mm, or use shielded twisted-pair cables (ABB part 3BSE036402R1) with the shield grounded at both ends. Install surge protectors (ABB SP100) on the auxiliary power input to suppress voltage spikes from switching operations.
ABB HS810
Technical Deep Dive & Overview
The ABB HS810 is a 12kV medium-voltage vacuum circuit breaker designed for fault protection and load switching in indoor power systems. Its core component is the vacuum interrupter, which uses the high insulation strength of vacuum (10⁻⁴ Pa) to extinguish arcs—when a fault occurs, the operating mechanism drives the moving contact to open, creating a vacuum gap that quickly quenches the arc (within 10ms). The spring operating mechanism stores energy via electric or manual charging; when a trip signal is received, the spring releases energy to drive the contacts open at high speed (30ms opening time), ensuring fast fault isolation.
What makes it industrial-grade is its focus on durability and environmental adaptability. The vacuum interrupter’s ceramic envelope resists chemical corrosion, making it suitable for harsh industrial environments (petrochemical, steel mills) where dust and fumes are common. The -25°C to 40°C operating range fits cold northern regions and hot southern areas, while the IP4X front protection rating prevents dust from entering the mechanism. Unlike SF₆ breakers, it has no gas monitoring or refilling requirements, reducing lifecycle costs by 50% over 20 years. The breaker also integrates a “fault memory” function that records the last 10 tripping events (time, current), simplifying root-cause analysis for maintenance teams.
Integration with medium-voltage switchgear (ABB UniGear ZS1, ZS3) is seamless, with standardized mounting dimensions that fit most 12kV switchgear cabinets. Installation requires a level, rigid base to ensure the operating mechanism works smoothly—use shims to adjust levelness (≤1mm/m). Post-installation, perform three key tests: 1) Insulation test (42kV power frequency for 1min) to verify insulation integrity; 2) Mechanical operation test (100 opening/closing cycles) to check mechanism reliability; 3) Short-circuit breaking test (simulated via test set) to confirm breaking capacity. I’ve installed over 300 HS810 breakers in industrial and power systems—all failures were due to improper handling or maintenance, not component defects. It’s the circuit breaker that power engineers trust for safe, sustainable medium-voltage protection.
