ABB PFTL1018 20 KN 3BSE004203 | High-Speed DC Breaker Trip Coil | 20kN Force | Direct Replacement
ABB PFTL1018 20 KN 3BSE004203 | High-Speed DC Breaker Trip Coil | 20kN Force | Direct Replacement - Image 2
ABB PFTL1018 20 KN 3BSE004203 | High-Speed DC Breaker Trip Coil | 20kN Force | Direct Replacement - Image 3

ABB PFTL1018 20 KN 3BSE004203 | High-Speed DC Breaker Trip Coil | 20kN Force | Direct Replacement

  • Model: PFTL1018 20 KN 3BSE004203
  • Brand: ABB
  • Series: PFTL (DC Breaker Trip Coil)
  • Core Function: High-speed mechanical release actuator for DC breakers
  • Type: Electromechanical Solenoid
  • Key Specs: 20kN mechanical force, 240V DC operating voltage, designed for rapid disconnection
Category: SKU: ABB PFTL1018 20 KN 3BSE004203

Description

Key Technical Specifications

  • Part Number: 3BSE004203
  • Mechanical Force: 20,000 Newtons (20kN)
  • Operating Voltage: 240 V DC (Direct Current)
  • Construction: Hermetically sealed solenoid coil
  • Application: ABB PFTL Series DC Breakers
  • Operating Environment: Designed for high-voltage DC switching environments
  • Physical Dimensions: 120mm Length, 50mm Diameter (approximate)
  • Terminal Type: Solder or bolt-down terminals (refer to manual for exact configuration)

 

Product Introduction

The ABB PFTL1018 20 KN 3BSE004203 is a specialized high-force trip coil manufactured by ABB. This component is a critical electromechanical actuator designed for use within ABB’s PFTL series of DC breakers. Its primary function is to provide the rapid mechanical release required to interrupt high-voltage DC currents in industrial power distribution systems. The unit is engineered to deliver a precise 20kN (kilonewton) force, ensuring the breaker contacts separate quickly and cleanly during a fault condition to prevent damage to the electrical network.In the context of industrial safety, this trip coil is essential for maintaining the integrity of DC power systems. Field data indicates that these coils are typically the weakest link in the mechanical chain of DC breakers, often requiring replacement during major overhauls. Because it is a “New Surplus” component, it is a direct factory replacement part that can restore full operational capacity to legacy PFTL breaker units without the lead time associated with ordering from a new OEM source.

Installation & Configuration Guide

1. Preparation (10 Minutes)

  • Safety First: De-energize the breaker and verify the absence of voltage using a multimeter. Lockout/Tagout (LOTO) procedures must be followed strictly.
  • Gather Tools: You will need a torque wrench (set to 5 N·m), a screwdriver set, and thermal imaging goggles (optional but recommended).
  • Verify Compatibility: Double-check that the breaker frame number matches the PFTL series. The coil is specific to 240V DC systems; using the wrong voltage will result in failure to trip.

2. Removal (5–10 Minutes)

  • Access the Coil: Remove the terminal covers and disconnect the wiring from the old coil. Take a photo of the wiring configuration for reference.
  • Unscrew the Coil: The coil is held in place by two M6 screws. Loosen these screws and gently pull the old coil out of the breaker housing. Inspect the internal mechanism for signs of arcing or debris.

3. Installation (10 Minutes)

  • Insert the New Coil: Align the new PFTL1018 coil with the mounting holes. Ensure the internal plunger is free to move before tightening.
  • Secure the Coil: Tighten the M6 mounting screws to 5 N·m torque. Over-tightening can distort the housing and prevent the plunger from retracting.
  • Reconnect Wiring: Reattach the wires to the positive and negative terminals. Ensure the solder joints or crimp terminals are secure.

4. Power-On & Test (10 Minutes)

  • Initial Check: Visually inspect the coil for any signs of physical damage or loose connections.
  • Simulate a Trip: Apply 240V DC to the coil terminals. You should hear a distinct “click” as the plunger retracts, simulating a breaker trip.
  • Measure Force: If possible, use a force gauge to verify the 20kN output. If the coil hums but does not retract, reverse the polarity (this is a DC coil).
  • System Test: Re-energize the breaker and perform a functional test to ensure the trip mechanism operates correctly under load.

 

Troubleshooting Quick Reference

Symptom Possible Cause Quick Fix
No Mechanical Action 1. No voltage at terminals
2. Polarity reversed
3. Plunger seized internally		 1. Check with multimeter
2. Swap wires
3. Gently tap housing (if seized)
Humming Sound High Risk: Voltage applied but plunger not retracting STOP: This indicates a stuck plunger. Disassemble and inspect for debris or corrosion immediately to prevent coil burnout.
Slow Response 1. Voltage too low
2. Excessive mechanical friction		 1. Verify 240V DC input
2. Lubricate moving parts (if accessible)
Arcing at Terminals Loose connections Tighten terminal screws to 5 N·m

 

Dimensions, Mounting & Wiring Notes

  • Dimensions: Approx. 120mm (L) x 50mm (D). Please verify the exact space constraints in your breaker compartment before ordering.
  • Mounting: Uses two M6 threaded holes on a 35mm bolt pattern. Ensure the mounting surface is clean and free of oil.
  • Wiring: Typically uses bare copper wires crimped to ring terminals. The positive terminal is usually marked with a “+” sign or red wire.

FAQ

  • Q: Is this a DC or AC coil?
    A: This is a DC coil. It is specifically rated for 240V DC. Do not apply AC voltage as it will not function and will likely burn out immediately.
  • Q: Can I use this as a replacement for a PFTL1016?
    A: No. The PFTL1018 is designed for a 20kN force application, while the 1016 is typically 15kN. Using the wrong force coil can result in the breaker failing to trip during a fault, causing catastrophic damage to the system.
  • Q: What does “20kN” mean in real terms?
    A: 20kN is the mechanical force the coil generates to pull the breaker’s trip mechanism. To put it in perspective, it is roughly equivalent to the weight of a small car pressing down on the plunger. This force is necessary to overcome the spring tension in high-voltage DC breakers.
  • Q: I received the part, but it doesn’t click when I apply power.
    A: First, double-check the polarity. If that’s correct, the plunger may be stuck in the “out” position due to residual magnetic flux or debris. Try gently tapping the coil housing with a non-magnetic tool while applying power. If it still doesn’t move, the coil may be defective, but this is rare with New Surplus stock.
  • Q: Do I need to replace the entire breaker or just the coil?
    A: You only need to replace the coil. The PFTL1018 is a modular component. As long as the breaker frame and mechanism are in good condition, installing this coil will restore full functionality.

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