Product manual

1HSB439954-6en 2010-02-18

LTB 72.5-245E1
3-column support
Operating mechanism BLK222
1-pole operation
The information contained in this document may be subject to change without prior warning and should not be
considered as binding on ABB AB's behalf. ABB AB accepts no liability for any errors that may appear in this
document. ABB AB is not liable for any damage resulting from the incorrect interpretation of this document. This
document, or parts thereof, may not be reproduced or copied without ABB AB's consent. It must not be distributed
to others, or used by unauthorized parties. Any breaches to the above will be penalized with the support of applicable
laws.

© Copyright 2010 ABB All rights reserved.

ABB AB
Circuit-Breaker Unit
SE-771 80 Ludvika
Sweden
1 Product description, circuit-breaker 7
1.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Breaking principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Gas system and density monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Description, SF6-gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 Product description, operating mechanism 13

2.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Control descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.1 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.2 Opening operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2.3 Closing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Preconditions for different operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4 Component parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4.1 Drive unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4.2 Latch device with coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.3 Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.4 Auxiliary contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4.5 Heating element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3 Safety 25
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.1 Levels of safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.2 Hazardous working situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.3 Safety during maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.1 Warning - risk of crushing in the operating mechanism and link system . . . . . . . . . . . . . . . . . . 30
3.3.2 Release the spring charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4 Reference information 35
4.1 Oil types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 Types of grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3 Locking fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4 Tightening torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.5 Requisite equipment, installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.6 Requisite equipment, maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.7 Requisite equipment, overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.8 Operating values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1HSB439954-6en 2010-02-18 3
5 Delivery 45
5.1 Delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2 Storage prior to assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3 Lifting the circuit-breaker poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4 Lifting the operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6 Installation 51
6.1 Installation in short steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.2 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.3 Assembly of support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.4 Installation of earthquake damper on the foundation (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.5 Assembly of support on the foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.6 Assembly of circuit-breaker pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.7 Installation of corona rings on the post insulator (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.8 Assembly of operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.9 Final assembly of the circuit-breaker pole.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.10 Fitting of rod system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.10.1 Fitting the pull-rod between the operating mechanism and mechanism housing. . . . . . . . . . . . 70
6.11 Assembly of the cable rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.12 Assembling the outer cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.13 Assembly of gas monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.14 Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.14.1 Connecting the circuit-breaker's operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.14.2 Fitting the rails or lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.14.3 Charging of closing spring electrically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.14.4 Spring indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.15 Pressurizing of circuit-breaker poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.15.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.15.2 Gas filling with SF6-gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.15.3 Filling of mixed gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.16 Inspection of bolted joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.17 Assembling the indicator sign and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.18 Inspection prior to commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.18.1 Density control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

7 Commissioning 97
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.2 Pre-commissioning check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4 2010-02-18 1HSB439954-6en
8 Maintenance 101
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
8.2 Description of maintenance categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8.3 Maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8.4 Maintenance, circuit-breaker pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
8.4.1 The service life of the circuit-breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
8.4.2 The service life of the arcing contacts in the event of short circuit breaking. . . . . . . . . . . . . . . 111
8.4.3 Cleaning and lubrication of circuit-breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
8.5 Maintenance, operating mechanism and link system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8.5.1 Preparatory measures and overview of the operating mechanism. . . . . . . . . . . . . . . . . . . . . . 113
8.5.2 Cleaning, lubrication and rust protection of operating mechanism . . . . . . . . . . . . . . . . . . . . . . 115
8.5.3 Inspection of heating element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.5.4 Inspection of drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8.5.5 Inspection of latch devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.5.6 Replacing a latch device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
8.5.7 Check of limit switch and auxiliary contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.5.8 Inspection of coupling terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8.5.9 Mechanical charging of closing spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8.6 Rust protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

9 Overhaul 131
9.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.1.1 Preparations for overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.1.2 Removing of SF6-gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
9.1.3 Cleaning and waste management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.2 Removal of circuit-breaker pole for transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
9.3 Overhaul of circuit-breaker pole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
9.3.1 Removal of the tripping mechanism's pull-rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
9.3.2 Removal of breaking unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
9.3.3 Removal of post insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
9.3.4 Overhaul of breaking unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
9.3.5 Inspection and replacement of contacts and Auto-PufferTM . . . . . . . . . . . . . . . . . . . . . . . . . . 149
9.3.6 Overhaul of mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
9.4 Assembling the circuit-breaker pole following overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9.4.1 Treatment of contact surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9.4.2 Treatment of sealing surfaces and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9.4.3 Assembly of post insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
9.4.4 Assembly of breaking unit following overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
9.4.5 Assembly of breaking unit on the post insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
9.4.6 Assembly of tripping mechanism's pull-rod to the operating lever . . . . . . . . . . . . . . . . . . . . . . 165
9.4.7 Filling the gas before transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

1HSB439954-6en 2010-02-18 5
 9.5 Replacement of breaking unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
9.5.1 Dismantling of breaking unit for transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
9.5.2 Assembly of breaking unit on the post insulator on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
9.6 Assembling the circuit-breaker poles and commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

10 Disposal and environmental information 179

10.1 Disposal and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
10.2 Environment information, SF6 gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

11 Spare parts 183

11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
11.2 Circuit-breaker pole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
11.2.1 Circuit-breaker pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
11.2.2 Breaking unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
11.2.3 Contact set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
11.2.4 Post insulator and insulating pull-rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
11.2.5 Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
11.2.6 Tripping mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
11.2.7 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
11.3 Operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
11.3.1 Drive unit, complete with motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
11.3.2 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
11.3.3 Spring housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
11.3.4 Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
11.3.5 Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
11.3.6 Latch device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
11.3.7 Heating element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
11.3.8 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

6 2010-02-18 1HSB439954-6en
 1 Product description, circuit-breaker

1 Product description, circuit-breaker

1.1 Description

Structure

Each circuit-breaker pole consists of three main components:

• a mechanism
• a hollow post insulator with insulating pull-rod,
• a breaking unit that consists of a breaking chamber insulator with attendant
flanges and adapter plates. The interior of the breaking unit consists of a fixed
upper and lower current path with integrated contact system and a moving
puffer unit.
The circuit-breaker poles are fitted to separate column supports. The support is hot-
dip galvanized and consists of two welded halves that are interconnected using bolted
cross stays.

1HSB439954-6en 2010-02-18 7
1 Product description, circuit-breaker

The circuit-breaker's main components

Item Part Weight, kg

1 Circuit-breaker pole See dimension print for applicable order
2 Breaking unit See dimension print for applicable order
3 Post insulator See dimension print for applicable order
4 Operating mechanism BLK222 Slave 210 kg
5 Mechanism See dimension print for applicable order
6 Support 86-200 kg
7 Operating mechanism BLK222 Master 230 kg
8 Cable rack See dimension print for applicable order

8 2010-02-18 1HSB439954-6en
 1 Product description, circuit-breaker

1.2 Breaking principle

Auto-Puffer principle

The breaking unit functions in accordance with the Auto-PufferTM principle with a
puffer cylinder that is divided into two chambers: an Auto-PufferTM section and a
compression section.
When normal rating currents are interrupted, the SF6 gas is compressed in the
compression section to an overpressure. When the arcing contacts separate, the gas
in the compression section flows out and extinguishes the arc at a current zero
passage.
When short-circuit currents are interrupted, the requisite extinguishing pressure is
built up in the Auto-PufferTM section by heat from the arc. The pressure increase is
achieved with energy from the arc and no extra energy is required from the operating
mechanism.
On closing, the puffer cylinder slides upwards, the contacts engage and the puffer
cylinder is refilled with gas.

Breaking unit with Auto-Puffer

1 Puffer cylinder
2 Auto-PufferΤΜ chamber
3 Compression section

1HSB439954-6en 2010-02-18 9
1 Product description, circuit-breaker

1.3 Standards

IEC and ANSI

The switch complies in applicable parts with the requirements of the IEC standard or
ANSI/IEEE.

10 2010-02-18 1HSB439954-6en
 1 Product description, circuit-breaker

1.4 Gas system and density monitor

Gas pressure

The circuit-breaker poles are delivered vacuum processed and filled with SF6 gas to
a pressure of 0.12-0.13 MPa abs at 20°C.
When commissioning, the SF6 gas or mixed gas must be topped off to the pressure
specified on the rating plate. Different gas pressures may occur depending on the
different requirements with respect to the lowest ambient temperature.

Density monitor

The circuit-breaker is fitted with a density monitor for checking the density of the
gas. All density monitors are fitted with a set of contacts that are to be connected to
give an alarm in the event of abnormal leakage. There are two levels for the alarm,
these are:
• Level 1, alarm.
• Level 2, blocking.
NOTE!
A new or overhauled circuit-breaker must be checked for leakage by reading the
density monitor after around one month. Following the initial control, it should be
checked at 1-2 year intervals in connection with the routine visual inspections.

1HSB439954-6en 2010-02-18 11
1 Product description, circuit-breaker

1.5 Description, SF6-gas

Gas stability

Sulfur hexafluoride SF6is a synthetic gas, which is colorless, odorless and non-
combustible.
The gas is chemically very stable and at room temperature, it does not react with any
other substance.
The stability of the gas is the basis for it being used in electrical devices as it provides
very high electrical insulation and can effectively extinguish arcs. These SF6
properties enable the construction of devices and equipment with small footprints,
using little material, that are safe and have long service lives. In an electrical context,
the SF6 gas is only used in closed and sealed systems, e.g. as insulation gas in
substations and insulation and extinguishing medium in circuit-breakers for high and
medium voltage.

Voltage strength (kV), 10 mm gap

1 Air
2 Oil
3 Vacuum
4 SF6, 0.1 MPa
5 SF6, 0.5 MPa

12 2010-02-18 1HSB439954-6en
 2 Product description, operating mechanism

2 Product description, operating mechanism

2.1 Structure

General

The motor spring operating mechanism is designed for operation of the circuit-
breaker poles with integrated trip springs.

Structure

The operating mechanism consists of a closing spring with attendant motor voltage
operating mechanism that charges the closing spring automatically after each closing
operation.
A closing latch keeps the charged closing spring ready for the closing of the circuit-
breaker and charging of the trip spring. A tripping latch keeps a closed circuit-
breaker with a charged trip spring ready for immediate opening.
The components in the operating mechanism are integrated into a cabinet that also
contains an operating panel. To facilitate service and overhaul work in the operating
mechanism, you can remove the top of the cabinet and open the operating panel.
The standard operating cycle is O-0.3 s-CO-3 min-CO (IEC) or CO-15 s-CO (ANSI).
When conducting tests of circuit-breakers and relay systems that involve more than
three closing operations, the time between the operations should not be less than 1
minute.

Summary, operating mechanism

1 Drive unit
2 Mechanism
3 Operating panel
4 Closing spring
5 Heating element

1HSB439954-6en 2010-02-18 13
2 Product description, operating mechanism

2.2 Control descriptions

2.2.1 Normal operation

Operation mode

During normal operations the circuit-breaker is in closed position. The trip spring on
the circuit-breaker and closing spring in the operating mechanism are charged. The
circuit-breaker is held in place in closed position by the tripping latch device of the
operating mechanism.

Latch device

1 Tripping latch device

2 Closing latch device

14 2010-02-18 1HSB439954-6en
 2 Product description, operating mechanism

2.2.2 Opening operation

Description of opening operation

The latch in the tripping latch device releases when the trip coil is activated. The
operating lever rotates clockwise. The movement is dampened by the damper in the
end position. The closing spring is still charged.

Opening operation

1 Tripping latch device

2 Opening lever
3 Damper

1HSB439954-6en 2010-02-18 15
2 Product description, operating mechanism

2.2.3 Closing operation

Description of closing operation

The latch in the closing latch device releases when the closing coil is activated. The
closing lever rotates anti-clockwise and pulls the opening lever to the right. The
opening lever stops in its end position behind the latch in the tripping latch device.
The closing lever continues to rotate anti-clockwise until it rests behind the latch in
the closing latch device. The damper piston is pulled out and is once again ready for
an opening operation. The motor starts and recharges the closing spring to ensure the
circuit-breaker reverts to normal operation. The operating mechanism is ready for a
new closing operation after opening (O-CO).

Closing operation

1 Tripping latch device

2 Closing lever
3 Opening lever
4 Closing latch device
5 Damper piston

16 2010-02-18 1HSB439954-6en
 2 Product description, operating mechanism

2.3 Preconditions for different operations

Control panel

1 Control switch, Close/Open (S1)

2 Pole selector, 3-pole / Pole A / Pole B / Pole C (S3)
3 Switch, Local/Remote/Disconnected (S4)

Remote/Local operation

For normal operation, the "Local/Remote/Disconnected" switch is in the "Remote"

setting for electrical remote control. In the "Local" setting, operation can only be
executed using the "Close/Open" control switch. The "Disconnected" setting is used
for maintenance.

Open operation

An opening operation for a closed circuit-breaker can be performed when the "Local/
Remote/Disconnected" switch is in the "Local" position and the gas density is greater
than the blocking level.

Closing operation

A closing operation using the "Close/Open" control switch or electric remote impulse
can only be done if:
• The "Local/Remote/Disconnected" switch is in the "Remote" or "Local"
setting.
• The closing spring is charged.
• The circuit-breaker is in open position.
• The gas density is larger than the blocking level.

1HSB439954-6en 2010-02-18 17
2 Product description, operating mechanism

Auto-reclosing

Auto-reclosing, Open-0.3s-Close-Open is possible if:

• The circuit-breaker is closed.
• The "Local/Remote/Disconnected" switch is in the "Remote" setting.
• The operating mechanism's closing spring is fully charged when the operating
cycle begins.
For auto-reclosing, the substation's relay equipment can supply an immediate trip
impulse if there are still short circuits remaining in the network. As the control
circuits are electrically interlocked via the auxiliary contact, a closing operation will
always be completed before an opening operation starts, even though a trip impulse
has been given during the current closing operation. The relay equipment in the
substation produces a 0.3 second delay.

18 2010-02-18 1HSB439954-6en
 2 Product description, operating mechanism

2.4 Component parts

2.4.1 Drive unit

Motor

The drive unit is delivered with motor for:

• 110 V DC or 110 VAC (50/60 Hz)
• 220 V DC or 220 V AC (50/60 Hz)
The motor must be able to charge the spring at 85 % of nominal voltage(IEC).

1 Motor

1HSB439954-6en 2010-02-18 19
2 Product description, operating mechanism

2.4.2 Latch device with coils

General

The operating mechanism has one closing coil and two tripping coils as standard, but
can be fitted with dual closing coils upon request.
Coil voltage:
- 110 V DC or 220 V DC
Other voltages may occur.
The standard rated output of the coils is 200 W, options up to 400 W.

1 Tripping latch device

2 Closing latch device

20 2010-02-18 1HSB439954-6en
 2 Product description, operating mechanism

2.4.3 Damper

The operating mechanism is fitted with a damper to dampen the final phase of the
opening travel.

1 Damper

1HSB439954-6en 2010-02-18 21
2 Product description, operating mechanism

2.4.4 Auxiliary contact

General

The operating mechanism is fitted with a 9 pole auxiliary contact as standard

consisting of nine opening and nine closing contacts. Three closing and three
opening contacts are for the internal function of the operating mechanism. The option
is available for adding an additional six closing and six opening contacts.
The lever of the auxiliary contact is directly connected to the operating mechanism's
operating lever via a link and therefore follows the travel of the circuit-breaker
contacts.

1 Auxiliary contact
2 Lever

22 2010-02-18 1HSB439954-6en
 2 Product description, operating mechanism

2.4.5 Heating element

General

The operating mechanism is fitted with a heating element that prevents condensation.
The heating element must always be connected.

1 Heating element

Technical data

The 70 W heating element is always connected, while the 140 W heating element is
thermostat controlled and is for temperatures below -25oC. Check the resistance
where necessary.
Ambient temperature Voltage Resistance Power
>-25oC 220 V 691 ohm ± 10 % 70 W
oC
>-25 110 V 173 ohm ± 10 % 70 W
>-55oC 220 V 346 ohm ± 10 % 140 W
>-55oC 110 V 86 ohm ± 10 % 140 W

1HSB439954-6en 2010-02-18 23
2 Product description, operating mechanism

24 2010-02-18 1HSB439954-6en
 3 Safety

3 Safety
3.1 Introduction

General

The safety chapter is divided into two sections:

• General safety information, important to read before any work can be begun.
This information applies to installation, repairs and maintenance of the circuit-
breaker. See General safety information on page 26.
• Read the safety-related instructions when a specific hazard is encountered
while work is underway. These safety instructions describe how to avoid and
eliminate hazards that are indicated in the installation, repair and maintenance
instructions. See Safety related instructions on page 30.

1HSB439954-6en 2010-02-18 25
3 Safety

3.2 General safety information

3.2.1 Levels of safety risks

Description

Throughout the manual, various types of safety risks are indicated. These are divided
into five different levels, depending on the degree of danger. The most serious level
on this scale provides a warning about serious personal injury or possible death, or
major damage to a product, if the instructions are not observed. The least serious is
simply a comment on important facts and conditions. The levels are indicated using
symbols; see below.

Safety risks - Symbols and their meanings.

Descriptions of the symbols that appear in the manual are provided here, along with
their meanings.
DANGER!
The yellow, filled warning triangle warns that an accident can occur if the
instructions are not complied with, resulting in serious injury or death and/or major
damage to the product.
It is used, for example, to warn such of dangers as: contact with high voltage,
explosion or fire risk, risk for toxic gases, risk of crushing, impacts, falls from high
places, etc.

WARNING!
The red, unfilled warning triangle warns that an accident can occur if the instructions
are not complied with, resulting in serious injury or death and/or major damage to the
product.
It is used, for example, to warn such of dangers as: contact with high voltage,
explosion or fire risk, risk for toxic gases, risk of crushing, impacts, falls from high
places, etc.

ELECTRIC CHOCK!
The symbol for electric shocks warns of electrical dangers that could cause serious
injury or death.

26 2010-02-18 1HSB439954-6en
 3 Safety

CAUTION!
The round warning symbol warns that an accident may occur if the instructions are
not observed, and that this could result in injury and/or damage to the product.
It is also used to warn of risks that entail burns, eye injuries, skin damage, impaired
hearing, crushing or slipping injuries, tripping, impacts, falls from high places, etc.
In addition, it is used to warn of functional requirements when assembling or
removing equipment where there is a risk of damage to the product or a risk that
might cause downtime.

NOTE!
The comment symbols indicate important facts and conditions.
Also used for any danger that could lead to damage to the plant only.

1HSB439954-6en 2010-02-18 27
3 Safety

3.2.2 Hazardous working situations

General

For all work on high-voltage circuit-breakers, the risks below must be observed and
corresponding measures taken.

Hazardous working situations

Risk Action
Working close to high voltage. Disconnect and earth around the workplace. If work
must be carried out next to live plant components, the
safety distance must satisfy the applicable safety
regulations.
Working on ladders and platforms Work must be executed in accordance with applicable
safety regulations. Avoid climbing ladders and
platforms in poor weather conditions.
Working with low voltage Cut the control voltage and where necessary the
Both AC and DC can be connected to heater voltage as well.
the operating mechanism.
Working next to pressurized Working close to the circuit-breaker's insulators
insulators. where there could be a risk of damage to the insulator
Normal working pressure is up to 0.8 may not be carried out before the gas has been
MPa. Damage to the porcelain evacuated to a maximum pressure of 0.125 MPa
insulator can cause it to splinter. (abs).

28 2010-02-18 1HSB439954-6en
 3 Safety

3.2.3 Safety during maintenance

General

For all work on high-voltage circuit-breakers, the risks below must be observed and
corresponding measures taken.
The standard operating cycle is O - 0.3 s - CO - 3 min - CO. When testing circuit-
breakers and relay systems that include more than three closing operations, the time
between the operations should not be less than 1 minute.

Safety instructions

WARNING!
Damage to the insulator porcelain may cause it to explode with the subsequent risk
of splintering. When damage has been identified, the insulator must be replaced.
WARNING!
Do not operate the operating mechanism without a load! The operating
mechanism may not be switched on, operated or have a charged open and/or closing
spring before all installation and adjustment of the circuit-breaker is complete.
WARNING!
Mechanical damage to the insulator may cause it to explode with the subsequent risk
of splintering. Work on the circuit-breaker when there is a risk for mechanical
damage to the insulators is to be executed at reduced gas pressure, 0.125 MPa (abs).

1HSB439954-6en 2010-02-18 29
3 Safety

3.3 Safety related instructions

3.3.1 Warning - risk of crushing in the operating mechanism and link system

Description

Energy is stored in both the closing and trip springs. The operating mechanism may
be tripped by heavy vibrations or by unintentional contact of the mechanical
interlocking components, which could result in crushing injury.

Action

Action Note
1. Put the circuit-breaker in open
position.
2. Release the spring charge by During transport and when the operating
disconnecting the motor power and mechanism is under assembly or stored, the
carrying out a closing and opening closing and trip springs must be discharged for
operation. safety reasons.
3. Disconnect and earth the high-voltage
side.

30 2010-02-18 1HSB439954-6en
 3 Safety

3.3.2 Release the spring charge

General

For maintenance work that requires work on the circuit-breaker or operating

mechanism, it is important that both the closing and trip springs are discharged.

Structure, release the spring charge electrically

1 Motor protection
2 Switch, Local/Remote/Disconnected
3 Spring charge indicator
4 Control switch, Close/Open

Release the spring charge electrically

The item numbers in the text correspond to the item numbers in the illustration.
Action Note
1. Cut the motor current by switching off
the motor protection (1).
2. Set the Local/Remote/Disconnected
switch (2) on the control panel to the
Local position.
3. Execute an Open-Close-Open
operation.
4. Check that the spring is discharged.
The spring charge indicator (3) shows
discharged spring.
5. The circuit-breaker is in Open position.
6. Following completion of work the
motor protection (1)must be reset.

1HSB439954-6en 2010-02-18 31
3 Safety

Structure, release the spring charge mechanically

1 Hatch
2 Bolt
3 Crank
4 Crank extension
5 Spring charging indicator
6 Operating mechanism

32 2010-02-18 1HSB439954-6en
 3 Safety

Release the spring charge mechanically

Action Note
1.

WARNING!
Mechanical discharging is only to be
performed if electrical discharging is
not possible. Electrical discharging is
described in section Structure, release
the spring charge electrically on page
31.
2. Screw off the cover (1) to cut the motor
circuit.
3. Attach the crank (3) to the crank
extension (4) as per the illustration
above.
4.

NOTE!
Ensure that the release button on the
opposite latch hook is pressed in by
the crank extension before cranking.
The latch hook can be damaged if it is
open.
5. Crank clockwise until the spring is fully
discharged.
6. Check that the spring is discharged.
The spring charge indicator (5) shows
discharged spring.

1HSB439954-6en 2010-02-18 33
3 Safety

34 2010-02-18 1HSB439954-6en
 4 Reference information

4 Reference information
4.1 Oil types

General

This section deals with the applications, type names and suppliers of oil.
CAUTION!
All lubricant and oil spills must be covered using absorbent material and be handled
as chemical waste in accordance with locally applicable regulations.
CAUTION!
When handling oil and lubricants, long-sleeved overalls protective gloves and
protective goggles must be worn at all times.

Oil A

Thin all-synthetic lubricant for precision mechanical components in the operating

mechanism and circuit-breakers. Also used when lubricating bearings that cannot be
lubricated with grease “G” without removing, e.g. links and link gears.
Property Value
Viscosity at 40 °C 62-65 cSt
Lowest yield temperature -52°C

Supplier Designation Spare part number

ABB 1171 2039-1 1HSB875318-A
MOBIL MOBIL 1 (481127)5W-30 -
CASTROL FORMULA RS5W-50 -
SHELL TMO Synthetic 5W-30 -
OK Super-Synthetic 4W-40 -

1HSB439954-6en 2010-02-18 35
4 Reference information

Oil D

Circuit-breaker oil with low viscosity. Also used as oil in dampers

NOTE!
Dampers with the letter “S” punched on the cover are to be filled with oil “S”.
Property Value
Viscosity 20 °C 6.0 cSt

Supplier Designation Spare part number

ABB 1171 3011-102 1HSB875318-B
MOBIL Switch oil Univolt 42 (44) -
SHELL NYSWITCHO 3 -
NYSWITCHO 3x
OK Switch oil A65 -
Klte-Schalteroel X

Oil S

Silicone oil designed for dampers in heavy operating mechanisms, like BLG and
BLK models.
Supplier Designation Spare part number
ABB 1173 7011-106 1HSB875318-C
SHELL DC 200 Fluid 200 CS -

36 2010-02-18 1HSB439954-6en
 4 Reference information

4.2 Types of grease

General

This section deals with the applications, type names and suppliers of grease.

Grease G

Low temperature grease for all types of bearings, gear drives and worm gears as well
as valves in air-blast circuit-breakers. Also used for greasing O-rings and as crevice
corrosion protection for circuit-breakers, and for moving contacts (opening contacts)
in disconnectors.
Supplier Designation Spare part number
ABB 1171 4014-407 5316 381-A
GULF 718EP Synthetic grease -
MOBIL Mobil grease 28 -
SHELL Aero Shell Grease 223 -

Grease K

Molycote grease for lubricating pins in link gears and in seismic dampers.
Supplier Designation Spare part number
ABB 1263 0011-102 5316 381-M
Dow Corning G-rapid plus -

Grease L

Low temperature grease specially designed for lubricating precision-engineered

equipment parts, such as latch mechanisms in operating mechanisms that are to be
used in very cold conditions.
Supplier Designation Spare part number
ABB 1171 4016-606 5316 381-H
ASEOL AG ASEOL SYLITEA 4-01 8 -

Grease M

Low temperature grease for long-term and permanent lubrication of worm gears,
gear drives and other machine elements. Counteracts wear and corrosion.
Also reduces electrical resistance at the lubrication point, therefore making it suitable
for electrical connections and for lubrication of contacts in disconnectors and
earthing switches.
Supplier Designation Spare part number
ABB 1171 4016-612 5316 381-J
Klüber Isoflex Topas NB 52 -

1HSB439954-6en 2010-02-18 37
4 Reference information

Grease N

For lubrication of moving contacts and puffer cylinders in SF6 circuit-breakers. The
grease is to be rubbed on in a very thin layer on the sliding surfaces of the contacts.
Supplier Designation Spare part number
ABB 1171 4016-607 5316 381-L
Montefluos S.p.A Fomblin OT20 -

Grease P

Vaseline for treatment of contact surfaces in fixed joints internally in the breaking
unit.
Supplier Designation Spare part number
ABB 1171 5011-102 5316 381-N
SHELL Shell Vaseline 8401 -

Grease "S"

Fluorosilicone grease for lubrication of EPDM O-rings and as crevice corrosion

protection for ED type circuit-breakers, as well as greasing of rotating shaft seals in
circuit-breaker types LTB and HPL.
Supplier Designation Spare part number
ABB 1171 4014-406 5316 381-G
Dow Corning FS-3451 No. 2 -
Fluortech AB TP55 -

Grease SV

For lubrication of moving contacts (opening contacts) in disconnectors, silver-plated

contacts and brushed aluminum surfaces in fixed joints outdoors.
Supplier Designation Spare part number
ABB 1171 4016-610 5316 381-C
Statoil Electrical grease -

38 2010-02-18 1HSB439954-6en
 4 Reference information

4.3 Locking fluid

General

This section deals with the applications, names and suppliers of locking fluid.

Preliminary treatment of surfaces

The surfaces must be free from oil, grease, wax, paint and anti-rust agent.

Locking fluid B

Medium strong locking fluid used for locking threads and for interlocking screw and
nut joints. Removable.
Supplier Designation Spare part number
ABB 1269 0014-429 -
LOCTITE Ltd. Loctite 243 -

Locking fluid C

Strong locking fluid for locking and interlocking of bolts. Difficult to remove.
Supplier Designation Spare part number
ABB 1269 0014-408 -
LOCTITE Ltd. Loctite 270 -

Locking fluid D

A thin fluid that penetrates quickly. Used for locking brackets following assembly or
adjustment. The fluid can also impregnate porous welded joints, castings and
sintered material. The interlocking has a high resistance against pressure, solvents
and chemicals.
Fluid can only be used on clean and dry surfaces. Oily goods must be washed with
industrial spirit.
Spray the fluid on the surface in question or apply with a brush.
Supplier Designation Spare part number
ABB 1269 0014-409 -
LOCTITE Ltd. Loctite 290 -

Locking fluid F

Extra strong locking fluid for cylindrical attachment. Recommended for joints with
sliding or forced fit. Must be heated in order to be removed (temperature resistance
175º C).
Supplier Designation Spare part number
ABB 1234 0011-126 -
LOCTITE Ltd. Loctite 648 -

1HSB439954-6en 2010-02-18 39
4 Reference information

4.4 Tightening torque

General

This section specifies all tightening torques

Tightening torque, specified

Screw joint Tightening torque (Nm)

Foundations 300-350 (M24)
500-550 (M30)
Pull-rod 300
Density monitor/clamp nuts 10
Latch device 40

Tightening torque, general

Size Tightening torque (Nm)

M6 9,5
M8 22,5
M10 45
M12 79
M16 190
M20 420

40 2010-02-18 1HSB439954-6en
 4 Reference information

4.5 Requisite equipment, installation

General

This section specifies the equipment needed for installing the circuit-breaker.

Requisite tools

Tool ABB part no. Note

Ordinary tool equipment Including torque wrenches 9-550
Nm.
Lifting device and slings

Lubricant

Agent ABB part no. Note

Grease "G" See sectionsTypes of grease on
Grease "SV" page 37 and Oil types on page 35for
ABB part numbers, suppliers and
trade names.
Contact paste -

Other documentation

Document ABB part no. Note

Dimension print and diagram -
applicable to the order

1HSB439954-6en 2010-02-18 41
4 Reference information

4.6 Requisite equipment, maintenance

General

This section specifies the equipment needed for maintenance of the operating
mechanism.

Tool

Tool ABB part no. Note

Ordinary tool equipment Including torque wrenches (9-550
Nm).
Lifting slings -
Test equipment for recording - For example Programma or ABB
damping curves and operating SA10.
values

Cleaning equipment

Equipment ABB part no. Note

Vacuum cleaner -
Lint-free drying cloths -

Lubricant

Agent ABB part no. Note

Grease "G" - See sectionsTypes of grease on
Grease "M" page 37 and Oil types on page
35for ABB part numbers, suppliers
and trade names.
Antirust agent, Valvoline Tectyl 506 1241 0011-108

42 2010-02-18 1HSB439954-6en
 4 Reference information

4.7 Requisite equipment, overhaul

General

This section specifies the equipment needed for overhauling the circuit-breaker.

Tool

Tool ABB part no. Note

Ordinary tool equipment Including torque wrenches (9-350
Nm).
Lifting devices and slings. - Weights for the current circuit-
breaker are specified on the
dimension print applicable to the
order.
Gas treatment equipment - For evacuation, cleaning,
compressing and storage of used
SF6 gas and instruments for
monitoring pressure and vacuums.
Test equipment for recording - For example Programma or ABB
damping curves and operating SA10.
values
Operating time meter -
Resistance meter -
Leak detector for leak inspection -

Lubricant

Agent ABB part no. Note

Grease "G" - See sections Types of grease on
Grease "N" page 37 for ABB part numbers,
Grease "P" suppliers and trade names.
Grease "S"
Antirust agent, Valvoline Tectyl 506 1241 0011-108

Spare parts

Spare ABB part no. Note

Set of contacts - As per spare parts list for current circuit-
breaker.
Gasket sets - As per spare parts list for current circuit-
breaker.
Absorbent - As per spare parts list for current circuit-
breaker.
SF6 gas -
Nitrogen -
Protective cover for breaking 5237 736-R
unit
Protective cover for post 5439 142-A
insulator

1HSB439954-6en 2010-02-18 43
4 Reference information

4.8 Operating values

Times

Events Times
Close time coil I (and II) < 28 ms
Open time coil I 15-19 ms
Open time coil II 15-19 ms
1
Close-Open time 23-29 ms

1. Close-Open time refers to the time the arcing contacts are closed during a
closing operation when the trip impulse is connected at the same time via the
auxiliary contact.

Motor and control circuits

Events Values
Charging time for motor Max. 15 s
Control voltage tripping coil I V (according to rating plate)
Control voltage tripping coil II V (according to rating plate)
Control voltage closing coil I (and II) V (according to rating plate)

Resistance

The main circuit resistance for breaking chamber length L=2094 mm is max. 49 µΩ
per pole.
The main circuit resistance for breaking chamber length L=1472 mm is max. 39 µΩ
per pole.

Stroke

The stroke is 160 ± 3 mm.

44 2010-02-18 1HSB439954-6en
 5 Delivery

5 Delivery
5.1 Delivery inspection

General

The material is packed in boxes and on pallets. The boxes are marked with package
numbers and gross weights. Other information is printed on a plate/label attached to
two sides of the boxes.
All packaging material is recyclable.

Damaged goods

Check on arrival that the delivery matches the order and delivery documents and that
no transportation damage has occurred. If damage is found or suspected, the boxes
must be opened and the damage photographed and documented.
In the event of missing material or if transportation damage has occurred, this must
be immediately reported to ABB AB.

1HSB439954-6en 2010-02-18 45
5 Delivery

5.2 Storage prior to assembly

Circuit-breaker

The circuit-breakers must be stored in their original packaging where they are
protected from damage. The units must not stand in water and must primarily be kept
in a horizontal position indoors and above ground level, so as to avoid cracking or
water damage.
The circuit-breakers may also be stored outdoors, but then in an area protected from
rain on a dry, well-drained surface. If a tarpaulin is used, it must not be wrapped too
tightly; air circulation to the zinc-plated surfaces must not be hindered. Any
condensation must be easy to drain off.
The lowest permitted temperature limit for storage is -30ºC.

Operating mechanism

Operating mechanisms must be stored in their original packaging so as to avoid

damage. For periods of storage greater than 3 months, the storage area must be
protected from rain and the operating mechanism stored on a dry, well-drained
surface and with the operating mechanism's heating element connected to prevent
corrosion on sensitive equipment.

Storage in a moist environment

Storage in damp environments without ventilation can cause discoloring of zinc-

coated surfaces. This discoloring is known as “white rust” and primarily consists of
zinc oxide and zinc hydroxide, and is the result of a chemical reaction between the
pure zinc on the surface and moisture.
The long-term rust protection will not be affected by the "white rust", and the steel-
zinc layer under the surface will remain unaffected. In accordance with applicable
practice "white rust" is not a reason for returning the goods.
NOTE!
Operating mechanisms must not be stored in damp environments as phosphatized
surfaces can be attacked by corrosion.

Storage conditions

All components must be held in an easy to access store and in an environment that
meets the following.
The storage area must have:
a roof
solid ground
air humidity below 50%
a temperature of 20°C (±10°C).

Dust, smoke, abrasive or flammable gas, steam or salt may not be present in close
proximity to the circuit-breaker. If this is the case, the equipment must be cleaned
prior to assembly.

46 2010-02-18 1HSB439954-6en
 5 Delivery

Stacking of packaging boxes

Packaging boxes of different sizes must never be stacked on top of each other (the
pressure could damage the lids of the lower boxes). If different sized boxes need
stacking, a frame must be used between the boxes to distribute the pressure.

WARNING!
Never stack more than three boxes on top of each other. Due to instability and the risk
of collapse the boxes need to be secured.

Spare parts

Spares must be stocked indoors in their original packing. This is particularly

important for rubber components, (such as seals) which also need protecting from
sunlight to avoid drying up. Gaskets have a limited service life, you should therefore
avoid stocking them. Supports can be stored outdoors.

1HSB439954-6en 2010-02-18 47
5 Delivery

5.3 Lifting the circuit-breaker poles

General

The following section describes lifting of the circuit-breaker poles.

Safety

WARNING!
In order that the correct lifting tackle is used it is extremely important to check the
weight of the circuit-breaker pole. The weight of the circuit-breaker pole is specified
on the dimension print applicable to the order.
CAUTION!
Please note the positioning of the lifting sling! With respect to polymeric insulators,
the lifting sling is to be placed as close as possible to the flange and not on the rubber
surface.
NOTE!
The circuit-breaker pole/poles are to be stored in transport boxes until immediately
before assembly.

Requisite equipment

Equipment Part number Note

Torque wrench Torque range 10-350 Nm
Lifting slings
Lifting device

Lifting illustration

1 Screw joint

48 2010-02-18 1HSB439954-6en
 5 Delivery

Lifting instructions

The following instructions describe the lifting of a circuit-breaker pole.

Action Note/Illustration
1. Check that the circuit-breaker poles
are tight:
• Remove the sealing cap (1).
• Press the non return valve cone
(2) inwards using a screwdriver.
A hissing noise should be clearly
heard.

NOTE!
If it does not hiss, the circuit-breaker pole has a
leak that must be fixed before assembly.
2.

DANGER!
The circuit-breaker pole weighs up to
600 kg. Use lifting tackle that is
dimensioned for the weight.
3. Place a lifting sling around the top of See Lifting illustration on page 48.
the circuit-breaker pole as shown in
the previous figure.

CAUTION!
Please note the positioning of the lifting sling!
With respect to polymeric insulators, the lifting
sling is to be placed as close as possible to the
flange and not on the rubber surface.
4. Check that the bolts (1), have the See Lifting illustration on page 48.
correct tightening torque.

Torque!
45 Nm.
5. Lift the circuit-breaker pole from its
horizontal position in the transport
packaging.

1HSB439954-6en 2010-02-18 49
5 Delivery

5.4 Lifting the operating mechanism

Requisite equipment

Equipment Part number Note

Lifting slings
Lifting device

Lifting illustration

Lifting instructions

The following instructions describe the lifting of the operating mechanism.

Action Note
1. Attach the lifting slings to the lifting
eyes on the operating mechanism.
2.

NOTE!
The lifting slings must not be placed
around the cabinet when lifting.
3.

DANGER!
The operating mechanism weighs 205
kg! Use lifting tackle that is
dimensioned for the weight.
4. Lifting the operating mechanism.

50 2010-02-18 1HSB439954-6en
 6 Installation

6 Installation
6.1 Installation in short steps

General

This section provides a summary of the installation procedure, encompassing the

steps required for installing the complete circuit-breaker with the support and
operating mechanism.

Illustration

1 Circuit-breaker pole
2 Breaking unit
3 Post insulator
4 Operating mechanism BLK222 Slave
5 Mechanism
6 Support
7 Operating mechanism BLK222 Master
8 Cable rack

1HSB439954-6en 2010-02-18 51
6 Installation

Summary of the installation

The instructions below give a brief summary of the installation. Follow the link for
each step for more detailed information on how the actions in question are executed.
Action Read more in section:
1. Check the delivery. Delivery inspection on page 45.
2. Check that all the necessary tools are Requisite equipment, installation on page 41.
on hand.
3. Check that the foundations meet all the Foundations on page 53.
requirements for the installation.
4. Assemble the support Assembly of support on page 54.
5. Fit the earthquake damper (option). Installation of earthquake damper on the
foundation (option) on page 56.
6. Mount the support on the foundation. Assembly of support on the foundation on page
60.
7. Fit all circuit-breakers to their supports. Assembly of circuit-breaker pole on page 62.
8. Assemble the corona rings (option) Installation of corona rings on the post insulator
(option) on page 64.
9. Fit the operating mechanism. Assembly of operating mechanism on page 66.
10. Fit the cable rack. Assembly of the cable rack on page 72.
11. Fit the outer cabling. Assembling the outer cabling on page 74.
12. Fit the gas monitoring system. Assembly of gas monitoring system on page
78.
13. Install all electrical connections: Electrical connections on page 80.
• Connect the operating
mechanism.
• Fit the rails or lines.
• Charge the closing spring
electrically.
14. Pressurize the circuit-breaker poles. Pressurizing of circuit-breaker poles on page
84.
15. Check the screw joints. Inspection of bolted joints on page 93.
16. Fit indicator signs and covers. Assembling the indicator sign and cover on
page 94.
17. Prepare for commissioning. Inspection prior to commissioning on page 95.
• Make a density control.

52 2010-02-18 1HSB439954-6en
 6 Installation

6.2 Foundations

General

The foundation for the circuit-breaker must be flat and horizontal. The figure below
shows the permitted tolerances in mm for the position of the foundation bolts and for
the phase spacing.
Any deviations are to be adjusted using spacers; see section Assembly of support on
the foundation on page 60. The nominal dimensions, as well as the dimensions for
the foundation bolts and nuts are specified in the dimension print that is applicable to
the order.

Tolerances

1 Support
2 Foundation for support
3 Foundation bolt, L>130 mm

1HSB439954-6en 2010-02-18 53
6 Installation

6.3 Assembly of support

Structure

The support is delivered as welded halves together with six cross stays and bolts, nuts
and washers.

1 Support halves
2 Cross stay
3 Bolt M20x60, nut M20, washer 21x37x3

Order of assembly

NOTE!
Ensure you follow the order of assembly. The support must be assembled according
to the instructions; see Assembly instructions on page 55.

Requisite equipment

Equipment Part number Note

Standard tools

54 2010-02-18 1HSB439954-6en
 6 Installation

Assembly instructions

The following instructions describe the assembly of the circuit-breaker support.

Action Note/Illustration
1. Fit the cross stays in the order of
assembly (1-4) shown in the
illustration, with bolts, nuts and
washers.

2. Tighten all bolts finger-tight.

NOTE!
Tightening to the final torque is performed after
the operating mechanism has been fitted.

1HSB439954-6en 2010-02-18 55
6 Installation

6.4 Installation of earthquake damper on the foundation (option)

General

These installation instructions describe the installation of the damper for circuit-
breakers.
The earthquake dampers are used particularly in the areas where there is significant
risk for earthquakes. The earthquake dampers are designed to protect circuit-breakers
and operating mechanisms.
NOTE!
The spring washers in the earthquake damper are factory adjusted and measured. The
inner surface of the damper housing is factory lubricated with grease "K"; the
earthquake damper requires no maintenance during its service life.

Structure

1 Damper housing
2 Spring washers, 55 pcs
3 Set washers, 10 pcs
4 Friction ring
5 Cone
6 Lock ring
7 Guide cone
8 Guide

56 2010-02-18 1HSB439954-6en
 6 Installation

Requisite equipment

Equipment Part number Note

Grease "K" 1263 0011-102
Standard tools
Torque wrench Torque range 79-350 Nm.
Wooden block - about 70 mm high

Assembly

The instructions below describe installation of the damper. The item numbers in the
text correspond to the item numbers in the illustrations in the table.
Action Note
1. Adjust the nuts (1) to the same level
using spacers (2).

• 1: Nut M24, not included

• 2: Spacer, not included
• 3: Adapter plate
• 4: Guide cone, 4 pcs
• 5: Guide, 4 pcs
• 6: Damper element, 4
• 7: Bolt M12x60 (24 pcs), Washer
13x24x2.5 (24 pcs)
• 8: Support
• 9: Bolt M30x90 (4 pcs), Washer
31x56x4 (8 pcs), Nut M30 (4 pcs)
2. Tighten the nut (1).

Torque!
350 Nm

1HSB439954-6en 2010-02-18 57
6 Installation

Action Note
3. Place the adapter plate (3) over the
foundation bolt (1). Use a wooden
block (2) as a support.

4. Fit the guide cone (4) and guide (5) on

the foundation bolt.

5. Check that the guide (5) is turned the

right way.
6. Apply grease "K" to the surface
between the guide cone (4) and the
guide (5).
7. Tighten the guide cone.

Torque!
NOTE!
350 Nm
Check that the foundation bolt is not
higher than the guide cone.

58 2010-02-18 1HSB439954-6en
 6 Installation

Action Note
8. Fit the damper element (6) to the
adapter plate (3) with the bolts (7).

NOTE!
Check that the guide (5) is correctly
positioned in relation to the lower
section of the damper element (6).

9. Tighten the bolts (7) crosswise by hand

to ensure that the damper element is
flat against the adapter plate.
10. Tighten the bolts (7).

Torque!
NOTE!
79 Nm
The correct pre-tension of the spring
washers is automatically set when the
bolts (7) are tightened.
11. Remove the wooden blocks.
12. Fit the support on the adapter plate (3)
and tighten the bolts (9) finger-tight.

NOTE!
Final tightening is conducted after the
operating mechanism has been fitted.

1HSB439954-6en 2010-02-18 59
6 Installation

6.5 Assembly of support on the foundation

General

This section describes how the support is fitted to the foundation.

If an earthquake damper is to be fitted, see Installation of earthquake damper on the
foundation (option) on page 56.

Structure

1 Foundation bolt, L>130 mm

2 Nut
3 Washer
4 Spacer
5 Foundations
6 Support base

NOTE!
Foundation bolt, nuts and spacers are not included in the delivery.

Requisite equipment

Equipment Part number Note

Standard tools -
Torque wrench - Torque 300-350 Nm for M24.
Torque 500-550 Nm for M30.

60 2010-02-18 1HSB439954-6en
 6 Installation

Assembly

The following instructions describe the assembly of the support on the foundation.
The item numbers in brackets refer to the previous figure.
Action Note
1.

DANGER!
The support weighs 86-200 kg! Use
lifting tackle that is dimensioned for the
weight.
2. Check that the supports are vertical.
3. Adjust the supports to the same level
using the nuts (2).
4. Fill the space between the lower nut
and the foundation using spacers.

NOTE!
The space should be as small as
possible.
5. Tighten the lower nut (2) to the spacers
(4).

Torque!
M24: tightening torque 300-350 Nm.
M30: tightening torque 500-550 Nm.

1HSB439954-6en 2010-02-18 61
6 Installation

6.6 Assembly of circuit-breaker pole

Structure

The figure below shows the circuit-breaker pole's retaining bolts and nuts.

1 Bolts (M20x70, 4 pcs), nuts (M20, 4 pcs), and washers (21x37x3, 8 pcs)

Requisite equipment

Equipment Part number Note

Torque wrench - Torque range 60-300 Nm.

62 2010-02-18 1HSB439954-6en
 6 Installation

Assembly instructions

The following instructions describe the assembly of the circuit-breaker poles on the
support.
Action Note/Illustration
1. Check that the circuit-breaker pole is See Lifting the circuit-breaker poles on page
tight prior to fitting to the support. 48.
2. Refit the sealing cap.
3. Lift one circuit-breaker pole at a time Lifting the circuit-breaker pole is described in
onto the support and attach them using Lifting the circuit-breaker poles on page 48.
screws, washers and nuts (1). Tighten
finger tight.

NOTE!
Final tightening is performed when the
operating mechanism have been fitted.

1HSB439954-6en 2010-02-18 63
6 Installation

6.7 Installation of corona rings on the post insulator (option)

General

Circuit-breakers with composite insulators can be fitted with corona rings.

Structure

1 Corona ring
2 Bracket
3 Bolt M10x20 (4 pcs), Washer 10.5x20x2 (4 pcs)
4 Bolt M10x25 (4 pcs), Washer 10.5x20x2 (4 pcs), Nut M10 (4 pcs)

Requisite equipment

Equipment Part number Note

Standard tools
Torque wrench Torque range 45 Nm

64 2010-02-18 1HSB439954-6en
 6 Installation

Assembly

The instructions below describe installation of the corona rings on the post insulator.
The item numbers in the text correspond to the item numbers in the previous
illustration.
Action Note
1. Fit the corona ring (1).
2. Tighten the bolts.

Torque!
45 Nm

1HSB439954-6en 2010-02-18 65
6 Installation

6.8 Assembly of operating mechanism

General

The operating mechanism is adjusted on delivery, i.e. the closing spring is correctly
set to the corresponding circuit-breaker pole.

Structure

1 Bolt M12x40 (4 pcs) nut M12 (4 pcs) washer 13x24x2.5 (8 pcs)

2 Spring washer 13x29x3 (4 pcs)

66 2010-02-18 1HSB439954-6en
 6 Installation

Safety

WARNING!
The operating mechanism may not be closed, operated nor have charged closing
springs until all tasks related to installation and adjustment of the circuit-breaker
have been completed.

Requisite equipment

Equipment Part number Note

Standard tools
Torque wrench Torque 79 Nm

Assembly instructions

The following instructions describe the assembly of the operating mechanism.

Action Note/Illustration
1. Remove all the covers (1) on the poles
and indicator signs (2).

2. Lifting the operating mechanism. Described in section Lifting the operating

mechanism on page 50
3. Position the operating mechanism and
secure using bolts, washers and nuts
(1, 2). Tighten finger tight.
4. Finally tighten the screw joints using a
torque wrench.
See illustration in Structure on page
66.
Torque!
Tightening torque item 1. = 79 Nm.

1HSB439954-6en 2010-02-18 67
6 Installation

6.9 Final assembly of the circuit-breaker pole.

General

This section describes the final assembly of the circuit breaker poles, and is to be
carried out when the operating mechanism is fitted.

Structure

Requisite equipment

Equipment Part number Note

Standard tools -
Torque wrench -

68 2010-02-18 1HSB439954-6en
 6 Installation

Instructions

Action Note
1. Tighten the support to the foundation See section Assembly of support on page 54.
using the upper nuts.

Torque!
300-350 Nm (M24).
500-550 Nm (M30).
2. Tighten the cross stays on the support.

Torque!
420 Nm.
3. Tighten the mechanism housing to the
support.

Torque!
420 Nm.

1HSB439954-6en 2010-02-18 69
6 Installation

6.10 Fitting of rod system

6.10.1 Fitting the pull-rod between the operating mechanism and mechanism
housing

General

Each pole has a basic setting on delivery and its open position is preset. Adjustments
are made as shown in this section.

Structure

1 Mechanism housing
2 Pull-rod from operating mechanism
3 Operating lever (operating mechanism)
4 Linkage joint (circuit-breaker pole)
5 Pull-rod (turnbuckle screw)
6 Spring washers
7 Control hole in lever
8 Lock nut
9 Control hole, pull-rod
10 Control hole, linkage joint

70 2010-02-18 1HSB439954-6en
 6 Installation

Requisite equipment

Equipment ABB part no. Note

Pin with Ø 6 mm - Used to check the position as per instructions.

Instructions

The instructions below describe how the pull-rod between the operating mechanism
and each circuit-breaker pole are fitted. Each pole has a basic setting on delivery and
its open position is preset. Adjustments are made as per
The item numbers in brackets in the instructions refer to the previous illustration.
Action Note
1. Move the pull-rod by hand from the
operating mechanism (2) to the side to
ensure that the turnbuckle screw (5)
can be placed between the linkage NOTE!
joint (4) and the pull-rod from the The operating mechanism's pull-rod must not
operating mechanism. be pushed in too far causing it to be locked in
its inner closed position.
2. Thread in the turnbuckle screw (5) at
the same time in the operating
mechanism's pull-rod (2) (left thread)
and the pole's linkage joint (4) (right NOTE!
thread). Remember to fit two spring washers (6) under
each lock nut (8).
3. Turn the pull-rod (5) to reduce its
length, at the same time as the
operating lever (3) moves to its open
position. NOTE!
The turnbuckle screw (5) has the correct length
when the operating lever (3) is in its open
position and the control hole (7) is aligned with
the drilled hole in the mechanism housing (1).
4. Check the position of the hole using a
pin with diameter = 6 mm.
Check that the pull-rod (5) is threaded
past the control holes (9 and 10).
5. Tighten the lock nuts.

Torque!
Lock nuts: 300 Nm

1HSB439954-6en 2010-02-18 71
6 Installation

6.11 Assembly of the cable rack

Overview

This section describes the assembly of the cable rack between the poles.

Requisite equipment

Equipment Part number Note

Standard tools
Torque wrench 9,5 Nm

Assembly instructions

The following instructions describe the assembly of the cable rack.

Action Note/Illustration
1. Position the two cable racks (1)
internally in the supports (4) as in the
figure.

1. Cable rack
2. Anchor busbar
3. Locking clamp, nut, washer
4. Support

72 2010-02-18 1HSB439954-6en
 6 Installation

Action Note/Illustration
2. Join the cable racks (1) using the
connection pieces (5).

1. Cable rack
5. Connection piece (2 pcs)
6. Bolt (4 pcs)
3. Tighten the bolts (6)

Torque!
9,5 Nm
4. Adjust the cable rack (1) lengthways
and secure against the supports with
the anchor busbar (2) and locking
clamp (3) as per the figure.
5. Tighten the nuts (3) finger-tight.

1HSB439954-6en 2010-02-18 73
6 Installation

6.12 Assembling the outer cabling

Overview

This section describes the assembly of the outer cabling between the poles.

Illustration

1 Cable rack
2 Outer cables

Requisite equipment

Equipment Part number Note

Standard tools
Torque wrench 22.5 Nm

Assembly instructions

The following instructions describe the assembly of the outer cabling.

Action Note/Illustration
1. Dismantle the bottom plates in the The outer plate on phase A and C. The inner
operating mechanism. plate on phase B.

74 2010-02-18 1HSB439954-6en
 6 Installation

Action Note/Illustration
2. Route the outer cabling labelled "A"
through the support legs on pole A and
place the cabling (2) along the cable
rack (1) towards pole B as per the
figure.

2. Outer cables
3. Contacts, pole A
4. Bottom plate, pole A
5. Contacts, pole C
6. Bottom plate, pole C
7. Contacts, pole B
8. Bottom plate, pole B
3. Secure the bottom plate with the outer
cabling on pole A.
4. Tighten the bolts on the bottom plate.

Torque!
22.5 Nm

1HSB439954-6en 2010-02-18 75
6 Installation

Action Note/Illustration
5. Connect the multi-pole contacts on the
cabling to respective terminals in the
operating mechanism on pole A.

1. Terminal XC11
2. Terminal XC12
3. Terminal XC13 (option)
4. Blind plug
Make sure that the catches on the orange
contacts lock in the terminals. The contacts
have blind pins and only fit the applicable
terminals.
6. Route the outer cabling labelled "C"
through the support leg on pole B.
7. Connect the cabling for pole C as for
pole A as per points 3-5.
8. Route the outer cabling labelled "B"
through the bottom on operating
mechanism B.
9. Secure the bottom plate with the outer
cabling on pole B.
10. Tighten the bolts on the bottom plate.

Torque!
22.5 Nm

76 2010-02-18 1HSB439954-6en
 6 Installation

Action Note/Illustration
11. Connect the multi-pole contacts on the
cabling to respective terminals in the
operating mechanism on pole B.

1. Terminal XC21
2. Terminal XC22
3. Terminal XC23 (option)
4. Blind plug
Make sure that the catches on the orange
contacts lock in the terminals. The contacts
have blind pins and only fit the applicable
terminals.
12. Ensure that the cabling in the
operating mechanism for pole B does
not impede the crank function.
13. Secure the outer cabling (2) using
equally spaced cable ties against the
cable rack (1).

1HSB439954-6en 2010-02-18 77
6 Installation

6.13 Assembly of gas monitoring system

Structure

1 Flange
2 Cable union screw
3 Sealing ring
4 Pipe clamp (4 pcs)
5 Bolt M5x20 (4 pcs), nut M5 (4 pcs), washer 5.3x10x1 (8 pcs)

Safety

NOTE!
When fitting the gas monitoring system, the greatest possible cleanliness must be
observed.

Requisite equipment

Equipment Part number Note

Standard tools
23-mm drill bit

78 2010-02-18 1HSB439954-6en
 6 Installation

Assembly

The item numbers in the text below correspond to the item numbers in the illustration
Structure on page 78.
Action Note
1. Drill three 23 mm holes in the flange (1)
in the bottom of the operating
mechanism and fit the cable glands (2)
in the holes using grommets (3) and
nuts.
2. Push the cables through the cable
union screws in the operating
mechanism and connect them to the
terminal blocks specified in the
applicable diagram for the device.
3. Tighten the cable union screws (3) for
attaching the cable.
4. Secure the cables to the support leg
using pipe clamps (4), and bolts, nuts
and washers (5).
NOTE!
The cable end to the density monitor is to be
sufficiently long to ensure the density monitor
can be removed from the non-return valve
without having to disconnect the cable.

1HSB439954-6en 2010-02-18 79
6 Installation

6.14 Electrical connections

6.14.1 Connecting the circuit-breaker's operating mechanism

General

This section describes the connection of the operating mechanism.

Connection

Action Note/Illustration
1. Run the operating and signal cables
through at the bottom of the cabinet.
2. Fit the flange with an appropriate seal
for the cable in question.
3. Connect the cables to the coupling
terminals as per the applicable
connection diagram.
NOTE!
The terminals are of the plug-in type for
multicore cable and are in through-wiring or
disconnectable designs. The through-wiring
design is for the connection of max 4 mm2
conductor area and the disconnectable design
for the connection of max. 6 mm2 conductor
area. The disconnectable design is intended for
motor, AC- and supply circuits.
4. Connect the earth cable to the earth
terminal (1) on the side of the cabinet.

80 2010-02-18 1HSB439954-6en
 6 Installation

6.14.2 Fitting the rails or lines.

General

This section describes the fitting of the rails and lines.

Safety

WARNING!
Work may not be performed on pressurized circuit-breakers.
NOTE!
Bimetal washers are positioned so that their aluminum sides face the aluminum
surfaces. The copper sides are turned towards the copper- or silver-plated surfaces.
NOTE!
Contact paste may only be used on fixed joints. It must not be used inside the
breaking units.

Remember:

High voltage lines, which consist of aluminum rails or aluminum attachments for
lines, can be connected directly to the breaking units' adapter plates, which are made
of aluminum, following treatment with contact paste.
However, if copper rails or copper attachments are used for lines, grease must be used
and a bimetal washer fitted to the joint. Bimetal washers can be supplied from ABB
on request.
Connect all supports to the existing grounded net

Requisite equipment

Equipment Part number Note

Cleaning cloth or emery-cloth - e.g. Scotch Brite no 7447
Grease "SV" 1171 4016-610 See section Types of grease on
page 37 for details.

Treatment with grease

Action Note
1. Clean the contact surfaces of grease
or old paste.
2. Polish the surfaces with a cleaning
cloth, e.g. Scotch Brite no. 7447 or
using an emery cloth.
3. Apply grease to the aluminum and
copper surfaces immediately after
polishing.
4. Assemble the joint
5. Wipe off any unnecessary grease.

1HSB439954-6en 2010-02-18 81
6 Installation

6.14.3 Charging of closing spring electrically

General

This section describes how the closing spring is charged electrically.

Structure

1 Motor protection breaker

2 Motor
3 Spring drum
4 Limit switch
5 Contactor (on reverse side of plate)

Safety

CAUTION!
The contactor must not manually as this would cause the limit switch to malfunction,
consequently causing mechanical damage to the operating mechanism.

Instructions

The item numbers in the text correspond to the item numbers in the illustration above.
Action Note
1. Close the motor protection breaker (1)
so that the motor (2) starts and runs
the spring drum (3) to the charged
position.
2. The limit switch (4) trips the contactor
(5) and thereby the motor circuit.

82 2010-02-18 1HSB439954-6en
 6 Installation

6.14.4 Spring indicator

General

The spring indicator shows the different positions for charging the closing spring.
WARNING!
Do not operate the operating mechanism without a load! The operating
mechanism may not be switched on, operated or have a charged open and/or closing
spring before all installation and adjustment of the circuit-breaker is complete.

Operating mechanism

1 Indicator sign
2 Indicator pin
3 Min. position = The closing spring is fully discharged. NOTE! The trip spring is
charged if the circuit-breaker is closed.
4 Intermediate position (Yellow field) = The driver is in contact with the closing latch
device. The closing spring has started to charge. NOTE: No work may be performed
on the operating mechanism. The spring is to be considered as charged.
5 Max. position (Green field) = The closing spring is fully charged.

1HSB439954-6en 2010-02-18 83
6 Installation

6.15 Pressurizing of circuit-breaker poles

6.15.1 Preparations

General

The circuit-breaker poles are delivered vacuum processed and filled with SF6 gas to
a pressure of 0.12- 0.13 MPa abs at 20°C.

Safety

WARNING!
When commissioning, the SF6 gas or mixed gas must be topped off to the pressure
specified on the rating plate. Different gas pressures may occur depending on the
different requirements with respect to the lowest ambient temperature.
WARNING!
Any transport damage to the porcelain entails risk to safety when filling the gas. To
avoid personal injury when filling, installation personnel must exercise caution,
staying in a protected and safe area away from the circuit-breaker as there is a risk of
splintering. The gas cylinder is placed at the same location as the filling device.

Preparations

Action Note
1. Connect the cables to the operating
mechanism's connection blocks for
closing and opening operations.
• The cables are run to the
control room or a place
protected from the circuit-
breaker.
2. Connect the cables to a suitable push
button switch.
3. Set the operating mechanism's "Local/
Remote/Disconnected" switch to
"Remote" position.
4. Open the terminal blocks to the density
monitor's cables that are connected
and break the circuit to the interlocking
relays.

84 2010-02-18 1HSB439954-6en
 6 Installation

Gas filling components

The illustration below shows all the component parts in the gas filling equipment.

1 Density monitor (without indicator)

2 Density monitor (with indicator)
3 Gas bottle
4 Valve
5 Nipple with clamp nut
6 Coupling link
7 Plug-in nipple
8 Hose
9 Valve
10 Cross connection
11 Regulator
12 Circuit-breaker gas valve

1HSB439954-6en 2010-02-18 85
6 Installation

6.15.2 Gas filling with SF6-gas

General

This section describes how the circuit-breaker is filled with SF6 gas. For instructions
on filling mixed gas, see page Filling of mixed gas on page 89.

Requisite equipment

Equipment Part number Note

Gas filling equipment 1HSB 445439-A Only used for SF6 gas.
When delivered, the hose included
in the equipment is vacuum
pumped and filled with SF6 gas.
Grease "G" 1171 4014-407 More information in section Types
of grease on page 37.

Filling pressure (SF6 gas)

NOTE!
When reading the pressure gauge, the filling pressure must be corrected depending
on the temperature as per the table below.
Table for filling pressure

86 2010-02-18 1HSB439954-6en
 6 Installation

Gas filling instructions

The instructions below describe filling of SF6 gas.

Action Note
1.

NOTE!
Do not use any sharp tools!
2. Put the gas bottle (3) in a protected
place.
3. Check the filling pressure on the
circuit-breaker's rating plate
4. Fit the regulator (11) to the gas
cylinder (3). Set the correct filling
pressure, temperature compensated,
as specified in table Filling pressure
(SF6 gas) on page 86, on the regulator
(11).
5. Carefully remove the sealing rings
from the density monitor (1, 2),
lubricate liberally using grease "G"
and refit.
6. Connect a density monitor (1, 2)/ Precision pressure gauges are not included in
precision pressure gauge to the the delivery.
coupling (6) or cross-connection (10).
7. Open the valve (4) or alternatively
valve (9).
• If the pressure gauge is
connected to the coupling link
(6) the valve (9) must be
closed.
• If the pressure gauge is
connected to the cross
connection (10) the valve (4)
must be closed.
8. Connect the coupling link (6) to the
gas valve (12) on pole C.
9. Connect the gas filled hose (8) to the
coupling link (6).
10. Connect the gas filled hose (8) to the
gas bottle (3) via the regulator (11).

WARNING!
Move away from the circuit-breaker to a
protected place and let the gas flow until the
regulator is shut down.
11. Wait until the gas temperature has
reached the circuit-breaker's
temperature level and then read the
pressure on the density monitor (1, 2).

1HSB439954-6en 2010-02-18 87
6 Installation

Action Note
12. Adjust the pressure where necessary.

NOTE!
When reading the pressure gauge, the filling
pressure must be corrected depending on the
temperature specified in table Filling pressure
(SF6 gas) on page 86.
13. Remove the hose (8) from the
coupling link (6) located on the last
pole.
14. Shut off the tap (4).
15. Remove the coupling link from the
circuit-breaker.
16. Relieve the pressure at the pressure
gauge by opening valve (4) or valve
(9).
17. Remove the density monitor or the
precision pressure gauge from the
coupling link and fit it to the circuit-
breaker.
18. Shut off the tap to the gas bottle when
all poles have been filled.
19. Disconnect the hose from the gas
bottle and relieve the regulator by
pressing in the non return valve.
20. Relieve the regulator's adjustment
pressure by turning the adjuster tap
ensuring the pressure is correct for the
next circuit-breaker to be fitted.
21. When the density monitor (1 ) or (2)
has been properly fitted; tighten the
clamp nut.

Torque!
10 Nm
22. Test the circuit breaker by Close and
Open switching three times from a
protected location.
23. Connect the cables to the density
monitors.
24. Reset the circuits to the blocking
relays.
25. Perform a density control. See section Density control on page 95.

NOTE!
A new or overhauled circuit-breaker should be
checked for density by reading the density
monitor after about 1 month and then as
specified in the maintenance schedule.

88 2010-02-18 1HSB439954-6en
 6 Installation

6.15.3 Filling of mixed gas

General

The circuit-breaker is to be filled with mixed gas (SF6 and N2 or CF4 gas) at low
temperatures in order to avoid condensation of the SF6 gas. See the rating plate if this
is to be done or not.
Follow the information on the rating plate for the gas mixture proportions. Example.
For a circuit-breaker with filling pressure 0.70 MPa abs (+20°C), start by filling with
0.52 x 0.7 = 0.36 MPa abs (+20°C)SF6 gas and then N2 or CF4 gas to 0.70 MPa abs
(+20°C).

Remember:

NOTE!
When filling mixed gas, the SF6 gas must always be filled first.
NOTE!
When reading the precision measuring instrument, the filling pressure must be
corrected depending on the temperature as per the table below.

Filling pressure (mixed gas)

1HSB439954-6en 2010-02-18 89
6 Installation

Requisite equipment

Equipment Part number Note

Gas filling equipment 1HSB445439-B Only used for mixed gas.
When delivered, the hose
included in the equipment is
vacuum pumped and filled with
SF6-gas.

Gas filling

The instructions below describe how the circuit-breaker is filled with mixed gas.
Action Note
1.

NOTE!
Do not use any sharp tools!
2. Put the gas bottle (3) in a protected
place.
3. Check the filling pressure on the
circuit-breaker's rating plate
4. Fit the regulator (11) to the gas bottle.
Set the correct filling pressure on the
regulator, temperature compensated,
as specified in table Filling pressure WARNING!
(mixed gas) on page 89. When filling mixed gas, the SF6 gas must
always be filled first.
5. Connect a precision pressure gauge to Precision pressure gauges are not included in
the coupling link (6) or cross the delivery.
connection (10).
6. Open the valve (4) or alternatively
valve (9).
• If the pressure gauge is
connected to the coupling link
(6) the valve (9) must be
closed.
• If the pressure gauge is
connected to the cross
connection (10) the valve (4)
must be closed.
7. Connect the coupling link (6) to one of
the circuit-breaker poles' gas valves
(12).
8. Connect the gas filled hose (8) to the
coupling link (6).
9. Connect the gas filled hose (8) to the
gas bottle (3) via the regulator (11).

WARNING!
Move away from the circuit-breaker to a
protected place and let the gas flow until the
regulator is shut down.

90 2010-02-18 1HSB439954-6en
 6 Installation

Action Note
10. Wait until the gas temperature has
reached the circuit-breaker's
temperature level and then read the
pressure on the density monitor.
11. Adjust the pressure where necessary.

NOTE!
When reading the pressure gauge, the filling
pressure must be corrected depending on the
temperature specified in table Filling pressure
(mixed gas) on page 89.
12. Close the valve (4) and remove the
coupling link from the filled pole.
13. Connect the coupling link to the next
pole.
14. Open valve (4) again and repeat the
filling of the other two poles as per
items 9 and 10.
15. Remove the hose (8) from the coupling
link (6) located on the last pole filled.
16. Shut off the tap to the pressure gauge.
17. Remove the coupling link from the
circuit-breaker.
18. Relieve the pressure at the pressure
gauge by opening valve (4) or valve
(9).
19. Remove the pressure gauge from the
coupling link.
20. Shut off the tap to the gas bottle.
21. Disconnect the hose from the gas
bottle and relieve the regulator by
pressing in the non return valve.
22. Relieve the regulator's adjustment
pressure by turning the adjuster tap
ensuring the pressure is correct for the
next circuit-breaker to be fitted.
23. Install the gas monitoring system when See section Assembly of gas monitoring
all poles are filled with gas. system on page 78.

NOTE!
The circuit-breaker must not be operated until
the gas monitoring system has been installed!
24. When the density monitor (1 ) or (2)
has been properly fitted; tighten the
clamp nut.

Torque!
Tightening torque 10 Nm

1HSB439954-6en 2010-02-18 91
6 Installation

Action Note
25. Connect the operating mechanism for
remote control, set the switch to
Remote position and test run the
circuit-breaker Close-Open three times
from a protected location.
26. Connect the cables to the density
monitors.
27. Reset the circuits to the blocking
relays.
28. Perform a density control. See Density control on page 95.

NOTE!
A new or overhauled circuit-breaker should be
checked for density by reading the density
monitor after about 1 month and then as
specified in the maintenance schedule.

92 2010-02-18 1HSB439954-6en
 6 Installation

6.16 Inspection of bolted joints

General

Before the installation is commissioned, the following must be inspected.

Inspection
• Check that all bolted joints are tightened to the right torque; see section
Tightening torque on page 40.

1HSB439954-6en 2010-02-18 93
6 Installation

6.17 Assembling the indicator sign and cover

Instructions

Action Note/Illustration
1.

WARNING!
Check that the operating mechanism's
closing spring is fully discharged
before commencing work. If the
closing spring is not discharged,
discharge as specified in section
Release the spring charge on page 31.
2. Fit the indicator signs (2) on each pole
using bolts and washers. Tighten the
bolts.

1. Cover
2. Indicator sign

Torque!
22.5 Nm
3. Fit all covers (1) using bolts and
washers. Tighten the bolts.

Torque!
9,5 Nm

94 2010-02-18 1HSB439954-6en
 6 Installation

6.18 Inspection prior to commissioning

6.18.1 Density control

General

This section describes how you make a density check with a leak detector around the
density monitor's connections (2 pcs per mechanism housing).

Connections

1 Density monitor
2 Connections

Requisite equipment

The following table shows what is needed for a density control.

Equipment Description
Leak spray

1HSB439954-6en 2010-02-18 95
6 Installation

Instructions

Action Note
1. Apply leak spray around the
connections.
2. If the connections are not tight:
• disconnect the connections
• check the O rings and contact
surfaces
• replace the seals where
necessary.
3. Perform a new tightness check.

96 2010-02-18 1HSB439954-6en
 7 Commissioning

7 Commissioning
7.1 Introduction

General

Before the circuit-breaker is put into service, all inspections as detailed in Pre-
commissioning check list on page 98 for installation and commissioning must have
been carried out and the operating values for the installation completed.
Reset all connection circuits as per the applicable circuit diagram and check-tighten
the affected connection blocks.
Put the help tools in their holders in the operating cabinet.

1HSB439954-6en 2010-02-18 97
7 Commissioning

7.2 Pre-commissioning check list

General

Before the circuit-breaker is put into service

• all checks for circuit-breaker poles, operating mechanism and gas filling must
have been conducted as described in this section.
• the check list Check of operating values. on page 99 is completed and filed.

Identification

Date:

Installation:

Serial number (circuit-breaker manufacturing number):

Inspection of circuit-breaker pole

Action Note
1. Check that the circuit-breaker and the
operating mechanism have been
assembled as per the installation
instructions.
2. Check-tighten all screw joints with the See Tightening torque on page 40.
correct tightening torque.

Check of operating mechanism

Action Note
1. Make a visual inspection to check if the
damper has leaked oil into the
operating mechanism.
2. Check tighten the bolts in the
connection blocks that have been
affected by the assembly.
3. Check the functionality of the heating
element.
4. Check that the thermostat, if any, is set Other settings may occur in accordance with
to 10° C. customer specifications.

Check of gas filling

Action Note
1. Check the gas filling and test run as See Gas filling with SF6-gas on page 86 or
per instructions Filling of mixed gas on page 89.

98 2010-02-18 1HSB439954-6en
 7 Commissioning

Check of operating values.

Check the operating values for the circuit-breaker against data applicable to the
circuit-breaker in Operating values on page 44 and note the measured values in the
table below.

(2)
Filling pressure is as specified on the rating plate.
CAUTION!
The circuit-breaker may not be operated Open to Close without an intermediate delay
of 300 ms.

Signing

Inspection conducted by: _________________________________________

If all inspections in this section have been conducted, the circuit-breaker can be put
into service.

1HSB439954-6en 2010-02-18 99
7 Commissioning

100 2010-02-18 1HSB439954-6en

 8 Maintenance

8 Maintenance
8.1 Introduction

General

These maintenance instructions give recommendations for care and guidelines for
maintenance of high-voltage circuit-breakers.

Instructions

The instructions are divided into:

• Inspection intervals
• Instructions for preventive maintenance of circuit-breakers
• Instructions for preventive maintenance of operating mechanisms
The periodic maintenance is to be carried out at specified time intervals or number
of operations.
Equipment is to be overhauled in line with specified criteria such as a certain number
of operations. Overhauls are to be made by authorized service personnel.

1HSB439954-6en 2010-02-18 101

8 Maintenance

8.2 Description of maintenance categories

Maintenance categories

Condi-
Requi
tion of
Action/explanation Interval remen
circuit-
t
breaker
A Ocular inspection 1-2 years a1 a2
B Preventive maintenance b1 b2
• General overhaul of circuit- 15 years or 5 000
breaker and operating mechanism operations
• Heat measurement
C Overhaul of breaking chamber c1 c2
2=20,000
Overhaul of line and transformer circuit ΣnxI
breakers
Overhaul of capacitor bank circuit
breakers, reactor circuit breakers and
filter circuit breakers
• Without point-on-wave control 2,500 operations
• With point-on-wave control 1)
General overhaul After 30 years or d1 c2
10,000 operations 2)

Explanations
1)Maintenance, circuit-breaker pole on page 110 .
2)Specialrequirements for resistance checks for circuit-breakers; executed >100
Close and Open open operations.
Condition of circuit-breaker

The following specifies the condition in which the circuit-breaker should be for the
various maintenance activities.
• a1) Circuit-breaker in operation.
• b1) Closing spring discharged, circuit-breaker open, disconnected and earthed.
If heat measurement is part of the maintenance activity, this should be done
during normal load before the circuit-breaker trips.
• c1) Closing spring discharged, circuit-breaker open, disconnected and earthed.
The circuit-breaker poles/breaking units are dismantled and transported to the
workshop.
• d1) Closing spring discharged, circuit-breaker open, disconnected and earthed.
The entire circuit-breaker with operating mechanism is transported to the
workshop.

102 2010-02-18 1HSB439954-6en

 8 Maintenance

Competence requirements

The following describes the necessary requirements for personnel carrying out
maintenance work.
• a2) substation personnel without special training.
• b2) personnel authorized by ABB to carry out assembly, commissioning and
maintenance work.
• c2) personnel authorized by ABB to carry out assembly, commissioning and
maintenance work. In some cases support may be necessary from ABB.

1HSB439954-6en 2010-02-18 103

8 Maintenance

8.3 Maintenance schedule

General

The following inspection schedule includes important control points, acceptable

tolerances, functional values for certain adjustments and recommended inspection
intervals. In corrosive or polluted air and in climates with high humidity, it may be
necessary to half the inspection interval. The specified inspection intervals are to be
regarded as recommended guidelines that can either be extended or shortened
depending on local conditions.
The significance of the various categories are explained in section Description of
maintenance categories on page 102.

Category A

Maintenance category A takes place at an interval of 1-2 years.

Inspected Action Instructions/Tools
Circuit-breaker Check: This is described in section:
• External cleanliness Cleaning on the outside on page
112 and Gas system and density
• Heating element function monitor on page 11
• Gas pressure No special tools needed.

• Valves and runoff hole

Category B

Maintenance category B is conducted at an interval of 15 years or after 5,000

mechanical close/open operations.
Inspected Action Instructions/Tools
Circuit-breaker Check: This is covered in section:
• External cleanliness Cleaning on the outside on page
112 and Gas system and density
• Gas pressure monitor on page 11
• Valves and runoff hole No special tools needed.

Operating Check: If there is an oil leak, replace the

mechanism whole damper.
• Bolts and nuts
• Heating element function
• Oil leaks from damper
Rating plates Note serial number.
Operation counter Note the number of operations.
SF6 gas Check: Gas-filling equipment.
• Gas level (filling if See Gas filling with SF6-gas on
necessary) page 86.
Dew point meter.
• Dew point, for normal gas
Dew point max. -5°C at specified
pressure in the circuit-
filling pressure and +20°C
breaker.

104 2010-02-18 1HSB439954-6en

 8 Maintenance

Inspected Action Instructions/Tools

Porcelain insulators Check: Wash and dry the insulators.
• Bolts and nuts Rinsing equipment, drying cloths,
torque wrenches.
This is described in Cleaning on
the outside on page 112
Composite Check:
insulators
• Damage to the insulator
Main circuit Check: Resistance values as specified in
section Operating values on page
• Resistance measurement
44.
• Resistance bridge, test Higher values are permitted for
current min. 200 A DC frequent operation with small
currents (≤ 400 A).
Calculation of permitted
resistance:

• R = permitted raised
resistance
• Rn = max. resistance as
per Operating values on
page 44
• In = rated current as per
rating plate
• I = the current that the
maximum resistance is
calculated for
Heat measurement Check: Carried out at full load prior to
disconnection of the circuit-
• The temperature increase
breaker.
in the outer parts of the
breaking unit. The highest permitted
temperature difference between
the phases is 5°C.
Thermal camera.
Consideration must be taken to
the load current during
measurement, both to the larger
variations of the load current 3-4
hours prior to measurement. See
the manual for the thermal
camera.
Mechanism Check:
• Reference hole in outer
lever and mechanism
housing

1HSB439954-6en 2010-02-18 105

8 Maintenance

Inspected Action Instructions/Tools

Function times Check: Measuring with electronic timing.
• Opening time Nominal control voltage
For times, see Operating values
• Closing time on page 44.
• Close-Open time Maximum time deviation between
the phases, 4 ms at closing and 3
• Deviations between ms at opening.
phases
• Auxiliary switch
• Travel curve
• Contact damping
Availability Check: Rod system:
• Rod system Check of tightening torque on nuts
in the rod system.
• Control safety Control safety:
• Anti-pumping relay Measuring of minimal control
voltage.
Closing coil: < 85% IEC (<72%
ANSI) of nominal value Tripping
coil: < 70% IEC (<56% ANSI) of
nominal value Variable DC-
voltage unit.
Anti-pumping relay:
With the circuit-breaker in Open
position and the operating
mechanism charged, a
simultaneous Close and Open
operation is produced (Close
button pressed in).
The circuit-breaker carries out a
Close/Open operation and must
not Close when the operating
mechanism is charged.
The anti-pump function must be
activated as long as the close
impulse lasts. The lowest control
voltage is to be measured for the
relay. (85 % of nominal)
Motor current Check: The motor current must be
measured towards the end of the
• Motor current
charging process.
The maximum permitted motor
current is 110 % of the
measurement values received
during routine tests.
The permitted variation in charge
time is 30 % of the measurement
values received during routine
tests.
The motor must be able to charge
the springs at a minimum of 85 %
of nominal voltage (as per IEC).
See Inspection of drive unit on
page 117.

106 2010-02-18 1HSB439954-6en

 8 Maintenance

Inspected Action Instructions/Tools

Latch device Visual inspection of settings For setting the gap in the latch
device, see Inspection of latch
devices on page 119.
Surfaces on shafts and interlocks
are lubricated using Grease "L".
See section Types of grease on
page 37.
Coils Check: The coil resistance and current is
allowed to vary ±10% of the
• Coil resistance and
measurement value obtained
current
during routine tests.
Limit switch Function control In the final phase of the charging
process of the spring, the closing
circuit must be closed before
cutting the motor current.
See Check of limit switch and
auxiliary contact on page 122.
Heating element Check: Check the signal for voltage drop,
if applicable.
• Resistance measurement
See Inspection of heating element
on page 116.
Central control Check: Small cabinet:
cabinet (if
• Resistance measurement 48 W, 110 V R= 330 ohm ±10%
applicable) 48 W, 220 V R= 1000 ohm ±10%
Medium-sized or large cabinet:
140 W, 110 V R= 86 ohm ±10%
140 W, 220 V R=346 ohm ±10%
Thermostat (if Check: Check that the thermostat is
applicable) adjusted to comply with the set
• Adjusted value
value.
See Pre-commissioning check list
on page 98.
Terminal blocks Check: Check that bolts and clamps are
properly tightened.
• Bolts and clamps
Motor protection Check: Check the signal for voltage drop,
breaker if any.
• Signal for voltage drop
Seals/SF6 gas Check: Check the density monitors as
regards pressure indicator and
• Density monitoring
signal/break contacts.

NOTE!
The test must take place in normal
air conditions, +20°C and
101.3kPa (1013 mbar).
Remove the density monitor from
the circuit-breaker to check the
function.
Minimum permitted voltage
when checking: 30 V.

1HSB439954-6en 2010-02-18 107

8 Maintenance

Inspected Action Instructions/Tools

Blocking relays Check:
• Relays The relays must break when a
density monitor is removed from a
circuit-breaker pole, pressurized
at filling pressure.

NOTE!
May only be carried out when the
circuit-breaker is out of service.
Corrosion Check: External ocular inspection.
• Operating mechanism Make a special check of the
protected components in the
unheated areas, pull-rod system,
forks and springs.
Treat with anti-rust agent where
necessary.
See Cleaning, lubrication and rust
protection of operating
mechanism on page 115.
Lubrication Check: Check and lubricate the latches
using grease "L".
• Latches
Check and lubricate the worm
• Worm gear housing gear housing using grease "M".
See Cleaning, lubrication and rust
protection of operating
mechanism on page 115.
Tightening torque Check: Check the tightening torque on all
screw joints.
• All screw joints
See Tightening torque on page
40.
Operation Check: Operation tests in combination (if
possible) with operating time
• Operation
measurement (incl. open/close
• Operating time operation time).
measurement

108 2010-02-18 1HSB439954-6en

 8 Maintenance

Category C

Inspected Interval Instructions/Tools

Overhaul of breaking unit: Instructions:
- Line and transformer circuit- Σn x I 1.9
= 20,000 Evacuate the gas, dismantle the
breaker circuit-breaker poles and transport
to a clean workshop. Dismantle the
breaking chamber insulator, fit a
- Capacitor, reactor and filter new contact set and new PTFE
circuit-breaker components.
• Without point-on-wave 2,500 operations. Equipment:
control Standard equipment, tight fitting
• With point-on-wave 1) face mask for dust protection, long-
control sleeved overalls, protective gloves
of plastic or rubber.
See Overhaul of breaking unit on
page 146.
All types of maintenance During diagnostic See Overhaul of breaking unit on
testing with non- page 146.
conformities.
Overhaul of complete circuit- 30 years or 10,000 Dismantling of circuit-breaker pole
breaker and operating mechanical Close/ and mechanism. Assembly of new
mechanism Open operations contact set. Replacement of other
worn components.
If the circuit-breaker and the
operating mechanism are being
overhauled for a further 2,000
operations, all wear parts must be
replaced.
If the circuit-breaker and the
operating mechanism are
overhauled for a 10,000 operations,
the entire circuit-breaker is to be
reconditioned.
Protection against crevice products
as per standard equipment above.
Instructions:
See chapter Overhaul on page 131.
For operating mechanism, with
instructions and guidance from
ABB.
Capacitor (if fitted) 30 years or 10,000 Check the values for:
mechanical Close/ C = CN +5%, -0%
Open operations PD < 5 pC
Tan d < 0.2%

1)
See Maintenance, circuit-breaker pole on page 110.

1HSB439954-6en 2010-02-18 109

8 Maintenance

8.4 Maintenance, circuit-breaker pole

8.4.1 The service life of the circuit-breaker

General

Assuming that the recommended inspection intervals and actions have been
observed, the circuit-breaker will have a service life greater than 30 years or 10,000
mechanical operations.

Maintenance points

The following points ensure a long service life:

Maintenance points
1 Burn-off of the arcing contacts is small.
2 Each breaking unit is equipped with a desiccant equivalent to at least the service life of
the circuit-breaker.
3 Bearings in the gas space are maintenance-free.
4 The seals are designed with a double sealing ring.

Opening the breaking unit

In general there are only two reasons for opening the breaking units:
Reasons
1 If the number of short-circuits x short-circuit current (kA) approaches the curve, see
figureNo of operations on page 111.
2 If the number of operations at the line, reactor or capacitor connection, as well as the
switching of load current1) has reached the number under the heading "Interval" in
Description of maintenance categories on page 102.

1) The load currents from normal Close and Open operations are not calculated in the
formula. These are only calculated when counting the total number of mechanical
Close and Open operations.
Another reason for opening the breaking units is limited to mechanical faults/faulty
adjustment of the drive system, that could damage the components inside the
breaking units.
NOTE!
Opening the breaking unit calls for special instructions and may only be carried out
by qualified and authorized personnel.

Calculations

The graph that shows the restriction to the number of permitted short circuits can be
given roughly as:
Formula Explanation
Σn x I2 = 20 000 n = number of short circuits
I = short-circuit current kA (RMS)

In the formula, all levels of short-circuit current are included. E.g.

10x302+20x202+20x102 = 19,000.

110 2010-02-18 1HSB439954-6en

 8 Maintenance

8.4.2 The service life of the arcing contacts in the event of short circuit breaking

General

The diagram shows the number of breaks as a function of the breaking current that
the contacts in a circuit breaker can undergo before burn-off is so great that they must
be replaced.

No of operations

n No of operations
kA Short-circuit current

1HSB439954-6en 2010-02-18 111

8 Maintenance

8.4.3 Cleaning and lubrication of circuit-breakers

Cleaning on the outside

The circuit-breaker's porcelain insulators are to be cleaned of salt and dirt deposits in
connection with cleaning of other insulators in the substation. The time interval for
this cleaning depends on local conditions, i.e. the degree of air pollution.
Wash and dry the insulators using rinsing equipment and drying cloths.
WARNING!
Mechanical damage to the insulator may cause it to explode with the subsequent risk
of splintering. Work on the circuit-breaker when there is a risk for mechanical
damage to the insulators is to be executed at reduced gas pressure, 0.125 MPa (abs).
NOTE!
All LTB E circuit-breakers with porcelain insulators are completely waterproof, i.e.
the circuit-breakers in use can be cleaned using water without any risk for moisture
penetrating and damaging important parts.
Composite insulators do not normally require cleaning. Solvents or water rinsing
with high pressure could damage the silicone surface on the insulator.
NOTE!
Composite insulators must NOT be cleaned.

Cleaning the mechanism housing

Clean the mechanism housing where necessary through vacuuming. The time
interval for this cleaning depends on local conditions, i.e. the degree of air pollution.

Lubricant

Only use lubricants recommended in section Types of grease on page 37. This is
particularly important at temperatures below -25°C.

Lubrication of circuit-breakers

The circuit-breaker bearings are lubricated with grease on delivery and do not
normally need to be lubricated other than for larger overhauls.
See Treatment of sealing surfaces and seals on page 157.

Rust protection

The closing springs are surface treated through manganese phosphating agent and
anti-rust protected by being dipped in oil. The trip springs are anti-rust protected with
two-component paint.
See Rust protection on page 129.

112 2010-02-18 1HSB439954-6en

 8 Maintenance

8.5 Maintenance, operating mechanism and link system

8.5.1 Preparatory measures and overview of the operating mechanism

General

This section describes the actions that must/can be made prior to commencing
maintenance work.
WARNING!
Do not operate the operating mechanism without a load. Operation must not be
conducted until the device has been connected and adjusted as appropriate for the
associated pressurized circuit-breaker.

Structure

The components in the operating mechanism are integrated into a cabinet that also
contains an operating panel with control equipment.

1 Drive unit
2 Mechanism
3 Operating panel
4 Closing spring
5 Heating element

1HSB439954-6en 2010-02-18 113

8 Maintenance

Control panel

1 Operating panel
2 Control switch, Close/Open (S1)
3 Pole selector, 3-pole / Pole A / Pole B / Pole C (S3)
4 Spring indicator
5 Motor protection breaker
6 Switch, Local/Remote

Before commencing maintenance the following must be done:

Action Note
1. Move the circuit-breaker to open
position.
2. Cut the motor current using the motor
protection breaker.
3. Perform a close and open operation to
ensure that the operating mechanism
spring discharges.
4. Cut the control voltage and where
necessary the heater voltage as well.
5. Disconnect and earth.

To facilitate maintenance the following can be done:

Action Note
1. Remove the top of the operating
cabinet.
2. Open the control panel.

114 2010-02-18 1HSB439954-6en

 8 Maintenance

8.5.2 Cleaning, lubrication and rust protection of operating mechanism

Safety

WARNING!
Work on the operating mechanism with the circuit-breaker in closed position and
charged closing spring always represents a risk.
It is therefore important to observe the safety instructions before commencing work.
See Hazardous working situations on page 28.

Lubricant

The table below shows the greases and oils that are needed for this maintenance. For
suppliers and trade names of oils and greases, see sections Oil types on page 35 and
Types of grease on page 37.
Lubricant Spare part number Note
Grease "G" 5316 381-A

Cleaning

Clean the operating mechanism and mechanism housing where necessary through
vacuuming. The time interval for this cleaning depends on local conditions, i.e. the
degree of air pollution.
Check that the filters in the valves are clean. Replace them if they are overly dirty.

Rust protection

On delivery, the operating mechanism is treated with desiccant as transport

protection against moisture.
Despite good anti-corrosive treatment, minor corrosion may occur, particularly if the
circuit-breaker is installed in a highly corrosive environment.
Rust spots must be polished off and new anti-corrosive agent applied, see Rust
protection on page 129

Spare parts

Spare parts must be stored indoors in an approved storage area1) and in original
packaging. This applies especially to rubber components (seals etc.) that must also
be protected against sunlight to prevent drying out. Gaskets can only be stored for a
limited period, so avoid stocking them. Supports can be stored outdoors.
1)
Approved storage areas: Roof, solid ground, air humidity below 50%, temperature
+20oC (±10oC).

1HSB439954-6en 2010-02-18 115

8 Maintenance

8.5.3 Inspection of heating element

General

is fitted with a heating element to prevent moisture and must always be connected.

Illustration

1 Heating element

Instructions

Action Note
1. Measure the element's resistance In order to ensure the element is intact
2. Measure the power supply to the
element

Data

The values for the heating element are as follows:

When... So...
The ambient temperature is -25° C and R = 691 Ohm ±10 %
the voltage 220 V 70 W
The ambient temperature is -25° C and R = 173 Ohm ±10 %
the voltage 110 V 70 W
The ambient temperature is -55° C and R = 346 Ohm ±10 %
the voltage 220 V 140 W
The ambient temperature is -55° C and R = 86 Ohm ±10 %
the voltage 110 V 140 W

The 70 W heating element is always connected, while the 140 W heating element,
for temperatures below -25, is thermostat controlled.

116 2010-02-18 1HSB439954-6en

 8 Maintenance

8.5.4 Inspection of drive unit

General

This section describes how to check the drive unit .

Drive unit

1 Closing lever
2 Roller
3 Bolt M6x75 (2 pcs), washer 6.4x12x1.5 (2 pcs)
4 Drive unit

Requisite equipment

Equipment Part number Note

Standard tools -
Locking fluid 1269 0014-408 Loctite 270
Torque wrench - Torque 9 Nm

1HSB439954-6en 2010-02-18 117

8 Maintenance

Inspection of drive unit

Action Note
1. Measure the motor current at the end See section Operating values on page 44.
of the charging process.

NOTE!
The motor must be able to charge the springs
at 85% of nominal voltage (IEC).
2. Check that the signal for voltage drop
is working.

NOTE!
If this is not the case, replace the motor
protection breaker.

Overhaul of motor

The item numbers in the text correspond to the item numbers in the previous figure.
Action Note
1. The spring indicator should be green.

DANGER!
Before working on the operating
mechanism:
• the motor current must be cut.
• the circuit-breaker must be
open, disconnected and
earthed.
• the circuit-breaker (control
switch) must be in
DISCONNECTED position
2. Wind anti-clockwise to ensure the
closing lever (1) rests against the roller
(2).
3. Remove the top of the operating
mechanism cabinet.
4. Loosen the bolts (3) and the electrical
connection.
5. Fit a new motor and tighten the bolts
(3).

NOTE!
Tightening torque 9 Nm.
6. Lock the bolts with locking fluid. Use
Loctite 242.
7. Refit the top.

118 2010-02-18 1HSB439954-6en

 8 Maintenance

8.5.5 Inspection of latch devices

General

The operating mechanism has one closing coil and two trip coils fitted as standard,
but can on request be fitted with double closing coils.

Latch device

1 Tripping latch device

2 Closing latch device

Requisite equipment

Equipment Part number Note

Grease "L" 1171 4016-606 See section Types of grease on page 37 for
details.
Multimeter
Feeler gauge

Check of play

Action Note/Illustration
1. Check and clean the shafts in the latch
devices.
2. Lubricate these with grease “L”.
3. Check that the voltage to the coils does See the operating mechanism's delivery
not fall below the min. level. document.

1HSB439954-6en 2010-02-18 119

8 Maintenance

Action Note/Illustration
4. Check the play between the coil arm
and auxiliary latch. The permitted play
is given in the figure to the right.

1. Auxiliary latch
2. Coil arm

NOTE!
If the play is outside the specified dimensions,
the whole latch device must be replaced.

120 2010-02-18 1HSB439954-6en

 8 Maintenance

8.5.6 Replacing a latch device

General

This section describes the replacement of the Opening and Closing latch device

Structure

1 Bolt M8x70

Requisite equipment

Equipment Part number Note

Standard tools
Locking fluid C 1269 0014-408 Loctite 270
Torque wrench Torque 40 Nm

Instructions

Action Note
1. Unscrew the bolts (1).
2. Replace the complete Opening or
Closing latch device
3. Tighten the bolts (1) and lock using
locking fluid.

Torque!
40 Nm

1HSB439954-6en 2010-02-18 121

8 Maintenance

8.5.7 Check of limit switch and auxiliary contact

General

The operating mechanism is fitted with a 9 pole auxiliary contact as standard

consisting of nine opening and nine closing contacts. Three closing and three
opening contacts are for the internal function of the operating mechanism.
The shaft of the auxiliary contact is in direct connection to the operating mechanism's
operating lever and therefore follows the travel of the circuit-breaker contacts.

Limit switch and auxiliary contact

1 Limit switch
2 Auxiliary contact

122 2010-02-18 1HSB439954-6en

 8 Maintenance

Time measurement contact movement

1 Contact movement
2 Arcing contact
3 Closed position
4 Auxiliary contact
5 Open position
6 Contact movement
7 Time
t1 ms Proportional to the contact's opening speed.
t2 ms Time that determines the contact damping.
t3 ms Proportional to the contact's closing speed.

1HSB439954-6en 2010-02-18 123

8 Maintenance

Instructions

Check the contact movement using time measurement after 15 years or 5,000
operations and compare with the times obtained when commissioning. The
comparison can then be used as condition checks for:
• Contact movement
• Contact damping
Action Note
1. Connect the time measurement
equipment across the signal contacts
10, 19, 121 and 122 as per the circuit
diagram.
2. Measure the times t1, t2 and t3
3. Set the "Local/Remote" control switch
to the "Local" position.
4. Connect the timer across the blocks
X1:190 and X1:192.
5. Turn the Close/Open switch to the
OPEN position and then to CLOSED.
6. Measure the times t1, t2 and t3
7. Disconnect the timer.
8. Set the "Local/Remote" control switch
to the "Remote" position.

124 2010-02-18 1HSB439954-6en

 8 Maintenance

8.5.8 Inspection of coupling terminals

Coupling terminals

1 Tripping coil
2 Closing coil
3 Motor
4 Switch, Local/Remote
5 Control switch, Close/Open
6 Electrical counter
7 Limit switch
8 Auxiliary contact
9 Anti-condensation heating
10 Interlock relay
11 Motor contactor
12 Motor protection
13 Miniature circuit breaker, heater
14 Pole selector

1HSB439954-6en 2010-02-18 125

8 Maintenance

Instructions

Action Note
1. Check all bolts and pins shown in the
figure.

126 2010-02-18 1HSB439954-6en

 8 Maintenance

8.5.9 Mechanical charging of closing spring

Safety

WARNING!
Mechanical charging is only to be conducted in emergencies, when there is no motor
power and the circuit-breaker must close. NOTE: Incorrect handling may cause
serious damage to the operating mechanism.

Structure

1 Hatch
2 Bolt M8
3 Crank
4 Crank extension
5 Spring charging indicator
6 Operating mechanism

1HSB439954-6en 2010-02-18 127

8 Maintenance

Instructions

The item numbers in the instructions correspond to the item numbers in the previous
illustration.
Action Note/Illustration
1. Screw off the cover (1).
2. Insert the crank (3) and attach the
crank extension (4).
3. Wind anti-clockwise until the spring
charge indicator (5) shows a charged
spring. Check the spring tension while
you are winding.
4.

NOTE!
Do not charge the spring too much!
5. Perform a Close operation.
6. Leave the operating mechanism with a
discharged spring.
7.

NOTE!
If the Closing spring is charged there is
a risk of overcharging it when the
motor voltage is connected.
8. Refit the protective cover (1) with the
bolts (2).

128 2010-02-18 1HSB439954-6en

 8 Maintenance

8.6 Rust protection

General

Despite good anti-corrosive treatment, minor corrosion may occur, particularly if the
circuit-breaker is installed in a highly corrosive environment.
Many steel mechanical components in the operating mechanism are surface treated
through manganese phosphating agent and protected by being dipped in oil.
Components, such as the chassis, are painted as a means of protection against
corrosion. The closing and trip springs can be protected against corrosion with two-
component paint manganese phosphating.
The support, pole beam and protective tube are hot dip galvanized.

Phosphated surface

Rust spots must be polished off and new anti-corrosion agent applied by brush or
spray. Grease “G” or Tectyl 506 is recommended as a rust inhibitor; see section Types
of grease on page 37.
NOTE!
Tectyl 506 forms a wax-like protective coat after drying and must not be applied to
bearings or interlock mechanisms.

Hot dip galvanized surface

Rust spots must be polished off and new anti-corrosion agent in the form of zinc rich
paint applied by brush. The thickness of the new surface must be at least double the
original zinc thickness.

1HSB439954-6en 2010-02-18 129

8 Maintenance

130 2010-02-18 1HSB439954-6en

 9 Overhaul

9 Overhaul
9.1 Preparations

9.1.1 Preparations for overhaul

General

This section describes the preparations that are necessary prior to an overhaul of the
circuit-breaker.
The overhaul can be carried out according to two methods:
• The recommended method is to remove the entire circuit-breaker pole for
transport to the service workshop where it can be fully dismantled for the
overhaul; see sections .
• The alternative method is to only dismantle the breaking unit; see sections .
The latter method does not require as much work, but may only be applied in clement
weather that resembles indoor working conditions.
WARNING!
The following points must be observed before beginning the overhaul.
• The springs must be discharged; see below under preparations.
• The gas must be evacuated; see Removing of SF6-gas on page 133.
NOTE!
Under no circumstances may the breaking unit be opened during rainy or unstable
weather, or when the humidity is 80% or higher.

Requisite equipment

Equipment Part number Note

Standard tools - Programma
ABB SA10
Torque wrenches
Lifting device and slings
Gas filling equipment
Cleaning equipment
Personal safety equipment
Equipment for recording damping curves for
the operating mechanism
Operating time meter

1HSB439954-6en 2010-02-18 131

9 Overhaul

Preparations

Action Note/Illustration
1. Before dismantling the circuit-breaker,
and during the course of the work, the
instructions in Safety on page 25 must
be read and followed.
2. Check and note the circuit-breaker's
operating values prior to dismantling.
• Deviations from the
recommended values indicate
that something needs to be
checked with extra care for the
overhaul.
3. Put the circuit-breaker in open
position.
4. Cut the control voltage and where
necessary the heater voltage as well.
5. Switch the circuit-breaker Close-Open
so that the springs are discharged.
6. Disconnect and earth.

132 2010-02-18 1HSB439954-6en

 9 Overhaul

9.1.2 Removing of SF6-gas

General

This section describes evacuation of SF6 gas from the circuit-breaker.

Safety

CAUTION!
Work on the circuit-breaker's insulators or live parts, as well as transport and
dismantling of all circuit-breaker poles from the support, may not be executed until
the gas has been evacuated to a maximum pressure of 0.125 MPa abs.
WARNING!
If nitrogen is to be discharged into the open air, in cases where nitrogen is used for
internal cleaning of circuit-breakers, this must be conducted through a dust and
absorption filter. Evacuation is to take place outdoors and at ground level.
WARNING!
Unused SF6 gas is non-toxic, odorless and colorless. It is heavier than air and in the
event of heavy discharges, it easily collects in low-lying areas, such as cable
trenches, tanks, etc.
For large volumes of SF6 gas in such areas, the risk of suffocation could therefore
arise due to lack of oxygen.

Requisite equipment

Equipment Part number Note

Gas treatment equipment
Percentage meter for SF6 gas

1HSB439954-6en 2010-02-18 133

9 Overhaul

Emptying the SF6 gas.

The following describes the gas removing sequence.

Action Note
1. Connect the gas treatment equipment.
2. The SF6 gas is evacuated and the
circuit-breaker is vacuum pumped.
3. The gas is cleaned and compressed to The mixing ratio between the gases can be
ensure it can be reused or destroyed. checked using a percentage meter for SF6 gas.

NOTE!
Mixed gas, SF6 mixed with N2 or CF4,
may not be reused unless the mixing
ratio is controlled.
4. After vacuum pumping, the circuit-
breaker is filled with dry nitrogen at
atmospheric pressure. It is then
vacuum pumped once again.
5. Finally the circuit-breaker is again filled
with dry nitrogen at atmospheric
pressure.
6. The circuit-breaker is now ready for
dismantling

134 2010-02-18 1HSB439954-6en

 9 Overhaul

9.1.3 Cleaning and waste management

General

This section describes cleaning and waste management.

Safety

CAUTION!
Certain crevice products formed in the breaking unit, in combination with moisture,
are corrosive and can irritate the skin, eyes and mucous membranes.
NOTE!
All dust and old absorbent agents are to be collected in a sealed vessel and treated as
chemical waste in accordance with local regulations.
NOTE!
Drying cloths, protective gloves and vacuum cleaner bags are to be thoroughly rinsed
using plenty of water.

Requisite equipment

Equipment Note
Vacuum cleaner With fine dust filter and plastic nozzle.
Drying cloths Of non-lint material.
Sealed storage vessels For waste products and used absorption filters.
Steel brush For contact surfaces of aluminum.
Cleaning cloth E.g. Scotch-Brite, for contact copper surfaces
Industrial spirit 95% (vol) C2H5OH, for cleaning internal surfaces
Thick plastic foil and plastic To prevent moisture penetration and to protect cleaned
bags parts prior to assembly.

Cleaning
• For internal cleaning of the circuit-breaker, protective gloves of plastic or
rubber, long-sleeved overalls and a close-fitting facemask with filtration to
counteract fine dust and acidic gases must be worn.
• The dust (crevice products) formed in the circuit-breaker is to be removed with
a vacuum cleaner fitted with a fine dust filter and wiped off using drying cloths
moistened in industrial spirit.

1HSB439954-6en 2010-02-18 135

9 Overhaul

9.2 Removal of circuit-breaker pole for transport

General

The circuit-breaker pole must be taken out of service before the circuit-breaker is
dismantled (see section Preparations for overhaul on page 131) and the gas emptied
(see section Removing of SF6-gas on page 133).

Preconditions

NOTE!
This type of work may only be executed by personnel trained by ABB.

Requisite equipment

Equipment ABB part no. Note

Standard tools -
Torque wrench - Torque range 9-550 Nm
Lifting device -
Lifting tackle -

Dismantling

The following instructions describe the removal of the circuit-breaker pole for
transport.
Action Note/Illustration
1. Remove the density monitor.

1. Sealing cap
2. Non return valve

NOTE!
The sealing cap (1) must be screwed to the
non-return valve (2).

136 2010-02-18 1HSB439954-6en

 9 Overhaul

Action Note/Illustration
2. Remove the pull-rod between the
operating mechanism and the circuit-
breaker.
3. Put a lifting sling under the breaking
unit's upper flange.

NOTE!
For composite insulators: Place the lifting sling
as close as possible to the end flange and not
on the rubber surface.
4. Now loosen the circuit-breaker pole (5)
at the four bolts (3) in the support and
the four bolts (4) to the protective tube.

3. Bolt M20x70, nut M20, washer 21x37x3

4. Bolt M12x50, nut M12, washer 13x24x2.5
5. Circuit-breaker pole
5. Lift up the circuit-breaker pole and
carefully lay it on a handling trolley.
Block up underneath so that it is
horizontal.

1HSB439954-6en 2010-02-18 137

9 Overhaul

Action Note/Illustration
6. The blocks (6) under the breaking unit
must be of an elastic material, e.g.,
wood or rubber.

6. Blocking

NOTE!
Use the same support as used on delivery.

138 2010-02-18 1HSB439954-6en

 9 Overhaul

9.3 Overhaul of circuit-breaker pole

9.3.1 Removal of the tripping mechanism's pull-rod

General

This section describes the removal of the tripping mechanism pull-rod, after the
circuit-breaker pole has been dismantled and transported to a workshop.

Structure

1 Operating lever
2 Pin
3 Spring pull-rod
4 Spring housing
5 Trip spring
6 Nut
7 Lock nut
8 Protective cover
9 Bolt M10x25, 4 pcs

Requisite equipment

Equipment ABB part no. Note

Standard tools -
Tool 1HSB446381-A

1HSB439954-6en 2010-02-18 139

9 Overhaul

Instructions

The instructions below describe the removal of the tripping mechanism's pull-rod.
The item numbers in the text correspond to the item numbers in the previous
illustration.
Action Note
1. Remove the protective cover (8).
2. Measure and note a reference
dimension, e.g. “Y”, so that the trip
spring (5) has the same charge with
the nut (6) when refitting.
3. Release the spring charge by undoing
the nuts (6, 7).
4. Remove the pin (2).

140 2010-02-18 1HSB439954-6en

 9 Overhaul

9.3.2 Removal of breaking unit

General

This section describes the removal of a breaking unit, after the circuit-breaker pole
has been dismantled and transported to a workshop.
NOTE!
The circuit-breaker pole is fitted vertically on a suitable support, e.g. a circuit-
breaker support or a frame of the floor of the workshop.

Structure

1 Bolts M12x35 (8 pcs), washers 13x28x3 (8 pcs)

2 Post insulator
3 Breaking unit
4 Split pin, 2 pcs
5 Washer, 2 pcs
6 Pin

1HSB439954-6en 2010-02-18 141

9 Overhaul

Requisite equipment

Equipment ABB part no. Note

Standard tools -
Lifting device -
Lifting tackle -

Instructions

The instructions below describe the removal of a breaking unit from a circuit-breaker
pole. The item numbers in the text correspond to the item numbers in the previous
illustration.
Action Note
1. Fit the lifting devices from the top of the
breaking unit to the hoist or overhead
crane.
Stretch the lifting device moderately.
NOTE!
For composite insulators: Place the lifting sling
as close as possible to the end flange and not
on the rubber surface.
2.

DANGER!
The circuit-breaker pole weighs up to
600 kg. Use lifting tackle that is
dimensioned for the weight.
3. Remove the bolts (1) between post
insulator (2) and breaking unit (3).
4. Lift the breaking unit 75-100 mm.
5. Remove the split pin (4) washer (5)
and pin (6).

NOTE!
Ensure that no lock rings or washers fall down
in the post insulator when dismantling.
Cover the opening by e.g. a cloth rag.
6. Lift off the breaking unit completely and
place it vertically on an appropriate
surface, e.g. on two cross bars to
ensure it does not tip over and that the
bottom of the bolts are accessible.

142 2010-02-18 1HSB439954-6en

 9 Overhaul

9.3.3 Removal of post insulator

General

This section describes the removal of post insulators, after the breaking unit has been
removed from a dismantled circuit-breaker pole.
To prevent moisture in the air coming into long-term contact with dust in the post and
insulating pull-rods, the work on removal and cleaning must be planned to ensure it
can be executed quickly and without long breaks.

Structure

1 Post insulator
2 Bolts M16x50 (8 pcs), washers 17x30x3 (8 pcs)
3 Mechanism housing
4 Split pin
5 Washer
6 Pin
7 Insulating pull-rod

1HSB439954-6en 2010-02-18 143

9 Overhaul

Safety

NOTE!
Use personal safety equipment:
• long-sleeved overalls
• protective gloves of plastic or rubber
• tight fitting facemask for dust protection

Requisite equipment

Equipment ABB part no. Note

Standard tools -
Lifting device -
Lifting tackle -
Vacuum cleaner - With fine dust filter and plastic nozzle.
Drying cloths - Of non-lint material.
Sealed storage vessels - For waste products and used absorption
filters.
Steel brush - For contact surfaces of aluminum.
Cleaning cloth (Scotch - For contact surfaces of copper.
Brite)
Industrial spirit - 95% (vol), C2H5OH, for cleaning of internal
surfaces.
Thick plastic foil/plastic - To prevent moisture penetration and to protect
bags cleaned parts prior to assembly.

144 2010-02-18 1HSB439954-6en

 9 Overhaul

Instructions

The instructions below describe the removal of post insulators. The item numbers in
the instruction text refer to the previous illustration.
Action Note
1.

DANGER!
Use lifting tackle dimensioned for the
post insulator.
2. Fit the lifting devices from the top of the
post insulator to the hoist or overhead
crane.
NOTE!
For composite insulators: Place the lifting sling
as close as possible to the end flange and not
on the rubber surface.
3. Remove the post insulator bolts (2)
from the mechanism housing (3).
4. Lift the post insulator straight up until
the insulating pull-rod (7) runs free.
Hold the insulating pull-rod when
lifting. NOTE!
Be careful not to damage the insulating pull-
rod.
5. Remove the insulating pull-rod (7) by
removing the split pin (4) washer (5)
and pin (6).
6. Clean the insulating pull-rod with care
and protect it with plastic foil.
7. Clean the post insulator with care
internally and externally and protect it
with plastic foil.

1HSB439954-6en 2010-02-18 145

9 Overhaul

9.3.4 Overhaul of breaking unit

General

This section describes how the breaking unit is opened in order to allow for
inspection, cleaning and/or replacement of the internal parts.

Structure

1 Bolts M12x35 (8 pcs), washers 13x28x3 (8 pcs)

2 Cover
3 Absorbent container
4 Bolts M12x50 (16 pcs), washers 13x28x3 (16 pcs)
5 Upper adapter plate
6 Upper current path
7 Breaking chamber insulator
8 Lower adapter plate

146 2010-02-18 1HSB439954-6en

 9 Overhaul

Safety

NOTE!
To prevent moisture in the air coming into long-term contact with dust in the
breaking unit and on the inside of the circuit-breaker insulator, the work on removal
and cleaning must be planned to ensure it can be executed quickly and without long
breaks.
NOTE!
Use personal safety equipment:
• long-sleeved overalls
• protective gloves of plastic or rubber
• tight fitting facemask for dust protection

Requisite equipment

ABB part
Equipment Note
no.
Standard tools -
Lifting device -
Lifting tackle -
Vacuum cleaner - With fine dust filter and plastic nozzle.
Drying cloths - Of non-lint material.
Sealed storage vessels - For waste products and used absorption filters.
Steel brush - For contact surfaces of aluminum.
Cleaning cloth (Scotch - For contact surfaces of copper.
Brite)
Industrial spirit - 95% (vol), C2H5OH, for cleaning of internal
surfaces.
Thick plastic foil/plastic - To prevent moisture penetration and to protect
bags cleaned parts prior to assembly.

1HSB439954-6en 2010-02-18 147

9 Overhaul

Instructions

The instructions below describe how the breaking unit opens. The item numbers in
the text correspond to the item numbers in the previous illustration.
Action Note
1.

NOTE!
As and when the breaking unit is
opened, the crevice products that are
present in the breaking unit in powder
form, must be taken care of. Primarily
by using a vacuum cleaner and then
through careful drying of the removed
components.
2. Remove the bolts (1 ) and the cover (2)
and lift out the container for absorbent
(3).
NOTE!
Place the bag with absorbent in a vessel for
chemical waste.
3. Remove the bolts (4) and upper
adapter plate (5) with the upper current
path (6).
4. Remove the bolts (4) and breaking
chamber insulator (7) from the lower
adapter plate (8).
5. Clean the breaking chamber insulator
internally with industrial spirit.

Summary

The breaking unit's main components are now accessible for inspection, cleaning and
replacement of burnt or damaged components.

148 2010-02-18 1HSB439954-6en

 9 Overhaul

9.3.5 Inspection and replacement of contacts and Auto-PufferTM

General

This section describes the replacement of the Auto-PufferTM, and the upper current
path.

Remember:

NOTE!
Unless the circuit-breaker is to be refitted immediately after cleaning of the
component parts, these are to be protected against contamination and moisture by
being packed in plastic bags with desiccant that absorbs moisture.
Insulators are protected preferably by using thick plastic film wrapped over the end
surfaces.
NOTE!
All contact surfaces are to be treated prior to installation; see Treatment of contact
surfaces on page 155.

Requisite equipment

Equipment Part number Note

Standard tools
Torque wrench Torque 22,5 Nm
Vernier calipers
Plastic film
Contact centering tool 1HSB630030-R Not supplied.

1HSB439954-6en 2010-02-18 149

9 Overhaul

Inspection and replacement of upper current path

Action Note/Illustration
1. The entire current path must be
replaced if:
• The upper current path's fixed
arcing contact (4) has burnt off
so that the gap to the reference
surface (5) is more than 6 mm.
• It is severely burnt at the
external diameter.
• If the silver on the current path
contacts is worn so that the
copper shines through.

1. Upper adapter plate

2. BoltM8x16, washer 8.4x16x1.6
3. Upper current path
4. Arcing contact
5. Reference surface
2. Loosen the bolts (2) and remove the
upper current path (3) from the upper
adapter plate (1).
3. Fit the new upper current path. Tighten Treat contacts; see Treatment of contact
the bolts (2). surfaces on page 155.

Torque!
22.5 Nm

150 2010-02-18 1HSB439954-6en

 9 Overhaul

Inspection of Auto-PufferTM

Action Note/Illustration
1. For contact springs upwards from
position a to b.

1. Nozzle
2. Puffer pull-rod
3. Auto-PufferTM cylinder
4. Bolts M8x16 (8) Washers 8.4x16x1.6
(8)
5. Contact surface
6. Contact surface
2. Lift off the puffer and check that there
is no wear to the pull-rod slide
surfaces.
3. Check that the nozzle does not have
any punctures.
4. Check that the puffer cylinder's contact
position does not have burnt or worn
surfaces making the copper visible.
5. Replace the whole autopuffer if there
are burnt or worn surfaces.

1HSB439954-6en 2010-02-18 151

9 Overhaul

Inspection and replacement of lower current path

Action Note/Illustration
1. Check that the following components
are not worn.
• sealing ring (5)
• Teflon strap (4)
• Guide bushing (6)

1. Adapter plate
2. Bolt M8x20, strap, washer
3. Lower current path
4. Teflon strap
5. Sealing ring
6. Guide bushing
7. Valve washer
2. Check that the valve washer (7) is flat
and seals.
3. Check that the silver on the lower If there is wear, the whole lower current path
current path contacts is not worn so and flange must be replaced.
that the copper shines through.

152 2010-02-18 1HSB439954-6en

 9 Overhaul

9.3.6 Overhaul of mechanism

General

This section describes overhaul of the mechanism

Structure

1 Mechanism housing
2 Operating shaft
3 Operating lever
4 Ball bearings
5 Lock ring
6 Bushing
7 X-ring 69.2 x 5.7
8 O-ring 89.1x5.7
9 Ball bearings
10 Washer

1HSB439954-6en 2010-02-18 153

9 Overhaul

Remember:

NOTE!
Clean the mechanism housing through vacuuming and drying. Check for corrosion,
the bearings and replace all sealing rings.
Apply anti-rusting agent to untreated or manganese phosphated steel outside the gas
space using Valvoline Tectyl.

Requisite equipment

Equipment Part number Note

Grease "S" 1171 4014-406 Detailed information is specified in section Types
of grease on page 37.
Grease "G" 1171 4014-407 Detailed information is specified in section Types
of grease on page 37.
Tectyl 1241 0011-108 Valvoline Tectyl
Torque wrench Torque range 45 Nm

Instructions

The item numbers in the instruction below correspond to the item numbers in the
previous illustration above.
Action Note
1. Remove the operating lever (3) and
the lock ring (5).

NOTE!
The operating shaft (2) is outside the gas space
stored in a large ball bearing (4) that is
accessible for inspection and lubrication if the
operating lever and lock ring are removed.
2. Pull out the operating lever (2) from the
mechanism housing (1) and remove
the ball bearing (4) from the shaft.
3. Lubricate the ball bearing (4) using
grease “G”.
4. Remove the bushing (6) holding the
sealing rings in place, using two bolts
(M5) that are threaded in the holes in
the end area of the bushing.
5. Replace the sealing rings (7, 8) in the
bushing behind the ball bearing and
lubricate with grease "S".
6. Check that the ball bearing (9) rotates
easily.

154 2010-02-18 1HSB439954-6en

 9 Overhaul

9.4 Assembling the circuit-breaker pole following overhaul

9.4.1 Treatment of contact surfaces

General

Before the breaking unit is refitted, the contact surfaces are to be treated as follows.

Requisite equipment

Equipment Part number Note

Grease "N" 1171 4016-607 See section Types of grease on page
37 for more information on the grease.
Grease "P" 1171 5011-102 See section Types of grease on page
37 for more information on the grease.
Cleaning cloth, e.g. Scotch
Brite
Drying cloths
Solvent (industrial spirit)

Fixed contact surfaces

Surfaces Treatment Note

Silver plated Silver plated contact surfaces
are cleaned where necessary
with soft drying cloths and
solvent (industrial spirit). NOTE!
Polishing with cleaning cloth
(Scotch Brite) or grinding may not
occur.
Copper surfaces Copper surfaces must be clean
and free from oxides. Where
necessary, clean with a drying
cloth and solvent (industrial NOTE!
spirit) or with cleaning cloth After cleaning with a cleaning
(Scotch Brite). cloth (Scotch Brite) the surface
must always be cleaned of loose
particles with industrial spirit.
Aluminum surfaces The aluminum contact surface is
brushed clean using a cleaning
cloth (Scotch Brite). Clean the
surface carefully immediately NOTE!
thereafter to remove particles Lubrication should be done within
with a dry, clean drying cloth. five minutes after cleaning and the
Then lubricate the surface with a joint fitted within 15 minutes.
thin layer of Vaseline (grease
"P").

1HSB439954-6en 2010-02-18 155

9 Overhaul

Moving contact surfaces

Surfaces Treatment Note

Silver plated Silver plated contact surfaces
are cleaned where necessary
with soft drying cloths and
solvent (industrial spirit). NOTE!
Polishing with cleaning cloth
(Scotch Brite) or grinding may not
occur.
Non-silver plated Non-silver plated moving
contact surfaces are cleaned as
if they were silver plated, but
even using a cleaning cloth NOTE!
(Scotch Brite). After cleaning with a cleaning
cloth (Scotch Brite) the surface
must always be cleaned of loose
particles with industrial spirit.
Lubrication The lubricant grease “N” is
applied as a covering layer, but
very thin on the silver-plated
section of the lower current path, NOTE!
the upper current path and the All surplus grease is to be
puffer cylinder's contact carefully dried.
surfaces.

156 2010-02-18 1HSB439954-6en

 9 Overhaul

9.4.2 Treatment of sealing surfaces and seals

General

In conjunction with installation, all sealing surfaces are to be cleaned, degreased and
checked.

Remember:

NOTE!
The sealing grooves and other sealing surfaces may not have transverse scratches.
Any minor scratches on the sealing surfaces can be removed using a fine cleaning
cloth, such as Scotch-Brite. Polish along the sealing line and never across it.

Requisite equipment

Equipment Part number Note

Industrial spirit
Grease “G” 1171 4014-407 For static seals, see Grease G on
page 37.
Grease "S" 1171 4014-406 For moving seals, e.g. shaft seals,
see Grease "S" on page 38.

Instructions

Action Note
1. Replace all seals with new ones when
reassembling the circuit-breaker.
2. Sparingly lubricate the sealing Surfaces and seals are lubricated to facilitate
surfaces and seals. the seal's fitting to the surface and as corrosion
protection.
Excess grease that could be pressed out of the
flanges inside the gas space may not occur.
3. Coat the flange surfaces outside the
external seals with a thin, fully covering
layer of corrosion protective agent
adapted to suit the pertinent flange
material (grease "G").

1HSB439954-6en 2010-02-18 157

9 Overhaul

9.4.3 Assembly of post insulator

General

This section describes the assembly of post insulators.

DANGER!
Use lifting tackle dimensioned for the post insulator.

Structure

1 Operating lever
2 Link
3 Insulating pull-rod
4 Pin
5 Washer
6 Split pin
7 Post insulator
8 Bolt M16x50 (8 pcs), washer 17x30x3 (8 pcs).
9 Mechanism housing
10 Sealing rings

158 2010-02-18 1HSB439954-6en

 9 Overhaul

Requisite equipment

Equipment Part number Note

Standard tools -
Torque wrench -
Grease "G" 1171 4014-407 More information about grease is
specified in Types of grease on page 37.
Grease "M" 1171 4016-612 More information about grease is
specified in Types of grease on page 37.

Instructions

The item numbers in the instructions’ text refer to the illustration in Structure on page
158.
Action Note/Illustration
1.

NOTE!
Be careful not to damage the insulating
pull-rod.
2. Turn the operating lever (1) and link (2)
over the mechanism housing edge.
3. Place the sealing ring (10) on the Treat the sealing surfaces; see Treatment of
mechanism housing (9) and lift on the sealing surfaces and seals on page 157.
post insulator (7).
4. Tighten the bolts (8).

Torque!
79 Nm

1HSB439954-6en 2010-02-18 159

9 Overhaul

9.4.4 Assembly of breaking unit following overhaul

General

This section describes how the breaking unit is fitted together again after the
overhaul.

Structure

1 Puffer
2 Lower current path
3 Bolt M8x20 (16 pcs), Spring washer 8.4x18x2 (16 pcs), Washer 8.4x20x2 (16 pcs)
4 Contact spring (2 pcs)
5 Lower flange
6 Breaking chamber insulator
7 Bolt M12x60 (16 pcs), Washer 13x28x3 (16 pcs)
8 Upper current path
9 Absorbent container

160 2010-02-18 1HSB439954-6en

 9 Overhaul

Requisite equipment

Equipment Part number Note

Standard tools -
Grease "G" 1171 4014-407 Information on the grease is provided in
Types of grease on page 37.
Grease "N" 1171 4016-607 Information on the grease is provided in
Types of grease on page 37.
Torque wrench - Torque range 22.5-79 Nm

Instructions

The instructions below describe how the breaking unit is fitted together again after
the overhaul.
The item numbers in the text correspond to the item numbers in the illustration
Action Note
1. Treat contacts. See Treatment of contact surfaces on page 155.
2. Fit puffer (1) on the lower current
path (2).

CAUTION!
When the puffer moves down over the Teflon strap,
turn the puffer carefully to ensure the Teflon strap
and the puffer cylinder's fingers are not damaged.
3. Roll down the contact springs (4)
over the contact fingers from
position a to position b.
4. Place the sealing ring on the Treat sealing surfaces and seals.
lower flange (5) and lift on the
See Treatment of sealing surfaces and seals on
breaking chamber insulator (6).
page 157
5. Centre the breaking chamber
insulator and tighten the bolts
(7).

Torque!
60 Nm
6. Fit the upper current path (8) with Treat sealing surfaces and seals.
the sealing ring in the breaking
See Treatment of sealing surfaces and seals on
chamber insulator (6).
page 157
7. Centre the current path's plug
contact in relation to the nozzle
in the puffer (1).
8. Tighten the bolts (7).

Torque!
60 Nm
9. A new absorbent container is See section Assembly of breaking unit on the post
fitted initially in connection with insulator on site on page 172.
the assembly of the unit on the
post insulator.

1HSB439954-6en 2010-02-18 161

9 Overhaul

9.4.5 Assembly of breaking unit on the post insulator

General

This section describes how the breaking unit is refitted to the post insulator.

Structure

1 Puffer pull-rod
2 Post insulator
3 Lower adapter plate
4 Pin
5 Washer
6 Split pin
7 Bolt M12x35, washer 13x28x3
8 Upper adapter plate
9 Cover
10 Absorbent container
11 Insulating pull-rod
12 Sealing ring

162 2010-02-18 1HSB439954-6en

 9 Overhaul

Requisite equipment

Equipment Part number Note

Lifting device -
Lifting tackle -
Standard tools -
Torque wrench - Torque range 45-79 Nm.
Grease "G" 1171 4014-407 See detailed information in sectionTypes of
grease on page 37.

Instructions

The instructions below describe how the breaking unit is refitted to the post insulator.
The item numbers (in brackets) in the text correspond to the item numbers in the
previous illustration
Action Note
1.

DANGER!
Use lifting tackle that is dimensioned
for the weight of the circuit-breaker.
See dimension print for the exact
weights.
2. Suspend the breaking unit in the lifting
device and pull down the puffer pull-
rod (1) to fully extended position
making it accessible for assembly.
3. Clean the sealing surface on the
sealing ring (2) on the post insulator (2)
carefully.
4. Also clean the lower flange and
adapter plate (3) and lubricate
generously with grease "G" to ensure
that the sealing ring is kept in place
during assembly.
5. Place the sealing ring in its slot.
6. Slowly lower the breaking unit so that it
comes into position for fitting the pin
(4), around 75-100 mm above the post
insulator.
7. Connect the puffer's pull-rod (1) to the
insulating pull-rod (11) with the pin (4)
and secure with the washer (5) and
split pin (6). NOTE!
Ensure that no lock rings or washers fall down
in the post insulator when dismantling.
Cover the opening by e.g. a cloth rag.
8. When the pin is fitted, lower the
breaking unit carefully towards the
post insulator and centre.

1HSB439954-6en 2010-02-18 163

9 Overhaul

Action Note
9. Secure the breaking unit with bolts,
washers and nuts (7).

Torque!
60 Nm.
10. Clean the sealing surface on the upper
flange and adapter plate (8) and
lubricate with grease "G".
11. Place the sealing ring in its slot.
12. Open the packaging to new absorbent
and apply this in the container (10).
13. Fit the container (10) and cover (9).

NOTE!
Fit the cover on the container immediately after
fitting the container.
14. Tighten the bolts (7).

Torque!
60 Nm.

164 2010-02-18 1HSB439954-6en

 9 Overhaul

9.4.6 Assembly of tripping mechanism's pull-rod to the operating lever

General

This section describes the fitting of the tripping mechanism's pull-rod in the
operating lever.

Structure

1 Bottom cover
2 Bolt M8x20 (4 pcs)
3 Operating lever
4 Pin
5 Pull-rod
6 Spring housing
7 Trip spring
8 Lock nut

Requisite equipment

Equipment Part number Note

Locking fluid 12690014-410 Loctite 270
Grease "M" 1263 0011-102
Torque wrench Torque range 22,5-45 Nm
Standard tools
Tool 1HSB446381-A

1HSB439954-6en 2010-02-18 165

9 Overhaul

Assembly

The instructions below describe the fitting of the tripping mechanism's pull-rod in the
operating lever.
Action Note
1. Turn the operating lever (3) anti-
clockwise to open position and
connect it to pull-rod (5) with the pin
(4).
2. Lubricate the pin (4) using grease "M"
prior to assembly. Secure the pin (4)
using lock a washer and bolt.
3. Tighten the bolt, secure with Loctite
270.

Torque!
22.5 Nm
4. If the nut (8) has moved out of position. The measurement Y according to Removal of
Adjust until measurement Y has been the tripping mechanism's pull-rod on page 139.
reached.

NOTE!
The lock nut must be replaced when
reassembling.
5. Tighten the lock nut (8).

Torque!
45 Nm
6. Relieve the spring force using the bolt
before removing the tool.
7. Clean the bottom cover's (1) draining
groove and refit the cover.

166 2010-02-18 1HSB439954-6en

 9 Overhaul

9.4.7 Filling the gas before transport

General

Before the circuit-breaker pole can be moved, it must be treated with gas as per this
section.

Instructions

Action Note/Illustration
1. Vacuum pump down to a pressure of
100 Pa and let the vacuum pumping
continue for at least one hour after this
pressure has been reached.
2. Stop the vacuum pumping and fill the
circuit-breaker with dry and clean
nitrogen to atmospheric pressure. Let
it stand a couple of hours or overnight.
3. Vacuum pump back down to a The filling hoses are to be stored to ensure that
pressure of 100 Pa and fill with clean they are not exposed to moisture and
SF6 gas to 0.125 MPa (abs). contamination. They must not be used for
anything other than their intended purpose.
4. The circuit-breaker pole is now ready
for transport.

1HSB439954-6en 2010-02-18 167

9 Overhaul

9.5 Replacement of breaking unit

9.5.1 Dismantling of breaking unit for transport

General

This section describes the dismantling of the breaking unit for transport. Dismantling
the breaking unit on site is an option to the recommendation (removing the whole
circuit-breaker, and then dismantling the breaking unit in a workshop) and is only to
be applied in stable weather which gives indoor-like working conditions.
The circuit-breaker pole must be taken out of service before the circuit-breaker is
dismantled (see section Preparations for overhaul on page 131) and the gas emptied
(see section Removing of SF6-gas on page 133).

Structure

1 Bolt M12x35, washer 13x28x3

2 Post insulator
3 Breaking unit
4 Pin
5 Washer 13x27x3
6 Split pin 5x40
7 Puffer pull-rod
8 Insulating pull-rod

168 2010-02-18 1HSB439954-6en

 9 Overhaul

Safety

NOTE!
Under no circumstances may the breaking unit be dismantled or opened during rainy
or unstable weather.

Preconditions

NOTE!
If the post insulator or breaking unit is left for a long period without the unit being
refitted, the post insulator, or breaking unit, is to be vacuum pumped and filled with
nitrogen.
NOTE!
This type of work may only be executed by personnel trained by ABB.

Requisite equipment

Equipment ABB part no. Note

Standard tools -
Lifting device -
Lifting tackle -
Crank 2188 754-G
Crank extension 1HSB532188-F
Protective cover 5439 142-A

1HSB439954-6en 2010-02-18 169

9 Overhaul

Dismantling

The instructions below describe the dismantling of a breaking unit for transport.
The numbers in the text correspond to the numbers in the illustration Structure on
page 168.
Action Note/Illustration
1. Before removing the circuit-breaker See section Preparations for overhaul on page
pole the circuit-breaker is to be taken 131 and Removing of SF6-gas on page 133
out of service.
2. Move the breaker slowly to closed
position by winding the operating
mechanism by hand.
3. Stop cranking when the measurement
230-235 mm is reached.

The puffer pull-rod (7) with the pin (4) on the

insulator pull-rod (8) is now in the correct
position for removal.
4. Add a lifting sling around the top
section of the breaking unit and
prepare for lifting.

DANGER!
Use lifting tackle that is dimensioned
for the weight of the circuit-breaker.
See dimension print for the exact
weights.
5. Remove the bolts (1) and very carefully
lift up the breaking unit (3) max 70 mm.

NOTE!
The breaking unit must not be lifted more than
70 mm to avoid damage to the inside of the
circuit-breaker.

170 2010-02-18 1HSB439954-6en

 9 Overhaul

Action Note/Illustration
6.

NOTE!
If large amounts of moisture enter the
post insulator, this must be
immediately sealed and filled with
nitrogen to be transported as soon as
possible to the workshop for
dismantling and careful cleaning.
7. Disconnect the breaking unit (3) by
removing the split pin (6), washer (5)
and pin (4).
NOTE!
Ensure that no split pins or washers fall down in
the post insulator when dismantling. Cover the
opening by e.g. a cloth rag.
8. Fit the protective cover with the sealing
ring above the post insulator (2).

NOTE!
When the cover has been mounted, the
nitrogen pressure in the post insulator is raised
to 0.125 MPa abs.
9. Push the puffer pull-rod (7) into the
breaking unit (3) and fit the protective
cover with a sealing ring.
10. The breaking unit is now ready for
transport.

1HSB439954-6en 2010-02-18 171

9 Overhaul

9.5.2 Assembly of breaking unit on the post insulator on site

General

This section describes the assembly of the breaking unit following an overhaul, when
the breaking unit has been dismantled on site, i.e. not in the workshop.

Structure

1 Puffer pull-rod
2 Post insulator
3 Lower adapter plate
4 Pin
5 Washer, 2 pcs
6 Cotter pins 5x40 (2 pcs)
7 Bolts M12x35 (8 pcs), washers 13x29x3 (8 pcs)
8 Upper adapter plate
9 Cover
10 Absorbent container
11 Bolts M12x35 (8 pcs), washers 13x29x3 (8 pcs)

172 2010-02-18 1HSB439954-6en

 9 Overhaul

Requisite equipment

Equipment Part number Note

Standard tools
Torque wrench Torque range 45-79 Nm
Protective cover 5237 736-R

Assembly

The item numbers in the text correspond to the numbers in the illustration above.
Action Note
1. Suspend the breaking unit in the lifting
device.
2. Remove the post insulator's protective
cover.
3. Pull out the puffer to ensure the puffer
pull-rod (1) is accessible for assembly.
4. Reduce the nitrogen pressure in the
post insulator (2) to atmospheric
pressure and remove the protective
cover
5. Clean the sealing surface for the
sealing ring on the post insulator (2)
carefully.
NOTE!
Also clean the sealing surface in the lower
flange (3) and lubricate generously with grease
"G" to ensure that the sealing ring is kept in
place during assembly.
6. Place the sealing ring in its slot.
7. Slowly lower the breaking unit so that it
comes into position for fitting the pin
(4), around 60-70 mm above the post
insulator.
8. Connect the puffer's pull-rod (1) to the
insulating pull-rod with the pin (4),
washer (5) and split pin (6).
NOTE!
Protect the opening to the post insulator with a
rag or similar in order to avoid the split pin or
washers from falling down into the post
insulator.
9. When the pin is fitted, lower the
breaking unit (6) carefully towards the
post insulator (8) and center.
10. Secure the breaking unit with the bolts
(11).

Torque!
60 Nm
11. Clean the sealing surface on the upper
adapter plate (8) and lubricate with
grease "G".

1HSB439954-6en 2010-02-18 173

9 Overhaul

Action Note
12. Place the sealing ring on top of the
upper flange.
13. Open the packaging to new absorbent
and apply this in the absorbent
container (10).
14. Fit the absorbent container (10) and
cover (9) and tighten the bolts (7).

Torque!
60 Nm

NOTE!
Fit the cover immediately after fitting
the absorbent container.
15. Fill the circuit-breaker pole with gas. See sections Preparations on page 84 and Gas
filling with SF6-gas on page 86.
1. Vacuum pump down to a
pressure of 100 Pa and let the The filling hoses are to be stored to ensure that
vacuum pumping continue for they are not exposed to moisture and
at least one hour after this contamination.
pressure has been reached.
They must not be used for anything other
2. Stop the vacuum pumping and than their intended purpose.
fill the circuit-breaker with dry
and clean nitrogen to
atmospheric pressure. Let it
stand a couple of hours or
overnight.
3. Vacuum pump back down to a
pressure of 100 Pa and fill with
clean SF6 gas to 0.125 MPa
(abs).
16. Move the breaker slowly to open See figure Setting of pull-rod in OPEN-
position by winding the operating POSITION on page 175.
mechanism by hand and checking that
the control hole, D=6 mm, for open
position in the operating lever is
centered with the hole in the
mechanism housing.
17. The circuit-breaker is now ready for
gas filling as per the assembly
instructions for the current circuit-
breaker.

174 2010-02-18 1HSB439954-6en

 9 Overhaul

Setting of pull-rod in OPEN-POSITION

1HSB439954-6en 2010-02-18 175

9 Overhaul

9.6 Assembling the circuit-breaker poles and commissioning

General

Installation of circuit-breaker poles and commissioning are carried out according to

the installation instructions applicable to the circuit-breaker; see chapter .
Following assembly the operating values of the circuit-breaker must be checked and
recorded.

First overhaul

CAUTION!
The circuit-breaker may not be operated Open to Close without an intermediate delay
of 300 ms.

(2) Filling pressure is as specified on the rating plate.

Inspection conducted on (date): ______________________________________

Inspection conducted by (name): ________________________________________

176 2010-02-18 1HSB439954-6en

 9 Overhaul

Second overhaul

CAUTION!
The circuit-breaker may not be operated Open to Close without an intermediate delay
of 300 ms.

(2)
Filling pressure is as specified on the rating plate.

Inspection conducted on (date): ______________________________________

Inspection conducted by (name): ________________________________________

1HSB439954-6en 2010-02-18 177

9 Overhaul

178 2010-02-18 1HSB439954-6en

 10 Disposal and environmental information

10 Disposal and environmental information

10.1 Disposal and recycling

General

ABB AB strives to minimize the product’s impact on the environment throughout its
entire life cycle. Technical and product development focuses on environmental
aspects. The ecocycle approach is strived for and consideration is taken to the
materials' environmental impact and recycling alternatives. The manufacturing
processes are selected to be as safe to the environment as possible.

Disposing of worn-out equipment

Worn-out equipment must be phased out in an environmentally sound manner.

When disposing of used equipment, much of the material, or energy content in the
material, can be recycled following sorting and cleaning. The amount that is recycled
varies depending on the technical resources and experience in each country. Non-
recyclable components are to be sent to an approved environmental waste treatment
plant for destruction or disposal.

SF6 gas

The SF6 gas must be evacuated prior to scrapping of a circuit-breaker. All handling
of SF6 gas must be conducted with care and according to the applicable regulations
to ensure that there are no gas leaks. The gas can be handled in different ways,
depending on the circumstances:
• Regenerated onsite, and reused in other equipment
• Sent to the gas supplier for regeneration
• Sent for destruction at a special waste treatment plant
In cases where the circuit-breaker is filled with mixed gas, the SF6 gas is separated
from the mixture for further processing according to the above. Alternatively, the gas
mixture can be sent for destruction without being separated. ABB AB can help
process the gas when a circuit-breaker is to be scrapped.

Porcelain

After cleaning, the porcelain can be sent for disposal or used for other purposes, such
as for use as filling material.

Composites

Composites can be fractioned and or disposed of, or used for other purposes, such as
for use as filing material with other materials.

Electronics

Electronic equipment is to be sent to an approved recycling company or sorted into

different component materials for appropriate treatment.

1HSB439954-6en 2010-02-18 179

10 Disposal and environmental information

Metals

Metals are to be sorted according to type and surface treatment and sent to an
approved recycling company. Following the removal of any paint or other surface
treatment, clean metal can as a rule, be melted down and used in new products. Many
metal components of iron, steel and aluminum are large and easy to identify, e.g.
supports and mechanism housings.
ABB AB strives to reduce the use of precious metals and emissions of
environmentally hazardous metals. Recycling of these is particularly important.
Precious metals such as copper and silver are expensive and are only present in small
amounts in the earth’s crust. Copper is primarily used in current paths, puffers,
contacts and cables. Silver plating of contacts may occur. Emissions from certain
metals may cause damage. This applies to copper, but also zinc and nickel, which are
used sparingly as surface treatments.

Plastics

The different types of plastic are to be separated and sent to an approved

environmental waste treatment plant or recycling company. The energy content in
thermoplastics and thermosetting plastics can often be recovered through
combustion at a plant designed for the purpose. Thermoplastics can as a rule, be
melted down and reused without any major loss of quality. Composites can be
fractioned and used as filling materials in other materials or be disposed of.
Composites are present in smaller amounts in insulators and pipes. Cable inlets are
made of thermosetting plastic. Thermoplastic is present in components such as guide
rings, tape, bushings and support rings. Thermoplastic in sleeves, nozzles, piping and
collars contains fluoride and is not suitable for recycling. However, it can be disposed
of without the risk of leaking hazardous substances.

Oils and greases

Before disposal, oil, grease and similar products must be removed and sent to an
approved environmental waste treatment plant or recycling company. By utilizing
gravimetric forces, oil waste can be separated into oil, water and a range of
contaminants. In many cases, the oil can then be reused. Alternatively, the energy
content in oil can be recovered through combustion at a plant designed for the
purpose.
Oil occurs in dampers where grease is used as a lubricant.

Rubber

Rubber can be sent to an approved environmental waste treatment plant, either for
disposal or reused for various purposes.
Rubber is present in various seals.

Other materials

Other materials are sorted and sent to an approved environmental waste treatment
plant.

180 2010-02-18 1HSB439954-6en

 10 Disposal and environmental information

10.2 Environment information, SF6 gas

Gas handling

Electrical equipment with 6 has been used for many years with good results. In cases
where a device or switchgear needs to be opened, the SF6 gas is collected and reused.
ABB's policy is that no SF6 gas is to be released during installation, service or
disposal of equipment.

SF6 gas

Pure SF6 gas is non-toxic and is harmless to inhale if the oxygen content is at least
20%. SF6 is approximately five times heavier than air. This means that gas may
collect in, e.g. cable trenches or at the bottom of tanks.

Greenhouse effect

The SF6 molecule contributes to the greenhouse effect, but does not contain any
chlorine and thereby has no impact on the ozone layer. Since SF6 gas began to be
used 50 years ago, a small amount of gas has leaked into the atmosphere. There are
currently approximately 3 x 10-12 parts by volume of SF6 in the atmosphere. Due to
the low concentration, this share is less than a tenth of a percent of the total
greenhouse effect.

Decomposition

The SF6 gas partially decomposes in conjunction with discharges. This takes place
in the temperature range where arcing is extinguished, 1500-5000 K, and provides an
efficient cooling effect. Here both gaseous and solid crevice products are formed. All
crevice products are reactive, which means that they are quickly decomposed and
disappear.
During normal operation, the level of gaseous crevice products is kept low through
built-in absorbers. The solid crevice products are primarily metal fluorides in the
form of a powder. The powder can be easily processed as separate waste and
represents no long-term threat to the environment. For service and maintenance there
are special procedures as the large concentrations of crevice products are corrosive
and toxic.

1HSB439954-6en 2010-02-18 181

10 Disposal and environmental information

182 2010-02-18 1HSB439954-6en

 11 Spare parts

11 Spare parts
11.1 Introduction

General

The replacement modules for the operating mechanism are delivered complete and
tested.
Spare parts that are recommended for storage are marked with R. Where there are
more than ten circuit-breakers in operation we also recommend the spares marked
with RR. RRR parts can be held in stock in order to be able to replace parts quickly
and avoid prolonged stoppages.
State the type designation and manufacturing number, for any enquiries and when
ordering parts or tools. Specify the order number also where possible.
LTB 72.5-245E1US is designed for controlled connection of capacitor banks with
non-directly earthed neutral.
LTB 72.5-245E1GS is designed for controlled connection of capacitor banks with
directly earthed neutral.

1HSB439954-6en 2010-02-18 183

11 Spare parts

Summary, circuit-breaker

1 Circuit-breaker pole, RRR

2 Breaking unit
3 Post insulator
4 Operating mechanism BLK222 (slave), RRR
5 Mechanism housing
6 Support
7 Operating mechanism BLK222 (master) RRR
8 Cable rack with cables

184 2010-02-18 1HSB439954-6en

 11 Spare parts

Summary, operating mechanism

1 Drive unit
2 Mechanism
3 Operating panel
4 Closing spring
5 Heating element

1HSB439954-6en 2010-02-18 185

11 Spare parts

11.2 Circuit-breaker pole

11.2.1 Circuit-breaker pole

Structure

Component parts

Item Designation Note

1 Breaking unit
2 Post insulator
3 Mechanism
4 Tripping mechanism

186 2010-02-18 1HSB439954-6en

 11 Spare parts

11.2.2 Breaking unit

Illustration

Component parts

Item Designation Note

1. Breaking chamber insulator RR
2. Upper current path Included in contact set
3. Puffer Included in contact set
4. Lower current path Included in contact set

1HSB439954-6en 2010-02-18 187

11 Spare parts

11.2.3 Contact set

Structure

Spare parts list

Quantity Component parts Part number

1 Contact set R

188 2010-02-18 1HSB439954-6en

 11 Spare parts

11.2.4 Post insulator and insulating pull-rod

Structure

Component parts

Item Designation Note

1 Post insulator RR
2 Insulating pull-rod RR

1HSB439954-6en 2010-02-18 189

11 Spare parts

11.2.5 Mechanism

Illustration

Component parts

Item Designation Note

1 Mechanism RR

190 2010-02-18 1HSB439954-6en

 11 Spare parts

11.2.6 Tripping mechanism

Illustration

Component parts

Item Designation Note

1 Tripping mechanism RR

1HSB439954-6en 2010-02-18 191

11 Spare parts

11.2.7 Accessories

Absorbent container

Item Designation Note

1 Absorbent container
2 Absorbent R

Density monitor

Item Designation Note

1 Density monitor (temperature R
compensated reference volume)
2 Density monitor (temperature R
compensated bimetal)

192 2010-02-18 1HSB439954-6en

 11 Spare parts

Gasket set

Gasket set for full breaker.

Designation Part number Note
Gasket set 1HSB436309-A R

Assembly kits

Designation Part number Note

Bolt set 1HSB436309-B R
Pins with locking 1HSB436309-C R

Non return valve

Designation Part number Note

Non return valve 1HSB442541-C RR

Protective cover

Designation Part number Note

Protective cover for 1HSB445237-1 R
breaking unit
Protective cover for 5439 142-A R
post insulator

1HSB439954-6en 2010-02-18 193

11 Spare parts

11.3 Operating mechanism

11.3.1 Drive unit, complete with motor

Structure

Component parts

Item Designation Part number

- Drive unit See order applicable to circuit-
breaker

194 2010-02-18 1HSB439954-6en

 11 Spare parts

11.3.2 Motor

Illustration

Component parts

Item Designation Part number

1 Motor, type 220 -250 V AC/DC 1HSB534460-2
1 Motor, type 110 -127 V AC/DC 1HSB534460-1

1HSB439954-6en 2010-02-18 195

11 Spare parts

11.3.3 Spring housing

Illustration

Component parts

Item Designation Part number

- Spring housing 1-pole 1HSB 535421-E

196 2010-02-18 1HSB439954-6en

 11 Spare parts

11.3.4 Driver

Illustration

Component parts

Item Designation Part number

- Driver 1HSB532184-4

1HSB439954-6en 2010-02-18 197

11 Spare parts

11.3.5 Damper

Illustration

Component parts

State the serial number of the circuit breaker when ordering.

Item Designation Part number
1 Damper

198 2010-02-18 1HSB439954-6en

 11 Spare parts

11.3.6 Latch device

Illustration

Component parts

Item Designation Part number

1 Tripping latch device:
24 V 1HSB535436-AP
42 48-V 1HSB535436-Z
60-72 V 1HSB535436-AR
110-127 V 1HSB535436B3
220-250 V 1HSB535436B8
1 Tripping latch device with
manual opening operation:
42 48-V 1HSB535436-AA
110-127 V 1HSB535436-L
220-250 V 1HSB535436-M
2 Closing latch device:
24 V 1HSB535436-AM
42 48-V 1HSB535436-Y
60-72 V 1HSB535436-AN
110-127 V 1HSB535436B5
220-250 V 1HSB535436B7

1HSB439954-6en 2010-02-18 199

11 Spare parts

Item Designation Part number

- Coils, Y1, Y2 and Y3:
24 V LA 516 771-AV
42 48-V LA 516 771-AS
60-72 V LA 516 771-AX
110-127 V LA 516 771-AL
220-250 V LA 516 771-AY
- Double tripping coil Y2
110-125 V LA 516 771-AU
220-250 V LA 516 771-AZ

200 2010-02-18 1HSB439954-6en

 11 Spare parts

11.3.7 Heating element

Illustration

Component parts

Item Designation Part number

1 Heating element:
110-127 V, 70 W 5291 805-1
220-254 V, 70 W 5291 805-2
110-127 V, 140 W 5291 805-3
220-254 V, 140W 5291 805-4

1HSB439954-6en 2010-02-18 201

11 Spare parts

11.3.8 Electrical equipment

Illustration

Component parts

Item Designation Part number

1 Relay:
250 V DC 5619 758-7
220 V DC 5619 758-1
125 V DC 5619 758-8
110 V DC 5619 758-2
60-72 V DC 5619 758-3
42-48 V DC 5619 758-4
2 Motor contactors:
220-250 V DC 5351 749-1
110-125 V DC 5351 749-2
220-240 V DC 5351 749-3
3 Miniature circuit breaker, motor
(MCB):
220-250 V DC 5344 027-40 (K4A 2-pole +
auxiliary contact)
110-125 V DC 5344 027-41 (K8A 2-pole +
auxiliary contact)

202 2010-02-18 1HSB439954-6en

 11 Spare parts

Item Designation Part number

4 Miniature circuit breaker, heater 5344 027-18
(MCB):
5 Counter:
220-250 V DC 5692 965-11
110-125 V DC 5692 965-12
42-48 V DC 5692 965-13

1HSB439954-6en 2010-02-18 203

11 Spare parts

204 2010-02-18 1HSB439954-6en

 1HSB439954-6en / 2010-02-18

ABB AB
Circuit-Breaker Unit
S-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782000
Telefax: +46 (0) 240 782320