Product manual

1HSB429954-10en 2009-03-09

LTB 72.5-145D1/B
2-column support
Operating mechanism FSA 1
3-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 2008 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 Functional overview and 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 and function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Closing and opening operations and charging of the closing spring . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Component parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.1 Drive unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.2 Latch device with coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.3 Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.4 Auxiliary contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.5 Heating element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4 Preconditions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.1 Preconditions for different operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.2 Auto-reclosing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3 Safety 23
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2.1 Levels of safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2.2 Hazardous working situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.3 Safety during maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.1 Warning - risk of crushing in the operating mechanism and link system . . . . . . . . . . . . . . . . . . 27
3.3.2 Release the spring charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4 Reference information 29
4.1 Oil types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Types of grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Locking fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4 Tightening torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5 Requisite equipment, installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.6 Requisite equipment, maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.7 Requisite equipment, overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.8 Operating values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5 Delivery 39
5.1 Delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2 Storage prior to assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.3 Lifting the circuit-breaker poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.4 Lifting the operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1HSB429954-10en 2009-03-09 3
6 Installation 47
6.1 Installation in short steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3 Assembly of support on the foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4 Assembly of pole beam on the support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.5 Fitting of operating mechanism on pole beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.6 Assembly of circuit-breaker poles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.7 Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.7.1 Connecting the circuit-breaker's operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.7.2 Fitting the rails or lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.8 Assembly of gas monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.9 Pressurizing of circuit-breaker poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.9.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.9.2 Gas filling with SF6-gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.9.3 Filling of mixed gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.10 Inspection prior to commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.10.1 Density check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.11 Inspection of screw joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

7 Commissioning 89
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.2 Pre-commissioning check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

8 Maintenance 93
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.2 The maintenance schedule for operating mechanism and circuit-breaker . . . . . . . . . . . . . . . . . . 94
8.3 The service life of the circuit-breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.4 The service life of the arcing contacts in the event of short circuit breaking . . . . . . . . . . . . . . . . 97
8.5 Activities after 1-2 years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.5.1 Ocular inspection and density check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.5.2 Cleaning and lubrication of circuit-breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
8.6 Activities after 3-6 years or 2,000 Close and Open operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8.6.1 Preventive maintenance of operating mechanism and circuit-breaker. . . . . . . . . . . . . . . . . . . 100
8.6.2 Overhaul of breaking unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.7 Activities after 15 years or 5,000 Close and Open operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8.7.1 Overhaul of the whole circuit-breaker and operating mechanism . . . . . . . . . . . . . . . . . . . . . . 104
8.7.2 Cleaning, lubrication and rust protection of operating mechanism. . . . . . . . . . . . . . . . . . . . . . 110
8.7.3 Inspection of latch devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
8.7.4 Inspection of drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8.7.5 Check of oil level in damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
8.7.6 Inspection of heating element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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9 Overhaul 117
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
9.2 Preparations for overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
9.3 Removing of SF6-gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
9.4 Cleaning and waste management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9.5 Removal of circuit-breaker pole for transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
9.6 Overhaul of circuit-breaker pole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.6.1 Dismantling of breaking unit from the post insulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.6.2 Removal of post insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9.6.3 Overhaul of mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.7 Assembly of circuit-breaker pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.7.1 Treatment of contact surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.7.2 Treatment of sealing surfaces and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
9.7.3 Assembly of post insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
9.7.4 Assembly of breaking unit on the post insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
9.7.5 Filling the gas before transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
9.8 Replacement of breaking unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
9.8.1 Dismantling of breaking unit for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
9.8.2 Assembly of breaking unit on site following overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
9.9 Assembling the circuit-breaker poles and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

10 Repairs 155
10.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
10.2 Operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.2.1 Removal and assembly of casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.2.2 Replacement of coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.2.3 Replacement of tripping latch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
10.2.4 Replacement of closing latch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
10.2.5 Replacement of tripping and closing latch device assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.2.6 Replacement of limit stop roller on the closing lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
10.2.7 Replacement of damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
10.2.8 Replacement of auxiliary contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
10.2.9 Replacement of gear housing and motor in the drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
10.2.10Replacement of limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
10.2.11Replacement of eye bolt and bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

11 Disposal and environmental information 199

11.1 Disposal and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
11.2 Environment information, SF6 gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

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12 Spares 203
12.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
12.2 Circuit-breaker pole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
12.2.1 Circuit-breaker pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
12.2.2 Breaking unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
12.2.3 Post insulator and insulating pull-rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
12.2.4 Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
12.2.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
12.3 Operating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
12.3.1 Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
12.3.2 Latch device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
12.3.3 Heating element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
12.3.4 Open and closing latch device assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
12.3.5 Eye bolt and bellows for transmission rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
12.3.6 Drive unit with motor and gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
12.3.7 Limit switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

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 1 Product description, circuit-breaker
1.1 Description

1 Product description, circuit-breaker

1.1 Description

Structure

The circuit-breaker consists of three separate circuit-breaker poles, operating

mechanism and link system.
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 a pole beam. The pole beam and two-column
support are both hot-dip galvanized.
The circuit-breaker poles are interconnected using torsion rods.

1HSB429954-10en 2009-03-09 7
1 Product description, circuit-breaker
1.1 Description

The circuit-breaker's main components

Item Part Weight

1 Circuit-breaker pole 130 kg (polymer), 300 kg (porcelain)
2 Breaking unit See dimension print for applicable order
3 Post insulator See dimension print for applicable order
4 Pole beam See dimension print for applicable order
5 Operating mechanism 150 kg
6 Support See dimension print for applicable order

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 1 Product description, circuit-breaker
1.2 Breaking principle

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

1HSB429954-10en 2009-03-09 9
1 Product description, circuit-breaker
1.3 Functional overview and standards

1.3 Functional overview and standards

Function of operating mechanism

The circuit-breaker is operated by a motor spring operating mechanism.

The operating mechanism is connected to the circuit-breaker poles' mechanism via a
transmission rod and two torsion rods.
The transmission rod runs from the switching shaft of the operating mechanism to
the mechanism of the circuit-breaker pole and thereby transfers closing and opening
travel to the circuit-breaker. The circuit-breaker is closed using an operating
mechanism that contains a closing spring. When closing, the trip spring is charged,
which is also located in the operating mechanism. The tripping latch in the operating
mechanism keeps the circuit-breaker in the closed position. For opening, only
tripping of the tripping latch is required.

Standard operating cycle

The standard operating cycle is O-0.3 s-CO-3 min-CO (IEC).

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.

Standards, IEC

The circuit-breakers comply with the requirements in the IEC 62271-100 standard
and are restrike free when breaking capacitive loads.

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 1 Product description, circuit-breaker
1.4 Gas system and density monitor

1.4 Gas system and density monitor

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 about one month. Following the initial check, it should be
checked at 1-2 year intervals in conjunction with routine visual inspections.

1HSB429954-10en 2009-03-09 11
1 Product description, circuit-breaker
1.5 Description, SF6-gas

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

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 2 Product description, Operating Mechanism
2.1 Structure and function

2 Product description, Operating Mechanism

2.1 Structure and function

General

The motor-charged spring operating mechanism is designed for operating the circuit-
breakers.

Structure

The operating mechanism is enclosed in a cabinet.

The operating mechanism consists primarily of two tension springs:
• The closing spring, which is automatically charged following each closing
operation.
• The trip spring, which is charged in the event of a closing operation.
The main components and construction of the operating mechanism are shown in
figure Summary, operating mechanism on page 14. In the door to the operating
cabinet there is an observation window where you can view the position of the
circuit-breaker and charged state of the closing spring. The electrical monitoring and
control units are located inside the door for easy access. The two tension springs are
to the right and left sides.
To facilitate maintenance and overhaul work, you can remove the operating
mechanism's casing.

Functional description

The closing spring is charged by a motor, via a worm gear, which generates power
and thereby the possibility of a closing operation. A closing latch device keeps the
closing spring charged and ready to close the circuit-breaker. In the event of closing,
power is transferred to charge and lock the trip spring, and the closing spring is
charged again by the motor. A tripping latch then keeps the trip spring charged and
thereby also keeps the circuit-breaker in closed position. When the signal for opening
occurs, the trip spring discharges and the circuit-breaker opens.

1HSB429954-10en 2009-03-09 13
2 Product description, Operating Mechanism
2.1 Structure and function

Summary, operating mechanism

A View from behind

B View from the front
1 Main shaft
2 Worm gear
3 Operating mechanism's opening lever
4 Motor
5 Auxiliary contacts
6 Closing spring
7 Hydraulic damper
8 Switching shaft
9 Counter for circuit-breaker operations
10 Position indicator
11 Spring indicator (charged spring on)
12 Manual closing operation
13 Closing coil
14 Manual opening operation
15 Operating mechanism's closing lever
16 Tripping coil
17 Trip spring

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 2 Product description, Operating Mechanism
2.2 Closing and opening operations and charging of the closing spring

2.2 Closing and opening operations and charging of the closing spring

Description of closing operation

When the signal indicates that the circuit breaker will close, the closing latch is
released from the main shaft and the closing spring trips. This means that the cam
disc rotates via the closing lever. The switching shaft is put in motion and the circuit-
breaker closes, at the same time as the trip spring in turn is charged and locked. The
motor then charges the closing spring following each closing operation, via the main
shaft and worm gear. When the spring is then charged, the circuit is broken by the
limit switch.

Description of opening operation

When the signal indicates that the circuit breaker will open, the tripping latch device
releases from the switching shaft and the trip spring trips, and thereby opens the
circuit-breaker.

Affected parts

1 Main shaft
2 Closing spring
3 Cam disc
4 Closing lever
5 Switching shaft
6 Trip spring
7 Motor

1HSB429954-10en 2009-03-09 15
2 Product description, Operating Mechanism
2.3.1 Drive unit

2.3 Component parts

2.3.1 Drive unit

Motor

The drive unit is delivered with motor for:

• 110 V DC or 110 V AC (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
2 Gear housing

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 2 Product description, Operating Mechanism
2.3.2 Latch device with coils

2.3.2 Latch device with coils

General

The operating mechanism has one closing coil and two trip coils as standard, but can
on request be fitted with double closing coils.
Coil voltage:
- 110 V DC or 220 V DC
The standard rated output of the coils is 500 W.

1HSB429954-10en 2009-03-09 17
2 Product description, Operating Mechanism
2.3.3 Damper

2.3.3 Damper

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

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 2 Product description, Operating Mechanism
2.3.4 Auxiliary contact

2.3.4 Auxiliary contact

General

The operating mechanism is fitted with a 10 pole auxiliary contact as standard

consisting of ten opening and ten closing contacts. Three closing and three opening
contacts are for the internal function of the operating mechanism.
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.

1HSB429954-10en 2009-03-09 19
2 Product description, Operating Mechanism
2.3.5 Heating element

2.3.5 Heating element

General

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

Technical data

The 70 W heating element is always connected, while the 140 W heating element is
thermostat controlled. Check the resistance where necessary.
Voltage Resistance Power
220 V 691 ohm 70 W
110 V 173 ohm 70 W
220 V 346 ohm 140 W
110 V 86 ohm 140 W

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 2 Product description, Operating Mechanism
2.4.1 Preconditions for different operations

2.4 Preconditions for operation

2.4.1 Preconditions for different operations

Control panel

S1 Control switch, Close/Open

S4 Switch, Local/Remote/Disconnected

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, the gas density is greater
than the blocking level and the "Close/Open" control switch is set to "Close".

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.

1HSB429954-10en 2009-03-09 21
2 Product description, Operating Mechanism
2.4.2 Auto-reclosing

2.4.2 Auto-reclosing

Preconditions

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.

22 2009-03-09 1HSB429954-10en
 3 Safety
3.1 Introduction

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 24.
• 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 27.

1HSB429954-10en 2009-03-09 23
3 Safety
3.2.1 Levels of safety risks

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.
Symbols Designation Implication
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 of such dangers as: contact
with high voltage, explosion or fire risk, risk for toxic gases,
risk of crushing, impacts, falls from high places, etc.
ELECTRIC The symbol for electric shocks warns of electrical dangers
SHOCK! that could cause serious injury or death.

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.

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 3 Safety
3.2.2 Hazardous working situations

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 Disconnect the control power and as necessary, the
Both AC and DC can be connected to heater power.
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).

1HSB429954-10en 2009-03-09 25
3 Safety
3.2.3 Safety during maintenance

3.2.3 Safety during maintenance

General

For all work on high-voltage circuit-breakers, the risks below must be observed and
the 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!
Mechanical damage to the insulator may cause it to explode with the subsequent risk
of splintering. Work on the circuit-breaker where there is a risk of mechanical
damage to the insulators is to be executed at reduced gas pressure, 0.125 MPa (abs).
WARNING!
Do not operate the operating mechanism without a load. The operating
mechanism may not be switched on, operated, or have a charged tripp and/or closing
spring until all circuit-breaker installation and adjustment tasks have been
completed.

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

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.

1HSB429954-10en 2009-03-09 27
3 Safety
3.3.2 Release the spring charge

3.3.2 Release the spring charge

General

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

it is important that and 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.

28 2009-03-09 1HSB429954-10en
 4 Reference information
4.1 Oil types

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 -

1HSB429954-10en 2009-03-09 29
4 Reference information
4.1 Oil types

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 -

30 2009-03-09 1HSB429954-10en
 4 Reference information
4.2 Types of grease

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 -

1HSB429954-10en 2009-03-09 31
4 Reference information
4.2 Types of grease

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 -

32 2009-03-09 1HSB429954-10en
 4 Reference information
4.3 Locking fluid

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 -

1HSB429954-10en 2009-03-09 33
4 Reference information
4.4 Tightening torque

4.4 Tightening torque

General

This section specifies all tightening torques

Tightening torque, specified

Screw joint Tightening torque (Nm)

Pole beam - support 300
Foundations 300-350
Density monitor 10
Transmission rod 140 (M20)
79 (M16)
Casing, operating mechanism 100 (M16)
Latch device 40
Drive unit 40
Lock nuts - insulating pull-rod turnbuckle screw 100
Roxtec - cable seal 1 and 10

Tightening torque, general

Size Tightening torque (Nm)

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

34 2009-03-09 1HSB429954-10en
 4 Reference information
4.5 Requisite equipment, installation

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 6880 768-7 Including torque wrenches 10-350
Nm.
Note: The tool equipment is not
included in the delivery, it must be
ordered separately.
Lifting device and slings
Control pin 1HSB539782-1 Delivered with the operating
mechanism placed inside the cabinet
Crank extension 1HYB400789-A Delivered with the operating
mechanism placed inside the
cabinet.
Torque tool 1HSB426883-3 Delivered in accessories box

Lubricant

Agent ABB part no. Note

Grease "G" See sectionsTypes of grease on
Grease "SV" page 31 and Oil types on page 29for
ABB part numbers, suppliers and
trade names.
Contact paste -

Other documentation

Document ABB part no. Note

Dimension print and diagram -
applicable to the order

1HSB429954-10en 2009-03-09 35
4 Reference information
4.6 Requisite equipment, maintenance

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 6880 768-7 Including torque wrenches (10-350
Nm).
Note: The tool equipment is not
included in the delivery, it must be
ordered separately.
Scale of measurements -
Vernier calipers -
Lifting slings -
Test equipment for recording - For example Programma or ABB
damping curves and operating SA10.
values
Torque tool 1HSB426883-3 Delivered in accessories box

Cleaning equipment

Equipment ABB part no. Note

Vacuum cleaner -
Lint-free drying cloths -

Lubricant

Agent ABB part no. Note

Grease "G" - See sections Types of grease on
Grease "M" page 31andOil types on page 29
for ABB part numbers, suppliers
and trade names.
Antirust agent, Valvoline Tectyl 506 1241 0011-108
Locking fluid, Loctite 270 1269 0014-408

36 2009-03-09 1HSB429954-10en
 4 Reference information
4.7 Requisite equipment, overhaul

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 6880 768-7 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
damping curves and operating ABB SA10.
values
Operating time meter -
Resistance meter -
Leak detector for leak inspection -
Torque tool 1HSB426883-3 Delivered in accessories box

Lubricant

Agent ABB part no. Note

Grease "G" - See sections Types of grease on
Grease "N" page 31 for ABB part numbers,
Grease "P" suppliers and trade names.
Grease "S"
Antirust agent, Valvoline Tectyl 506 1241 0011-108

Spares

Spare ABB part no. Note

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 unit 5237 736-R
Protective cover for post insulator 5439 142-A

1HSB429954-10en 2009-03-09 37
4 Reference information
4.8 Operating values

4.8 Operating values

Times

Events Times
Close time coil I (and II) Max. 75 ms
Open time coil I Max. 45 ms
Open time coil II Max. 45 ms
1
Close-Open time Max. 65 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
Main circuit resistance per pole:
Pole Resistance
LTB 72.5D1/B <40µΩ
LTB 145D1/B <40µΩ

Stroke

The stroke length is 85 -1/+2 mm.

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 5 Delivery
5.1 Delivery inspection

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.

1HSB429954-10en 2009-03-09 39
5 Delivery
5.2 Storage prior to assembly

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 a moist environment with no ventilation could cause discoloration of the

zinc-plated surfaces. Discoloration is known as "white rust" and mainly consists of
zinc oxide and zinc hydroxide and is a 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.

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 5 Delivery
5.2 Storage prior to assembly

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.

Spares

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.

1HSB429954-10en 2009-03-09 41
5 Delivery
5.3 Lifting the circuit-breaker poles

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

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 5 Delivery
5.3 Lifting the circuit-breaker poles

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 lifting tackle used to lift the circuit-
breaker pole must be dimensioned for
the weight.
• The polymer circuit-breaker
pole weighs about 130 kg.
• The porcelain circuit-breaker
pole weighs about 300 kg.
See dimensional drawing for exact
weights.
3. Place a lifting sling around the top of See Lifting illustration on page 42.
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.

1HSB429954-10en 2009-03-09 43
5 Delivery
5.3 Lifting the circuit-breaker poles

Action Note/Illustration
4. Check that the bolts (1), have the See Lifting illustration on page 42.
correct tightening torque.

Torque!
79 Nm.
5. Lift the circuit-breaker pole from its
horizontal position in the transport
packaging.
Start with pole B1.

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 5 Delivery
5.4 Lifting the operating mechanism

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 150 kg! Use lifting tackle that is
dimensioned for the weight.
4. Lifting the operating mechanism.

1HSB429954-10en 2009-03-09 45
5 Delivery
5.4 Lifting the operating mechanism

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 6 Installation
6.1 Installation in short steps

6 Installation
6.1 Installation in short steps

General

This section provides a summary of the installation procedure, that is the steps
required for installing the complete circuit-breaker with support and operating
mechanism.

Illustration

1 Circuit-breaker pole
2 Pole beam
3 Support
4 Operating mechanism

1HSB429954-10en 2009-03-09 47
6 Installation
6.1 Installation in short steps

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 39.
2. Check that all the necessary tools are Requisite equipment, installation on page 35.
on hand.
3. Check that the foundations meet all the Foundations on page 49.
requirements for the installation.
4. Fit the support legs on the foundations. Assembly of support on the foundation on page
50.
5. Fit the pole beam to the support legs. Assembly of pole beam on the support on page
52.
6. Fit the operating mechanism on the Fitting of operating mechanism on pole beam
pole beam. on page 54.
7. Fit all circuit-breaker poles. Assembly of circuit-breaker poles. on page 56.
8. Fit the gas monitoring system. Assembly of gas monitoring system on page
71.
9. Install all electrical connections: Electrical connections on page 68.
• Connect the operating
mechanism.
• Fit the rails or lines.
• Charge the closing spring.
10. Pressurize the circuit-breaker poles. Pressurizing of circuit-breaker poles on page
78.
11. Prepare for commissioning.
• Perform a density check. Density check on page 87.
• Check the screw joints. Inspection of screw joints on page 88.

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 6 Installation
6.2 Foundations

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 corrected using spacers, see section Assembly of support on
the foundation on page 50. 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 Foundation for support 1

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

1HSB429954-10en 2009-03-09 49
6 Installation
6.3 Assembly of support on the foundation

6.3 Assembly of support on the foundation

General

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

Structure

1 Foundation bolt, L>130 mm

2 Nut
3 Washer
4 Spacer
5 Foundations
6 Support plate

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

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 6 Installation
6.3 Assembly of support on the foundation

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 legs are heavy! Use lifting
tackle that is dimensioned for the
weight. See dimension print for
applicable order.
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!
300-350 Nm
6.

NOTE!
Make the final tightening of the
supports after the adjustment and
assembly of the pole beam.

1HSB429954-10en 2009-03-09 51
6 Installation
6.4 Assembly of pole beam on the support

6.4 Assembly of pole beam on the support

General

The pole beam and gas tubes are assembled on delivery.

Structure

The figure below shows the pole beam's retaining bolts and nuts.

1 Pole beam
2 Support
3 Bolt M20x60 (8 pcs), Washer (16 pcs), Nut M20 (8 pcs)

Requisite equipment

Equipment Part number Note

Torque wrench - Torque range 300-350 Nm

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 6 Installation
6.4 Assembly of pole beam on the support

Assembly instructions

The following instructions describe the assembly of the pole beam on the support.
Action Note/Illustration
1. Lift the pole beam (1)
2. Carefully lower the pole beam (1) onto
the support legs (2).

3. Attach and tighten the bolts (3)

between the support (2) and pole
beam (1).

Torque!
300 Nm.
4. Make the final tightening of the support
in the foundation.

Torque!
300-350 Nm.

1HSB429954-10en 2009-03-09 53
6 Installation
6.5 Fitting of operating mechanism on pole beam

6.5 Fitting of operating mechanism on pole beam

General

The operating mechanism is already adjusted on delivery, and is supplied with the
closing spring correctly set.

Structure

1 Operating mechanism
2 Lifting brackets (4 pcs)
3 Pole beam
4 Washer 17x30x3 (4 pcs), Spring washer 17x27.4x3.5 (4 pcs), Nut M16 (4 pcs)

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 6 Installation
6.5 Fitting of operating mechanism on pole beam

Safety

WARNING!
The operating mechanism must not be switched on, operated or have a charged
closing spring before all assembly and adjustments have been completed to the
circuit-breaker.
CAUTION!
The operating mechanism may only be lifted by the assigned lifting brackets

Requisite equipment

Equipment Part number Note

Standard tools -
Lifting tackle -
Lifting device -
Torque wrench - Torque range 10-350 Nm

Fitting of operating mechanism on pole beam

The following instructions describe the assembly of the operating mechanism.

Action Note
1. Lift the operating mechanism using
straps and lifting device.
2. Fit the lifting bracket bolts (1) to the
pole beam.

3. Fit the nuts with washers (2) Attach the

washer, spring washer and nuts on the
bolts.

Torque!
190 Nm.

1HSB429954-10en 2009-03-09 55
6 Installation
6.6 Assembly of circuit-breaker poles.

6.6 Assembly of circuit-breaker poles.

General

This section describes the assembly of the circuit-breaker poles and torsion tubes.
The circuit-breaker poles are fitted in the order B1, A1 and finally C1, see the
illustration below.

Structure

The figure below shows the order of assembly of the circuit-breaker poles.

1 Circuit-breaker pole B1
2 Circuit-breaker pole A1
3 Circuit-breaker pole C1

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 6 Installation
6.6 Assembly of circuit-breaker poles.

Requisite equipment

Equipment Part number Note

Standard tools 6880-768-7
Torque tool 1HSB426883-3
Torque wrench - Torque range 10-350 Nm
Control pin 1HSB539782-1
Grease "G" See section Types of grease on page 31 for
details
Grease "M" See section Types of grease on page 31 for
details

Assembly instructions

The following instructions describe the assembly of the circuit-breaker poles on the
pole beam and the fitting of the torsion tubes. Lifting the circuit-breaker pole is
described in Lifting the circuit-breaker poles section on page 48.
Action Note/Illustration
1. Check that the circuit-breaker pole is
tight prior to fitting to the support.
• Remove the sealing cap (3).
• Press the non return valve cone
(2) inwards using a screwdriver.

1. Mark
2. Non return valve
3. Sealing cap

NOTE!
A hissing noise should then be clearly heard
from the pole. If it does not hiss, the circuit-
breaker pole has a leak that must be fixed
before assembly.
2. Refit the sealing cap.

1HSB429954-10en 2009-03-09 57
6 Installation
6.6 Assembly of circuit-breaker poles.

Action Note/Illustration
3. Lift the circuit-breaker pole B1 in place
and fit it on the pole beam.

1. Circuit-breaker pole
2. Bolt M16x60 (4 pcs), washer 17x30x3
(8 pcs), nut M16 (4 pcs).
3. Pole beam

NOTE!
Check that the outer lever is positioned on the
same side as the transmission rod.

NOTE!
Lifting the circuit-breaker pole is described in
Lifting the circuit-breaker poles on page 42.

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 6 Installation
6.6 Assembly of circuit-breaker poles.

Action Note/Illustration
4. Fit the bolts, washers and nuts (1) and
tighten finger tight.

1. Bolt M16x60 (4 pcs), washer 17x30x3

(8 pcs), nut M16 (4 pcs).

NOTE!
Final tightening is executed when all the circuit-
breaker poles have been fitted.
5. Remove the transport plate (1) from
the operating lever (2).

1. Transport plate
2. Operating lever

NOTE!
Make sure the outer lever is fitted as per the
illustration.

1HSB429954-10en 2009-03-09 59
6 Installation
6.6 Assembly of circuit-breaker poles.

Action Note/Illustration
6. Lubricate the shaft end (2) and spline
in the torsion tube using Grease "G".
Fit the short torsion tube (1) between
B1 and A1 on the free shaft end (2).

1. Torsion tube, short

2. Shaft end

NOTE!
A blind tooth is to be fitted into the spline. Never
use force when assembling.

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 6 Installation
6.6 Assembly of circuit-breaker poles.

Action Note/Illustration
7. Fit the circuit-breaker pole A1 on the
pole beam.
• Lower the circuit-breaker pole
to the correct height. The
mechanism housing flange
should be slightly touching the
top of the pole beam.
• Lubricate the shaft end and
spline in the torsion tube using
Grease "G".
• Move circuit-breaker pole A1
towards B1 and guide the
operating shaft (2) into the
torsion tube (1).
Use a torque tool if the position of the
operating shaft needs adjusting. Fit the
free shaft end on circuit-breaker pole
A1.

1. Torsion tube, short

2. Shaft end

NOTE!
A blind tooth is to be fitted into the spline. Never
use force when assembling.

1HSB429954-10en 2009-03-09 61
6 Installation
6.6 Assembly of circuit-breaker poles.

Action Note/Illustration
8. Fit the bolts, washers and nuts (1) and
tighten finger tight.

1. Bolt M16x60 (4 pcs), washer 17x30x3

(8 pcs), nut M16 (4 pcs)

NOTE!
Final tightening is executed when all the circuit-
breaker poles have been fitted.

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 6 Installation
6.6 Assembly of circuit-breaker poles.

Action Note/Illustration
9. Fit the remaining circuit-breaker pole
C1.
• Lubricate the shaft end and
spline in the torsion tube using
Grease "G", applies to both B1
and C1.
• Fit the torsion tube (1) on the
free shaft end on circuit-
breaker pole B1.
• Lower the circuit-breaker pole
to the correct height. The
mechanism housing flange
should be slightly touching the
top of the pole beam.
• Move the circuit-breaker
towards the circuit-breaker pole
already fitted and guide the
operating shaft (2) into the
torsion tube (1).
Use a torque tool if the position of the
operating shaft needs adjusting. Fit the
free shaft end on circuit-breaker pole
C1.

1. Torsion tube, long

2. Shaft end

NOTE!
A blind tooth is to be fitted into the spline. Never
use force when assembling.

1HSB429954-10en 2009-03-09 63
6 Installation
6.6 Assembly of circuit-breaker poles.

Action Note/Illustration
10. Fit the bolts, washers and nuts (1) and
tighten finger tight.

1. Bolt M16x60 (4 pcs), washer 17x30x3

(8 pcs), nut M16 (4 pcs)

NOTE!
Final tightening is executed when all the circuit-
breaker poles have been fitted.
11. Fix the poles by tightening all bolts (1)
between the poles and pole beam.

Torque!
190Nm.

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 6 Installation
6.6 Assembly of circuit-breaker poles.

Action Note/Illustration
12. Put the circuit-breaker in open
position.
• Fit the torque tool on the circuit-
breaker's free shaft end (1) to
enable movement of the circuit-
breaker.
• Turn the shaft to ensure that the
hole in the outer lever (2) and
the hole in the mechanism
housing (3) are aligned. Verify
with the control pin (4).
• Remove the torque tool.

1. Circuit-breaker's free shaft end

2. Outer lever
3. Control hole
4. Control pin
13. Check that the hole on the
transmission rod's eye bolt is aligned
with the hole in the outer lever when
the circuit-breaker is open.
If this is the case, continue to point 15.

1HSB429954-10en 2009-03-09 65
6 Installation
6.6 Assembly of circuit-breaker poles.

Action Note/Illustration
14. • Unscrew the lock nuts (1).
• Adjust the length of the
transmission rod by turning the
rod (2) to ensure that the hole
on the transmission rod and the
outer lever are aligned.

NOTE!
This action is only taken if the length of
the transmission rod needs adjusting.

1. Lock nuts
2. Adjusting rod
15. Fit the pin and lock washer (2)
between the eye bolt on the operating
mechanism's transmission rod and the
outer lever on circuit-breaker pole B1.
• Lubricate the pin (2) using
Grease "M".

1. Outer lever
2. Pin D=17, lock washer SL 12.

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 6 Installation
6.6 Assembly of circuit-breaker poles.

Action Note/Illustration
16. Tighten the lock nuts on the
transmission rod.

Torque!
M20: 140 Nm.
M16: 79 Nm.
NOTE!
This action is only taken if the length of
the transmission rod is adjusted.
17. Verify with a control pin that the hole in
the outer lever and the hole in the
mechanism housing are aligned.

1HSB429954-10en 2009-03-09 67
6 Installation
6.7.1 Connecting the circuit-breaker's operating mechanism

6.7 Electrical connections

6.7.1 Connecting the circuit-breaker's operating mechanism

General

This section describes the connection of the operating mechanism.

Safety

WARNING!
Incorrectly connected motor cables may cause personal injury and serious
mechanical damage.

Connection

Action Note/Illustration
1. Run the cables for the operating and
signal lines through the cable inlets (1)
at the bottom of the cabinet.

1. Cable inlets

NOTE!
The cables must be run to ensure they do not
prevent manual charging of the closing spring
with a hand crank.
2. Fit the flange with an appropriate seal
for the cable in question.

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 6 Installation
6.7.1 Connecting the circuit-breaker's operating mechanism

Action Note/Illustration
3. Connect the cables to the coupling
terminals as per the applicable
connection diagram.
NOTE!
The blocks are of the plug-in type and available
in through design with a connection of max 4
mm2 multicore conductor area, and as
disconnectable design with a connection of
max. 6 mm2 multicore conductor area designed
for motor, AC and supply circuits.
4. Connect the earth cable to the earth
terminal (1) on the side of the cabinet.

1. Earthing terminal

1HSB429954-10en 2009-03-09 69
6 Installation
6.7.2 Fitting the rails or lines.

6.7.2 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 31 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.

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 6 Installation
6.8 Assembly of gas monitoring system

6.8 Assembly of gas monitoring system

General

This section describes the assembly of the gas monitoring system. The gas tubes are
fitted to the pole beam on delivery, but are not connected. Connection is described in
this section.
The density monitor can be an indicating or non-indicating model.
NOTE!
If the circuit-breaker is to be filled with mixed gas, the gas monitoring system has to
be fitted after filling with gas!

Structure

1 Density monitor
2 Connection cable
3 Cable ties
4 Roxtec cable seal

1HSB429954-10en 2009-03-09 71
6 Installation
6.8 Assembly of gas monitoring system

Requisite equipment

Equipment Part number Note

Standard tools -
Torque wrench - Torque 1-10 Nm
Grease "G" 1171 4014-407 See section Types of
grease on page 31 for
details.
Roxtec sealing kit - Packed in the accessories
box.
Loctite 270 - See section Locking fluid on
page 33 for details.

Assembly

The gas tubes are fitted on delivery, but are not connected.
If the circuit-breaker is filled with mixed gas, the gas tubes are fitted after the gas has
been filled; see section Filling of mixed gas on page 83.
The operating mechanism is delivered with a seal fitted in the hole for the density
monitor's cable seal. This seal is removed when fitting the gas monitoring system.
Action Note
1.

NOTE!
When fitting the gas monitoring
system, the greatest possible
cleanliness must be observed.
2.

NOTE!
Ensure that the gas tubes do not come
into contact with the pole beam. Risk of
galvanic corrosion.

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 6 Installation
6.8 Assembly of gas monitoring system

Action Note
3. Connect the gas tubes to the circuit-
breaker poles.
Lubricate the O rings using “G” grease
prior to assembly.

1. Clamp nut
2. Non return valve
3. O-ring

NOTE!
Only thread on the clamp nut (1) to the slot in
the non-return valve (2) ensuring the
connection is tight, but the non-return valve has
not opened.
4. When all circuit-breaker poles are
connected in this way: tighten the
clamp nut (1).

Torque!
10 Nm

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6 Installation
6.8 Assembly of gas monitoring system

Action Note
5. Connect the density monitor (1) to the
gas block.
Lubricate the O rings (3) using grease
"G" prior to assembly.

• 1. Density monitor
• 2. Cabling
• 3. O rings
6. Tighten the density monitor (1) when
the gas has been filled.
7. Remove the seal (1) from the top of the
operating mechanism.

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 6 Installation
6.8 Assembly of gas monitoring system

Action Note
8. Fit the Roxtec seal in the hole. Make
sure the rubber seal (1) is in place.

1. Rubber seal
2. Seal
3. Nut
9. Tighten the nut (3) on the bottom. Use Loctite 270

Torque!
10 Nm
10. Guide the density monitor's cable (1)
into the operating mechanism through
the Roxtec seal.

1HSB429954-10en 2009-03-09 75
6 Installation
6.8 Assembly of gas monitoring system

Action Note
11. Adjust the size of the two seal halves
by removing layers of rubber. Place the
halves around the cable (1) and check
that the measurement agrees with the
figure to the right.

1. Cable
12. Thoroughly lubricate the inside of the The Roxtec grease is packed in the bag for the
seal halves using Roxtec grease. seal.
Lubricate the outside sparingly.
13. Fit the seal halves around the cable
and press them into the cable entry.

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 6 Installation
6.8 Assembly of gas monitoring system

Action Note
14. Tighten the tensioning screws (1)
crosswise.

NOTE!
Make sure the cable runs straight
through the cable entry when
tightening.

Torque!
1 Nm
15. Use a cable tie to attach the cable to
the component plate inside the
operating mechanism.
16. Connect the cable from the operating
mechanism to the density monitor and
attach the cable in the holes on the
pole beam (1) using cable ties.

• 1. Holes for cable ties, 2 pcs

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6 Installation
6.9.1 Preparations

6.9 Pressurizing of circuit-breaker poles

6.9.1 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!
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.
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.

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. Close the motor circuit-breaker to
charge the closing spring.
5. Open the terminal blocks to the density
monitor's cables that are connected
and break the circuit to the interlocking
relays.
6. Connect the performance testing
device with variable control voltage
and time measurement.

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 6 Installation
6.9.1 Preparations

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

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6 Installation
6.9.2 Gas filling with SF6-gas

6.9.2 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 83.

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 31.

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

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 6 Installation
6.9.2 Gas filling with SF6-gas

Gas filling instructions

The instructions below describe filling of SF6 gas. The item numbers in parenthesis
refer to figureGas filling components on page 79.
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 80, 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
circuit-breaker's gas block.
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).

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6 Installation
6.9.2 Gas filling with SF6-gas

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 80.
13. Remove the hose (8) from the coupling
link (6) located on the gas block.
14. Shut off the tap (4).
15. Remove the coupling link from the gas
block.
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. Switch the circuit-breaker to Close and
Open 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 check See section Density check on page 87.

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.

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 6 Installation
6.9.3 Filling of mixed gas

6.9.3 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)

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6 Installation
6.9.3 Filling of mixed gas

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.
Note that the poles are filled separately and one at a time. The item numbers in
parenthesis refer to figure Gas filling components on page 79.
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 83. 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).
WARNING!
When filling mixed gas, the poles must be filled
one at a time.
8. Connect the gas filled hose (8) to the
coupling link (6).

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 6 Installation
6.9.3 Filling of mixed gas

Action Note
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.
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 83.
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 71.

NOTE!
The circuit-breaker must not be operated until
the gas monitoring system has been installed!

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6 Installation
6.9.3 Filling of mixed gas

Action Note
24. When the density monitor (1 ) or (2)
has been properly fitted; tighten the
clamp nut.

Torque!
Tightening torque 10 Nm
25. Switch the circuit-breaker to close and
open three times from a protected
place.
26. Connect the cables to the density
monitors.
27. Reset the circuits to the blocking
relays.
28. Perform a density check See Density check on page 87.

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.

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 6 Installation
6.10.1 Density check

6.10 Inspection prior to commissioning

6.10.1 Density check

General

This section describes how you make a density check with a leak detector around the
gas block and the gas tube connections.

Requisite equipment

The following table shows what is needed for a density check

Equipment Description
Leak spray

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.

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6 Installation
6.11 Inspection of screw joints

6.11 Inspection of screw joints

General

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

Inspection
• Use the control pin to check that the operating lever's control hole is aligned
with the pre-drilled hole in the mechanism housing. The control pin is placed
inside the operating mechanism's cabinet. The part number is given in section
Requisite equipment, installation on page 35.
• Check that all screw joints are tightened at the right torque, see section
Tightening torque on page 34.

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 7 Commissioning
7.1 Introduction

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 90 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.

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7 Commissioning
7.2 Pre-commissioning check list

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 91 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 34.
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.

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 7 Commissioning
7.2 Pre-commissioning check list

Check of gas filling

Action Note
1. Check the gas filling and test run as See Gas filling with SF6-gas on page 80 or
per instructions Filling of mixed gas on page 83.

Check of operating values.

Check the operating values for the circuit-breaker against data applicable to the
circuit-breaker in Operating values on page 38 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 from 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.

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7 Commissioning
7.2 Pre-commissioning check list

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 8 Maintenance
8.1 Introduction

8 Maintenance
8.1 Introduction

Chapter structure

This chapter contains information for the necessary maintenance activities. The
chapter is structured as follows:
• The maintenance schedule that contains intervals and competence levels for
the various maintenance activities.
• Information on the circuit-breaker's service life.
• Activities at 1-2 year intervals.
• Activities at 3-6 years or 2,000 Close and Open operation intervals.
• Activities at 15 years or 5,000 Close and Open operation intervals.
There are also activities to be carried out after 30 years or 10,000 Close and Open
operations.
These are detailed in chapter Maintenance on page 93.
NOTE!
In corrosive or polluted air and in climates with high humidity, it may be necessary
to half the inspection period.
The specified inspection intervals are to be regarded as recommended guidelines that
can either be extended or shortened depending on local conditions.

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8 Maintenance
8.2 The maintenance schedule for operating mechanism and circuit-breaker

8.2 The maintenance schedule for operating mechanism and circuit-breaker

Planning of maintenance activities

The activities in each interval are to be planned separately, i.e. they do not appear in
the instructions for later intervals. For example, if activities executed at 1-2 year
intervals are to be conducted regularly and it is up to the customer to plan the time so
that, by way of suggestion, activity no 2 coincides with the activities to be carried out
at 3-6 year intervals, etc.

Maintenance schedule

Compe-
Interval tence Maintenance activity Instructions
level
1-2 years A Visual inspection Ocular inspection and density
check on page 98.
3-6 years or B Preventive maintenance of Preventive maintenance of
2,000 Close and operating mechanism and operating mechanism and
Open operations circuit-breaker circuit-breaker on page 100.
C Overhaul of breaking
chamber at the
unsynchronized capacitor
bank, reactor and filter circuit-
breaker
15 years or 5,000 B Overhaul of circuit-breaker Overhaul of the whole circuit-
Close and Open and operating mechanism breaker and operating
operations mechanism on page 104.
C Overhaul of breaking
chamber at the synchronized
capacitor bank, reactor and
filter circuit-breaker
30 years or C General overhaul of complete If the circuit-breaker and the
10,000 Close circuit-breaker and operating operating mechanism are
and Open mechanism: overhauled for a further
operations 10,000 operations, all moving
• dismantling of circuit-
parts must be replaced.
breaker pole and link
gear If the circuit-breaker and the
operating mechanism are
• assembly of new overhauled for a further 2,000
contact set operations, certain worn parts
must be replaced.
• replacement of other
worn components. See chapter Overhaul on
page 117.
ΣnxI2=20,000 C Overhaul of breaking
chamber at the line and
transformer circuit-breaker

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 8 Maintenance
8.2 The maintenance schedule for operating mechanism and circuit-breaker

Competence levels

The different maintenance activities require different competence levels for the
personnel carrying out the work. The significance of the different levels is:
• A: substation personnel without special training.
• B: personnel authorized by ABB to carry out assembly, commissioning and
maintenance work.
• C: personnel authorized by ABB to carry out assembly, commissioning and
maintenance work. In some cases support may be necessary from ABB.

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8 Maintenance
8.3 The service life of the circuit-breaker

8.3 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 Desiccant is applied to each breaking unit corresponding to not less than 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.

Replacing breaking units

In general, there are only two reasons for replacing the breaking units:
Reasons
1 If the number of short-circuits x short-circuit current (kA) approaches the curve, see
figure No of operations on page 97.
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 The
maintenance schedule for operating mechanism and circuit-breaker on page 94.

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 replacing the breaking units is limited to mechanical faults/faulty
adjustment of the drive system, which 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
2
Σn x I = 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.

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 8 Maintenance
8.4 The service life of the arcing contacts in the event of short circuit breaking

8.4 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 handle before burn-off is so great that they must
be replaced.

No of operations

n No of operations
kA Short-circuit current

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8 Maintenance
8.5.1 Ocular inspection and density check

8.5 Activities after 1-2 years

8.5.1 Ocular inspection and density check

General

This section specifies the maintenance activities that must be carried out on the
circuit-breaker and the operating mechanism after 1-2 years.

Competence level

Personnel who carry out maintenance work are to have competence level A: they
must be substation personnel but do not need to have any special training.

Condition of circuit-breaker

The circuit-breaker may be in operation.

Ocular inspection and density check of the circuit-breaker

Component Check... Instructions/more information

Circuit-breaker external cleanliness. The interval for cleaning depends on local
Clean where conditions, i.e. the degree of air pollution.
necessary More information on cleaning is given in section
Cleaning and lubrication of circuit-breakers on
page 99.
Gas pressure pressure and density. Check the circuit-breaker by reading the density
monitor.

Ocular inspection of the operating mechanism

Component Check... Instructions

Heating element function. Replace if defective.
Valves and runoff hole function.

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 8 Maintenance
8.5.2 Cleaning and lubrication of circuit-breakers

8.5.2 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 where there is a risk of mechanical
damage to the insulators is to be executed at reduced gas pressure, 0.125 MPa (abs).
NOTE!
Composite insulators must NOT be cleaned.

Lubricant

Only use the lubricant recommended in section Types of grease on page 31. 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 137.

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8 Maintenance
8.6.1 Preventive maintenance of operating mechanism and circuit-breaker

8.6 Activities after 3-6 years or 2,000 Close and Open operations

8.6.1 Preventive maintenance of operating mechanism and circuit-breaker

General

This section specifies all the maintenance activities that must be carried out on the
operating mechanism after 3-6 years or 2,000 Close and Open operations.
DANGER!
Before working on the operating mechanism:
• the motor current must be cut.
• the circuit-breaker must be open, disconnected and earthed.
• the closing and trip springs must be discharged; see section Release the spring
charge on page 28.
• the circuit-breaker (control switch) must be in DISCONNECTED position

Competence level

Personnel who carry out maintenance work are to have competence level B:
personnel must be authorized by ABB to carry out assembly, commissioning and
maintenance work.

Condition of circuit-breaker

The circuit-breaker must be open, disconnected and earthed.

Requisite equipment

Equipment Part number Note

Grease “M” 1171 4016-612 More information on the various greases
is given in section Types of grease on
page 31.
Thermal camera
Electronic timing for the
circuit-breaker's function
times
Anti-rust agent Where there is the need of anti-rust
treatment.

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 8 Maintenance
8.6.1 Preventive maintenance of operating mechanism and circuit-breaker

Preventive maintenance, circuit-breaker

The table below specifies all the actions that need to be taken for preventive
maintenance of the circuit-breaker.
Component Action More information
Complete circuit- Heat measurement: check the Heat measurement is carried out
breaker temperature increase in the at full load prior to disconnection
outer parts of the circuit-breaker. of the circuit-breaker.
The highest permitted
temperature difference between
the phases is 5°C.
Use a 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.
Complete circuit- Look for corrosion. External ocular inspection. Treat
breaker with anti-rust agent where
necessary.
Complete circuit- Simple operational tests. Execute a simple operational test,
breaker if possible in combination with the
measurement of operational times
(including Close-Open times).

Preventive maintenance, operating mechanism

The table below specifies all the actions that need to be taken for preventive
maintenance for the operating mechanism.
Component Action More information
Worm gear (worm and Clean and lubricate with grease Does not need to be
gear wheel) “G”. removed.
Rating plate on each Check and note the serial number.
cabinet
Operation counter Check and note the number of
operations.

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8 Maintenance
8.6.1 Preventive maintenance of operating mechanism and circuit-breaker

Structure

1 Worm gear (worm and gear wheel)

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 8 Maintenance
8.6.2 Overhaul of breaking unit

8.6.2 Overhaul of breaking unit

General

This section contains information on overhauling the breaking units. The interval is
2,000, 5,000 Close and Open operations or Σn x I2=20,000, depending on the type of
circuit-breaker; see The maintenance schedule for operating mechanism and circuit-
breaker on page 94.

Competence level

Personnel who carry out maintenance work are to have competence level C:
personnel authorized by ABB to carry out assembly, commissioning and
maintenance work. In some cases support may be necessary from ABB.

Condition of circuit-breaker

The closing and trip springs are to be discharged, the circuit-breaker is to be in open
position, disconnected and earthed. The entire circuit-breaker pole, with breaking
unit, is to be removed and transported to the workshop.

Requisite equipment

Equipment Part number Note

Standard equipment -

Overhaul of breaking chamber

The instructions below are a general description of overhauling breaking units.

Action Note
1.

NOTE!
Use personal protective equipment:
• long-sleeved overalls
• protective gloves of plastic or
rubber
• tight fitting facemask for dust
protection
2. Remove the circuit-breaker pole and See section Removal of circuit-breaker pole for
transport to the workshop. transport on page 123.
3. Lift off the breaking unit. See section Dismantling of breaking unit from
the post insulator on page 126.

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8 Maintenance
8.7.1 Overhaul of the whole circuit-breaker and operating mechanism

8.7 Activities after 15 years or 5,000 Close and Open operations

8.7.1 Overhaul of the whole circuit-breaker and operating mechanism

General

This section specifies the maintenance activities that must be carried out on the
circuit-breaker and the operating mechanism after 15 years or 5,000 mechanical
Close and Open operations.
Note that the activities for the circuit-breaker and the operating mechanism are
described in two separate tables. However, the list of equipment is common to all
activities.

Competence level

Personnel who carry out maintenance work are to have competence level B:
personnel authorized by ABB to carry out assembly, commissioning and
maintenance work.

Condition of circuit-breaker

The closing and trip springs are to be discharged, the circuit-breaker is to be in open
position, disconnected and earthed.

Requisite equipment

Below is a list of the tools necessary for an overhaul of the circuit-breaker and
operating mechanism. In addition to these tools, other equipment and expendable
supplies that may be specified in cross-referenced sections could also be necessary.
Equipment Part number Note
Rinsing equipment for cleaning
insulators
Electronic timing for the circuit-
breaker's function times
Gas filling equipment Where there is the need of gas filling
Dew point meter
Torque wrenches
Measurement equipment for
resistance
Measurement equipment for
voltage
Control pin 1HSB539782-1
Anti-rust agent Where there is the need of anti-rust
treatment.
Torque tool 1HSB426883-3 Packed in accessories box.

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 8 Maintenance
8.7.1 Overhaul of the whole circuit-breaker and operating mechanism

Overhaul of the whole circuit-breaker

The table below specifies all the components that need to be checked for the overhaul
of the circuit-breaker. Any tools and expendable material is detailed in the table and
is also listed in the previous table.
Instructions/more informa-
Component Check...
tion
Porcelain insulators tightening torque for nuts and Use torque wrenches. The correct
bolts. tightening torque is specified in
Tightening torque on page 34.
Composite insulators insulator, with reference to
damage.
Circuit-breaker, • Opening time Measuring with electronic timing.
function times Nominal control voltage
• Closing time
For times, see Operating values on
• Close-Open time page 38.
• Deviations between Maximum time deviation between
phases the phases, 5 ms at closing and 3
ms at opening.
• Backup switch
• Coupling times
• Contact damping
SF6 gas gas pressure, by reading the Correct pressure specifications for
density monitor. different temperatures are on the
rating plates.
Fill with gas, if necessary, using
gas filling equipment, see Gas
filling with SF6-gas on page 80.
SF6 gas dew point, for normal gas Use a dew point meter.
pressure in the circuit-breaker. Dew point max. -5°C at specified
filling pressure and +20°C.
Density monitoring the density monitor's pressure Remove the density monitor from
(SF6 gas) indicator and signal and break the circuit-breaker to check the
contacts. function.

NOTE!
The test must take place in normal
air conditions, +20 °C and 101.3
kPa (1,013 mbar).
Minimum permitted voltage
when checking: 30 V.

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8 Maintenance
8.7.1 Overhaul of the whole circuit-breaker and operating mechanism

Instructions/more informa-
Component Check...
tion
Main circuit resistance through Resistance values as specified in
measurement. section Operating values on page
(200 A DC) 38.
Higher values are permitted for
frequent operation with small
currents (≤ 400 A).
Calculation of permitted resistance:

• R = permitted raised
resistance
• Rn = max. resistance as per
Operating values on page
38
• In = rated current as per
rating plate
• I = the current that the
maximum resistance is
calculated for
Link gear open-position, by checking that Verify with control pin
the reference hole in the
operating lever is aligned with
the hole in the link gear's
mechanism housing.

Overhaul of the operating mechanism

The table below specifies all the components that need to be checked for the overhaul
of the operating mechanism. Any tools and expendable material are detailed in the
table and are also listed in Requisite equipment on page 104.
Component Check... Instructions/more information
Operating external condition, with External ocular inspection.
mechanism regard to cleanliness Clean and lubricate where necessary.
and any corrosion. Treat with anti-rust agent where necessary.
See Cleaning, lubrication and rust
protection of operating mechanism on page
110.
Retaining bolts and that they are in position. No tools needed.
nuts
Damper that the damper has no If there is an oil leak, the whole damper
oil leaks. must be replaced!
See section Replacement of damper on
page 182 for instructions and spare part
numbers.

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 8 Maintenance
8.7.1 Overhaul of the whole circuit-breaker and operating mechanism

Component Check... Instructions/more information

Damper oil level. Check the oil level by removing the damper
or by ultrasound testing.
See Replacement of damper on page 182.
Blocking relays the relays. The relays must break when a density
monitor is removed from a circuit-breaker
pole pressurized at filling pressure.

NOTE!
The performance test is to be carried out
when the circuit-breaker is out of service.
Control voltage availability (minimum Measure the minimum control voltage.
control voltage). Closing time coil: < 85% of nominal value.
Opening time coil: < 70% of nominal value.
Variable DC-voltage unit.
Anti-pumping relay availability (relay's An Open-Close operation at the rated
lowest control voltage). voltage with a closing impulse that lasts for
30 seconds must be possible without
"pumping" of the circuit-breaker, i.e., when
the circuit-breaker executes repeated
Close-Open operations.
The relay's lowest control voltage is
measured.
Motor motor current. The motor current must be measured
towards the end of the charging process.
See Operating values on page 38.
Max. charging time: 15 seconds.
The motor must be able to charge the spring
at 85% of nominal voltage (IEC).
See Inspection of drive unit on page 114.
Latch device Settings, visually. For setting the gap in the latch device, see
Lubricate the shafts. Inspection of latch devices on page 112.
Surfaces on shafts and interlocks are
lubricated using Grease "L". See section
Types of grease on page 31.
Coils coil resistance and The coil resistance and current is allowed to
current. vary ±10 % of the measurement values
received during routine tests.
Limit switch function. In the final phase of the charging process of
the closing spring, the closing circuit must
be closed before cutting the motor current.
Heating element in resistance and signal for See Inspection of heating element on page
the operating voltage drop. 116.
cabinet
Heating element in resistance. 140 W, 110 V R= 86 Ohm ±10 %
central cabinet (if 140 W, 220 V R=346 Ohm ±10 %
applicable)
Thermostat (if that the thermostat is See Pre-commissioning check list on page
applicable) adjusted as per the set 90.
value.

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8 Maintenance
8.7.1 Overhaul of the whole circuit-breaker and operating mechanism

Component Check... Instructions/more information

Terminal blocks that bolts and clamps are Note that the blocks may be located in both
properly tightened. the operating cabinet and central cabinet, if
these are installed.
Starter switch signal for voltage drop. Note that the starter switch may be located
in both the operating cabinet and central
cabinet, if these are installed.
Interlocks and worm function and lubrication. Lubricate interlocks and worm gear
gear housing. housing. See Preventive maintenance,
operating mechanism on page 101.
Open and closing cleanliness and See Preventive maintenance of operating
latch device lubrication. mechanism and circuit-breaker on page
assemblies 100.
All components in tightening torque on all See Tightening torque on page 34.
the operating screw joints.
mechanism
Eye bolt for general wear. Replace if damaged! See section
transmission rod Replacement of eye bolt and bellows on
page 194.
Bellows for cracks in material, leaks. Replace if damaged! See section
transmission rod Replacement of eye bolt and bellows on
page 194.

Cleaning and lubrication of operating mechanism

The following components are to be cleaned and lubricated when they are fitted in
the operating mechanism. The components are highlighted in the illustration that
follows after the table.
Clean and
Item Component lubricate More information
with...
1 Limit stop roller on the operating Grease "G"
mechanism's closing lever
2/3 Rollers on the closing and tripping Grease "L"
latch assembly levers
4 Contact surface for interlock, closing Grease "G" Clean and lubricate the work
surfaces.
5 Contact surface for interlock, Grease "G" Clean and lubricate the work
opening surfaces.
6 Pins for spring locking (3 pcs) Grease "G" Lubricate the worn surfaces.
7 Pin for the closing spring's lever Grease "G" Lubricate the worn surfaces.
8 Eye bolt for transmission rod Grease "G" Note: The eye bolt must be
removed before cleaning and
lubrication! Removal is described
in section Replacement of eye
bolt and bellows on page 194.

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 8 Maintenance
8.7.1 Overhaul of the whole circuit-breaker and operating mechanism

1 Limit stop roller on the operating mechanism's closing lever

2 Roller on the closing latch device assembly lever
3 Roller on the tripping latch device assembly lever
4 Contact surface for interlock, closing
5 Contact surface for interlock, opening
6 Pins for spring locking (3 pcs)
7 Pin for the closing spring's lever
8 Eye bolt for transmission rod

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8 Maintenance
8.7.2 Cleaning, lubrication and rust protection of operating mechanism

8.7.2 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 25.

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 29 and
Types of grease on page 31.
Lubricant Spare part number Note
Grease "G" 5316 381-A
Oil "S" 1HSB875318-C

Cleaning

Clean the operating mechanism 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.

Lubrication

The operating mechanism's ball, roller and needle bearings, and shafts are lubricated
with grease for each function as specified in Types of grease on page 31 and under
normal conditions, require no maintenance. The worm gear and worm screw (worm
transmission) are to be lubricated as specified in the maintenance schedule; see
section Preventive maintenance of operating mechanism and circuit-breaker on page
100.
The dampers are filled with "S" oil on delivery.

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 8 Maintenance
8.7.2 Cleaning, lubrication and rust protection of operating mechanism

Rust protection

Certain steel mechanical components in the operating mechanism are surface treated
through manganese phosphating agent and protected by being dipped in oil. This
applies primarily to levers, interlocks, gear wheel, components in the link system and
brackets for the cam discs. Other components, such as the chassis, are painted as a
means of rust protection. The closing and trip springs are anti-rust protected with
two-component paint.
On delivery, the operating mechanism is treated with desiccant as transport
protection against moisture.
Despite good anti-rust treatment, minor rust attacks may occur after a few years,
particularly if the circuit-breaker is installed in a highly corrosive environment. Rust
spots must be polished off and new anti-rust agent applied by brush or spray. Grease
“G” or Tectyl 506 is recommended as a rust inhibitor; see section Types of grease on
page 31.
NOTE!
Tectyl 506 forms a wax-like protective coat after drying and must not be applied to
bearings and interlock mechanisms or to gear wheels.

Spares

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
oC (±10oC).
+20

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8 Maintenance
8.7.3 Inspection of latch devices

8.7.3 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 31 for
details.
Multimeter
Feeler gauge

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 8 Maintenance
8.7.3 Inspection of latch devices

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

NOTE!
If the play is outside the specified dimensions,
the whole latch device must be replaced.
This is described in sections Replacement of
closing latch assembly on page 166
andReplacement of tripping latch assembly on
page 163.

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8 Maintenance
8.7.4 Inspection of drive unit

8.7.4 Inspection of drive unit

General

This section describes how to check the drive unit.

Requisite equipment

Equipment Part number Note

Standard tools -

Inspection of drive unit

Action Note
1. Measure the motor current at the end See section Operating values on page 38.
of the charging process.

NOTE!
The motor must be able to charge the springs
at 85 % of nominal voltage (IEC).
If this is not the case, replace the motor as per
section Replacement of gear housing and
motor in the drive unit on page 187.

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 8 Maintenance
8.7.5 Check of oil level in damper

8.7.5 Check of oil level in damper

General

This section describes how to check the oil level in the damper.

Requisite equipment

Equipment ABB part no. Note

Oil "S" 1173 7011-106 The oil is specified in section Oil types on page
29.
Ultrasound equipment, if - If the level is to be checked using ultrasound
any. equipment.

Structure

Instructions

Action Note
1. If the oil level is to be checked using Damper removal is described in section
ultrasound equipment, the damper can Replacement of damper on page 182.
remain in place. Otherwise it must be
removed.
2. Check the oil level
Where necessary, top up with oil "S".

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8 Maintenance
8.7.6 Inspection of heating element

8.7.6 Inspection of heating element

General

The operating cabinet is fitted with a heating element to prevent condensation and
must always be connected.

Illustration

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

See section Heating element on page 20 for values.

The 70 W heating element is always connected, while the 140 W heating element is
thermostat controlled.

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 9 Overhaul
9.1 Introduction

9 Overhaul
9.1 Introduction

General

This chapter includes instructions for a general overhaul of complete circuit-breaker.

The time interval for the overhaul is specified in The maintenance schedule for
operating mechanism and circuit-breaker on page 94.

Scope

If the overhaul is made for a further 10,000 operations, all moving parts must be
replaced.
If the overhaul is made for a further 2,000 operations, certain worn parts must be
replaced.

Competence level

Personnel who carry out maintenance work as per this chapter are to have
competence level C: they must be authorized by ABB to carry out assembly,
commissioning and maintenance work. In some cases support may be necessary from
ABB.

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9 Overhaul
9.2 Preparations for overhaul

9.2 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 Removal of circuit-breaker pole for transport on page
123.
• The alternative method is to only dismantle the breaking unit; see sections
Replacement of breaking unit on page 145.
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 120.
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 9-350 Nm
Lifting device and slings
Gas filling equipment
Cleaning equipment
Personal safety equipment
Equipment for recording damping curves for
the operating mechanism
Operating time meter
Torque tool 1HSB426883-3 Delivered in
accessories box

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 9 Overhaul
9.2 Preparations for overhaul

Preparations

Action Note/Illustration
1. Before dismantling the circuit-breaker,
and during the course of the work, the
instructions in Safety on page 23 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.

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9 Overhaul
9.3 Removing of SF6-gas

9.3 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

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 9 Overhaul
9.3 Removing of SF6-gas

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

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9 Overhaul
9.4 Cleaning and waste management

9.4 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 aluminum contact surfaces
Cleaning cloth E.g. Scotch-Brite, for contact copper surfaces
Industrial spirit 95% (vol) C2H5OH, for cleaning internal surfaces
Thick plastic foil and plastic For prevention of moisture penetration and to protect
bags cleaned parts prior to installation.

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.

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 9 Overhaul
9.5 Removal of circuit-breaker pole for transport

9.5 Removal of circuit-breaker pole for transport

General

Before removing the circuit-breaker pole, the circuit-breaker is to be taken out of

service, see section Preparations for overhaul on page 118, and the gas removed, see
section Removing of SF6-gas on page 120.

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 9-350 Nm
Torque tool 1HSB426883-3
Lifting device -
Lifting tackle -

Dismantling

The following instructions describe the removal of the circuit-breaker pole for
transport.
Action Note/Illustration
1. Loosen the poles' gas connections by
unscrewing all three nuts to the mark
(1) on the non-return valve (2).

1. Mark
2. Non return valve
3. Sealing cap
2. Now remove all nuts
3. Fit the sealing caps (3).

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9 Overhaul
9.5 Removal of circuit-breaker pole for transport

Action Note/Illustration
4.

DANGER!
The lifting tackle used to lift the circuit-
breaker pole must be dimensioned for
the weight.
• The polymer circuit-breaker
pole weighs about 130 kg.
• The porcelain circuit-breaker
pole weighs about 300 kg.
See dimensional drawing for exact
weights.
5. Put a lifting sling under the breaking
unit's upper flange and secure with a
lifting crane.
NOTE!
For composite insulators: Place the lifting sling
as close as possible to the flange. Do not place
it on the rubber surface.
6. Remove the transmission rod's eye
bolt from the circuit-breaker's outer
lever by removing the shaft end (1)
after you have removed the lock
washer at the rear.

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 9 Overhaul
9.5 Removal of circuit-breaker pole for transport

Action Note/Illustration
7. Loosen the circuit-breaker pole at the
four bolts (1) in the pole beam.

1. Bolt M 16x60, nut M16, washer 17x30x3

8. Release the circuit-breaker's operating
shaft from the torsion rod by pushing
the circuit-breaker pole laterally. Start
with pole A or pole C and end with pole NOTE!
B. When the circuit-breaker pole is removed, the
torsion rod will hang freely. The torsion rods are
painted and must be handled with caution thus
ensuring they are not damaged.
9. Lift up the circuit-breaker pole and
carefully lay it on a handling trolley.
Block up underneath so that it is
horizontal.
10. The blocks (3) under the breaking
unit's insulators are to be of elastic
material e.g. wood or rubber.

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9 Overhaul
9.6.1 Dismantling of breaking unit from the post insulator

9.6 Overhaul of circuit-breaker pole

9.6.1 Dismantling of breaking unit from the post insulator

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 Operating shaft
2 Bolt M12x80 (4 pcs), washer 13x28x3 (8 pcs), nut M12 (4 pcs)
3 Post insulator
4 Breaking unit
5 Lock washer SL12
6 Pin D=12
7 Insulating pull-rod

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 9 Overhaul
9.6.1 Dismantling of breaking unit from the post insulator

Requisite equipment

Equipment ABB part no. Note

Standard tools -
Lifting device -
Lifting tackle -
Torque tool 1HSB426883-3

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. Turn the operating shaft (1) anti-
clockwise to the contacts' closed
position.
NOTE!
Use the torque tool.
2.

DANGER!
The lifting tackle used to lift the circuit-
breaker pole must be dimensioned for
the weight.
• The polymer circuit-breaker
pole weighs about 130 kg.
• The porcelain circuit-breaker
pole weighs about 300 kg.
See dimensional drawing for exact
weights.
3. Fit the lifting devices from the top of the
breaking unit to the hoist or overhead
crane.
NOTE!
Stretch the lifting device moderately.
For composite insulators: Place the lifting sling
as close as possible to the end flange and not
on the rubber surface.
4. Remove the bolts (2) between post
insulator (3) and breaking unit (4)
5. Lift the breaking unit 75 - 100 mm.

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

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9 Overhaul
9.6.1 Dismantling of breaking unit from the post insulator

Action Note
6. Remove the lock washer (5) and the
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.
7. 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.

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 9 Overhaul
9.6.2 Removal of post insulator

9.6.2 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 Bolt M 16x50, washer 17x30x3
3 Mechanism housing
4 Lock washer SL1 6
5 Pin D=20
6 Insulating pull-rod
7 Lower lock nut
8 Turnbuckle screw
9 Upper lock nut

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9 Overhaul
9.6.2 Removal of post insulator

Safety

NOTE!
Use personal protective 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.
Torque tool 1HSB426883-3 Delivered in accessories box

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. See dimensional
drawing for exact weights.
2. Fit the lifting devices from the top of the
post insulator to the hoist or overhead
crane.
3. Remove the post insulator bolts (2)
from the mechanism housing (3).

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 9 Overhaul
9.6.2 Removal of post insulator

Action Note
4. If the insulating pull-rod is to be
dismantled, the x distance must be
measured on the old bar:
Lift the post insulator sufficiently so
that the internal turnbuckle screw (8) is
accessible for measurement and
measure the x dimension. Save the
note for the assembly.

5. Remove the nuts (7, 9) to loosen the

turnbuckle screw (8).
6. Lift the post insulator (1) straight up
from the mechanism housing (3) until
the insulating pull-rod (6) moves freely.
Hold the insulating pull-rod when NOTE!
lifting. Be careful not to damage the insulating pull-
rod.
7. Clean the insulating pull-rod with care
and protect it with plastic foil.
8. Clean the post insulator with care
internally and externally and protect it
with plastic foil.

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9 Overhaul
9.6.3 Overhaul of mechanism

9.6.3 Overhaul of mechanism

General

This section describes the overhaul of the complete mechanism (shown in the figure
below).

Structure

1 Mechanism housing
2 Inner operating lever
3 Operating shaft
4 Radial seal
5 Lock ring
6 Ball bearings
7 Bushing
8 O-ring 49.2 x 5.7 (located outside bushing pos. 7)
9 X-ring 49.2 x 5.7 (located inside bushing pos. 7)
10 Pin D = 20 mm
11 Linkage joint
12 Lock washer SL1 6

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 9 Overhaul
9.6.3 Overhaul of mechanism

Remember!

NOTE!
Clean the mechanism through vacuuming and drying. Check the bearings and replace
all sealing rings.

Requisite equipment

Equipment Part number Note

Grease "S" 1171 4014-406 Detailed information is specified in section Types
of grease on page 31.
Grease "G" 1171 4014-407 Detailed information is specified in section Types
of grease on page 31.

Instructions

The item numbers in the instructions below correspond to the item numbers in
Structure on page 132.
Action Note
1. Remove the radial seals (4).
2. Remove the lock rings (5).
3. Knock/pull out the operating shaft (3). The ball bearings and the bushing on one side
follow when you knock/pull out the operating
shaft.
4. Knock/pull out the other ball bearings
and the other bushing.
5. Inspect the ball bearings (6). Replace the ball bearings where damage is
identified!
• Do not lubricate these.
6. Inspect the bushings (7) that keep the Replace the bushings if damage is discovered.
sealing rings in place.
7. Replace the sealing rings (8, 9) in the
bushings (7) and lubricate with grease
"S".
• Fill the space between the
sealing rings with grease.
8. Press in the bushing (7) and ball
bearings (6) on one side. Fit the circlip
(5).
NOTE!
Turn the bearings' sealing rings toward the
circlip and place the bushing against the gas
space.
Press in the bearings and bushing together to
avoid creating an air pocket.
9. Refit the operating shaft (3) through The shaft (3) and the inner operating lever (2)
the inner operating lever (2). each have a blind tooth and these must be
aligned. Be sure to rotate the shaft (3) correctly
in order to guide it through the inner operating
lever (2).

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9 Overhaul
9.6.3 Overhaul of mechanism

Action Note
10. Press in the bushing (7) and ball
bearings (6) on the other side. Fit the
circlip (5).
NOTE!
Turn the bearings' sealing rings toward the
circlip and place the bushing against the gas
space.
Press in the bearings and bushing together to
avoid creating an air pocket.
11. Apply grease "G" to the circlips (5).
12. Fit the new radial seals (4).

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 9 Overhaul
9.7.1 Treatment of contact surfaces

9.7 Assembly of circuit-breaker pole

9.7.1 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
31 for more information on the grease.
Grease "P" 1171 5011-102 See section Types of grease on page
31 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 "P"grease.

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9 Overhaul
9.7.1 Treatment of contact surfaces

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.

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 9 Overhaul
9.7.2 Treatment of sealing surfaces and seals

9.7.2 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 31.
Grease "S" 1171 4014-406 For moving seals, e.g. shaft seals,
see Grease "S" on page 32.

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").

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9 Overhaul
9.7.3 Assembly of post insulator

9.7.3 Assembly of post insulator

General

This section describes the assembly of post insulators.

Structure

1 Post insulator
2 Bolt M16x50 (4 pcs) Washer 17x30x3 (8 pcs)
3 Mechanism housing
4 Insulating pull-rod
5 Sealing ring 169.5x5.6
6 Lower lock nut
7 Turnbuckle screw
8 Upper lock nut
9 The insulating pull-rod's key handle

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 9 Overhaul
9.7.3 Assembly of post insulator

Requisite equipment

Equipment Part number Note

Standard tools -
Torque wrench - Torque 79-100 Nm.
Torque tool 1HSB426883-3
Locking fluid "C" 1269 0014-408 More information about locking fluid is
specified in Locking fluid on page 33.
Grease "G" 1171 4014-407 More information about grease is
specified in Types of grease on page 31.

Instructions

The item numbers in the instructions’ text refer to the illustration in Structure on page
138.
Action Note/Illustration
1.

NOTE!
Be careful not to damage the insulating
pull-rod.
2. If the insulating pull-rod has been
removed, the x distance is adjusted in
accordance with the dimension of the
old pull-rod:
Adjust the x dimension so that it
matches the notation made when the
post insulator was removed.

NOTE!
The turnbuckle screw (7) must be
screwed in the same amount in the
linkage joint and the insulating pull-rod.

3. Tighten both nuts (6, 8) that lock the

turnbuckle screw. Use locking fluid "C"

Torque!
100 Nm.
4. Lubricate and place the sealing ring (5)
on the mechanism housing (3).

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9 Overhaul
9.7.3 Assembly of post insulator

Action Note/Illustration
5.

DANGER!
The lifting tackle used to lift the circuit-
breaker pole must be dimensioned for
the weight.
• The polymer circuit-breaker
pole weighs about 130 kg.
• The porcelain circuit-breaker
pole weighs about 300 kg.
See dimensional drawing for exact
weights.
6. Lift the post insulator (1).

NOTE!
Hold the insulating pull-rod during assembly so
that it does not scratch the post insulator.
7. Fit bolts with washers (2) and tighten.

Torque!
79 Nm

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 9 Overhaul
9.7.4 Assembly of breaking unit on the post insulator

9.7.4 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 O-ring 169.5x5.6
3 Post insulator
4 Lower adapter plate
5 Pin D=12
6 Lock washer SL12
7 Bolt M12x80 (4 pcs), washer 13x28x3 (8 pcs), nut M12 (4 pcs)
8 Insulating pull-rod
9 Upper adapter plate
10 Sealing ring 194.6x5.6
11 Container for absorbent
12 Cover
13 Bolt M10x30, washer 10.5x20x2
14 Breaking unit

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9 Overhaul
9.7.4 Assembly of breaking unit on the post insulator

Requisite equipment

Equipment Part number Note

Lifting device -
Lifting tackle -
Standard tools -
Torque tool 1HSB426883-3
Torque wrench - Torque range 45-79 Nm.
Grease “G” 1171 4014-407 See detailed information in section Types
of grease on page 31.

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. For assembly of replacement unit:
Reduce the nitrogen pressure in the
breaking unit (14) to atmospheric
pressure and remove the protective
cover.
3. 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. NOTE!
For composite insulators: Place the lifting sling
as close as possible to the end flange and not
on the rubber surface.
4. Clean the sealing surface on the
sealing ring (2) on the post insulator (3)
carefully.
5. Also clean the lower flange and
adapter plate (4) and lubricate
generously with grease “G” to ensure
the sealing ring is kept in place during
assembly.
6. Place the sealing ring (2) in its slot.
7. Slowly lower the breaking unit (14) so
that it comes into position for fitting the
pin (5), around 75-100 mm above the
post insulator (3).

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 9 Overhaul
9.7.4 Assembly of breaking unit on the post insulator

Action Note
8. Connect the puffer's pull-rod (1) to the
insulating pull-rod (8) with the pin (5)
and lock using a lock washer (6).
9. When the pin is fitted, lower the
breaking unit carefully down towards
the post insulator and centre.
10. Secure the breaking unit with bolts,
washers and nuts (7).

Torque!
79 Nm.
11. Remove the bolts (13 ) and the cover
(12) and lift out the container for the
absorbent (11).
12. Clean the sealing surface on the upper
flange and adapter plate (9) and
lubricate with grease “G”.
13. Place the sealing ring (10) on top of the
upper flange.
14. Open the packaging to new absorbent
and apply this in the container (11).
15. Fit the container (11) and cover (12).
16. Tighten the bolts (13).

Torque!
45 Nm.

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9 Overhaul
9.7.5 Filling the gas before transport

9.7.5 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.

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 9 Overhaul
9.8.1 Dismantling of breaking unit for transport

9.8 Replacement of breaking unit

9.8.1 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 alternative 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 must be removed from service before the breaking unit is
dismantled, see Preparations for overhaul on page 118, the gas evacuated, see
Removing of SF6-gas on page 120, and filled to atmospheric pressure with nitrogen.

Preconditions

NOTE!
Under no circumstances may the breaking unit be dismantled or opened during rainy
or unstable weather.
NOTE!
This type of work may only be executed by personnel trained by ABB.
NOTE!
If the post insulator or breaking unit is left for a long period without being refitted,
the post insulator, or breaking unit, is to be vacuum pumped and filled with nitrogen.

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9 Overhaul
9.8.1 Dismantling of breaking unit for transport

Structure

1 Operating lever
2 Bolt M12x80 (4 pcs), washer 13x28x3 (8 pcs), nut M12 (4 pcs)
3 Post insulator
4 Breaking unit
5 Lock washer SL12
6 Pin D=12
7 Insulating pull-rod

Requisite equipment

Equipment ABB part no. Note

Standard tools -
Lifting device -
Lifting tackle -
Torque tool 1HSB426883-3
Protective cover A 5439 142-A Fitted above the post insulator.
Protective cover R 5237 736-R Fitted on the breaking unit

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 9 Overhaul
9.8.1 Dismantling of breaking unit for transport

Instructions

The instructions below describe the dismantling of a breaking unit for transport.
Unless otherwise stated, the position numbers in brackets refer to the previous
illustration.
Action Note
1. Before removing the breaking unit the Se Preparations for overhaul on page 118 and
circuit-breaker is to be taken out of Removing of SF6-gas on page 120.
service.
2. Fill the circuit-breaker with nitrogen to
atmospheric pressure.
3. Remove the transmission rod eye bolt
from the circuit-breaker's outer
operating lever by removing the shaft
end (1) after you have removed the SL
lock washer, see the figure to the right.

4. Turn the operating lever (1) anti-

clockwise to the contacts' closed
position.
NOTE!
Use the torque tool!
5.

DANGER!
The lifting tackle used to lift the circuit-
breaker pole must be dimensioned for
the weight.
• The polymer circuit-breaker
pole weighs about 130 kg.
• The porcelain circuit-breaker
pole weighs about 300 kg.
See dimensional drawing for exact
weights.
6. Fit the lifting devices from the top of the
breaking unit to the hoist or overhead
crane.
NOTE!
Stretch the lifting device moderately.
For composite insulators: Place the lifting sling
as close as possible to the end flange and not
on the rubber surface.

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9 Overhaul
9.8.1 Dismantling of breaking unit for transport

Action Note
7. Remove the bolts (2) between post
insulator (3) and breaking unit (4)
8. Lift the breaking unit 75-100 mm.

NOTE!
The breaking unit must not be lifted more than
100 mm to avoid damage to the inside of the
circuit-breaker.
9. Remove the lock washer (5) and the
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.
10. Lift off the breaking unit completely and
place it vertically on a suitable surface,
such as on two cross bars, to ensure it
does not tip over. 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.
11. Press the insulating pull-rod (7) down
into the post insulator (3) so that the
entire insulating pull-rod is below the
edge.
12. Fit the protective cover A with the The cover part number is specified in Requisite
sealing ring above the post insulator equipment on page 146.
(3).

NOTE!
When the protective cover has been fitted, the
nitrogen pressure in the post insulator is raised
to 0.125 MPa abs.
13. Push the puffer pull-rod into the
breaking unit (4).
14. Fit protective cover R with a sealing The cover part number is specified in Requisite
ring on the breaking unit. equipment on page 146.
15. The breaking unit is now ready for
transport.

NOTE!
If the post insulator or breaking unit is left in this
condition for a long period without the unit
being refitted, the post insulator, or breaking
unit, is to be vacuum pumped and filled with
nitrogen.

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 9 Overhaul
9.8.2 Assembly of breaking unit on site following overhaul

9.8.2 Assembly of breaking unit on site following overhaul

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 O-ring 169.5x5.6
3 Post insulator
4 Lower adapter plate
5 Pin D=12
6 Lock washer SL12
7 Bolt M12x80 (4 pcs), washer 13x28x3 (8 pcs), nut M12 (4 pcs)
8 Insulating pull-rod
9 Upper adapter plate
10 Sealing ring 194.6x5.6
11 Container for absorbent
12 Cover
13 Bolt M10x30, washer 10.5x20x2
14 Breaking unit
15 Operating shaft

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9 Overhaul
9.8.2 Assembly of breaking unit on site following overhaul

Requisite equipment

Equipment Part number Note

Lifting device -
Lifting tackle -
Standard tools -
Torque wrench - Torque range 45-79 Nm.
Torque tool 1HSB426883-3
Grease “G” 1171 4014-407 See detailed information in section Types
of grease on page 31.
Control pin 1HSB539782-1 Used to check the open position after
assembly.

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 remove the protective
cover.
NOTE!
For composite insulators: Place the lifting sling
as close as possible to the end flange and not
on the rubber surface.
3. Pull down the puffer pull-rod (1) to fully
extended position making it accessible
for assembly.
4. Reduce the nitrogen pressure in the The protective covers must be removed on all
post insulator (3) to atmospheric poles at the same time.
pressure and remove the protective
cover from the post insulator.
5. Turn the operating lever (15) anti-
clockwise to its closed position to
ensure that the breaking unit can be
fitted. NOTE!
Use the torque tool.
6. Clean the sealing surface on the
sealing ring (2) on the post insulator (3)
carefully.

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 9 Overhaul
9.8.2 Assembly of breaking unit on site following overhaul

Action Note
7. Also clean the lower flange and
adapter plate (4) and lubricate
generously with grease “G” to ensure
the sealing ring is kept in place during
assembly.
8. Place the sealing ring (2) in its slot.
9. Slowly lower the breaking unit (14) so
that it comes into position for fitting the
pin (5), around 75-100 mm above the
post insulator (3).
10. Connect the puffer's pull-rod (1) to the
insulating pull-rod (8) with the pin (5)
and lock using a lock washer (6).
11. When the pin is fitted, lower the
breaking unit carefully towards the
post insulator and centre.
12. Secure the breaking unit with bolts,
washers and nuts (7).

Torque!
79 Nm.
13. Remove the bolts (13 ) and the cover
(12) and lift out the container for the
absorbent (11).
14. Clean the sealing surface on the upper
flange and adapter plate (9) and
lubricate with grease “G”.
15. Place the sealing ring (10) on top of the
upper flange.
16. Open the packaging to new absorbent
and apply this in the container (11).
17. Fit the container (11) and cover (12).
18. Tighten the bolts (13).

Torque!
45 Nm.

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9 Overhaul
9.8.2 Assembly of breaking unit on site following overhaul

Action Note
19. Attach the transmission rod's eye bolt
to the circuit-breaker pole's operating
lever with the shaft end (1) and lock
with a lock washer at the rear, see the
figure to the right.

20. Check the open position using the The part number of the guide pin is specified in
control pin that is to run through the Requisite equipment on page 150.
hole of the outer lever and the hole in
the mechanism housing.
21. Fill the circuit-breaker pole with gas.
1. Vacuum pump down to a
pressure of 100 Pa and let the
NOTE!
vacuum pumping continue for
at least one hour after this Store the filling hoses in a way that does
pressure has been reached. expose them to moisture and contamination.
They must not be used for anything other than
2. Stop the vacuum pumping and 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).
22. The circuit-breaker is now ready for See Gas filling with SF6-gas on page 80.
gas filling.

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 9 Overhaul
9.9 Assembling the circuit-breaker poles and commissioning

9.9 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 Installation
on page 47. Following assembly the operating values of the circuit-breaker must be
checked and recorded.

First overhaul

CAUTION!
The circuit-breaker may not be operated from 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): ________________________________________

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9 Overhaul
9.9 Assembling the circuit-breaker poles and commissioning

Second overhaul

CAUTION!
The circuit-breaker may not be operated from 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): ________________________________________

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 10 Repairs
10.1 Overview

10 Repairs
10.1 Overview

General

This chapter contains instructions on how you replace the operating mechanism's
spare parts, that feature in chapter Spares on page 203.
There is also information on each section on the equipment required to implement
the repairs in question, i.e. relevant spare part numbers, tools to be used, lubricant, etc

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10 Repairs
10.2.1 Removal and assembly of casing

10.2 Operating mechanism

10.2.1 Removal and assembly of casing

General

The operating mechanism's casing may at times have to be removed in order to

access components of the operating mechanism. This section contains information
on removing and fitting the casing.

Structure

The illustrations below show the casing on the operating mechanism.

1 Retaining bolts for casing, M16 x 35 (4 pcs)

2 Retaining bolts for casing, M10 x 20 (4 pcs)

Requisite equipment

Equipment Part number Note

Standard tools -

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 10 Repairs
10.2.1 Removal and assembly of casing

Removal of the casing

The instructions below describe how you remove the casing from the operating
mechanism.
Action Note/Illustration
1.

DANGER!
Before working on the operating
mechanism:
• the motor current must be cut.
• the circuit-breaker must be
open, disconnected and
earthed.
• the closing and trip springs
must be discharged; see
section Release the spring
charge on page 28.
• the circuit-breaker (control
switch) must be in
DISCONNECTED position
2. Remove the earth plate (1) inside the
cabinet.

1. Earth plate

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10 Repairs
10.2.1 Removal and assembly of casing

Action Note/Illustration
3. Remove the cable plate under the
cabinet by unscrewing the retaining
bolts (1).

1. Bolt M8x25, (8 pcs)

4. Unlock the bolts (1) at the rear of the
casing and the bolts (2) underneath.
Lower the whole casing carefully.

1. Bolt M16x35, (4 pcs).

2. Bolt M10x20, (4 pcs).

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 10 Repairs
10.2.1 Removal and assembly of casing

Removal of the casing.

The instructions below describe how the casing is fitted to the operating mechanism.
Action Note
1. Move the casing up over the operating
mechanism and attach using the four
bolts (1) at the rear and the retaining
bolts (2) under the cabinet.

1. Bolt M16x35 (4 pcs).

2. Bolt M10x20 (4 pcs).

Torque!
M16: 100 Nm
M10: 45 Nm
2. Attach the cable plate using retaining
bolts (1) under the casing.

1. Bolt M8x25 (8 pcs)

Torque!
M8: 22.5 Nm

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10 Repairs
10.2.1 Removal and assembly of casing

Action Note
3. Refit the earth plate (1) inside the
cabinet.

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 10 Repairs
10.2.2 Replacement of coil

10.2.2 Replacement of coil

General

This section contains information on replacing the closing coil Y3 and trip coils Y1
and Y2.

Structure

The figure below shows the position of the coils in the operating mechanism. The
figure shows the operating mechanism without casing, but the coils can be replaced
without removing the casing.

1 Closing coil Y3
2 Tripping coil Y1
3 Tripping coil Y2

Requisite equipment

Equipment Part number Note

Closing coil Y3 (110/220 V) EXIN400834-R9
Tripping coil Y1 (110/220 V) EXIN400834-R9
Tripping coil Y2 (11 0/220 V) EXIN400833-R9
Standard tools

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10 Repairs
10.2.2 Replacement of coil

Replacement of coil

The instructions below describe the removal and assembly of the coils. The same
instructions apply to all coils.
Action Note/Illustration
1.

DANGER!
Before working on the operating
mechanism:
• the motor current must be cut.
• the circuit-breaker must be
open, disconnected and
earthed.
• the closing and trip springs
must be discharged; see
section Release the spring
charge on page 28.
• the circuit-breaker (control
switch) must be in
DISCONNECTED position
2. Remove the cover (1) from the coil to
be replaced.

3. Remove the cables from the coil.

4. Loosen both retaining nuts but only
remove one nut completely.
5. Remove the coil by pushing it up and
down.
6. Remove the cover to the new coil and
fit the coil in the cabinet by screwing it
to the retaining nuts.
7. Attach the cables to the coil.

NOTE!
Check the voltage!
8. Fit the cover.

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 10 Repairs
10.2.3 Replacement of tripping latch assembly

10.2.3 Replacement of tripping latch assembly

General

This section describes the replacement of the complete tripping latch assembly
including the coils.

Structure

The figure below shows the position of the tripping latch assembly in the operating
mechanism.

1 Tripping latch assembly

Requisite equipment

Equipment Part number Note

Tripping latch EXIN200410-R1
assembly
Locking fluid 1269 0014-408 Loctite 270
Standard tools
Torque wrenches 40 Nm
Liquefied petroleum May be needed to loosen the nuts
gas burner that are locked with Loctite.

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10 Repairs
10.2.3 Replacement of tripping latch assembly

Removal of tripping latch assembly

The instructions below describe how the tripping latch assembly is removed from the
operating cabinet.
Action Note
1.

DANGER!
Before working on the operating
mechanism:
• the motor current must be cut.
• the circuit-breaker must be
open, disconnected and
earthed.
• the closing and trip springs
must be discharged; see
section Release the spring
charge on page 28.
• the circuit-breaker (control
switch) must be in
DISCONNECTED position
2. Remove the casing from the operating
mechanism.
3. Remove the closing and trip springs to Follow the instructions Replacement of tripping
facilitate manual movement of the and closing latch device assembly on page 172
operating mechanism's opening lever. up until the point when the bolt is unscrewed
from the spring. Note that the spring does not
The lever is otherwise in the way when
need to be fully removed, but can be loosened
you need to remove the tripping latch
at one end.
device assembly.

NOTE!
Before removing the closing and trip
springs you must measure the A
dimension of the closing spring and the
B dimension of the trip spring!
Information on these dimensions is
given in section Replacement of
tripping and closing latch device
assembly on page 172.
4. Remove the covers from the trip coils
and remove their cables.
5. Remove the latch device from the
operating mechanism by removing the
retaining nuts on the outside.
The nuts are locked with Loctite and
may need to be heated carefully using
a LP-gas burner in order to be
removed.

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10.2.3 Replacement of tripping latch assembly

Action Note
6. Rotate the operating lever's opening
lever to release the latch device and
remove the assembly from the
operating mechanism.
There is not a lot of space for this task
and the latch device may need to be
positioned at different angles in order
to pull it out.

Assembly of tripping latch assembly

The instructions below describe how the tripping latch assembly is fitted inside the
operating mechanism.
Action Note
1. Angle and push in the latch device
under the operating mechanism's
opening lever.
2. Attach the latch device using the three
retaining nuts on the outside of the
operating mechanism. Use locking
fluid. NOTE!
Locking fluid, Loctite 270

Torque!
40 Nm
3. Connect the cables to each coil and
refit the old covers.
4. Refit the closing and trip springs. Note Follow the instructions Replacement of tripping
the original A and B dimensions! and closing latch device assembly on page
172.
5. Refit the operating mechanism casing. Described in section Removal and assembly of
casing on page 156.

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10.2.4 Replacement of closing latch assembly

10.2.4 Replacement of closing latch assembly

General

This section describes the replacement of the complete closing latch assembly
including the coils.

Structure

The figure below shows the position of the closing latch assembly in the operating
mechanism.

1 Closing latch assembly

Requisite equipment

Equipment Part number Note

Closing latch EXIN200416-R1
assembly
Locking fluid 1269 0014-408 Loctite 270
Standard tools
Torque wrenches 40 Nm
Liquefied petroleum May be needed to loosen the nuts
gas burner that are locked with Loctite.

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10.2.4 Replacement of closing latch assembly

Removal of closing latch assembly

The instructions below describe how the closing latch assembly is removed from the
operating cabinet.
Action Note/Illustration
1.

DANGER!
Before working on the operating
mechanism:
• the motor current must be cut.
• the circuit-breaker must be
open, disconnected and
earthed.
• the closing and trip springs
must be discharged; see
section Release the spring
charge on page 28.
• the circuit-breaker (control
switch) must be in
DISCONNECTED position
2. Remove the casing from the operating
mechanism.
3. Remove the closing and trip springs to Follow the instructions Replacement of tripping
facilitate manual movement of the and closing latch device assembly on page 172
operating mechanism's closing lever. up until the point when the bolt is unscrewed
from the spring. Note that the spring does not
The lever is otherwise in the way when
need to be fully removed, but can be loosened
you need to remove the closing latch
at one end.
device assembly.

NOTE!
Before removing the closing and trip
springs you must measure the A
dimension of the closing spring and the
B dimension of the trip spring!
Information on these dimensions is
given in section Replacement of
tripping and closing latch device
assembly on page 172.

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10.2.4 Replacement of closing latch assembly

Action Note/Illustration
4. Remove the pin installed in between
as shown in the figure to the right, and
a small black pin further forward on the
latch device.

1. Attachment slot for spring; the picture is

taken from the rear of the operating
mechanism.
5. Remove the pin fully as shown in the
illustration in the previous step.
6. Loosen the damper from its upper
bracket.
7. Remove the position indicator module.
8. Remove the bolt (1) that holds the
operating mechanism's closing lever in
place on the main shaft.

9. Push the closing lever to the side of the

main shaft, to make room for removing
the latch device.
10. Remove the covers from the coils and
remove their cables.

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10.2.4 Replacement of closing latch assembly

Action Note/Illustration
11. Remove the latch device from the
operating mechanism by removing the
retaining nuts on the outside.
The nuts are locked with Loctite and
may need to be heated carefully using
a LP-gas burner in order to be
removed.
12. Pull out the latch device from the
cabinet.

CAUTION!
The latch device's two plates are not
linked together which means they can
fall apart when the assembly is pulled
out!
There is not a lot of space for this task
and the latch device may need to be
positioned at different angles in order
to pull it out.

Assembly of closing latch assembly

The instructions below describe how the closing latch assembly is fitted inside the
operating mechanism.
Action Note/Illustration
1. Angle and push in the latch device into
the operating mechanism.
NOTE: Ensure that the mechanical
interlock arm (1 ) on the latch device
runs against the head (2) on the main
shaft, see the figure to the right!

1. Mechanical interlock arm.

2. Head
3. Main shaft

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10.2.4 Replacement of closing latch assembly

Action Note/Illustration
2. Attach the latch device using the two
retaining nuts on the outside of the
operating mechanism. Use locking
fluid. NOTE!
Locking fluid, Loctite 270

Torque!
40 Nm
3. Connect the cables to each coil and
refit the old covers.
4. Push the closing lever back to the
correct position on the main shaft and
attach it using the retaining bolt.
5. Refit the position indicator module.
6. Attach the damper.
7. Refit the pin to the spring bracket
(shown in the figure in the next step).

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10.2.4 Replacement of closing latch assembly

Action Note/Illustration
8. Refit the spring in the latch device. The
short hook on the spring (2) is to be
attached around the slot on the pin (1)
and the long hook on the spring (3) is
to be attached around the small black
pin on the latch device.
Note that the spring is to be turned to
ensure the opening on the hooks is
facing down!

1. Attachment slot for spring; the picture is

taken from the rear of the operating
mechanism.
2. Short hook on spring
3. Long hook on spring
9. Refit the closing and trip springs. Note Follow the instructions Replacement of tripping
the original A and B dimensions! and closing latch device assembly on page
172.
10. Refit the operating mechanism casing. Described in section Removal and assembly of
casing on page 156.

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10.2.5 Replacement of tripping and closing latch device assembly

10.2.5 Replacement of tripping and closing latch device assembly

General

This section describes the replacement of closing and trip springs that are delivered
as a complete assembly with the spring fitted to the attendant brackets.

Structure

The figure below shows the position of the closing and trip springs in the operating
mechanism.

1 Closing spring
2 Trip spring

Requisite equipment

Equipment Part number Note

Closing spring assembly 1HYB300784-A
Trip spring assembly 1HYB300785-A
Standard tools -
Locking fluid 1269 0014-408 Loctite 270

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10.2.5 Replacement of tripping and closing latch device assembly

Measurement of A-dimension of closing spring

The new closing spring must have the exact same pre tension as the old one when it
is fitted. Therefore, there must be a certain distance, known as A-dimension,
measured on the old spring before it is removed in order for the new spring to be
adjusted when fitting. The figure below shows the surfaces between which the A -
dimension is to be measured.

A The A dimension is the distance between the cast surface on the spring bracket and
the surface of the external diameter of the cylinder where the spring bolt runs
through.

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10.2.5 Replacement of tripping and closing latch device assembly

Measurement of B-dimension of trip spring

The new trip spring must have the exact same pre tension as the old one when it is
fitted. Therefore, there must be a certain distance, known as B-dimension, measured
on the old spring before it is removed in order for the new spring to be adjusted when
fitting. The figure below shows the surfaces where the B-dimension is to be
measured.

B The B dimension is the distance between the cast surface on the spring bracket and
the top side of the brass washer.

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10.2.5 Replacement of tripping and closing latch device assembly

Removal of spring assembly

The instructions below describe how the spring assembly is removed from the
operating mechanism. The instructions differ a little for the closing and trip springs,
which is also noted in the relevant steps in the instructions.
Action Note/Illustration
1.

DANGER!
Before working on the operating
mechanism:
• the motor current must be cut.
• the circuit-breaker must be
open, disconnected and
earthed.
• the closing and trip springs
must be discharged; see
section Release the spring
charge on page 28.
• the circuit-breaker (control
switch) must be in
DISCONNECTED position
2. Remove the casing from the operating Described in section Removal and assembly of
mechanism. casing on page 156.
3. Measure the A-dimension on the The dimensions are shown in the figures
closing spring or the B-dimension on Measurement of A-dimension of closing spring
the trip spring and save the notes until on page 173 and Measurement of B-dimension
assembling the new spring. of trip spring on page 174.

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10.2.5 Replacement of tripping and closing latch device assembly

Action Note/Illustration
4. Loosen the two nuts (1) on the spring. Closing spring:

Trip spring:

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10.2.5 Replacement of tripping and closing latch device assembly

Action Note/Illustration
5. Unscrew the bolt from the spring. Closing spring:

Trip spring:

6. Loosen the other end of the spring.

7. Pull out the spring.
Note the spacers that are located on
the inside and outside. Save the
washers as they must be put back
when the new spring is fitted.

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10.2.5 Replacement of tripping and closing latch device assembly

Fitting the spring assembly

The instructions below describe how the spring assembly is fitted inside the
operating mechanism. The instructions differ a little for the closing and trip springs,
which is also noted in the relevant steps in the instructions.
Action Note/Illustration
1. The spring must be turned the right Closing spring:
way in the operating mechanism, i.e.,
turned so that the the correct sides of
the spring are turned inward and
outward in the operating mechanism!
See detail figures to the right to
determine which side is to be facing
outwards.

Trip spring:

2. Use a spacer on the inside and one on

the outside of the spring bracket's
attachment hole and attach:
NOTE!
• the closing spring in the upper
end. Locking fluid, Loctite 270

• the trip spring in the lower end.

Use locking fluid.
3. Screw in the bolt to the spring. Screw The dimensions are shown in the figures
until the value of the A-dimension of Measurement of A-dimension of closing spring
the old closing spring and the B- on page 173 and Measurement of B-dimension
dimension of the old trip spring of trip spring on page 174.
matches the new spring.

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10.2.5 Replacement of tripping and closing latch device assembly

Action Note/Illustration
4. Tighten both nuts (1) on the closing Closing spring:
and trip springs.

Trip spring:

5. Refit the operating mechanism casing. Described in section Removal and assembly of
casing on page 156.

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10.2.6 Replacement of limit stop roller on the closing lever

10.2.6 Replacement of limit stop roller on the closing lever

General

This section contains information on the replacement of the limit stop roller on the
closing lever.

Structure

The figure below shows the position of the limit stop roller in the operating
mechanism.

1 Limit stop roller on the operating mechanism's closing lever

Requisite equipment

Equipment Part number Note

Limit stop roller Ø25 mm EXIN400805P1 The new limit stop roller must have the
same dimension as the old roller.
Needle bearing for roller Ø25 2213 887-20 Use a new bearing when replacing the
mm roller!
Limit stop roller Ø26.5 mm EXIN400805P2 The new limit stop roller must have the
same dimension as the old roller.
Needle bearing for roller 2213 887-20 Use a new bearing when replacing the
Ø26.5 mm roller!
Standard tools -
Grease “G” 1171 4014-407 More information on grease is given in
section Types of grease on page 31.

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10.2.6 Replacement of limit stop roller on the closing lever

Replacement of limit stop roller

The instructions below describe how the limit stop roller on the operating
mechanism's closing lever is replaced.
Action Note/Illustration
1.

DANGER!
Before working on the operating
mechanism:
• the motor current must be cut.
• the circuit-breaker must be open,
disconnected and earthed.
• the closing and trip springs must be
discharged; see section Release
the spring charge on page 28.
• the circuit-breaker (control switch)
must be in DISCONNECTED
position
2.

NOTE!
The new limit stop roller must have the
same dimension as the old roller.
3. Remove the safety washer (1).

4. Push out the shaft (2) and pull out the roller
(3). Take care of the two spacers on each
side of the roller.
5. Lubricate the new needle bearing with
grease “G” and put it in the new roller.
6. Place a spacer at each end of the roller, put
the parts in place and push in the shaft
through the washers and the roller with the
bearing.
7. Refit the safety washer and attach with the
bolt.

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10.2.7 Replacement of damper

10.2.7 Replacement of damper

General

This section contains information on replacing the damper.

Structure

The figure below shows the position of the damper in the operating mechanism as
seen from behind.

1 Damper

Requisite equipment

Equipment Part number Note

Damper 1HYB300862-A
Standard tools -
Split pins 9ABA113-62 2 pcs, 4x25 mm

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10.2.7 Replacement of damper

Replacement of damper

The instructions below describe how the damper is removed/fitted.

Action Note/Illustration
1.

DANGER!
Before working on the operating mechanism:
• the motor current must be cut.
• the circuit-breaker must be open,
disconnected and earthed.
• the closing and trip springs must be
discharged; see section Release the
spring charge on page 28.
• the circuit-breaker (control switch)
must be in DISCONNECTED position
2. Remove the casing from the operating Described in section Removal and
mechanism. assembly of casing on page 156.
3. Remove the split pin at the damper's upper
bracket.
4. Remove one of the split pins at the damper's
lower bracket.

5. Pull out the shaft end from each bracket and

remove the damper from the operating
mechanism.
6. Pull out the piston and measure the
maximum stroke.
7. Adjust the stroke of the new damper to match
the stroke on the old damper.
8. Put the new damper in place in the operating
mechanism and push the shaft end into the
upper and lower brackets.
9. Secure the shaft ends using new split pins. The dimension is specified in the table
Requisite equipment on page 182.
10. Refit the operating mechanism casing. Described in section Removal and
assembly of casing on page 156.

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10.2.8 Replacement of auxiliary contact

10.2.8 Replacement of auxiliary contact

General

This section contains information on replacing the auxiliary contact.

Structure

The figure below shows the position of the auxiliary contact in the operating
mechanism.

1 Auxiliary contact

Requisite equipment

Equipment Part number Note

Auxiliary contact EXIN300762-R1
Standard tools

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10.2.8 Replacement of auxiliary contact

Replacement of auxiliary contact

The instructions below describe how the auxiliary contact is removed/fitted.

Action Note/Illustration
1.

DANGER!
Before working on the operating
mechanism:
• the motor current must be cut.
• the circuit-breaker must be
open, disconnected and
earthed.
• the closing and trip springs
must be discharged; see
section Release the spring
charge on page 28.
• the circuit-breaker (control
switch) must be in
DISCONNECTED position
2. Remove the casing from the operating Described in section Removal and assembly of
mechanism. casing on page 156.
3. Remove the damper's upper bracket in Removal of the damper is described in section
order to release the linkage. Replacement of damper on page 182.
4. Remove the linkage's lower bracket
and remove the whole linkage.
5. Dismantle all contacts from the
auxiliary contact.
6. Remove the four retaining bolts (1) and
remove the auxiliary contact.

7. Fit the new auxiliary contact using the

four retaining bolts.
8. Reconnect all contacts to the new
auxiliary contact.

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10.2.8 Replacement of auxiliary contact

Action Note/Illustration
9. Refit the linkage.
1. Tighten the bolt (1) in the lower
bracket.
2. Refit the linkage in its upper
bracket together with the
damper.

1. The stop bolt for the linkage's lower

bracket, view from the side of the
operating mechanism.
Assembly of the damper is described in section
Replacement of damper on page 182.
10. Refit the casing on the operating Described in section Removal and assembly of
mechanism. casing on page 156.

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10.2.9 Replacement of gear housing and motor in the drive unit

10.2.9 Replacement of gear housing and motor in the drive unit

General

This section contains information on replacing the gear housing and motor in the
drive unit.

Structure

The figure below shows the position of the gear housing and motor in the operating
mechanism.

1 Gear housing
2 Motor

Requisite equipment

Equipment Part number Note

Gear housing EXIN300801-R1
Motor, type 220 V AC/DC EXIN-300802-R1
Motor, type 110 VAC/DC EXIN300802-R2
Standard tools -
Torque wrenches 40 Nm
Locking fluid 1269 0014-408 Loctite 270
Liquefied petroleum gas - May be needed to loosen the nuts that
burner are locked with Loctite.

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10.2.9 Replacement of gear housing and motor in the drive unit

Dismantling the complete drive unit

The instructions below describe how the complete drive unit with gears and motor is
removed from the operating mechanism.
Action Note/Illustration
1.

DANGER!
Before working on the operating
mechanism:
• the motor current must be cut.
• the circuit-breaker must be
open, disconnected and
earthed.
• the closing and trip springs
must be discharged; see
section Release the spring
charge on page 28.
• the circuit-breaker (control
switch) must be in
DISCONNECTED position
2. Remove the casing from the operating Described in section Removal and assembly of
mechanism. casing on page 156.
3. Remove the entire drive unit by
loosening the two retaining bolts (1)
from the side.

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10.2.9 Replacement of gear housing and motor in the drive unit

Action Note/Illustration
4. Lower the unit and remove the link
pipe that runs upwards.

5. Lift out the unit.

Replacement of gear housing/motor

The instructions below describe how the drive unit is dismantled, i.e., how the gear
housing and motor are replaced, following the removal of the entire drive unit for the
operating mechanism as per the previous instructions.
Action Note
1. Remove the four retaining bolts on the
motor.
2. Pull the motor out of the gear housing.
Ensure that the bushing remains in
place inside the gear housing when
fitting a new motor.
3. Replace the defect component and
refit the gear housing and motor.
Ensure the motor drive runs through
the bushing inside the gear housing.
4. Tighten the four retaining bolts on the
motor.
5. Fit the complete drive unit in the
operating mechanism again, as per the
following instructions.

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10.2.9 Replacement of gear housing and motor in the drive unit

Fitting the complete drive unit

The instructions below describe how the complete drive unit with gear housing and
motor is fitted in the operating mechanism.
Action Note/Illustration
1. Place the drive unit in the operating
mechanism together with the link pipe.

2. Attach the drive unit using the two

retaining bolts (1).
Use locking fluid.

NOTE!
Loctite 270

Torque!
40 Nm
3. Refit the operating mechanism casing. Described in section Removal and assembly of
casing on page 156.

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10.2.10 Replacement of limit switch

10.2.10 Replacement of limit switch

General

This section contains information on replacing the limit switch.

Structure

The figure below shows the position of the limit switch in the operating mechanism.

1 Limit switch

Requisite equipment

Equipment Part number Note

Limit switch, complete 1HYN700023R1
Blue contact HAGT444559P2
Yellow contact HAGT444559P5
Standard tools

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10.2.10 Replacement of limit switch

Replacement of limit switch

The instructions below describe how the limit switch is removed/fitted.

Action Note/Illustration
1.

DANGER!
Before working on the operating
mechanism:
• the motor current must be cut.
• the circuit-breaker must be
open, disconnected and
earthed.
• the closing and trip springs
must be discharged; see
section Release the spring
charge on page 28.
• the circuit-breaker (control
switch) must be in
DISCONNECTED position
2. Remove the casing from the operating Described in section Removal and assembly of
mechanism. casing on page 156.
3. Remove the two retaining bolts (1) and
remove the spring pin (2). Remove the
limit switch.

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10.2.10 Replacement of limit switch

Action Note/Illustration
4. Disconnect the cables from the limit
switch.
If there is only one of the contacts that
needs replacing, loosen the relevant
cables and replace the particular
contact.

5. Reconnect the cables to the new limit

switch.
6. Fit the new limit switch using the two
retaining bolts and insert the spring
pin.
7. Check the position of the limit switch
by placing a feeler gauge t = 0.3 mm,
between the spring arm and limit
switch wheel, see figure to the right.
The spring arm should just press
slightly against the bridge that drives
the contacts, in the position shown in
the figure.
Contact ABB AB for more instructions,
if the inspection shows that the
position of the new limit switch seems
incorrect.

t = 0.3 mm
8. Refit the casing on the operating Described in section Removal and assembly of
mechanism. casing on page 156.

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10.2.11 Replacement of eye bolt and bellows

10.2.11 Replacement of eye bolt and bellows

General

This section contains information on replacing the transmission rod's eye bolt and
bellows

Structure

The figure below shows the position of the transmission rod, eye bolt and bellows

1 Eye bolt for transmission rod

2 Bellows
3 Transmission rod

Requisite equipment

Equipment Part number Note

Eye bolt SWT331162R4
Bellows 1HYN400073P1
Standard tools -
Grease "G" 1171 4014-407 More information on the grease is given in
section Types of grease on page 31.
Strap Used for attaching the new bellows.

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10.2.11 Replacement of eye bolt and bellows

Removal of transmission rod

The instructions below describe how the transmission rod is removed from the
cabinet.
Action Note/Illustration
1.

DANGER!
Before working on the operating
mechanism:
• the motor current must be cut.
• the circuit-breaker must be
open, disconnected and
earthed.
• the closing and trip springs
must be discharged; see
section Release the spring
charge on page 28.
• the circuit-breaker (control
switch) must be in
DISCONNECTED position
2. Remove the casing from the operating Described in section Removal and assembly of
mechanism. casing on page 156.
3. Remove the pin (1) from the
transmission rod's upper bracket by
first removing the SL lock.

4. Cut the strap that holds the bellows in

place on the transmission rod.

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10.2.11 Replacement of eye bolt and bellows

Action Note/Illustration
5. Loosen the support bolt (2) from the
opening lever at the transmission rod's
lower bracket.

6. Remove the whole transmission rod

from the operating mechanism by
threading it through the bellows and
down through the top of the cabinet.

Replacement of eye bolt

The instructions below describe how the eye bolt is replaced on the transmission rod,
after the rod has been removed as per the previous instructions.
Action Note
1. Remove the retaining nut and unscrew
the eye bolt.
2. Lubricate the new eye bolt using "G"
grease.
3. Use the same washer, nut and bolt in
the new eye bolt.

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10.2.11 Replacement of eye bolt and bellows

Replacement of bellow

The instructions below describe how the bellows are replaced on the transmission
rod, after the rod has been removed as per the previous instructions.
Action Note/Illustration
1. Cut the strap on the bottom edge of the
bellows.
2. Fit new bellows and attach them with a
strap on the bottom edge.

Fitting of transmission rod

The instructions below describe how the transmission rod is refitted in the operating
mechanism.
Action Note/Illustration
1. Thread the transmission rod through
the top of the cabinet and through the
bellows up on the roof.
NOTE!
Check that the C-C distance between the eye
bolts is 456 mm.
2. Attach the bellows on the rod using a
strap (1).

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10.2.11 Replacement of eye bolt and bellows

Action Note/Illustration
3. Fit the transmission rod to the lower
bracket and lock using the support
screw (2) to the opening lever.

4. Fit the transmission rod to the upper

bracket and lock the pin (1) using SL
lock.

5. Refit the operating mechanism casing. Described in section Removal and assembly of
casing on page 156.

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 11 Disposal and environmental information
11.1 Disposal and recycling

11 Disposal and environmental information

11.1 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.

Circuit-breaker's component parts

The table below shows the circuit-breaker materials, its parts by weight and
examples of application areas.
Parts by weight in
Material percent Example of application areas

Porcelain Approx. Insulator

68
Composites Approx. Insulator
17
Metal
- Iron, steel and Approx. Approx. Supports, mechanism housing
aluminum 30 80 Current paths, puffer, contacts, cables
- copper
Rubber around 0.5 Approx. 1 Seals
Div. plastics Approx. Approx. 1 Insulators, pipes, cable entries, guide
0.5 ring, tape, bushings. Thermoplastic in
sleeves, nozzles, piping and collars
contain fluoride and are not suitable for
recycling, but can be disposed of.
Chemicals <0.5 <1

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11 Disposal and environmental information
11.1 Disposal and recycling

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.

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.

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 11 Disposal and environmental information
11.1 Disposal and recycling

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.

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11.2 Environment information, SF6 gas

11.2 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.

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 12 Spares
12.1 Introduction

12 Spares
12.1 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.

Summary, circuit-breaker

1 Circuit-breaker pole, RRR

2 Breaking unit
3 Post insulator
4 Pole beam with gas system
5 Operating mechanism, RRR
6 Support

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12.1 Introduction

Summary, operating mechanism

1 Damper
2 Closing coil
3 Tripping coils (2 pcs)
4 Closing spring assembly
5 Trip spring assembly
6 Drive unit with motor
7 Limit stop roller on closing lever
8 Bracket for limit switch

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 12 Spares
12.2.1 Circuit-breaker pole

12.2 Circuit-breaker pole

12.2.1 Circuit-breaker pole

Structure

Component parts

Item Designation Note

1 Breaking unit
2 Post insulator
3 Mechanism

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12 Spares
12.2.2 Breaking unit

12.2.2 Breaking unit

Illustration

Component parts

Item Designation Note

1. Complete breaking unit RR

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 12 Spares
12.2.3 Post insulator and insulating pull-rod

12.2.3 Post insulator and insulating pull-rod

Structure

Component parts

Item Designation Note

1 Post insulator RR
2 Insulating pull-rod RR

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12.2.4 Mechanism

12.2.4 Mechanism

Illustration

Component parts

Item Designation Note

1 Mechanism RR

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 12 Spares
12.2.5 Accessories

12.2.5 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)

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12.2.5 Accessories

Gasket set

Gasket set for full breaker.

Designation Part number Note
Gasket set 1HSB422100-CM R

Non return valve

Item Designation Part number Note

1 Non return valve 1HSB442541-C RR

Protective cover

Designation Part number Note

Protective cover for 5237 736-R R
breaking unit
Protective cover for 5439 142-A R
post insulator

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 12 Spares
12.3.1 Damper

12.3 Operating mechanism

12.3.1 Damper

Illustration

Component parts

Item Designation Part number Note

1 Damper 1HYB300862-A RR

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12 Spares
12.3.2 Latch device

12.3.2 Latch device

Illustration

Component parts

Item Designation Part number Note

1 Tripping latch assembly EXIN200410-R1 RR
- Closing latch assembly EXIN200416-R1 RR
2 Closing coil (11 0/220 V) EXIN400834-R9 R
2 Tripping coil 1 (110/220 V) EXIN400834-R9 R
- Tripping coil 2 (110/220 V) EXIN400833-R9 R

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 12 Spares
12.3.3 Heating element

12.3.3 Heating element

Illustration

Component parts

Item Designation Part number Note

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

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12.3.4 Open and closing latch device assembly

12.3.4 Open and closing latch device assembly

Structure

Component parts

Item Designation Part number Note

1 Closing spring assembly 1HYB300784-A RR
1 Trip spring assembly 1HYB300785-A RR

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 12 Spares
12.3.5 Eye bolt and bellows for transmission rod

12.3.5 Eye bolt and bellows for transmission rod

Structure

Component parts

Item Designation Part number Note

1 Eye bolt SWT331162R4 RR
2 Bellows 1HYN400073P1 RR

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12 Spares
12.3.6 Drive unit with motor and gear housing

12.3.6 Drive unit with motor and gear housing

Structure

Component parts

Item Designation Part number Note

1 Motor, type 220 V AC/DC EXIN300802-R1 R
1 Motor, type 110 VAC/DC EXIN300802-R2 R
2 Gear housing EXIN300801R1 RR

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12.3.7 Limit switch

12.3.7 Limit switch

Structure

Component parts

Item Designation Part number Note

1 Limit switch, complete 1HYN700023R1 RR
2 Blue contact HAGT444559P2 R
3 Yellow contact HAGT444559P5 R

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12.3.7 Limit switch

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 1HSB429954-10en / 2009-03-09

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