Instructional Manual For 145kV Breaker

Product manual
LTB 72.5-170D1/B 1HSB429954-10en
2-column support
Operating mechanism FSA 1
3-pole operation
2012-05-10
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 2012 ABB All rights reserved.

ABB AB
Circuit Breaker Unit
SE-771 80 Ludvika
Sweden
Telephone: +46(0) 240 782000

Telefax: +46(0) 240 782320
www.abb.com
1 Product description, circuit-breaker 7
1.1 Description ...........................................................................................................................................................7
1.2 Breaking principle ................................................................................................................................................9
1.3 Standards ............................................................................................................................................................10
1.4 Functional overview ........................................................................................................................................... 11
1.5 Gas system and density monitor ......................................................................................................................12
1.6 Description, SF6-gas..........................................................................................................................................13
2 Product description, operating mechanism 15

2.1 Structure and function .......................................................................................................................................15
2.2 Closing and opening operations and charging of the closing spring...........................................................17
2.3 Component parts ................................................................................................................................................18
2.3.1 Drive unit ...................................................................................................................................................18
2.3.2 Latch device with coils ..............................................................................................................................19
2.3.3 Damper .....................................................................................................................................................20
2.3.4 Auxiliary contact ........................................................................................................................................21
2.3.5 Heating element ........................................................................................................................................22
2.4 Preconditions for operation ..............................................................................................................................23
2.4.1 Preconditions for different operations .......................................................................................................23
3 Safety 25
3.1 Introduction ........................................................................................................................................................25
3.2 General safety information ................................................................................................................................26
3.2.1 Levels of safety risks.................................................................................................................................26
3.2.2 Hazardous working situations ...................................................................................................................28
3.2.3 Safety during maintenance .......................................................................................................................29
3.3 Safety related instructions ................................................................................................................................30
3.3.1 Warning - risk of crushing in the operating mechanism and link system ..................................................30
3.3.2 Discharging springs...................................................................................................................................31
4 Reference information 33
4.1 Oil types ..............................................................................................................................................................33
4.2 Types of grease ..................................................................................................................................................35
4.3 Locking fluid .......................................................................................................................................................37
4.4 Tightening torque ...............................................................................................................................................38
4.5 Requisite equipment, installation .....................................................................................................................39
4.6 Requisite equipment, maintenance ..................................................................................................................40
4.7 Requisite equipment, overhaul .........................................................................................................................41
4.8 Operating values ................................................................................................................................................42
5 Delivery 43
5.1 Delivery inspection ............................................................................................................................................43
5.2 Storage prior to assembly .................................................................................................................................44
5.3 Lifting the circuit breaker poles ........................................................................................................................46
5.4 Lifting the operating mechanism ......................................................................................................................48
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6 Installation 49
6.1 Installation in short steps ..................................................................................................................................49
6.2 Foundations........................................................................................................................................................51
6.3 Assembly of support on the foundation ..........................................................................................................52
6.4 Assembly of pole beam on the support ...........................................................................................................54
6.5 Fitting of operating mechanism on pole beam................................................................................................56
6.6 Assembly of circuit breaker poles. ...................................................................................................................58
6.7 Assembly of gas monitoring system................................................................................................................69
6.8 Electrical connections .......................................................................................................................................76
6.8.1 Connecting the circuit breaker's operating mechanism ............................................................................76
6.8.2 Fitting the rails or lines. .............................................................................................................................78
6.9 Pressurizing of circuit-breaker poles ...............................................................................................................79
6.9.1 Preparations..............................................................................................................................................79
6.9.2 Gas filling with SF6-gas ............................................................................................................................81
6.9.3 Filling of mixed gas ...................................................................................................................................85
6.10 Inspection prior to commissioning ..................................................................................................................89
6.10.1 Tightness check ........................................................................................................................................89
6.11 Inspection of bolt joints .....................................................................................................................................90
7 Commissioning 91
7.1 Introduction ........................................................................................................................................................91
7.2 Pre-commissioning check list...........................................................................................................................92
8 Maintenance 95
8.1 Introduction ........................................................................................................................................................95
8.2 Description of maintenance categories ...........................................................................................................96
8.3 Maintenance schedule .......................................................................................................................................97
8.4 Maintenance, circuit breaker pole ..................................................................................................................104
8.4.1 The service life of the circuit breaker ......................................................................................................104
8.4.2 The service life of the arcing contacts in the event of short circuit breaking ...........................................105
8.4.3 Cleaning and lubrication of circuit breakers ............................................................................................106
8.5 Maintenance, operating mechanism and link system...................................................................................107
8.5.1 Cleaning, lubrication, and rust protection of operating mechanism ........................................................107
8.5.2 Inspection of heating element ................................................................................................................. 110
8.5.3 Inspection of drive unit ............................................................................................................................ 111
8.5.4 Inspection of latch devices ...................................................................................................................... 112
8.5.5 Check of oil level in damper .................................................................................................................... 114
8.6 Rust protection .................................................................................................................................................115
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9 Overhaul 117
9.1 Preparations ..................................................................................................................................................... 117
9.1.1 Introduction............................................................................................................................................. 117
9.1.2 Preparations for overhaul ....................................................................................................................... 118
9.1.3 Evacuation of SF6 gas ........................................................................................................................... 120
9.1.4 Cleaning and waste management .......................................................................................................... 122
9.2 Removal of circuit-breaker pole for transport............................................................................................... 123
9.3 Overhaul of circuit-breaker pole..................................................................................................................... 126
9.3.1 Removal of the breaking unit from the post insulator ............................................................................. 126
9.3.2 Removal of post insulator ....................................................................................................................... 128
9.3.3 Overhaul of mechanism.......................................................................................................................... 131
9.4 Assembly of circuit-breaker pole ................................................................................................................... 134
9.4.1 Treatment of contact surfaces ................................................................................................................ 134
9.4.2 Treatment of sealing surfaces and seals ................................................................................................ 136
9.4.3 Assembly of post insulator...................................................................................................................... 137
9.4.4 Assembly of breaking unit on the post insulator ..................................................................................... 140
9.4.5 Filling gas before transport ..................................................................................................................... 143
9.5 Replacement of breaking unit......................................................................................................................... 144
9.5.1 Dismantling of breaking unit for transport............................................................................................... 144
9.5.2 Assembly of the breaking unit on site following an overhaul .................................................................. 148
9.6 Installation of circuit breaker poles and commissioning............................................................................. 152
10 Repairs 155
10.1 Overview ........................................................................................................................................................... 155
10.2 Operating mechanism ..................................................................................................................................... 156
10.2.1 Removal and assembly of casing........................................................................................................... 156
10.2.2 Coil replacement..................................................................................................................................... 160
10.2.3 Replacement of tripping latch assembly................................................................................................. 162
10.2.4 Replacement of closing latch assembly ................................................................................................. 165
10.2.5 Replacement of tripping and closing latch device assembly .................................................................. 170
10.2.6 Limit stop roller replacement on the closing lever .................................................................................. 178
10.2.7 Replacement of damper ......................................................................................................................... 180
10.2.8 Auxiliary contact replacement................................................................................................................. 182
10.2.9 Replacement of gear housing and motor in the drive unit ...................................................................... 185
10.2.10 Limit switch replacement ........................................................................................................................ 189
10.2.11 Replacement of eye bolt and bellows..................................................................................................... 192
11 Disposal and environmental information 197

11.1 Disposal and recycling.................................................................................................................................... 197
11.2 Environment information, SF6 gas ................................................................................................................ 199
1HSB429954-10en 2012-05-10 5
12 Spare parts 201
12.1 Introduction ......................................................................................................................................................201
12.2 Circuit-breaker pole .........................................................................................................................................203
12.2.1 Circuit-breaker pole.................................................................................................................................203
12.2.2 Breaking unit ...........................................................................................................................................204
12.2.3 Post insulator and insulating pull-rod ......................................................................................................205
12.2.4 Mechanism..............................................................................................................................................206
12.2.5 Accessories.............................................................................................................................................207
12.3 Operating mechanism......................................................................................................................................209
12.3.1 Damper ...................................................................................................................................................209
12.3.2 Latch device ............................................................................................................................................210
12.3.3 Heating element ...................................................................................................................................... 211
12.3.4 Open and closing latch device assembly ................................................................................................212
12.3.5 Eye bolt and bellows for transmission rod...............................................................................................213
12.3.6 Drive unit with motor and gear housing...................................................................................................214
12.3.7 Limit switch..............................................................................................................................................215
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1 Product description, circuit-breaker

1.1 Description
Assembly
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 2012-05-10 7
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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1.2 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 gas in the compression section is compressed
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 2012-05-10 9
1.3 Standards
IEC and ANSI/IEEE
The switch complies in applicable parts with the requirements of the IEC standard or
ANSI/IEEE.
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1.4 Functional overview
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.
1HSB429954-10en 2012-05-10 11
1.5 Gas system and density monitor
Gas pressure
The circuit breaker poles are delivered vacuum processed and filled with SF6 gas to a pressure
of 0.12-0.13 MPa abs at 20°C.
When commissioning, the SF6 gas or mixed gas must be topped off to the pressure specified
on the rating plate. Different gas pressures may occur depending on the different requirements
with respect to the lowest ambient temperature.
Density monitor
The circuit-breaker is fitted with a density monitor for checking the density of the gas. All
density monitors are fitted with a set of contacts that are to be connected to give an alarm in
the event of leakage. There are two levels for the alarm, these are:
• Level 1, alarm.
• Level 2, blocking.
NOTE!
A new or reconditioned circuit-breaker must be checked for tightness through reading the
density monitor after about one month. Following the initial control, it should be checked at 1-
2 year intervals in connection with the routine visual inspections.
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1.6 Description, SF6-gas
Gas stability
Sulfur hexafluoride SF6 is 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.
Dielectric strength (kV), 10 mm gap
1 Air
2 Oil
3 Vacuum
4 SF6, 0.1 MPa
5 SF6, 0.5 MPa
1HSB429954-10en 2012-05-10 13
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2 Product description, operating mechanism

2.1 Structure and function
General
The motor-charged spring operating mechanism is designed for operating the circuit breakers.
Assembly
The operating mechanism is enclosed in a cabinet.

The operating mechanism consists primary of two tension springs:
• The closing spring, which is automatically charged following each closing operation.
• The trip spring, which is charged during closing operations.
The main components and construction of the operating mechanism are shown in figure
Summary, operating mechanism on page 16. In the door to the operating cabinet, there is an
observation window for viewing 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.
The operating mechanism casing can be removed to facilitate maintenance and overhaul work.
Functional description
The closing spring is charged by a motor, via a worm gear, which produces the force and
thereby the possibility of a closing operation. A closing latch keeps the closing spring charged
and ready to close the circuit breaker. In the event of closing, force 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 is discharged and the circuit breaker opens.
1HSB429954-10en 2012-05-10 15
Summary, operating mechanism
A View from the rear

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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2.2 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 entails that the cam disc rotates via the closing
lever. The switching shaft is put in motion and the circuit-breaker closes. The trip spring in
turn, is charged and locked at the same time. The motor then charges the closing spring
following each closing operation, via the main shaft and worm gear. When the spring is
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 releases from the
switching shaft and the trip spring trips, thereby opening 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 2012-05-10 17
2.3 Component parts
2.3.1 Drive unit
Motor
The drive unit is delivered with motor for:

• 110 V DC or 110 VAC (50/60 Hz)
• 220 V DC or 220 V AC (50/60 Hz)
The motor must be able to charge the spring at 85% of nominal voltage (IEC).
1 Motor
2 Gear housing
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2.3.2 Latch device with coils
General
The operating mechanism has one closing coil and two tripping coils as standard, but can be
fitted with dual closing coils upon request.
Coil voltage:
- 110 V DC or 220 V DC
The standard rated output of the coils is 500 W.
1HSB429954-10en 2012-05-10 19
2.3.3 Damper
The operating mechanism is fitted with a damper to dampen the final phase of the tripping
travel.
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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 2012-05-10 21
2.3.5 Heating element
General
The operating mechanism is fitted with a heating element that prevents moisture. The heating
element must always be connected.
Technical data
The 70 W heating element is always connected, while the 140 W or 2 x 140 W heating
elements, for temperatures below -25°C, are thermostat controlled. Check the resistance where
necessary.
Voltage Resistance ±10 % Power
220 V 691 ohm 70 W
346 ohm 140 W
2 x 346 ohm 2 x 140 W
110 V 173 ohm 70 W
86 ohm 140 W
2 x 86 ohm 2 x 140 W
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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.
Tripping operation
A tripping operation for a closed circuit breaker can be performed when the "Local/Remote/
Disconnected" switch is in the "Local" position and the gas density is greater than the blocking
level.
Closing operation
A closing operation using the "Close/Open" control switch or electric remote impulse can only
be done if:
• The "Local/Remote/Disconnected" switch is in the "Remote" or "Local" setting.
• The closing spring is charged.
• The circuit breaker is in the open position and unlocked.
• The gas density is larger than the blocking level.
1HSB429954-10en 2012-05-10 23
Auto-reclosing
Auto-reclosing, Open-0.3s-Close-Open is possible if:

• The circuit breaker is closed.
• The "Local/Remote/Disconnected" switch is in the "Remote" setting.
• The operating mechanism's closing spring is fully charged when the operating cycle
begins.
For auto-reclosing, the substation's relay equipment can supply an immediate tripping 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
tripping operation starts, even though a tripping impulse has been given during the current
closing operation.
WARNING!
A delay of 0.3 s must always occur and will normally take place via the relay equipment in the
substation.
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3 Safety
3 Safety
3.1 Introduction
General
The safety chapter is divided into two sections:

• General safety information, important to read before any work can be begun. This
information applies to installation, repairs and maintenance of the circuit-breaker. See
General safety information on page 26.
• Read the safety-related instructions when a specific hazard is encountered while work is
underway. These safety instructions describe how to avoid and eliminate hazards that are
indicated in the installation, repair and maintenance instructions. See Safety related
instructions on page 30.
1HSB429954-10en 2012-05-10 25
3 Safety
3.2 General safety information
3.2.1 Levels of safety risks
Description
Throughout the manual, various types of safety risks are indicated. These are divided into five
different levels, depending on the degree of danger. The most serious level on this scale
provides a warning about serious personal injury or possible death, or major damage to a
product, if the instructions are not observed. The least serious is simply a comment on
important facts and conditions. The levels are indicated using symbols; see below.
Safety risks - Symbols and their meanings.
Descriptions of the symbols that appear in the manual are provided here, along with their
meanings.
DANGER!
The yellow, filled warning triangle warns that an accident will occur if the instructions are not
complied with and that it will result in serious personal 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 and accident can occur if the instructions are not
complied with and that it will result in serious personal injury or death and/or major damage
to the product.
It is used, for example, to warn such of dangers as: contact with high voltage, explosion or fire
risk, risk for toxic gases, risk of crushing, impacts, falls from high places, etc.
ELECTRIC SHOCK!
The symbol for electric shocks warns of electrical dangers that could cause serious injury or
death.
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3 Safety
CAUTION!
The round warning symbol warns that an accident may occur if the instructions are not
observed, and that this could result in injury and/or damage to the product.
It is also used to warn of risks that entail burns, eye injuries, skin damage, impaired hearing,
crushing or slipping injuries, tripping, impacts, falls from high places, etc.
In addition, it is used to warn of functional requirements when assembling or removing
equipment where there is a risk of damage to the product or a risk that might cause downtime.
NOTE!
The comment symbols indicate important facts and conditions.
Also used for any danger that could lead to damage to the plant only.
1HSB429954-10en 2012-05-10 27
3 Safety
3.2.2 Hazardous working situations
General
For all work on high-voltage circuit breakers, the risks below must be observed and
corresponding measures taken.
Hazardous working situations

Risk Action
Working close to high voltage. Disconnect and earth around the workplace. If work must be
carried out next to live plant components, the safety distance
must satisfy the applicable safety regulations.
Working on ladders and platforms Work must be executed in accordance with applicable
safety regulations. Avoid climbing ladders and platforms in
poor weather conditions.
Working with low voltage Cut the control voltage and where necessary the heater
Both AC and DC can be connected to the voltage as well.
operating mechanism and control
cabinet.
Working next to pressurized insulators. Work in proximity of the circuit breaker's insulators entailing
At normal working pressure, damage to risk for damage to the insulator may not be carried out until
the porcelain could cause it to splinter. the gas has been emptied to max. 0.125 MPa (abs.)
pressure.
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3 Safety
3.2.3 Safety during maintenance
General
For all work on high-voltage circuit breakers, the risks below must be observed and
corresponding measures taken.
The standard operating cycle is O - 0.3 s - CO - 3 min - CO. When testing circuit-breakers and
relay systems that include more than three closing operations, the time between the operations
should not be less than 1 minute.
Safety instructions
WARNING!
Damage to the insulator porcelain could cause it to splinter. When damage has been identified,
the insulator must be replaced.
WARNING!
Do not operate the operating mechanism without a load! The operating mechanism may
not be switched on, operated or have a charged trip and/or closing spring before all installation
and adjustment of the circuit-breaker is complete.
WARNING!
Work on the circuit breaker when there is a risk for mechanical damage to the insulators is to
be executed at reduced gas pressure, 0.125 MPa (abs).
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3 Safety
3.3 Safety related instructions
3.3.1 Warning - risk of crushing in the operating mechanism and link system
Description
Energy is stored in both the closing and trip springs. The operating mechanism may be tripped
by heavy vibrations or by unintentional contact of the mechanical interlocking components,
which could result in crushing injury.
Action
Action Note
1. Move the circuit breaker to the open position.
2. Discharging springs by disconnecting the motor During transport and when the operating
power and carrying out a closing and tripping mechanism is under assembly or stored, the
operation. closing and trip springs must be discharged for
safety reasons.
3. Disconnect and earth the high-voltage side.
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3 Safety
3.3.2 Discharging springs
General
For maintenance work that requires work on the circuit breaker or operating mechanism, it is
important that both the closing and trip springs are uncharged.
Overview, discharging springs electrically
1 Protective motor switch

2 Switch, Local/Remote/Disconnected
3 Spring charge indicator
4 Control switch, Close/Open
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3 Safety
Discharging springs electrically
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 Tripping-Closing-Tripping
operation.
4. Check that the spring is uncharged. The spring
charge indicator (3) shows uncharged spring.
5. The circuit breaker is in Open position.
6. Following completion of work the motor
protection (1)must be reset.
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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 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 -
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

ABB 1171 3011-102 1HSB875318-B
MOBIL Switch oil Univolt 42 (44) -
SHELL NYSWITCHO 3 -
NYSWITCHO 3x
OK Switch oil A65 -
Klte-Schalteroel X
1HSB429954-10en 2012-05-10 33
Oil S
Silicone oil designed for dampers in heavy operating mechanisms, like BLG and BLK models.
ABB 1173 7011-106 1HSB875318-C
SHELL DC 200 Fluid 200 CS -
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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.
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.
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 latching mechanisms in operating mechanisms that are to work in very cold
conditions.
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.
ABB 1171 4016-612 5316 381-J
Klüber Isoflex Topas NB 52 -
1HSB429954-10en 2012-05-10 35
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.
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.
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.
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.
ABB 1171 4016-610 5316 381-C
Statoil Electrical grease -
36 2012-05-10 1HSB429954-10en
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.
ABB 1269 0014-429 -
LOCTITE Ltd. Loctite 243 -
Locking fluid C
Strong locking fluid for locking and interlocking of bolts. Difficult to remove.
ABB 1269 0014-408 -
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 ethanol.
Spray the fluid on the surface in question or apply with a brush.
ABB 1269 0014-409 -
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).
ABB 1234 0011-126 -
1HSB429954-10en 2012-05-10 37
4.4 Tightening torque
General
This section specifies all tightening torques
Tightening torque, specified

Bolt joint Tightening torque (Nm)
Foundations 300-350 (M24)
500-550 (M30)
Density monitor/clamp nuts 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
38 2012-05-10 1HSB429954-10en
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 Torque wrenches 9-350 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 sections Types of grease on page 35 and
Grease "SV" Oil types on page 33 for ABB part numbers,
Grease "M" suppliers and trade names.
Contact paste -
Other documentation
Document ABB part no. Note
Dimension print and diagram -
applicable to the order
1HSB429954-10en 2012-05-10 39
4.6 Requisite equipment, maintenance
General
This section specifies the equipment needed for maintenance of the operating mechanism.
Tool
Ordinary tool equipment 6880 768-7 Torque wrenches (9-350 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 SA10.
damping curves and operating
values
Control pin 1HSB539782-1
Cleaning equipment
Equipment ABB part no. Note
Vacuum cleaner -
Lint-free drying cloths -
Lubricant
Grease "G" - See sections Types of grease on page 35 and
Grease "L" Oil types on page 33 for ABB part numbers,
Grease "M" suppliers and trade names.
Oil "S"
Antirust agent, Valvoline Tectyl 506 1241 0011-108
Locking fluid, Loctite 270 1269 0014-408
40 2012-05-10 1HSB429954-10en
4.7 Requisite equipment, overhaul
General
This section specifies the equipment needed for overhauling the circuit breaker.
Tool
Ordinary tool equipment 6880 768-7 Torque wrenches (9-350 Nm).
Lifting devices and slings. - Weights for the current circuit breaker are
specified on the dimension print applicable to
the order.
Gas treatment equipment - For evacuation, cleaning, compressing and
storage of used SF6 gas and instruments for
monitoring pressure and vacuums.
Test equipment for recording - For example Programma or ABB SA10.
damping curves and operating
values
Operating time meter -
Ohmmeter -
Leak detector for leak inspection -
Lubricant
Grease "G" - See sections Types of grease on page 35 for
Grease "N" ABB part numbers, suppliers and trade
Grease "P" names.
Grease "S"
Antirust agent, Valvoline Tectyl 506 1241 0011-108
Spare parts
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 5237 736-R
unit
Protective cover for post 5439 142-A
insulator
1HSB429954-10en 2012-05-10 41
4.8 Operating values
Times
Events Times
Close time coil I (and II) < 75 ms
Open time coil I < 45 ms
Open time coil II < 45 ms
Close-Open time 1 < 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 <42 µΩ
LTB 145D1/B <42 µΩ
LTB 170D1/B <46µΩ
Stroke
The stroke length is 85 -1/+2 mm.
42 2012-05-10 1HSB429954-10en
5 Delivery
5 Delivery
5.1 Delivery inspection
General
The material is packed in boxes and on pallets. The boxes are marked with package numbers
and gross weights. Other information is printed on a plate/label attached to two sides of the
boxes.
All packaging material is recyclable.
Damaged goods
Check on arrival that the delivery matches the order and delivery documents and that no
transportation damage has occurred. If damage is found or suspected, the boxes must be
opened and the damage photographed and documented.
In the event of missing material or if transportation damage has occurred, this must be
immediately reported to ABB AB.
1HSB429954-10en 2012-05-10 43
5 Delivery
5.2 Storage prior to assembly
circuit breaker
The circuit breakers must be stored in their original packaging where they are protected from
damage. The units must not stand in water and must primarily be kept in a horizontal position
indoors and above ground level, so as to avoid cracking or water damage.
The circuit breakers may also be stored outdoors, but then in an area protected from rain on a
dry, well-drained surface. If a tarpaulin is used, it must not be wrapped too tightly; air
circulation to the zinc-plated surfaces must not be hindered. Any moisture 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 moist environments without ventilation can cause discoloring of zinc-coated

surfaces. This discoloring is known as “white rust” and primarily consists of zinc oxide and
zinc hydroxide, and is the result of a chemical reaction between the pure zinc on the surface
and moisture.
The long-term rust protection will not be affected by the "white rust", and the steel-zinc layer
under the surface will remain unaffected. In accordance with applicable practice "white rust"
is not a reason for returning the goods.
NOTE!
Operating mechanisms must not be stored in damp environments as phosphatized surfaces can
be attacked by corrosion.
Storage requirements
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.
44 2012-05-10 1HSB429954-10en
5 Delivery
Stacking of packaging boxes
Packaging boxes of different sizes must never be stacked on top of each other (the pressure
could damage the lids of the lower boxes). If different sized boxes need stacking, a frame must
be used between the boxes to distribute the pressure.
WARNING!
Never stack more than three boxes on top of each other. Due to instability and the risk of
collapse the boxes need to be secured.
Spare parts
Spares must be stocked indoors in their original packing. This is particularly important for
rubber components, (such as seals) which also need protecting from sunlight to avoid drying
up. Gaskets have a limited service life, you should therefore avoid stocking them. Supports can
be stored outdoors.
1HSB429954-10en 2012-05-10 45
5 Delivery
5.3 Lifting the circuit breaker poles
General
The following section describes lifting of the circuit breaker poles.
Safety
WARNING!
In order that the correct lifting tackle is used it is extremely important to check the weight of
the circuit breaker pole. The weight of the circuit breaker pole is specified on the dimension
print applicable to the order.
CAUTION!
Please note the positioning of the lifting sling! With respect to polymeric insulators, the lifting
sling is to be placed as close as possible to the flange and not on the rubber surface.
NOTE!
The circuit breaker pole/poles are to be stored in transport boxes until immediately before
assembly.
Requisite equipment
Equipment Part number Note

Torque wrench Torque range 10-350 Nm
Lifting slings
Lifting device
Lifting illustration
1 Bolt joint
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5 Delivery
Lifting instructions
The following instructions describe the lifting of a circuit breaker pole.

Action Note/Illustration
1.
DANGER!
Lifting tackle that is dimensioned for the weight
must be used to lift the circuit breaker pole.
See dimension print for the exact weights.
2. Place a lifting sling around the top of the circuit See Lifting illustration on page 46.
breaker pole.
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.
3. Check that the bolts (1), have the correct See Lifting illustration on page 46.
tightening torque.
Torque!
79 Nm
4. Lift the circuit breaker pole from its horizontal
position in the transport packaging.
Start with pole B1.
1HSB429954-10en 2012-05-10 47
5 Delivery
5.4 Lifting the operating mechanism
Requisite equipment
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!
Use lifting tackle that is dimensioned for the
weight.
4. Lifting the operating mechanism.
48 2012-05-10 1HSB429954-10en
6 Installation
6 Installation
6.1 Installation in short steps
General
This section provides a summary of the installation procedure, i.e. at what stages the complete
circuit breaker with the support and operating mechanism andare to be installed.
WARNING!
Before assembling, check that the serial numbers on the support, circuit breaker pole and
operating mechanism match.
Overview
1 Circuit breaker pole

2 Pole beam
3 Support
4 Operating mechanism
1HSB429954-10en 2012-05-10 49
6 Installation
Summary of the installation
The instructions below provide 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 43.
2. Check that all the necessary tools are on hand. Requisite equipment, installation on page 39.
3. Check that the foundations meet all Foundations on page 51.
requirements for the installation.
4. Fit the support legs on the foundations. Assembly of support on the foundation on page
52.
5. Fit the pole beam on the support legs. Assembly of pole beam on the support on page
54.
6. Fit the operating mechanism. Fitting of operating mechanism on pole beam
on page 56.
7. Fit all circuit breaker poles. Assembly of circuit breaker poles. on page 58.
8. Fit the gas monitoring system. Assembly of gas monitoring system on page
69.
9. Install all electrical connections: Electrical connections on page 76.
• Connect the operating mechanism.
• Fit the rails or lines.
• Charge the closing spring electrically.
10. Pressurize the circuit breaker poles. Pressurizing of circuit-breaker poles on page
79.
11. Prepare for commissioning. Tightness check on page 89.
• Perform a tightness check. Inspection of bolt joints on page 90.
• Check the bolt joints.
50 2012-05-10 1HSB429954-10en
6 Installation
6.2 Foundations
General
The foundation for the circuit-breaker must be flat and horizontal. The figure below shows the
permitted tolerances in mm for the position of the foundation bolts and for the phase spacing.
Any deviations are to be adjusted using spacers; see section Assembly of support on the
foundation on page 52. 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 2012-05-10 51
6 Installation
6.3 Assembly of support on the foundation
General
This section describes how the support is fitted to the foundation.
Assembly
1 Foundation bolt, L>130 mm

2 Nut
3 Washer
4 Spacer
5 Foundations
6 Support base
NOTE!
Foundation bolt, nuts and spacers are not included in the delivery.
Requisite equipment
Standard tools -
Torque wrench - Torque 300-350 Nm for M24.
Torque 500-550 Nm for M30.
52 2012-05-10 1HSB429954-10en
6 Installation
Assembly
The following instructions describe the assembly of the support on the foundation.
Action Note
1.
DANGER!
weight.
2. Check that the supports are vertical.
3. Adjust the supports to the same level using the
nuts (2).
4. Fill the space between the lower nut and the
foundation using spacers.
NOTE!
The space should be as small as possible.
5. Tighten the lower nut (2) to the spacers (4).
Torque!
M24: tightening torque 300-350 Nm.
M30: tightening torque 500-550 Nm.
6.
NOTE!
Conduct final tightening of the supports after
fitting .
1HSB429954-10en 2012-05-10 53
6 Installation
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 Bolts M20x60 (8 pcs), washers (16 pcs), nuts M20 (8 pcs)
4 Washer Ø22 mm (option)
Requisite equipment

Torque wrench - Torque range 300-420 Nm
54 2012-05-10 1HSB429954-10en
6 Installation
Assembly instructions
The following instructions describe the installation of the pole beam on the support.
1. Lift the pole beam (1).
2. Carefully lower the pole beam (1) on to the
support legs (2).
3. Attach and tighten the bolts (3) between the

support (2) and pole beam (1).
Torque!
420 Nm.
4. Conduct final tightening of the support in the
foundation.
Torque!
300-350 Nm.
1HSB429954-10en 2012-05-10 55
6 Installation
6.5 Fitting of operating mechanism on pole beam
General
The operating mechanism is already adjusted on delivery, and with the closing spring correctly
set.
Assembly
1 Operating mechanism
2 Lifting brackets (4 pcs)
3 Pole beam
4 Washers 17x30x3 (4 pcs), spring washers 17x27.4x3.5 (4 pcs), nuts M16 (4 pcs)
56 2012-05-10 1HSB429954-10en
6 Installation
Safety
WARNING!
The operating mechanism may not be closed, operated nor have charged closing springs until
all tasks related to installation and adjustment of the circuit-breaker have been completed.
CAUTION!
The operating mechanism may only be lifted at the designated lifting brackets
Requisite equipment

Standard tools -
Lifting tackle -
Lifting device -
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
a 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 2012-05-10 57
6 Installation
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 installed in the order B1, A1 and finally C1.
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
Requisite equipment

Standard tools 6880-768-7
Torque tool 1HSB426883-3
Control pin 1HSB539782-1
Grease "G" See section Types of grease on page 35 for details
Grease "M" See section Types of grease on page 35 for details
58 2012-05-10 1HSB429954-10en
6 Installation
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 on page 46.
1. Lift the circuit breaker pole B1 in place and fit it
on the pole beam.
1. circuit breaker pole

2. Screw M16x60 (4 pcs), washer
17x30x3 (8 pcs), bolt M16 (4 pcs) ,
washer Ø18 mm (option).
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 46.
1HSB429954-10en 2012-05-10 59
6 Installation
2. Fit the bolts, washers and nuts (1) and tighten
finger tight.
1. Bolt M16x60 (4 pcs), washer 17x30x3

(8 pcs), nut M16 (4 pcs).
2. Washer Ø18 mm (option)
NOTE!
Final tightening is executed when all the circuit
breaker poles have been fitted.
3. 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.
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6 Installation
4. 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.
1HSB429954-10en 2012-05-10 61
6 Installation
5. 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!
62 2012-05-10 1HSB429954-10en
6 Installation
finger tight.

(8 pcs), nut M16 (4 pcs)
NOTE!
1HSB429954-10en 2012-05-10 63
6 Installation
7. 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!
64 2012-05-10 1HSB429954-10en
6 Installation
finger tight.

(8 pcs), nut M16 (4 pcs)
NOTE!
9. Fix the poles by tightening all bolts (1) between
the poles and pole beam.
Torque!
190Nm.
1HSB429954-10en 2012-05-10 65
6 Installation
10. 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
11. 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.
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6 Installation
12. • 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
13. 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.
14. Tighten the lock nuts on the transmission rod.
Torque!
M20: 140 Nm.
NOTE! M16: 79 Nm.
This action is only taken if the length of the
transmission rod is adjusted.
1HSB429954-10en 2012-05-10 67
6 Installation
15. Verify with a control pin that the hole in the outer
lever and the hole in the mechanism housing
are aligned.
68 2012-05-10 1HSB429954-10en
6 Installation
6.7 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 2012-05-10 69
6 Installation
Requisite equipment

Standard tools -
Torque wrench - Torque 1-10 Nm
Grease "G" 1171 4014-407 See section Types of grease on page
35 for details.
Roxtec sealing kit - Packed in the accessories box.
Loctite 270 - See section Locking fluid on page 37
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 85.
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
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
1HSB429954-10en 2012-05-10 71
6 Installation
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
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6 Installation
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 2012-05-10 73
6 Installation
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 seal The Roxtec grease is packed in the bag for the
halves using Roxtec grease. Lubricate the seal.
outside sparingly.
13. Fit the seal halves around the cable and press
them into the cable entry.
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6 Installation
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 circuit
board inside the operating mechanism.
16. Connect the cable to the coupling terminals as
per the applicable connection diagram and
secure the cable in the holes in the pole beam
(1) using cable ties.
• 1. Holes for cable ties, 2 pcs
1HSB429954-10en 2012-05-10 75
6 Installation
6.8 Electrical connections
6.8.1 Connecting the circuit breaker's operating mechanism
General
This section describes the connection of the operating mechanism.
Connection
1. Run the operating and signal cables through
cable inlets (1) at the bottom of the cabinet.
1. Cable inlets
2. Fit the flange with an appropriate seal for the
cable in question.
3. Connect the cables to the coupling terminals as
per the applicable connection diagram.
NOTE!
The terminals are of the plug-in type for
multicore cable and are in through-wiring or
disconnectable designs. The through-wiring
design is for the connection of max 4 mm2
conductor area and the disconnectable design
for the connection of max. 6 mm2 conductor
area. The disconnectable design is intended for
motor, AC- and supply circuits.
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4. Connect the earth cable to the earthing terminal
(1) on the side of the cabinet.
1. Earthing terminal
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6.8.2 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 bars or copper attachments are used for conductors, grease must be used
and a bimetal washer fitted to the connection. Bimetallic washers can be supplied from ABB
on request.
Connect all supports to the existing grounded net
Requisite equipment
Cleaning cloth or emery-cloth - e.g. Scotch Brite no 7447
Grease "SV" 1171 4016-610 See section Types of grease on
page 35 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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6.9 Pressurizing of circuit-breaker poles
6.9.1 Preparations
General
The circuit breaker poles are delivered vacuum processed and filled with SF gas to a pressure
of 0.12- 0.13 MPa abs at 20°C.
Safety
WARNING!
When commissioning, the SF6 gas or mixed gas must be topped off to the pressure specified
on the rating plate. Different gas pressures may occur depending on the different requirements
with respect to the lowest ambient temperature.
WARNING!
Any transport damage to the porcelain entails risk to safety when filling the gas. To avoid
personal injury when filling, installation personnel must exercise caution, staying in a
protected and safe area away from the circuit-breaker as there is a risk of splintering. The gas
cylinder is placed at the same location as the filling device.
Preparations
Action Note
1. Connect the cables to the operating
mechanism's connection blocks for closing and
tripping operations.
• The cables are run to the control room
or a place protected from the circuit-
breaker.
2. Connect the cables to suitable push button
switches.
3. Set the operating mechanism's "Local/
Remote/Disconnected" switch to "Remote"
position.
4. Close the motor protection switch to tension 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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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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6.9.2 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 85.
WARNING!
If the density monitor is turned AFTER tightening, there is a risk of damaging the capillary
tube inside the density monitor, resulting in gas leakage, faulty indication and/or alarms not
triggering.
All warranty obligations are invalidated by incorrect operation.
Requisite equipment
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 35.
Torque wrench 10 Nm
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
Gas filling instructions
The instructions below describe filling with SF6 gas.

Action Note
1.
NOTE!
Do not use any sharp tools!
2. Put the gas bottle (3) in a protected place.
3. Check the filling pressure on the circuit-
breaker's rating plate
4. Fit the regulator (11) to the gas cylinder (3). Set
the correct filling pressure, temperature
compensated, as specified in table Filling
pressure (SF6 gas) on page 81, 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 Precision pressure gauges are not included in
pressure gauge to the coupling (6) or cross- the delivery.
connection (10).
WARNING!
If the density monitor is turned AFTER
tightening, there is a risk of damaging the
capillary tube inside the density monitor,
resulting in gas leakage, faulty indication and/
or alarms not triggering.
All warranty obligations are invalidated by
incorrect operation.
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.
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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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 81.
13. Remove the hose (8) from the coupling link (6).
14. Close the valve (4).
15. Remove the coupling link.
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. Fit the density monitor straight, as illustrated.
WARNING!
22. When the density monitor (1 ) or (2) has been

properly fitted; tighten the clamp nut.
Torque!
10 Nm
23. Test the circuit breaker by Close and Open
switching three times from a protected location.
24. Connect the cables to the density monitors.
25. Reset the circuits to the blocking relays.
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Action Note
26. Perform a tightness check. See section Tightness check on page 89.
NOTE!
A new or overhauled circuit-breaker should be
tightness checked by reading the density
monitor after about 1 month and then as
specified in the maintenance schedule.
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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).
WARNING!
If the density monitor is turned AFTER tightening, there is a risk of damaging the capillary
tube inside the density monitor, resulting in gas leakage, faulty indication and/or alarms not
triggering.
All warranty obligations are invalidated by incorrect operation.
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
Requisite equipment
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.
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 (mixed gas) on page 85. WARNING!
When filling mixed gas, the SF6 gas must
always be filled first.
5. Connect a precision pressure gauge to the Precision pressure gauges are not included in
coupling link (6) or cross connection (10). the delivery.
WARNING!
6. Open the valve (4) or alternatively valve (9).
the coupling link (6) the valve (9) must
be closed.
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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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 85.
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 all See section Assembly of gas monitoring
poles are filled with gas. system on page 69.
NOTE!
The circuit breaker must not be operated until
the gas monitoring system has been installed!
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6 Installation
Action Note
24. Fit the density monitor straight, as illustrated.
WARNING!
resulting in gas leakage, faulty indication and/or
alarms not triggering.
25. When the density monitor (1 ) or (2) has been

properly fitted; tighten the clamp nut.
Torque!
10 Nm
26. Connect the operating mechanism for remote
control, set the switch to Remote position and
test run the circuit breaker Close-Open three
times from a protected location.
27. Connect the cables to the density monitors.
28. Reset the circuits to the blocking relays.
29. Perform a tightness check. See Tightness check on page 89.
NOTE!
A new or overhauled circuit-breaker should be
tightness checked by reading the density
monitor after about 1 month and then as
specified in the maintenance schedule.
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6.10 Inspection prior to commissioning
6.10.1 Tightness check
General
This section describes how to perform a leak check with a leak detector around the gas block
and the gas tube connections.
Connections
Requisite equipment
The following table shows what is needed for a tightness 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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6.11 Inspection of bolt joints
General
Before the installation is commissioned, the following must be inspected.
Inspection
• Check that all bolted joints are tightened to the right torque; see section Tightening
torque on page 38.
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7 Commissioning
7 Commissioning
7.1 Introduction
General
Before the circuit breaker is put into service, all inspections as detailed in Pre-commissioning
check list on page 92 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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7.2 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 93 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 bolt joints with the correct See Tightening torque on page 38.
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 to 10° Other settings may occur in accordance with
C. customer specifications.
Check of gas filling
Action Note
1. Check the gas filling and test run as per See Gas filling with SF6-gas on page 81 or
instructions Filling of mixed gas on page 85.
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Check of operating values.
Check the operating values for the circuit breaker against data applicable to the circuit breaker
in Operating values on page 42 and note the measured values in the table below.
(2) Filling pressure is as specified on the rating plate.

CAUTION!
The circuit breaker may not be operated Open to Close without an intermediate delay of 300
ms.
Signing
Inspection conducted by: _________________________________________

If all inspections in this section have been conducted, the circuit breaker can be put into service.
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8 Maintenance
8 Maintenance
8.1 Introduction
General
These maintenance instructions give recommendations for care and guidelines for
maintenance of high-voltage circuit breakers.
Instructions
The instructions are divided into:

• Inspection intervals
• Instructions for preventive maintenance of circuit breakers
• Instructions for preventive maintenance of operating mechanisms
The periodic maintenance is to be carried out at specified time intervals or number of
operations.
Equipment is to be overhauled in line with specified criteria such as a certain number of
operations. Overhauls are to be made by authorized service personnel.
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8 Maintenance
8.2 Description of maintenance categories
Maintenance categories
Action/explanation Interval Condition of Requirement
circuit breaker
A Ocular inspection 1-2 years a1 a2
B Preventive maintenance b1 b2
• General overhaul of circuit 15 years or 5 000
breaker and operating mechanism operations
• Heat measurement
C Overhaul of breaking chamber c1 c2
Overhaul of line and transformer circuit ΣnxI2=20 000
breakers
Overhaul of capacitor bank circuit
breakers, reactor circuit breakers and
filter circuit breakers
• Without point-on-wave control 2,500 operations
• With point-on-wave control 1)
General overhaul After 30 years or d1 c2
10 000 operations 2)
Explanations
1)Maintenance, circuit breaker pole on page 104 .
2) Special requirements for resistance checks for circuit breakers; executed >100 Close and
tripping operations per year.
Condition of circuit breaker
The following specifies the condition in which the circuit breaker should be for the various
maintenance activities.
• a1) circuit breaker in operation.
• b1) Closing spring discharged, circuit breaker open, disconnected and earthed. If heat
measurement is part of the maintenance activity, this should be done during normal load
before the circuit breaker trips.
• c1) Closing spring discharged, circuit breaker open, disconnected and earthed. The
circuit breaker poles/breaking units are dismantled and transported to the workshop.
• d1) Closing spring discharged, circuit breaker open, disconnected and earthed. The
entire circuit breaker with operating mechanism is transported to the workshop.
Competence requirements
The following describes the necessary requirements for personnel carrying out maintenance
work.
• a2) substation personnel without special training.
• b2) personnel authorized by ABB to carry out assembly, commissioning and
maintenance work.
• c2) personnel authorized by ABB to carry out assembly, commissioning and
maintenance work. In some cases support may be necessary from ABB.
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8 Maintenance
8.3 Maintenance schedule
General
The following inspection schedule includes important control points, acceptable tolerances,
functional values for certain adjustments and recommended inspection intervals. In corrosive
or polluted air and in climates with high humidity, it may be necessary to half the inspection
interval. The specified inspection intervals are to be regarded as recommended guidelines that
can either be extended or shortened depending on local conditions.
The significance of the various categories are explained in section Description of maintenance
categories on page 96.
Category A
Maintenance category A takes place at an interval of 1-2 years.

Inspected Action Instructions/Tools
circuit breaker Check: This is described in section:
• External cleanliness Exterior cleaning on page 106 and
Gas system and density monitor on
• Heating element function page 12
• Gas pressure No special tools needed.
• Valves and draining holes
Category B
Maintenance category B takes place at an interval of 15 years or 5,000 mechanical close/open

operations.
circuit breaker Check: This is covered in section:
• External cleanliness Exterior cleaning on page 106 and Gas
system and density monitor on page 12
• Gas pressure No special tools needed.
• Valves and draining holes
Operating Check: If there is an oil leak, replace the whole
mechanism damper.
• Bolts and nuts
• Heating element function
• Oil leaks from damper
Rating plates Note serial number.
Operation counter Note the number of operations.
SF6 gas Check: Gas-filling equipment.
• Gas level (filling if See Gas filling with SF6-gas on page 81.
necessary) Dew point meter.
Dew point max. -5°C at specified filling
• Dew point, for normal gas
pressure and +20°C
pressure in the circuit
breaker.
Porcelain insulators Check: Wash and dry the insulators.
• Bolts and nuts Rinsing equipment, drying cloths, torque
wrenches.
This is described in Exterior cleaning on
page 106
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8 Maintenance

Composite insulators Check:
• Damage to the insulator
Main circuit Check: Resistance values as specified in section
Operating values on page 42.
• Resistance measurement
In the case of circuit breakers with a load
• Resistance bridge, using a current of less than 400 A, a resistance
test current of 200-400 A value of up to 1000 uOhm is permitted per
DC breaking unit. .
Heat measurement Check: Carried out at full load prior to
disconnection of the circuit breaker.
• The temperature increase
in the outer parts of the The highest permitted temperature
breaking unit. difference between the phases is 5°C.
Thermal camera.
Consideration must be taken to the load
current during measurement, both to the
larger variations of the load current 3-4
hours prior to measurement. See the
manual for the thermal camera.
Mechanism Check:
• Reference hole in outer
lever and mechanism
housing
Function times Check: Measuring with electronic timing.
• Opening time Nominal control voltage
For times, see Operating values on page
• Closing time 42.
• Close-Open time Maximum time deviation between the
phases, 4 ms at closing and 3 ms at
• Deviations between opening.
phases
• Auxiliary switch
• Travel curve
• Contact damping
Availability Check: Rod system:
• Rod system Check of tightening torque for nuts in the
rod system
• Control safety Control safety:
• Anti-pumping relay Measurement of minimal control voltage
Closing coil: < 85% IEC (<72% ANSI) of
nominal value Tripping coil: < 70% IEC
(<56% ANSI) of nominal value Variable
DC-voltage unit.
Anti-pumping relay:
With the circuit breaker in Open position
and the operating mechanism charged, a
simultaneous Close and Open operation is
produced (Close button pressed in).
The circuit breaker carries out a Close/
Open operation and must not Close when
the operating mechanism is charged.
The anti-pump function must be activated
as long as the close impulse lasts. The
lowest control voltage is to be measured for
the relay. (85 % of nominal)
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8 Maintenance

Motor Check: The motor current must be measured
towards the end of the charging process.
• Motor current
The maximum permitted motor current is
110 % of the measurement values received
during routine tests.
The permitted variation in charge time is
30% of the measurement value obtained
during routine tests.
The motor must be able to charge the
springs at a minimum of 85% of nominal
voltage (as per IEC).
See Inspection of drive unit on page 111.
Latch device Visual inspection of settings For setting the gap in the latch device, see
Inspection of latch devices on page 112.
Surfaces on shafts and latches are
lubricated using Grease "L". See section
Types of grease on page 35.
Coils Check: The coil resistance and current is allowed
to vary ±10% of the measurement value
• Coil resistance and current
obtained during routine tests.
Heating element Check: Check the signal for voltage drop, if
applicable.
See Inspection of heating element on page
110.
Central control Check: Small cabinet:
cabinet (if applicable) 48 W, 110 V R= 330 ohm ±10%
48 W, 220 V R= 1000 ohm ±10%
Medium-sized or large cabinet:
140 W, 110 V R= 86 ohm ±10%
140 W, 220 V R=346 ohm ±10%
Thermostat (if Check: Check that the thermostat is adjusted to
applicable) comply with the set value.
• Adjusted value
See Pre-commissioning check list on page
92.
Terminal blocks Check: Check that bolts and clamps are properly
tightened.
• Bolts and clamps
Protective motor Check: Check the signal for voltage drop, if any.
switch
• Signal for voltage drop
Seals/SF6 gas Check: Check the density monitors as regards
pressure indicator and signal/break
• Density monitoring
contacts.
NOTE!
The test must take place in normal air
conditions, +20 °C and 101.3 kPa
(1,013 mbar).
Remove the density monitor from the
circuit breaker to check the function.
Minimum permitted voltage when
checking: 30 V.
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8 Maintenance

Blocking relays Check:
• Relays The relays must break when a density
monitor is removed from a circuit breaker
pole, pressurized at filling pressure.
NOTE!
May only be carried out when the circuit
breaker is out of service.
Corrosion Check: External ocular inspection.
• Operating mechanism Make a special check of the protected
components in the unheated areas, pull-
rod system, forks and springs.
Treat with anti-rust agent where necessary.
See Cleaning, lubrication, and rust
protection of operating mechanism on
page 107.
Lubrication Check: Check and lubricate the latches using
grease "L".
• Latches
Check and lubricate the worm gear using
• Worm gear grease "M".
See Cleaning, lubrication, and rust
protection of operating mechanism on
page 107.
Tightening torque Check: Check the tightening torque on all bolt
joints.
• All bolt joints
See Tightening torque on page 38.
Operation Check: Operation tests in combination (if possible)
with operating time measurement (incl.
• Operation
open/close operation time).
• Operating time
measurement
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8 Maintenance
Category C
Inspected Interval Instructions/Tools

Overhaul of breaking unit: Instructions:
2 Evacuate the gas, dismantle the circuit
- Line and transformer circuit Σn x I = 20 000
breaker breaker poles and transport to a clean
workshop. Dismantle the breaking chamber
insulator, fit a new contact set and new PTFE
- Capacitor, reactor and filter components.
circuit breaker Equipment:
• Without point-on-wave 2,500 operations. Standard equipment, tight fitting face mask for
control dust protection, long-sleeved overalls,
• With point-on-wave 1) protective gloves of plastic or rubber.
control
All types of maintenance During diagnostic
testing with non-
conformities.
Overhaul of complete circuit 30 years or 10,000 Dismantling of circuit breaker pole and
breaker and operating mechanical Close/ mechanism. Assembly of new contact set.
mechanism Open operations Replacement of other worn components.
If the circuit breaker and the operating
mechanism are being overhauled for a further
2,000 operations, all wear parts must be
replaced.
If the circuit breaker and the operating
mechanism are overhauled for a further
10,000 operations, the entire circuit breaker is
to be reconditioned.
Protection against crevice products as per
standard equipment above
Instructions:
See chapter Overhaul on page 117.
For operating mechanism, with instructions
and guidance from ABB
1) See Maintenance, circuit breaker pole on page 104.
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8 Maintenance
8.4 Maintenance, circuit breaker pole
8.4.1 The service life of the circuit breaker
General
Assuming that the recommended inspection intervals and actions have been observed, the
circuit breaker will have a service life greater than 30 years or 10,000 mechanical operations.
Maintenance points
The following points ensure a long service life:

Maintenance points
1 Burn-off of the arcing contacts is small.
2 Each breaking unit is equipped with a desiccant equivalent to at least the service life of the circuit
breaker.
3 Bearings in the gas space are maintenance-free.
4 The seals are designed with a double sealing ring.
Opening the breaking unit
In general there are only two reasons for opening the breaking units:
Reasons
1 If the number of short-circuits x short-circuit current (kA) approaches the curve, see figure No. of
operations on page 105.
2 If the number of operations at the line, reactor or capacitor connection, as well as the switching of
load current1) has reached the number under the heading "Interval" in Description of maintenance
categories on page 96.
1)
The load currents from normal Close and Open operations are not calculated in the formula.
These are only calculated when counting the total number of mechanical Close and Open
operations.
Another reason for opening the breaking units is limited to mechanical faults/faulty adjustment
of the drive system, that could damage the components inside the breaking units.
NOTE!
Opening the breaking unit calls for special instructions and may only be carried out by
qualified and authorized personnel.
Calculations
The graph that shows the restriction to the number of permitted short circuits can be given
roughly as:
Formula Explanation
Σn x I2 = 20 000 n = number of short circuits
I = short-circuit current kA (RMS)
In the formula, all levels of short-circuit current are included. E.g. 10x302+20x202+20x102 =
19,000.
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8.4.2 The service life of the arcing contacts in the event of short circuit breaking
General
The diagram shows the number of breaks as a function of the breaking current that the contacts
in a circuit breaker can undergo before burn-off is so great that they must be replaced.
No. of operations
n No. of operations
kA Short-circuit current
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8.4.3 Cleaning and lubrication of circuit breakers
Exterior cleaning
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!
Work on the circuit breaker when there is a risk for mechanical damage to the insulators is to
be executed at reduced gas pressure, 0.125 MPa (abs).
NOTE!
All circuit breakers with porcelain insulators are completely waterproof, i.e. the circuit
breakers in use can be cleaned using water without any risk of moisture penetrating and
damaging important parts.
Composite insulators do not normally require cleaning. Solvents or water rinsing with high
pressure could damage the silicone surface on the insulator.
Lubricant
Only use lubricants recommended in section Types of grease on page 35. 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 136.
Rust protection
See Rust protection on page 115.
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8.5 Maintenance, operating mechanism and link system
8.5.1 Cleaning, lubrication, and rust protection of operating mechanism
Safety
WARNING!
Work on the operating mechanism with the circuit breaker in closed position and charged
springs always represents a risk.
It is therefore important to observe the safety instructions before commencing work. See
Hazardous working situations on page 28.
Lubricant
The table below shows the greases and oils that are needed for this maintenance. For suppliers
and trade names of oils and greases, see sections Oil types on page 33 and Types of grease on
page 35.
Lubricant Part number Note
Grease "L" 5316 381-H
Grease "M" 5316 381-J
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.
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8 Maintenance
Lubrication
The dampers are filled with "S" oil on delivery.

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 35 and under normal
conditions, require no maintenance. Lubrication points in the operating mechanism are in the
maintenance schedule, see below.
Item Component Clean and More information

lubricate with...
1 Limit stop roller on the operating Grease "M"
mechanism's closing lever
2/3 Rollers on the closing and tripping Grease "L"
latch device levers
4 Contact surface for latch, closing Grease "M" Clean and lubricate the work surfaces.
5 Contact surface for latch, opening Grease "M" Clean and lubricate the work surfaces.
6 Pins for spring locking (3 pcs) Grease "M" Lubricate the worn surfaces.
7 Pin for the closing spring's lever Grease "M" Lubricate the worn surfaces.
8 Eye bolt for transmission rod Grease "M" Check the bellows for cracks and
leakage. Note: The eye bolt must be
removed before cleaning and lubrication!
Removal is described in section
Replacement of eye bolt and bellows on
page 192.
9 Worm gear Grease "M" Clean and lubricate.
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Rust protection
On delivery, the operating mechanism is treated with desiccant as transport protection against
moisture.
Despite good anti-rust treatment, minor corrosion may occur, particularly if the circuit breaker
is installed in a highly corrosive environment.
Rust spots must be polished off and new anti-rust agent applied, see Rust protection on page
115
Spare parts
Spare parts must be stored indoors in an approved storage area1) and in original packaging.
This applies especially to rubber components (seals etc.) that must also be protected against
sunlight to prevent drying out. Gaskets can be stored only for a limited period, so avoid
stocking them. Supports can be stored outdoors.
1)Approved storage areas: Roof, solid ground, air humidity below 50%, temperature +20oC
(±10oC).
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8.5.2 Inspection of heating element
General
Operating mechanism is fitted with a heating element to prevent moisture, and this must
always be connected.
Heating element
Instructions
Action Note
1. Measure the element's resistance In order to ensure the element is intact
2. Measure the power supply to the element
Data
See section Heating element on page 22 for values.

The 70 W heating element is always connected, while the 140 W or 2 x 140 W heating
elements, for temperatures below -25°C, are thermostat controlled.
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8.5.3 Inspection of drive unit
General
This section describes how to check the drive unit.
Requisite equipment
Standard tools -
Inspection of drive unit
Action Note
1. Measure the motor current at the end of the See section Operating values on page 42.
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
specified in section Replacement of gear
housing and motor in the drive unit on page
185.
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8.5.4 Inspection of latch devices
General
The operating mechanism has one closing coil and two trip coils fitted as standard, but can be
fitted with double closing coils on request.
Latch device
1 Tripping latch device

2 Closing latch device
Requisite equipment

Grease "L" 1171 4016-606 See section Types of grease on page 35 for details.
Multimeter
Feeler gage
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Check of play
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 not fall See the operating mechanism's delivery
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 165 and
Replacement of tripping latch assembly on
page 162.
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8.5.5 Check of oil level in damper
General
This section describes how to check the oil level in the damper.
Requisite equipment
Oil "S" 1173 7011-106 The oil is specified in section Oil types on page 33.
Ultrasound equipment, if - If the level is to be checked using ultrasound equipment.
any.
Damper
Instructions
Action Note
1. If the oil level is to be checked using ultrasound Damper removal is described in section
equipment, the damper can remain in place. Replacement of damper on page 180.
Otherwise it must be removed.
2. Check the oil level
As necessary, top up with oil "S".
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8.6 Rust protection
General
Despite good anti-rust treatment, minor corrosion may occur, particularly if the circuit breaker
is installed in a highly corrosive environment.
Many steel mechanical components in the operating mechanism are surface treated through
manganese phosphating agent and protected by being dipped in oil. Components, such as the
chassis, are painted as a means of protection against corrosion. The closing and trip springs can
be protected against corrosion with two-component paint manganese phosphating.
The support, pole beam and protective tube are hot dip galvanized.
Phosphated surface
Rust spots must be polished off and new anti-corrosion agent applied by brush or spray. Grease
“G” or Tectyl 506 is recommended as a rust inhibitor; see section Types of grease on page 35.
NOTE!
Tectyl 506 forms a wax-like protective coat after drying and must not be applied to bearings or
latch mechanisms.
Hot dip galvanized surface
Rust spots must be polished off and new anti-corrosion agent in the form of zinc rich paint
applied by brush. The thickness of the new surface must be at least double the original zinc
thickness.
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9 Overhaul
9.1 Preparations
9.1.1 Introduction
General
This chapter includes instructions for a general overhaul of the complete circuit breaker. The
time interval for the overhaul is specified in Maintenance schedule on page 97.
Scope
If the overhaul is conducted for a further 10,000 operations, all moving parts must be replaced.
If the overhaul is conducted 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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9.1.2 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 144.
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 uncharged; see below under preparations.
• The gas must be evacuated; see Evacuation 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
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
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Preparations
1. Before dismantling the circuit breaker, and
during the course of the work, the instructions
in Safety on page 25 must be read and
followed.
2. Check and note the circuit breaker's operating
values prior to dismantling.
• Deviations from the recommended
values indicate that something needs to
be checked with extra care for the
overhaul.
3. Put the circuit-breaker in open position.
4. Cut the motor voltage and where necessary the
heater voltage as well.
5. Switch the circuit breaker between the open,
closed and open positions so that the springs
are uncharged.
6. Disconnect and earth.
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9.1.3 Evacuation 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

Gas treatment equipment
Percentage meter for SF6 gas
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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 ensure The mixing ratio between the gases can be
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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9.1.4 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 contact surfaces of aluminum.
Cleaning cloth E.g. Scotch-Brite, for contact copper surfaces
Ethanol 95% (vol) C2H5OH, for cleaning internal surfaces
Thick plastic foil and plastic bags To prevent moisture penetration and to protect cleaned parts prior
to assembly.
Cleaning
• For internal cleaning of the circuit breaker, protective gloves of plastic or rubber, long-
sleeved overalls and a close-fitting facemask with filtration to counteract fine dust and
acidic gases must be worn.
• The dust (crevice products) formed in the circuit breaker is to be removed with a vacuum
cleaner fitted with a fine dust filter and wiped off using drying cloths moistened in
industrial spirit.
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9.2 Removal of circuit-breaker pole for transport
General
The circuit-breaker pole must be taken out of service before the circuit-breaker is dismantled
(see section Preparations for overhaul on page 118) and the gas emptied (see section
Evacuation of SF6 gas on page 120).
Preconditions
NOTE!
This type of work may only be executed by personnel trained by ABB.
Requisite equipment

Standard tools -
Lifting device -
Lifting tackle -
Dismantling
The following instructions describe the removal of the circuit-breaker pole for transport.
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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4.
DANGER!
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 removing the lock washer at
the rear.
7. Loosen the circuit-breaker pole at the four bolts

(1) in the pole beam.
1. Bolt M 16x60, nut M16, washer 17x30x3
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8. Release the circuit-breaker pole's operating
shaft from the torsion rod by sliding the circuit-
breaker pole sideways. Start with pole A or pole
C and finish with pole B. NOTE!
Once the circuit-breaker pole has been
dismantled, the torsion rod will hang free. The
torsion rods are painted and must be handled
with care to prevent damage.
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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9.3 Overhaul of circuit-breaker pole
9.3.1 Removal of the 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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Requisite equipment

Standard tools -
Lifting device -
Lifting tackle -
Instructions
The instructions below describe the removal of a breaking unit from a circuit-breaker pole.
Action Note
1. Turn the operating shaft (1) counter-clockwise
to the contacts' closed position.
NOTE!
Use the torque tool!
2.
DANGER!
3. Fit the lifting devices from the top of the
breaking unit to the hoist or overhead crane.
Stretch the lifting device moderately.
NOTE!
For composite insulators: Place the lifting sling
as close as possible to the end flange and not
on the rubber surface.
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.
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 a suitable surface, such as on two
cross bars, to ensure it does not tip over.
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9.3.2 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
7 Lower lock nut
8 Turnbuckle screw
9 Upper lock nut
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Safety
NOTE!
Use personal safety equipment:
• long-sleeved overalls
• protective gloves of plastic or rubber
• tight fitting facemask for dust protection
Requisite equipment
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.
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9 Overhaul
Instructions
The instructions below describe the removal of post insulators.

Action Note
1.
DANGER!
Use lifting tackle dimensioned for the post
insulator.
2. Fit the lifting devices from the top of the post
insulator to the hoist or overhead crane.
3. Remove the post insulator bolts (2) from the
mechanism housing (3).
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 lifting. NOTE!
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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9.3.3 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
Remember:
NOTE!
Clean the mechanism through vacuuming and drying. Check the bearings and replace all
sealing rings.
Requisite equipment
Grease "S" 1171 4014-406 Detailed information is specified in section Types of grease
on page 35.
Tectyl 1241 0011-108 Valvoline Tectyl
Instructions
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 sealing Replace the bushings if damage is discovered.
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.
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Action Note
9. Refit the operating shaft (3) through the inner The shaft (3) and the inner operating lever (2)
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).
NOTE!
Make sure the inner operating lever (2) faces
the right direction. The operating shaft's (3)
short protrusion should point toward the gas
valve.
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. Fit the lock rings (5) and coat them with Tectyl.
12. Fit the new radial seals (4).
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9.4 Assembly of circuit-breaker pole
9.4.1 Treatment of contact surfaces
General
Before the breaking unit is refitted, the contact surfaces are to be treated as follows.
Requisite equipment
Grease "N" 1171 4016-607 See section Types of grease on page 35 for more
information on the grease.
Grease "P" 1171 5011-102 See section Types of grease on page 35 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 (ethanol) or NOTE!
with cleaning cloth (Scotch After cleaning with a cleaning cloth (Scotch
Brite). Brite) the surface must always be cleaned of
loose particles with ethanol.
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 five
with a dry, clean drying cloth. minutes after cleaning and the joint fitted
Then lubricate the surface with a within 15 minutes.
thin layer of Vaseline (grease
"P").
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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 ethanol.
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 carefully dried.
puffer cylinder's contact
surfaces.
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9.4.2 Treatment of sealing surfaces and seals
General
In conjunction with installation, all sealing surfaces are to be cleaned, degreased and checked.
Remember:
NOTE!
Be careful of the sealing surfaces. Place the parts on a suitable surface, such as wooden blocks,
so that the sealing surfaces will not be damaged.
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

Ethanol
Grease “G” 1171 4014-407 For static seals, see Grease G on page 35.
Grease "S" 1171 4014-406 For moving seals, e.g. shaft seals, see
Grease "S" on page 36.
Instructions
Action Note
1. Replace all seals with new ones when
reassembling the circuit breaker.
2. Sparingly lubricate the sealing surfaces and Surfaces and seals are lubricated to facilitate
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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9.4.3 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
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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Requisite equipment
Standard tools -
Torque wrench - Torque 79-100 Nm.
Locking fluid "C" 1269 0014-408 More information about locking fluid is
specified in Locking fluid on page 37.
Grease "G" 1171 4014-407 More information about grease is specified in
Types of grease on page 35.
Instructions
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).
5.
DANGER!
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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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9.4.4 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
9 Upper adapter plate
11 Container for absorbent
12 Cover
13 Bolt M10x30, washer 10.5x20x2
14 Breaking unit
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Requisite equipment
Lifting device -
Lifting tackle -
Standard tools -
Torque wrench - Torque range 45-79 Nm.
Grease "G" 1171 4014-407 See detailed information in section Types of
grease on page 35.
Instructions
The instructions below describe how the breaking unit is refitted to the post insulator.
Action Note
1.
DANGER!
weight of the circuit breaker. See dimension
print for the exact weights.
2. When assembling the 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!
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 that the sealing ring is kept in place
during assembly.
6. Place the sealing ring (2) in its groove.
7. Slowly lower the breaking unit (14) so that it
comes into position for fitting the pin (5), about
75-100 mm above the post insulator (3).
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 towards the post insulator and centre.
10. Secure the breaking unit with bolts, washers
and nuts (7).
Torque!
79 Nm
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Action Note
11. Remove the bolts (13) and the cover (12) and
lift out the absorbent container (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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9.4.5 Filling gas before transport
General
Before the circuit breaker pole can be moved, it must be treated with gas as per this section.
Instructions
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 pressure of 100 The filling hoses are to be stored to ensure that
Pa and fill with clean SF6 gas to 0.125 MPa they are not exposed to moisture and
(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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9.5 Replacement of breaking unit
9.5.1 Dismantling of breaking unit for transport
General
This section describes the dismantling of the breaking unit for transport. Dismantling the
breaking unit on site is an option to the recommendation (removing the whole circuit-breaker,
and then dismantling the breaking unit in a workshop) and is only to be applied in stable
weather which gives indoor-like working conditions.
The circuit-breaker must be removed from service before the breaking unit is dismantled, see
Preparations for overhaul on page 118, the gas evacuated, see Evacuation 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 to be left for an extended period without being refitted,
the post insulator, alternatively the breaking unit, must be vacuum pumped and filled with
nitrogen.
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Circuit-breaker pole
1 Operating lever
3 Post insulator
4 Breaking unit
5 Lock washer SL12
6 Pin D=12
Requisite equipment

Standard tools -
Lifting device -
Lifting tackle -
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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Instructions
The instructions below describe the dismantling of a breaking unit for transport.
Action Note
1. Before removing the breaking unit the circuit- Se Preparations for overhaul on page 118 and
breaker is to be taken out of service. Evacuation of SF6 gas on page 120.
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!
5.
DANGER!
6. Fit the lifting devices from the top of the
breaking unit to the hoist or overhead crane.
Stretch the lifting device moderately.
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.
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Action Note
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 sealing ring The cover part number is specified in Requisite
above the post insulator (3). equipment on page 145.
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 ring on the The cover part number is specified in Requisite
breaking unit. equipment on page 145.
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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9.5.2 Assembly of the breaking unit on site following an 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.
Circuit-breaker pole
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
9 Upper adapter plate
11 Container for absorbent
12 Cover
13 Bolt M10x30, washer 10.5x20x2
14 Breaking unit
15 Operating shaft
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Requisite equipment
Lifting device -
Lifting tackle -
Standard tools -
Torque wrench - Torque range 45-79 Nm.
Grease "G" 1171 4014-407 See detailed information in section Types of grease on
page 35.
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.
Action Note
1.
DANGER!
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!
3. Pull down the puffer pull-rod (1) to its fully
extended position so that it is accessible for
assembly.
4. Reduce the nitrogen pressure in the post The protective covers must be removed on all
insulator (3) to atmospheric pressure and poles at the same time.
remove the protective cover from the post
insulator.
5. Turn the operating lever (15 ) counter-
clockwise to its closed position to ensure that
the breaking unit can be fitted.
NOTE!
6. Clean the sealing surface on the sealing ring
(2) on the post insulator (3) carefully.
7. Also clean the lower flange and adapter plate
(4) and lubricate generously with grease "G" to
ensure that the sealing ring is kept in place
during assembly.
8. Place the sealing ring (2) in its groove.
9. Slowly lower the breaking unit (14) so that it
comes into position for fitting the pin (5).
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).
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Action Note
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 absorbent container (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.
19. Attach the transmission rod eye bolt to the
circuit-breaker pole's operating lever with the
shaft end (1) and secure with a lock washer at
the rear; see the figure to the right.
20. Check the open position using a control pin. The part number of the control pin is specified
This should pass through the hole in the outer in Requisite equipment on page 149.
lever and the hole on the mechanism housing.
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Action Note
21. Fill the circuit-breaker pole with gas.
1. Vacuum pump down to a pressure of
100 Pa and let the vacuum pumping
NOTE!
continue for at least one hour after this
pressure has been reached. The filling hoses are to be stored to ensure that
they are not exposed to moisture and
2. Stop the vacuum pumping and fill the contamination.
circuit-breaker with dry and clean They must not be used for anything other than
nitrogen to atmospheric pressure. Let it their intended purpose.
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 gas filling. See Gas filling with SF6-gas on page 81.
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9.6 Installation of 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 49.
Following assembly the operating values of the circuit breaker must be checked and recorded.
First overhaul
CAUTION!
ms.
(2) Filling pressure is as specified on the rating plate.
Inspection conducted on (date): ______________________________________
Inspection conducted by (name): ________________________________________
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Second overhaul
CAUTION!
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
General
This chapter contains instructions on replacing the operating mechanism's spare parts as
specified in chapter Spare parts on page 201.
There is also information in each section about the equipment required to carry out the
pertinent repairs, e.g. relevant spare part numbers, tools to be used, lubricants, etc.
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10.2 Operating mechanism
10.2.1 Removal and assembly of casing
General
The operating mechanism casing may need to be removed to access the component parts of the
operating mechanism. This section contains information on removing and fitting the casing.
Casing
The figures show the operating mechanism casing.
1 Retaining bolts for the casing, M16 x 35 (4 pcs).

2 Retaining bolts for the casing, M10 x 20 (4 pcs).
Requisite equipment
Standard tools -
Torque wrenches -
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Removal of the casing
The instructions below describes removal of the casing from the operating mechanism.
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
uncharged; see section Discharging
springs on page 31.
• the circuit breaker (control switch) must
be in DISCONNECTED position
2. Remove the ground plate (1) inside the cabinet.
1. Ground plate
3. Remove the cable plate under the cabinet by
unscrewing the retaining bolts (1).
1. Bolts M8x25 (8 pcs)
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4. Unscrew the bolts (1) at the rear of the casing
and the bolts (2) underneath. Carefully lower
the entire casing.
1. Bolts M16x35, (4 pcs).

2. Bolts M10x20 (4 pcs).
Fitting the casing
The instructions below describe fitting of the casing 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. Bolts M16x35, (4 pcs).

2. Bolts M10x20 (4 pcs).
Torque!
M16: 100 Nm
M10: 45 Nm
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Action Note
2. Attach the cable plate under the casing using
retaining bolts (1).
1. Bolts M8x25 (8 pcs)
Torque!
M8: 22.5 Nm
3. Reconnect all cabling inside the cabinet.
4. Refit the ground plate (1) inside the cabinet.
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10.2.2 Coil replacement
General
This section contains information on replacing the closing coil Y3 and tripping coils Y1 and
Y2.
Coils
The figure below shows the position of the coils in the operating mechanism. The figure shows
the operating mechanism without the 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
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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Coil replacement
The instructions below describe the removal and assembly of the coils. The same instructions
apply to all coils.
1.
DANGER!
springs on page 31.
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 either pushing it up or
down.
6. Remove the cover on the new coil and fit the
coil in the cabinet by tightening the retaining
nuts.
7. Attach the cables to the coil.
NOTE!
Check the voltage!
8. Fit the cover.
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10.2.3 Replacement of tripping latch assembly
General
This section describes the replacement of the complete tripping latch assembly including the
coils.
Tripping latch assembly
The figure below shows the position of the tripping latch assembly in the operating
mechanism.
1 Tripping latch assembly
Requisite equipment
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 that are
gas burner locked with Loctite.
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Removal of tripping latch assembly
The instructions below describe how the tripping latch assembly is removed from the operating
cabinet.
Action Note
1.
DANGER!
springs on page 31.
2. Remove the casing from the operating
mechanism.
3. Remove the closing and trip springs to facilitate Follow the instructions Replacement of tripping
manual movement of the operating and closing latch device assembly on page 170
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 you
need to be fully removed, but can be loosened
need to remove the tripping latch device
at one end.
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
provided in section Replacement of tripping
and closing latch device assembly on page
170.
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.
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.
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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 the Follow the instructions Replacement of tripping
original A and B dimensions! and closing latch device assembly on page
170.
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
General
This section describes the replacement of the complete closing latch assembly including the
coils.
Closing latch assembly
The figure below shows the position of the closing latch assembly in the operating mechanism.
1 Closing latch assembly
Requisite equipment
Closing latch EXIN200416-R1
assembly
Standard tools
Liquefied petroleum May be needed to loosen the nuts that are locked with
gas burner Loctite.
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Removal of closing latch assembly
The instructions below describe how the closing latch assembly is removed from the operating
cabinet.
1.
DANGER!
springs on page 31.
2. Remove the casing from the operating
mechanism.
3. Remove the closing and trip springs to facilitate Follow the instructions Replacement of tripping
manual movement of the operating and closing latch device assembly on page 170
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 you
need to be fully removed, but can be loosened
need to remove the closing latch device
at one end.
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
provided in section Replacement of tripping
and closing latch device assembly on page
170.
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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.
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.
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12. Pull out the latch device from the cabinet.
CAUTION!
The latch device's two plates are not attached
to one another, 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.
1. Angle and push in the latch device into the
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
2. Attach the latch device using the two retaining
nuts on the outside of the operating
mechanism. Use locking fluid.
NOTE!
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.
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6. Attach the damper.
7. Refit the pin to the spring bracket (shown in the
figure in the next step).
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 the Follow the instructions Replacement of tripping
original A and B dimensions! and closing latch device assembly on page
170.
casing on page 156.
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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.
Spring assembly
The figure below shows the position of the closing and trip springs in the operating mechanism.
1 Closing spring
2 Trip spring
Requisite equipment
Closing spring assembly 1HYB300784-A
Trip spring assembly 1HYB300785-A
Standard tools -
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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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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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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.
1.
DANGER!
springs on page 31.
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 closing spring The dimensions are shown in the figures
or the B-dimension on the trip spring and save Measurement of A-dimension of closing spring
the notes until assembling the new spring. on page 171 and Measurement of B-dimension
of trip spring on page 172.
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10 Repairs
4. Loosen the two nuts (1) on the spring. Closing spring:
Trip spring:
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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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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.
1. The spring must be turned the right way in the Closing spring:
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:
• the closing spring in the upper end.
NOTE!
• the trip spring in the lower end.
Use locking fluid.
3. Screw in the bolt to the spring. Screw until the The dimensions are shown in the figures
value of the A-dimension of the old closing Measurement of A-dimension of closing spring
spring and the B-dimension of the old trip on page 171 and Measurement of B-dimension
spring matches the new spring. of trip spring on page 172.
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4. Tighten both nuts (1) on the closing and trip Closing spring:
springs.
Trip spring:
casing on page 156.
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10.2.6 Limit stop roller replacement on the closing lever
General
This section contains information on the replacement of the limit stop roller on the closing
lever.
Limit stop roller
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
Limit stop roller Ø25 mm EXIN400805P1 The new limit stop roller must have the same
dimension as the old roller.
Needle bearings for roller Ø25 mm 2213 887-20 Use a new bearing when replacing the roller!
Limit stop roller Ø26.5 mm EXIN400805P2 The new limit stop roller must have the same
Needle bearings for roller Ø26.5 2213 887-20 Use a new bearing when replacing the roller!
mm
Standard tools -
Grease "M" 5316 381-J More information on the grease is given in
section Types of grease on page 35.
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10 Repairs
Replacement of limit stop roller
The instructions below describe replacement of the limit stop roller on the operating
mechanism's closing lever.
1.
DANGER!
springs on page 31.
2.
NOTE!
The new limit stop roller must have the same
3. Remove the safety washer (1).
4. Push out the shaft (2) and pull out the roller (3).
Set aside the two spacers on each side of the
roller for reuse.
5. Lubricate the new needle bearing with grease
"M" and put it in the new roller cage.
6. Place a spacer at each end of the roller,
position the parts and push in the shaft through
the washers and the roller with the bearing.
7. Refit the safety washer and secure with the
bolt.
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10 Repairs
10.2.7 Replacement of damper
General
This section contains information on replacing the damper.
Damper
The figure below shows the position of the damper in the operating mechanism as seen from
behind.
1 Damper
Requisite equipment
Damper 1HYB300862-A
Standard tools -
Split pins 9ABA113-62 2 pcs, 4x25 mm
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10 Repairs
Replacement of damper
The instructions below describe how the damper is removed/fitted.

1.
DANGER!
springs on page 31.
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 180.
casing on page 156.
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10 Repairs
10.2.8 Auxiliary contact replacement
General
This section contains information on replacing the auxiliary contact.
Auxiliary contact
The figure below shows the position of the auxiliary contact in the operating mechanism.
1 Auxiliary contact
Requisite equipment
Auxiliary contact EXIN300762-R1
Standard tools
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10 Repairs
Auxiliary contact replacement
The instructions below describe removal/refilling of the auxiliary contact.

1.
DANGER!
springs on page 31.
3. Remove the damper's upper bracket to release Removal of the damper is described in section
the linkage. Replacement of damper on page 180.
4. Remove the linkage's lower bracket and the
entire linkage.
5. Remove all contacts from the auxiliary contact.
6. Loosen 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 Repairs
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, viewed from the side of the
Fitting the damper is described in section
Replacement of damper on page 180.
casing on page 156.
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10 Repairs
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.
Gear housing and motor
The figure below shows the position of the gear housing and motor in the operating
mechanism.
1 Gear housing
2 Motor
Requisite equipment
Gear housing EXIN300801-R1
Motor, type 220 V AC/DC EXIN300802-R1
Motor, type 110 VAC/DC EXIN300802-R2
Standard tools -
Liquefied petroleum gas - May be needed to loosen the nuts that are locked
burner with Loctite.
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10 Repairs
Dismantling the complete drive unit
The instructions below describe how the complete drive unit with gears and motor is removed
from the operating mechanism.
1.
DANGER!
springs on page 31.
3. Remove the entire drive unit by loosening the
two retaining bolts (1) from the side.
4. Lower the unit and remove the link pipe that

runs upwards.
5. Lift out the unit.
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10 Repairs
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 Repairs
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.
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
casing on page 156.
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10 Repairs
10.2.10 Limit switch replacement
General
This section contains information on replacing the limit switch.
Limit switch
The figure below shows the position of the limit switch in the operating mechanism.
1 Limit switch
Requisite equipment
Limit switch, complete 1HYN700023R1
Blue contact HAGT444559P2
Yellow contact HAGT444559P5
Standard tools
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10 Repairs
Limit switch replacement
The instructions below describe removal/fitting of the limit switch.

1.
DANGER!
springs on page 31.
3. Remove the two retaining bolts (1) and remove
the spring pin (2). Remove the limit switch.
4. Disconnect the cables from the limit switch.

If only one of the contacts requires
replacement, disconnect the relevant cables
and replace the contact.
5. Reconnect the cables to the new limit switch.
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10 Repairs
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 blade (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 further instructions if the
position of the new limit switch seems to be
incorrect.
t = 0.3 mm
casing on page 156.
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10 Repairs
10.2.11 Replacement of eye bolt and bellows
General
This section contains information on replacing the transmission rod's eye bolt and bellows
Eye bolt and bellows
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
Eye bolt SWT331162R4
Bellows 1HYN400073P1
Standard tools -
Grease "M" 5316 381-J More information on the grease is given in section Types
of grease on page 35.
Strap Used for attaching the new bellows.
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10 Repairs
Removal of transmission rod
The instructions below describe how the transmission rod is removed from the cabinet.
1.
DANGER!
springs on page 31.
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 Repairs
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 "M" grease.
3. Use the same washer, nut and bolt in the new
eye bolt.
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10 Repairs
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.
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.
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 Repairs
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.
casing on page 156.
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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.
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. On request, ABB AB may provide a quote for final
disposal of used gas in connection with the scrapping of a circuit breaker.
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 sent to landfill, or used for other purposes, such as filling
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.
1HSB429954-10en 2012-05-10 195

Metals
Metals are to be sorted according to type and surface treatment and sent to an approved
recycling company. Following the removal of any paint or other surface treatment, clean metal
can as a rule, be melted down and used in new products. Many metal components of iron, steel
and aluminum are large and easy to identify, e.g. supports and mechanism housings.
ABB AB strives to reduce the use of precious metals and emissions of environmentally
hazardous metals. Recycling of these is particularly important. Precious metals such as copper
and silver are expensive and are only present in small amounts in the earth’s crust. Copper is
primarily used in current paths, puffers, contacts and cables. Silver plating of contacts may
occur. Emissions from certain metals may cause damage. This applies to copper, but also zinc
and nickel, which are used sparingly as surface treatments.
Plastics
The different types of plastic are to be separated and sent to an approved environmental waste
treatment plant or recycling company. The energy content in thermoplastics and thermosetting
plastics can often be recovered through combustion at a plant designed for the purpose.
Thermoplastics can as a rule, be melted down and reused without any major loss of quality.
Composites can be fractioned and used as filling materials in other materials or be disposed of.
Composites are present in smaller amounts in insulators and pipes. Cable inlets are made of
thermosetting plastic. Thermoplastic is present in components such as guide rings, tape,
bushings and support rings. Thermoplastic in sleeves, nozzles, piping and collars contains
fluoride and is not suitable for recycling. However, it can be disposed of without the risk of
leaking hazardous substances.
Oils and greases
Before disposal, oil, grease and similar products must be removed and sent to an approved
environmental waste treatment plant or recycling company. By utilizing gravimetric forces, oil
waste can be separated into oil, water and a range of contaminants. In many cases, the oil can
then be reused. Alternatively, the energy content in oil can be recovered through combustion
at a plant designed for the purpose.
Oil occurs in dampers where grease is used as a lubricant.
Rubber
Rubber can be sent to an approved environmental waste treatment plant, either for disposal or
reused for various purposes.
Rubber is present in various seals.
Other materials
Other materials are sorted and sent to an approved environmental waste treatment plant.
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11.2 Environment information, SF6 gas
Gas handling
Electrical equipment with SF6 has been used for many years with good results. In cases where
a device or substation 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.
1HSB429954-10en 2012-05-10 197

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12 Spare parts
12 Spare parts
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 Spare parts
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 Spare parts
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 Spare parts
12.2.2 Breaking unit
Illustration
Component parts

1. Complete breaking unit RR
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12 Spare parts
12.2.3 Post insulator and insulating pull-rod
Structure
Component parts

1 Post insulator RR
2 Insulating pull-rod RR
1HSB429954-10en 2012-05-10 203

12 Spare parts
12.2.4 Mechanism
Illustration
Component parts

1 Mechanism RR
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12 Spare parts
12.2.5 Accessories
Absorbent container

1 Absorbent container
2 Absorbent R
Density monitor

1 Density monitor (temperature R
compensated reference volume)
2 Density monitor (temperature R
compensated bimetal)
1HSB429954-10en 2012-05-10 205

12 Spare parts
Gasket set
Gasket set for full circuit-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 Spare parts
12.3 Operating mechanism
12.3.1 Damper
Illustration
Component parts

1 Damper 1HYB300862-A RR
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12 Spare parts
12.3.2 Latch device
Illustration
Component parts

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 Spare parts
12.3.3 Heating element
Overview
Component parts

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 Spare parts
12.3.4 Open and closing latch device assembly
Component parts

1 Closing spring assembly 1HYB300784-A RR
1 Trip spring assembly 1HYB300785-A RR
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12 Spare parts
12.3.5 Eye bolt and bellows for transmission rod
Structure
Component parts

1 Eye bolt SWT331162R4 RR
2 Bellows 1HYN400073P1 RR
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12 Spare parts
12.3.6 Drive unit with motor and gear housing
Component parts

1 Motor, type 220 V AC/DC EXIN-300802-R1 R
1 Motor, type 110 VAC/DC EXIN-300802-R2 R
2 Gear housing EXIN-300801-R1 RR
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12 Spare parts
12.3.7 Limit switch
Component parts

1 Limit switch, complete 1HYN700023R1 RR
2 Blue contact HAGT444559P2 R
3 Yellow contact HAGT444559P5 R
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12 Spare parts
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12 Spare parts
1HSB429954-10en 2012-05-10 215

12 Spare parts
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Non Conformance Report
ABB AB, High Voltage Circuit Breakers
Name Phone
E‐mail
Reporting company Date
SEABB OrderNo
Serial No Serial No
Breaker Operating device
Type of
Breaker
End customer
Site Country
Delivery address (incl. postal code) for spares

Contact person (name and phone)
Type of Operating Mechanism:
BLK 82 BLK 222 BLK 152 BLG FSA BCM MD
Circuit breaker type:
LTB D LTB E HPL
Disconnector/option:
WCB DCB Truck Spareparts Other
Specification of problem:
Delayed delivery Incomplete delivery Wrong delivery Torque
Documentation Poor packing Corrosion Wiring
Not according to spec Transport damage Functional values Mechanical failure
Quality of material Storage of material Leakage gas/oil/water
Other
Who discovered the problem:
End customer ABB representative Other
When was the problem discovered
Before Installation During Installation During Commissioning After Energizing

Description of problem:

Contact information:
ABB AB Telephone: +46(0) 240 782000
CustomerComplaints Telefax: +46(0) 240 782320 Click here to send!
SE‐771 80 Ludvika, Sweden bqc.customercomplaints@se.abb.com

1HSB429954-10en / 2012-05-10

Instructional Manual For 145kV Breaker

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Instructional Manual For 145kV Breaker

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Product manual

LTB 72.5-170D1/B 1HSB429954-10en

© Copyright 2012 ABB All rights reserved.

Telephone: +46(0) 240 782000

2 Product description, operating mechanism 15

11 Disposal and environmental information 197

1 Product description, circuit-breaker

The circuit breaker's main components

Item Part Weight

1.2 Breaking principle

Breaking unit with Auto-Puffer

IEC and ANSI/IEEE

1.4 Functional overview

Function of operating mechanism

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

Standard operating cycle

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

1.5 Gas system and density monitor

1.6 Description, SF6-gas

Dielectric strength (kV), 10 mm gap

2 Product description, operating mechanism

The operating mechanism is enclosed in a cabinet.

Summary, operating mechanism

A View from the rear

Description of closing operation

Description of opening operation

2.3 Component parts

2.3.1 Drive unit

The drive unit is delivered with motor for:

2.3.2 Latch device with coils

2.3.4 Auxiliary contact

2.3.5 Heating element

2.4 Preconditions for operation

2.4.1 Preconditions for different operations

S1 Control switch, Close/Open

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

The safety chapter is divided into two sections:

3.2 General safety information

3.2.1 Levels of safety risks

Safety risks - Symbols and their meanings.

3.2.2 Hazardous working situations

Hazardous working situations

3.2.3 Safety during maintenance

3.3 Safety related instructions

3.3.2 Discharging springs

Overview, discharging springs electrically

1 Protective motor switch

Discharging springs electrically

Supplier Designation Part number

Supplier Designation Part number

4.2 Types of grease

Low temperature grease specially designed for lubricating precision-engineered equipment

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

4.3 Locking fluid

Preliminary treatment of surfaces

4.4 Tightening torque

This section specifies all tightening torques

Tightening torque, specified

Tightening torque, general

4.5 Requisite equipment, installation

4.6 Requisite equipment, maintenance

4.7 Requisite equipment, overhaul

4.8 Operating values