Product Manual - Donutsdocshare01.docshare.tips/files/28158/281585885.pdfOn opening the puffer...

Product Manual1HSB445416-14 en

HPL 245-550B2

BLG 1002A

1-pole operation

12

43

56789

1110ABB Power Technology Products AB

S-771 80 LUDVIKA

PRODUCT MANUALPRODUCT DESCRIPTION- Circuit-Breaker

PRODUCT DESCRIPTION- Operating Mechanism

ASSEMBLY INSTRUCTIONS

CHECKLIST

OPERATING AND MAINTENANCEINSTRUCTIONS

LUBRICANTS

MAINTENANCE INSTRUCTIONS- Operating Mechanism

OVERHAUL INSTRUCTIONS- Circuit-Breaker

SPARE PARTS- Circuit-Breaker

SPARE PARTS- Operating Mechanism

ABB Power Technology Products

SF6 Circuit-Breaker HPL 245-550B2 with operatingmechanism BLG 1002A1-pole operation

1HSB445455-14 en

Product Description

The information in this document is subject to alteration without prior notice and should not be regar-ded as an undertaking from ABB Power Technology Products AB. ABB Power Technology ProductsAB takes no responsibility for errors that can occur in the documentation.

ABB Power Technology Products AB is not responsible for damage incurred due to the misuse of thisdocument.

The document, or parts thereof, may not be reproduced or copied without prior permission from ABBPower Technology Products AB. It may not either be imparted to third party or otherwise be used wit-hout authorisation. Infringement hereof will be subject to action in accordance with applicable laws.

© ABB Power Technology Products AB

Article number: 1HSB445455-14 en

Date: 2002-04-04

Product Description

1HSB445455-14 en i

LIST OF CONTENTS

1. Description.......................................................................... 11.1 Design of the circuit-breaker.......................................................... 1

1.2 The circuit-breaker’s gas system.................................................... 2

1.3 Operating mechanism..................................................................... 3

1.4 Standards........................................................................................ 3

Product Description

ii 1HSB445455-14 en

FIGURES

Figure 1-1. Circuit-breaker type HPL 245-550B2 ............................................ 1

Figure 1-2. Circuit-breaker pole, Opening - Closing ........................................ 2

Product Description Description

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1. DescriptionHigh-voltage circuit-breaker HPL 245-550B2, with three operating mechanismstype BLG 1002A.

1.1 Design of the circuit-breaker

The circuit-breaker is made up of three separate poles. These consist of threeparts. At the bottom is a mechanism in an alloy housing, above this is hollow pinsulators through which the operating insulator runs and at the top is the breaunit.

Each breaking unit consists of two breaking chamber insulators, which togethewith two flanges and an upper mechanism housing make up the enclosure, anupper and lower current path with a contact system. The puffer runs in the lowcurrent path. The fixed contacts are integrated in the upper and lower current p

In those cases where each pole contains several breaking units in series, thebreaking units can be connected in parallel with grading capacitors. The polesmounted on separate hot-dipped galvanised column frames. The frame consistwo welded formed plate halves, which are interconnected with bolted cross st

Weights for component parts:

Figure 1-1. Circuit-breaker type HPL 245-550B2

Item Part Weight, kg

1 Circuit-breakerpole

See dimensiondrawing

2 Operatingmechanism

465

3 Frame 86-200

B10068

1

2

3

1HSB445455-14 en 1

Description Product Description

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1.2 The circuit-breaker’s gas system

The circuit-breaker poles are permanently filled with SF6 gas at a pressure of 0.7MPa abs at 20°C on breakers whose performance is limited by a lowest ambientemperature of≥ -30°C.

On breakers whose ambient temperature is≥ -40°C the breaker is filled to a pressureof 0.5 MPa abs at 20°C. On breakers whose ambient temperature is≥ -55°C thebreaker is filled with a mixture of SF6 and N2 gas or CF4 gas at a pressure of 0.7MPa abs at 20°C. The poles are fitted with density monitors to monitor the pressu

1.2.1 Opening and closing

On opening the puffer cylinder (1) is drawn downwards towards the fixed pistonthe enclosed gas is compressed and forced at a high velocity out through the n(2) and the arcing contacts (3).

Figure 1-2. Circuit-breaker pole, Opening - Closing

When the arcing contacts have separated an arc is produced which at high cuobstructs the nozzle (2). When the current approaches the passage through zegas starts to flow out through the puffer cylinder. The specially designed nozzlensures that the gas flow is directed towards the arc. The gas is allowed to passboth down through the moving arcing contact and up passt the fixed arcing conWhen the arc has been cooled, it is extinguished and the current is interrupted

There are separate normal current contacts, which open before and close aftearcing contacts. They are not affected by the arc on interrruption.

On closing, the puffer cylinder (1) slides upwards, the contacts engage one anand the puffer cylinder is refilled with gas.

21 3

2 1HSB445455-14 en


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1.3 Operating mechanism

The HPL circuit-breaker is operated by a motor-charged spring operatingmechanism type BLG.

The operating mechanism is connected to the poles’ mechanisms via a pull-rosystem.

The breaker is closed by means of the operating mechanism, which houses thclosing springs. On closing, the opening springs are tensioned, which arepermanently fixed to the poles’ mechanisms. The trip latch in the operatingmechanism keeps the breaker in the closed position. Opening of the circuit-breonly requires the release of the trip latch.

The normal operating cycle is:

O-0.3 s-CO-3 min-CO (according to IEC) or CO-15 s-CO (according to ANSI).

1.4 Standards

The circuit-breakers comply with the requirements according to IEC Publicatio60056 and in most cases also ANSI C37 and are restrike-free when breaking acapacitive load.

1HSB445455-14 en 3

1HSB445455-14 en0204

ABB Power Technology Products ABHead OfficeSE-771 80 LUDVIKASWEDENTelephone: +46 (0) 240 782 000Telefax: +46 (0) 240 714 928


SF6 Circuit-Breaker Operating Mechanismtype BLG 1002A

1HSB515432-100 en rev3

Product Description

The information in this document is subject to alteration without prior notice and should not be regar-ded as an undertaking from ABB Power Technology Products AB. ABB Power Technology ProductsAB takes no responsibility for errors that can occur in the document.


The document, or parts thereof, may not be reproduced or copied without prior permission from ABBPower Technology Products AB. It may not either be imparted to a third party or otherwise be used wit-hout authorisation. Infringement hereof will be subject to action in accordance with applicable laws.


Article number: 1HSB515432-100 en rev3

Date: 2002-06-10

Product Description

1HSB515432-100 en rev3 i

LIST OF CONTENTS

1. Description.......................................................................... 11.1 Normal operating mode.................................................................. 2

1.2 Opening operation.......................................................................... 3

1.3 Closing operation ........................................................................... 4

2. Component units ................................................................ 52.1 Drive unit........................................................................................ 5

2.2 Mechanical interlock...................................................................... 5

2.3 Catch gear....................................................................................... 6

2.4 Dashpots......................................................................................... 6

2.5 Auxiliary contact............................................................................ 7

2.6 Heater element ............................................................................... 8

Product Description

ii 1HSB515432-100 en rev 3

FIGURES

Figure 1-1. Operating mechanism ..................................................................... 1

Figure 1-2. Normal operating mode. ................................................................. 2

Figure 1-3. Opening operation. ......................................................................... 3

Figure 1-4. Closing operation. .......................................................................... 4

Figure 2-1. Drive unit. ....................................................................................... 5

Figure 2-2. Interlocking mechanism. ................................................................ 5

Figure 2-3. Catch gear. ...................................................................................... 6

Figure 2-4. Closing and Opening dashpots. ...................................................... 6

Figure 2-5. Limit switch with auxiliary contact. ............................................... 7

Figure 2-6. Heater element. ............................................................................... 8


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1. DescriptionThe spring operating mechanism BLG 1002A is intended for operating a circuibreaker with integrated opening springs. The opening springs are chargedautomatically by the mechanism on closing of the circuit-breaker, whereby therequisite energy for opening is obtained. Under no circumstances may themechanism be operated with the spring battery charged, without first being fitteand trimmed with the associated circuit-breaker.

In principle the operating mechanism consists of a spring battery, which is chaby a motor fitted with a worm gear, and a mechanism for actuating the openingclosing action. The spring battery is automatically charged after each closingoperation.

The component parts of the operating mechanism are integrated in a cabinet, walso contains a control panel with operating equipment. The top and doors of tcabinet can be removed to facilitate service and overhaul procedures.

The standard operating cycle is O - 0.3 s - CO - 3 min - CO. The time betweenclosing operations should not be less than 1 minute during the testing of circuibreakers and relay systems involving more than 3 closing operations.

Figure 1-1. Operating mechanism

Item

1 Drive unit


3 Control panel

4 Spring battery

5 Heater element

1

2

4

3

5

B20001

1HSB515432-100 en rev3 1


e

1.1 Normal operating mode

During normal service the circuit-breaker is in the closed position. The openingspring (14) on the circuit-breaker and the closing springs (7) in the operatingmechanism are charged. The circuit-breaker is kept in the closed position by thoperating mechanism’s opening catch gear (1).

Figure 1-2. Normal operating mode.

Item

1 Opening catch gear

7 Closing springs

14 Opening spring14

7

1

B20028

2 1HSB515432-100 en rev3


akertoion

1.2 Opening operation

The latch in the opening catch gear (1) is released on opening of the circuit-bre(1). The opening spring (14) pulls, via the pull-rod (13), the operating lever (4) the left. The movement is damped by the opening dashpot (3) at the end positbefore the operating lever (4) rests against the cam disc (5).

Figure 1-3. Opening operation.

Item


3 Opening dashpot

4 Operating lever

5 Cam disc

13 Pull-rod

14 Opening spring

14

5

1

13

4

3

B20029

1HSB515432-100 en rev3 3


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1.3 Closing operation

On closing of the circuit-breaker, the latch is released in the closing catch gearThe chain section (17) is released and transfers the closing spring’s (7) energy tcam disc (5). The cam disc rotates 360˚ clockwise and pulls the operating leveto the right until the opening catch gear (1) engages. The movement is dampethe end position by the closing dashpot (12). The opening spring (14) is chargedthe pull-rod (13).

The chain section (18) travels up the same path as the chain section (17) travedown.

Figure 1-4. Closing operation.

Item


2 Closing catch gear

4 Operating lever

5 Cam disc

7 Closing springs

12 Closing dashpot

13 Pull-rod

14 Opening spring

17 Chain section

18 Chain section

12

18

5

14

13 2

7

17

4

1

B20031

4 1HSB515432-100 en rev3

Product Description Component units

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2. Component units

2.1 Drive unit

The drive unit is supplied with one or two motor options for 60, 110 or 220 V Dand 50, 60 Hz AC.

The motor should be able to charge the springs at 85% of the nominal voltage (I

Figure 2-1. Drive unit.

2.2 Mechanical interlock

The interlocking mechanism prevents a closing operation from being carried othe circuit-breaker is already in the closed position or if the operating mechanisclosing springs are uncharged or not fully charged, which can occur, for examplthe closing catch gear is opened by hand or if a mechanical fault occurs in the cgear.

Figure 2-2. Interlocking mechanism.

Item

1 Drive unit

Item

1 Limit switch

2 Interlocking lever

3 Interlocking disc

4 Cam disc

5 Operating rod

6 Operating lever shaft

1

B20031

1

4

3

2

65B20007

1HSB515432-100 en rev3 5

Component units Product Description

side.

y

with

nal

2.3 Catch gear

The operating mechanism is fitted as standard with one closing coil and twoopening coils, but on request can be equipped with double coils on the closing

The standard voltage of the coil is 110, 220 V DC or AC, but other voltages maoccur.

The rated output of the coils is 200 W as standard. As an option there are coilsa rated output of 450 W when 2-cycle interruption at 60 Hz is demanded.

Figure 2-3. Catch gear.

2.4 Dashpots

The operating mechanism is equipped with one Closing dashpot to brake therotating movement of the cam disc and one Opening dashpot to dampen the fiphase of the opening movement.

Figure 2-4. Closing and Opening dashpots.

Item

1 Catch gear

Item

1 Closing dashpot

2 Opening dashpot

1B20034

1

2

B20024

6 1HSB515432-100 en rev3

Product Description Component units

acting

ker

2.5 Auxiliary contact

The operating mechanism is equipped as standard with a 6-pole auxiliary contconsisting of six opening and six closing contacts. Three closing and one opencontact are used for the functioning of the operating mechanism. There is apossibility of supplementing with six or twelve extra contacts.

The shaft of the auxiliary contact is in direct connection with the operatingmechanism’s operating lever and accordingly follows the movement of the breacontacts.

Figure 2-5. Limit switch with auxiliary contact.

Item

1 Limit switch

2 Auxiliary contact

21B20035

1HSB515432-100 en rev3 7

Component units Product Description

2.6 Heater element

The operating mechanism is equipped with a heater element to preventcondensation from forming and should always be connected.

Figure 2-6. Heater element.

Item

1 Heater element

13 2

5 46

1B20036

8 1HSB515432-100 en rev3

1HSB515432-100 en rev30206



SF6 Circuit-Breaker HPL 245-550B2 withoperating mechanismBLG 1002A1-pole operation

1HSB445410-14 en

Assembly Instructions






Date: 2002-04-05


... 3

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LIST OF CONTENTS

1. General ................................................................................ 1

2. Safety................................................................................... 32.1 Warning text ................................................................................

2.2 Safety, general ............................................................................

3. Delivery ............................................................................... 53.1 Weights.......................................................................................

3.2 Unpacking ...................................................................................

3.3 Storage before assembly ............................................................

4. Assembly............................................................................. 94.1 Preparations................................................................................

4.2 Frame assembly..........................................................................

4.3 Assembling the frame on the foundation ....................................

4.4 Assembling the post insulator on the frame................................

4.5 Preparations for assembling the operating mechanism..............

4.6 Assembly of corona ring .............................................................

4.7 Assembling the operating mechanism ........................................

4.8 Final assembly of the post insulator............................................

4.9 Assembling the breaking unit......................................................

4.10 Dismantling the off-loading tool ..................................................

4.11 Assembly the opening device “High-speed”................................

4.12 Assembling the pull-rods ............................................................

4.13 Inspecting the bolted joints, etc...................................................

5. Electrical connections ..................................................... 295.1 Connection of the operating mechanism.....................................

5.2 Assembly of busbars or overhead lines......................................

5.3 Tensioning the closing springs ....................................................

6. Pressurising the poles ..................................................... 316.1 Preparations................................................................................

6.2 Gas filling with SF6 gas ..............................................................

6.3 Gas filling with mixed gas............................................................

6.4 Gas monitoring system...............................................................

6.5 Leakage test................................................................................

6.6 Fitting the signs and cover ..........................................................

7. Commissioning................................................................. 39

1HSB445410-14 en i


.. 41

. 41

... 41

.. 41

8. Operating values...............................................................418.1 Times ..........................................................................................

8.2 Motor and control circuits ...........................................................

8.3 Resistance..................................................................................

8.4 Contact stroke.............................................................................

ii 1HSB445410-14 en


.......5

.....6

......9

....10

.....11

.....12

...13

....13

....14

....14

....15

....16

.....17

....18

....19

....20

...21

....22

....23

..24

....25

...26

....26

....27

.....29

....30

....32

...34

....36

....37

FIGURES

Figure 3-1. Component parts. .....................................................................

Figure 3-2. Lifting the operating mechanism. ..............................................

Figure 4-1. Assembly markings. ..................................................................

Figure 4-2. Foundation. ................................................................................

Figure 4-3. Frame assembly. .......................................................................

Figure 4-4. Frame assembly on the foundation. .........................................

Figure 4-5. Lifting the post insulator. ...........................................................

Figure 4-6. The post insulator’s non-return valve. .......................................

Figure 4-7. Fitting the post insulator on the frame. .....................................

Figure 4-8. Dismantling the signs and cover. ...............................................

Figure 4-9. Assembly corona ring ...............................................................

Figure 4-10. Assembling the operating mechanism. .....................................

Figure 4-11. Post insulator on the frame. ......................................................

Figure 4-12. Dismantling the transport cover. ...............................................

Figure 4-13. Assembling the breaking unit. ...................................................

Figure 4-14. Joining together the breaking unit and operating insulator. ......

Figure 4-15. Dismantling the locking washer. ................................................

Figure 4-16. Assembling the capacitor. .........................................................

Figure 4-17. Assembling the corona rings. ....................................................

Figure 4-18. Dismantling the off-loading tool. ................................................

Figure 4-19. Assembling the opening device .................................................

Figure 4-20. Checking the closing arm’s locking lug. ....................................

Figure 4-21. Adjusting the operating mechanism. .........................................

Figure 4-22. Assembling the pull-rod. ...........................................................

Figure 5-1. Operating mechanism. ..............................................................

Figure 5-2. Charging the closing springs. ....................................................

Figure 6-1. Gas filling. .................................................................................

Figure 6-2. Density monitor and union nut. ..................................................

Figure 6-3. Gas monitoring. .........................................................................

Figure 6-4. Fitting the signs and cover. ........................................................

1HSB445410-14 en iii

Assembly Instructions General

ng

1. GeneralThis Assembly Instruction Manual applies to the SF6 circuit-breaker typeHPL 245-550B2 with three operating mechanisms type BLG 1002A for 1-poleoperation and contains all essential information for assembly and commissioni

Read through the entire Assembly Manual before starting the assembly work.

1HSB445410-14 en 1

Assembly Instructions Safety

ld be

2. Safety

2.1 Warning text

Warning text occurs where required and indicates that the text in question shouobserved extra carefully. The warning texts are marked as set out below:

DANGER

indicates an immediate hazardous situation that, if not avoided, will resultin death or serious injury.

WARNING

indicates an immediate hazardous situation that, if not avoided,can resultin death or serious injury.

CAUTION

indicates a hazardous situation thatcan result inminor or moderateinjury .

N.B. used for hazards that may only result indamage to the installation.

1HSB445410-14 en 3

Safety Assembly Instructions

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2.2 Safety, general

WARNING

Circuit-breaker with pressurised porcelain insulators.Mechanical damage to the porcelaincan cause it toexplode with thefollowing risk ofsplintering.Work on the circuit-breaker that brings about the risk of mechanicaldamage to the insulators should be carried out at a reduced gas pressur0.15 MPa (abs).

WARNING

Do not operate the operating mechanism unloaded!Operations shall take place only after the mechanism has been connecteand adjusted to the associated pressurised circuit-breaker.

The standard operating cycle is O - 0.3 s - CO - 3 min.-CO. The time betweenclosing operations should not be less than 1 minute during the testing of circuibreakers and relay systems involving more than 3 closing operations.

4 1HSB445410-14 en

Assembly Instructions Delivery

is

3. DeliveryCheck on arrival that the delivery corresponds with the order and deliverydocuments and that no transport damage has occurred.

If any material is missing or if transport damage has occurred, please report thimmediately to ABB Power Technology Products AB, HV Products/ CircuitBreaker Division.

3.1 Weights

The weights of the components are as follows:

Figure 3-1. Component parts.

Item PartWeight,

kg

1 Breaking unit stated ontheapplicabledimensiondrawingfor theorder.

2 Post insulator stated ontheapplicabledimensiondrawingfor theorder.


465

4 Frame 86-200

2

4

1

3

B10068

1HSB445410-14 en 5

Delivery Assembly Instructions

case

net,

acket

3.2 Unpacking

The material are packed in a crates and on pallets. The crate is marked with thenumber and the gross weight. Other information is written on a plywoodboard/label, which is attached to two of the crate’s sides.

The operating mechanism must be lifted using the lifting eyes on top of the cabiseeFigure 3-2. Slings mustnot be placed around the cabinet when lifting.

One sling should be attached to the lifting eye and another sling around the bron the bottom when the operating mechanism is supplied in a crate, seeFigure 3-2.

The blocking beams should be stored for future maintenance and overhauling.

The circuit-breakers shall be kept in the transport packing until just beforeassembly.

All packing material can be recycled.

Figure 3-2. Lifting the operating mechanism.

Supplied in a crateSupplied on a pallet

B20023

6 1HSB445410-14 en

Assembly Instructions Delivery

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3.3 Storage before assembly

3.3.1 General

The circuit-breakers are normally delivered in units adapted for transport.Intermediate storage of these units should be avoided. If intermediate storage not be avoided the units should be stored indoors or under a roof. They shouldbe stored horizontally above ground level to avoid cracking or water damage. Uarrival it is important that the plastic cover is removed in order to prevent corrodue to condensation (except for spare parts, seesection 3.3.5).

Storage in a humid climate, without proper ventilation, can lead to discolouringzinc coated surfaces. This discolouring is known as white rust, and consists mof zinc oxide and zinc hydroxide and is a result of a chemical process betweenzinc on the surface and moisture.

The long term rust protection is not affected because the steel-zinc layer undesurface remains unaffected. According to Swedish standard the presence of wrust is no reason to reject goods.

Upon arrival each unit should be checked regarding the following:

The delivery corresponds with the order and shipping documents

Damage due to transport and missing parts

If damage is discovered or suspected the case should be opened and photos tReport damage as well as missing parts.

All components should be rationally stored for easy access. All material shouldstored in an approved store1, exceptions are stated below. Dust, smoke, corrosiveinflammable gas, steam or salt must not pollute the surrounding air otherwise equipment must be cleaned before construction.

The original cases can be used for storage, but the plastic covering should beremoved. The assembly units’ coupling pieces as well as connections are provwith transport covers or protective covers which must not be removed until shobefore the circuit-breakers are assembled.

3.3.2 Stacking of cases

Cases of different widths shall normally not be stacked (the pressure may destthe covers of the lower cases). If cases of different widths need to be stacked, framework must be used between the cases in order to distribute the pressure eStacking of more than three cases is not allowed. It must be noted that stackincauses instability sidewise and therefore the cases must be secured, i.e., prevfrom tumbling down or rolling over.

1. An approved store is defined as consisting of:rooffirm basehumidity below 50%temperature 20˚C (±10˚C)

1HSB445410-14 en 7

Delivery Assembly Instructions

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3.3.3 Operating mechanism

The operating mechanism should be unpacked on arrival. If it is not kept in anapproved store, the heating element must be connected and permanently switon to prevent the control equipment from corrosion or damage due to freezing

3.3.4 Circuit-breakers

The circuit-breakers should be stored in their original cases where they are propprotected from damage. The units shall not stand in water. The circuit-breakerbe stored outdoors. If this happens they should be protected by at least a tarpThe tarpaulin must not be so tight that air circulation to zinc coated surfaces isprevented. Any condense should easily drip off.

The lowest permitted ambient temperature for storage is -30˚C.

3.3.5 Spare parts

Spare parts shall be kept indoors in an approved store and in their original pacThis is especially important for rubber components (seals etc.), which must alsprotected from sunlight to avoid drying. Gaskets have a limited storage life, so avstoring them. Frames can be stored outdoors.

8 1HSB445410-14 en

Assembly Instructions Assembly

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.

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4. Assembly

4.1 Preparations

Before starting the assembly, make certain that all requisite tools and documenton hand.

• Standard tools with torque wrenches (9 - 430 Nm).

• Lifting device and lifting slings.

• Lubricants, see Lubricants 1HSB445409-1 for suppliers and brand namesGrease “G”: ABB Art. No. 1171 4014-407Grease “SV”: ABB Art. No. 1171 4016-610.

• Contact paste.

• Applicable dimension drawings and diagrams for the order.

4.1.1 Assembly markings

On delivery the circuit-breakers are supplied dismantled in two gas-tight transpunits. The component parts are marked to facilitate assembly. The circuit-breapoles and operating mechanisms have been tested together. Breaking units aninsulators having the same marking, e.g., A1, are coupled together. Breaking uand post insulators only need to be coupled together mechanically and after thfilled with gas.

Check that the assembly markings correspond withFigure 4-1 and that the serialnumber on the operating mechanism corresponds with the serial number of thcircuit-breaker.

Figure 4-1. Assembly markings.

Item

1 Operatingmechanism A

2 Operatingmechanism B

3 Operatingmechanism C

4 Post insulator A1

5 Post insulator B1

6 Post insulator C1

7 Breaking unit A1

8 Breaking unit B1

9 Breaking unit C1

3

2

1

8

7

9 5

4

6

B10069

1HSB445410-14 en 9

Assembly Assembly Instructions

ing

ts.

4.1.2 Foundation

The circuit-breaker’s foundation must be flat and level. Adjust any deviations usspacer washers, see “Chapter 4.3, Assembling the frame on the foundation”. Figure4-2 shows the permitted deviations in mm for the position of the foundation bolThe dimension of the foundation bolts and nuts are stated on the applicabledimension drawing for the order. The nominal dimensions are stated on theapplicable dimension drawing for the order.

Figure 4-2. Foundation.

±1

±1

Length = >110B10004

10 1HSB445410-14 en


4.2 Frame assembly

The frame is supplied in welded halves with six cross stays and nuts, bolts andwashers.

Bolt the halves together as shown inFigure 4-3. Fit the cross stays according tothe numbering 1-4, using the supplied nuts, bolts and washers.

N.B. Make sure the stays are fitted as set out inFigure 4-3 and to the intendedoperating mechanism.

Tighten the bolted joints to a torque of 430 Nm.

Figure 4-3. Frame assembly.

Item

1 Frame halves 2 pcs.

2 Stays 6 pcs.

3 Bolts M20x60

Nuts M20

Washers 21x37x3

8 pcs.

8 pcs.

16 pcs.

4

3

2

1

1

23

TIGHTENING TORQUE430 Nm

B10005

1HSB445410-14 en 11


nuts

or

4.3 Assembling the frame on the foundation

Check that the frames are upright and adjust them to the same level using the(2). The dimension of the foundation bolts, washers and nuts are stated on theapplicable dimension drawing for the order.

Fill the gap between the lower nut and foundation with spacer washers;this shouldbe as small as possible.

Tighten the lower nut against the spacer washers (4). For the final tightening of theframe, use the upper nut, which is tightened to a torque of 300-350 Nm if M24500-550 Nm if M30.

Foundation bolts, spacer washers and nuts are not supplied.

Figure 4-4. Frame assembly on the foundation.

Item

1 Foundation bolts, L > 110 mm(Not supplied)

2 Nuts (Not supplied) 8 pcs.

3 Washers (Not supplied) 8 pcs.

4 Spacer washers (Not supplied)

5 Foundation

6 Frame foot

201

2

6

4

5

310

10

>110

2

B10006

300-350 Nmor

500-550 Nm

TIGHTENING TORQUE

12 1HSB445410-14 en


ort

4.4 Assembling the post insulator on the frame

Place a lifting sling around the top of the post insulator as shown inFigure 4-5and,using this method, lift the post insulator from its horizontal position in the transpcrate.

Note the position of the lifting sling! If polymeric insulators: Place the lifting slingas close to the terminal flange as possible and not on the rubber surface.

.

Figure 4-5. Lifting the post insulator.

Check that the post insulatordoes not leak before assemblyon the frame.

1. Undo the sealing cap (1).

2. Press the non-returnvalve’s disk (2) inwardsusing a rod with adiameter of about 5 mm.A clear hissing noiseshould be heard from thepole.If no hissing noiseis heard, the postinsulator leaks. Thismust be rectified beforeassembly.

3. Fit the sealing cap (1).

Figure 4-6. The post insulator’s non-return valve.

B10086

2

1

B10008

1HSB445410-14 en 13


tted.

Assembly a post insulator on each frame according toFigure 4-7. Fit the bolts (1)and tighten by hand.

N.B. Final tightening is carried out when the operating mechanism has been fi

Figure 4-7. Fitting the post insulator on the frame.

4.5 Preparations for assembling the operating mechanism

Remove all the pole covers (1) andthe Close-Open signs (2), to gainthe best possible access to the polemechanisms.

Figure 4-8. Dismantling the signs and cover.

Item

1 Bolts M20x60

Nuts M20

Washers 21x36x3

4 pcs.4 pcs.

8 pcs.

Item

1 Cover

2 Sign

3 Coupling link

1

B10087

1 32B10012

14 1HSB445410-14 en


ing

4.6 Assembly of corona ring

If the circuit-breaker have polymeric insulators assembly the supplied corona rassection 4-9.

Figure 4-9. Assembly corona ring

Item

1 Corona ring 1 pcs

2 Bracket 4 pcs

3 Bolts M10 4 pcs

4 Washer 10,5x20x2 12 pcs

5 Bolts M10 4 pcs

6 Nuts M10 4 pcs

12

3,4

4,5,6


1HSB445410-14 en 15


sing

4.7 Assembling the operating mechanism

On delivery the operating mechanism has been set and is supplied with the closprings correctly adjusted.

The operating mechanism is fitted as set out inFigure 4-10.

Fit all bolts and tighten them by hand. Then tighten the bolted joints (1) with atightening torque of 79 Nm.

Figure 4-10. Assembling the operating mechanism.

Item

1 Bolts M12

Nuts M12

Washers 13x24x2.5

10 pcs.

10 pcs.

20 pcs.

2 Spring washer 13x29x3 4 pcs.

1

1

1

1


B10088

2

16 1HSB445410-14 en


4.8 Final assembly of the post insulator

Tighten the post insulator to the frame with a torque of 300 Nm.

Figure 4-11. Post insulator on the frame.

B10089


1HSB445410-14 en 17


(5)

t it

4.9 Assembling the breaking unit

Place a lift sling around the breaking unit as shown inFigure 4-12 and lift thebreaking unit horizontally out of the transport packaging.

N.B. The breaking unit should be balanced and lifted horizontally.

1. Dismantle the transport cover (1) and the cover (3) from the breaking unitand the transport cover (6) on the post insulator (7). Save all the transportcovers for future overhaul work.

N.B. The locking washer (8) under the cover (3) should remain in place so thaholds the breaking unit’s contact system in the sealed position.

Figure 4-12. Dismantling the transport cover.

Item

1 Transport cover with sealingring

2 Bolts M12x50

Washers 13x28x3

Nuts M12

8 pcs.

16 pcs.

8 pcs.

3 Cover with 2 sealing rings

4 Bolts M10x25

Washers 10.5x22x2

4 pcs.

4 pcs.

5 Breaking unit


7 Post insulator

8 Locking washer

1 2

4

5

6

7

B10090

3

8

18 1HSB445410-14 en


G”.once

nit.

.

2. Check that the sealing ring (1) is well-cleaned and apply a layer of grease “Also apply a thin layer of grease “G” on the sealing face for the sealing ringthe post insulator’s top flange and a generous layer of grease on the surfaoutside of the sealing groove. Place the sealing ring (1) in its groove.

3. Lower the breaking unit (2) onto the post insulator (3). Centre the breaking uon the operating insulator (4). Check that the sealing ring (1) is in position

N.B. The breaking unit should be lowered straight over the operating insulator

Figure 4-13. Assembling the breaking unit.

Item

1 Sealing ring

2 Breaking unit

3 Post insulator

4 Operating insulator1

2

3

B10091

4

1HSB445410-14 en 19


the
4. Join together the breaking unit (1) and the post insulator (2) by hand usingnuts, bolts and washers (3).
5. Fit the pin (4) and circlip (5). Check that the circlip (5) sits correctly in itsgroove.The operating insulator can be adjusted vertically, if necessary, using theadjuster screw (6) once the nut (7) has been loosened.

Figure 4-14. Joining together the breaking unit and operating insulator.

Item

1 Breaking unit

2 Post insulator

3 Bolts M12x70

Washers 13x24 x2.5

Nuts M12

4 pcs.

8 pcs.

4 pcs.

4 Pin, D= 22 mm

5 Circlip

6 Adjuster screw 1 pcs.

7 Locking nut 1 pcs.

3

7

6

2

5

4

1

B10092

20 1HSB445410-14 en


ull

ease

olts

(7),

6. Screw in a bolt (2), M8, in the threaded hole in the locking washer (1) and pit out, seeFigure 4-15.

7. Check that the sealing rings and sealing faces are clean. Apply a layer of gr“G” to the sealing rings and sealing faces.

8. Refit the sealing cover (3) without damaging the sealing face. Tighten the b(4) with a tightening torque of 45 Nm.

9. Tighten the breaking unit (5) against the post insulator (6) using the bolts tightening torque 79 Nm.

Figure 4-15. Dismantling the locking washer.

Item

1 Locking washer

2 Bolt M8

3 Sealing cover

4 Bolts M10x25

Washers 10.5x22x2

4 pcs.

4 pcs.

5 Breaking unit

6 Post insulator

7 Bolts M12x70

Washers 13x24 x2.5

Nuts M12

4 pcs.

8 pcs.

4 pcs.



6

1

2

3

B10093

4

7

5

1HSB445410-14 en 21


nd.

d

4.9.1 Assembling the capacitors

In those cases where capacitors are supplied, assemble them as follows:

1. Fit the capacitor brackets (1) on the capacitors. Tighten the bolts (2) by ha

2. Attach a lifting device on the capacitor and lift it into position.

3. Fit the bracket against the flange, separated by the spacer washer (5), antighten the bolts (4) by hand.

4. Fit the bracket on the upper mechanism housing (3) using the bolts (4).

5. Tighten the bolts (2)with a tightening torque of 79 Nm.

6. Tighten the bolts (4) with a torque of 60 Nm.

Repeat points 2-6 to fit the other capacitor.

Figure 4-16. Assembling the capacitor.

Item

1 Capacitor brackets 2 pcs.

2 Bolts M12x35

Spring washer

4 pcs.

4 pcs.

3 Upper mechanism housing

4 Bolts M12x30

Washers 13x28x3

4 pcs.

4 pcs.

5 Spacer washer



1

2

3

5

4

2

4

B10120

22 1HSB445410-14 en


by

4.9.2 Assembling the corona rings

In those cases where corona rings are supplied, assemble them as follows.

1. Remove the bolts (1) that hold the flange against the breaking chamberinsulator.

2. Lift the corona ring (2) into position and refit the bolts (1). Tighten the boltshand.

3. Fit the bolt (3) with washers and nut.

4. Tighten all bolts (1 and 3) with a tightening torque of 60 Nm.

Repeat points 1-4 to fit the other corona rings.

Figure 4-17. Assembling the corona rings.

Item

1 Bolts M12x50

Washers 13x28x3

2 pcs.

2 pcs.

2 Corona ring

3 Bolt M10x30

Washers 10.5x20x2

Nut M10

1 pcs.

2 pcs.

1 pcs.


32

1

1

B10121

1HSB445410-14 en 23


the

h a

4.10 Dismantling the off-loading tool

• Off-load the spring pressure using the adjuster screw (4) before dismantlingbottom cover (1) and the tool (3).

• Refit the bottom cover (1) and tighten the bolts (2) with atightening torque of 45 Nm.

• Fit the bolt (5) and washer in the bottom cover (1) and tighten the bolts wittightening torque of 79 Nm.

Figure 4-18. Dismantling the off-loading tool.

Item

1 Bottom cover

2 Bolts M10x50 4 pcs.

3 Tool 1HSB446381-A

4 Adjuster screw

5 Bolt M16x30

Washer 17x30x3

1 pcs.

1 pcs.



B10095

3 14 25

24 1HSB445410-14 en


n the and

(1).

s

4.11 Assembly the Opening device “High-speed”

Deassemble the bolt, washer and pin (1).

Mount the complete Opening device “High-speed”(2), seal the surface betweeopening device and the mechanism housing with silicone.Fit the bolts,washersnuts (3) and tighten with tightening torque 79 Nm.

Fit the coupling link (4) from the opening device and the coupling link from theoperating mechanism (5) in the operating lever (6). Fit the pin,washer and boltTighten with tightening torque 22,5 Nm. Secure with Loctite 270.

Seal the slots (7) in the opening device with silicone. The slot facing downwardshall be open for drainage.

Figure 4-19. Assembling the Opening device “High-speed”

Item

1 Bolt M8x16

Washer

Pin

1 pcs.

1 pcs.

1pcs.

2 Opening device“High-speed”

3 Bolt M12x50

Washers 13x24x2.5

Nuts M12

4 pcs.

4 pcs.

4pcs.

4 Coupling link

5 Coupling link

6 Operating lever

7 Slots


TIGHTENING TORQUE22,5 Nm

2

1

3

4

5

7

6

1HSB445410-14 en 25


nthe

s.

(2)

ge

4.12 Assembling the pull-rods

Each pole is supplied set to a basic setting. Adjust the poles to the correct Opeposition when fitting the operating rod between the operating mechanism and pole.

Pull-rod assembly takes place in stages:

• Preparations for assembling the pull-rods.

• Assembling the pull-rods between the operating mechanisms and the pole

4.12.1 Preparations for assembling the pull-rods

• Check that the closing arm’s (1) locking lug rests against the closing latchroller.

Figure 4-20. Checking the closing arm’s locking lug.

• Adjust the operating mechanism as set out inFigure 4-21. Press down thelocking lug (1) on the operating lever by inserting a tool, for example, a larscrewdriver, in the hole (2). Insert a screwdriver in hole (3) and press theoperating lever to the right.

Figure 4-21. Adjusting the operating mechanism.

2

1B10013

23

B10035

3

12

26 1HSB445410-14 en


are

om

(2)

ting

ck The

ism B

Item

1

2

3

4

5

6

7

8

9

10

4.12.2 Assembling the pull-rod between the operating mechanism A and pole A1

Each pole is supplied set to a basic setting and its Closed and Open positionsdetermined. Adjustment is made as set out below (seeFigure 4-22).

• Move the operating lever (3) and the pull-rod (2) from the operatingmechanism by hand, towards its Closed position sufficiently far so that thepull-rod (5) can be placed between the coupling link (4) and the pull-rod frthe operating mechanism.

• Simultaneously screw the pull-rod (5) into the operating mechanism’s pull rod(right-hand thread) and the pole’s coupling link (4) (left-hand thread).

N.B. Remember the two spring washers (6) under each locking nut (8).

• Turn the pull-rod (5) so its length decreases at the same time as the operalever (3) moves towards its Open position.The pull-rod (5) is the right lengthwhen the operating lever (3) is in its Open position and the alignmentcheck hole (7) is directly aligned with the predrilled hole in the mechanismhousing (1).Check the position of the hole using a 6 mm diameter rod. Chethat the pull-rod (5) is screwed past the alignment check holes (9 and 10).tightening torque for the locking nuts is 430 Nm.

Figure 4-22. Assembling the pull-rod.

Repeat the procedure to assemble the pull-rods between the operating mechanand pole B1 and between operating mechanism C and pole C1.

Mechanism housing

Pull-rod from operatingmechanism

Operating lever

Coupling link, pole

Pull-rod (turnbuckle screw)

Spring washers

Alignment check hole in arm

Locking nuts

Alignment check hole in pull-rod

Alignment check hole incoupling link

1

2 3

4

5

6

9

8

10

7B10014


1HSB445410-14 en 27


ce

4.13 Inspecting the bolted joints, etc.• Check using a 6 mm diameter rod that the arms’ alignment check hole is

aligned with the predrilled hole in the mechanism housing.

• Check that all bolted joints are tightened to the correct torque in accordanwith the table below.

Bolted joint Tightening torque, Nm

Frame 430

Foundation 300-350 or 500-550

Operating mechanism 79

Post insulator before lifting 60

Post insulator 300

Sealing cover 45

Breaking unit 79

Mechanism housing 79

Capacitor upper mechanismhousing

60

Corona ring 60

Bottom cover 45

Bottom cover center bolt 79

Pull-rod 430

Density monitor 10

Close and Open mechanism 22,5

Mechanism cover 9

28 1HSB445410-14 en

Assembly Instructions Electrical connections

ttomn.ring

ctor

torscted

es,hers

5. Electrical connections

5.1 Connection of the operating mechanism

Operation and signal cables are routed through the connection flange at the boof the cabinet. Fit the flange with a suitable cable gland for the cable in questioConnect the cables to the terminal blocks in accordance with the applicable widiagram. The terminal blocks are of a snap-in type and are designed both forthrough wiring with termination of a stranded conductor with a cross-section ofmax. 4 mm2, and as disconnectable blocks with termination of a stranded conduwith a cross-section of max. 6 mm2 intended for motor circuits, AC circuits andsupply circuits.

Connect the earth wire to the earth terminal (1) on the side of the cabinet.

Figure 5-1. Operating mechanism.

5.2 Assembly of busbars or overhead lines

WARNING

Work must not be carried out on a pressurised circuit-breaker.

High-voltage conductors consisting of aluminium busbars or aluminium connecfor overhead lines can, after being treated with contact paste, be directly conneto the breaking unit’s terminal flags, which are also made of aluminium.

However, if copper busbars or copper connectors are used for the overhead lingrease should be used and a bimetallic washer fitted in the joint. Bimetallic wascan be supplied by ABB on request.

1B10015

1HSB445410-14 en 29

Electrical connections Assembly Instructions

7 or

ings(15)

Using contact paste or grease

1. Clean all grease and old paste from the contact surfaces.

2. Rub down the surfaces using an abrasive cloth, e.g. Scotch Brite No. 744emery cloth.

3. Apply immediately:- Contact paste on aluminium surfaces.- Grease “SV”, ABB’s Art. No. 1171 4016-610, on copper surfaces.

4. Assemble the joint with the paste or grease still applied.

5. Wipe off any excess paste or grease.

N.B. Position the bimetallic washers so that their aluminium sides face thealuminium surfaces and the copper sides face the copper surfaces or thesilver-plated surfaces.

N.B. The contact paste may only be used on fixed joints.It must not be usedinside the breaking units.

5.3 Tensioning the closing springsThe circuit-breaker is closed and the motor is started to charge the closing spr(7). The drive sprocket (11) rotates anticlockwise and pulls up the chain sectionso that the spring yoke (19) is lifted and charges the closing springs. The chainsection (16) runs down, while the chain sections (17) and (18) do not move.

Figure 5-2. Charging the closing springs.

Item

7 Closing springs

11 Drive sprocket

15 Chain section

16 Chain section

17 Chain section

18 Chain section

19 Spring yoke

1715

16

7

11

19

18

B20027

30 1HSB445410-14 en

Assembly Instructions Pressurising the poles

r,

ith

a-

ord

6. Pressurising the polesThe circuit-breaker poles are supplied vacuum-processed and filled with SF6 gas ata pressure of 0.12- 0.13 MPa abs at 20˚C.

6.1 Preparations

WARNING

During commissioning, the SF6 gas or the gas mixture needs to be refilledto the pressure stated on the rating plate. Different gas pressures can occudepending on different requirements with regard to the lowest ambienttemperature.

Pressurisation takes place directly from a gas cylinder using the gas fillingequipment, article number 1HSB 445439-A for SF6 gas and 1HSB 445439-B forgas mixture.

The gas hose for the filling equipment is supplied vacuum-pumped and filled wSF6 gas.

WARNING

To avoid personal injury while refilling, due to possible transport damageto the porcelain, assembly personnel must exercise great care and stay inprotected and safe area (with regard to splintering) away from the circuitbreaker. The gas cylinder and refilling equipment should be placed in thesame area.

• Connect the control cables to the operating mechanism’s terminal blocks fopening and closing. The cables are routed to the control room or protectearea away from the breaker.

• Connect the cables to appropriate pushbutton switches.

• Set the operating mechanism’s control switch in the remote position.

• Switch on the motor starter so the closing springs are tensioned.

1HSB445410-14 en 31

Pressurising the poles Assembly Instructions

ower

e

6.2 Gas filling with SF 6 gas

Figure 6-1. Gas filling.

1. Place the gas cylinder (1) in a protected area.

2. Check the filling pressure and any gas mixture (at ambient temperatures lthan -40 ˚C) on the circuit-breaker’s rating plate.

3. Fit the regulator (2) on the gas cylinder. Set the right filling pressure,compensated for the temperature as set out inTable 6-1 or Table 6-2, on theregulator.

4. Pull the sealing rings off the density monitor with your fingers (3).

N.B. Do not use sharp tools.

5. Lubricate the sealing rings thoroughly with grease “G” and refit them on thdensity monitor.

Item

1 Gas cylinder

2 Regulator

3 Density monitor

4 Coupling

5 Valve

6 The breaker’s gas valve

7 Hose

8 Adaptor

9 Nipple with union nut

10 Equal union cross

11 Valve1

3

2

4 75

6

89

B10016 1110

32 1HSB445410-14 en


s

e

lator

levelsure

(11).

6. Connect the density monitor (3) to the coupling (4) or the equal union cros(10). Open valve (5) or, alternatively, valve (11). If the density monitor isconnected to coupling (4), then valve (11) should be closed. However, if thdensity monitor is connected to the equal union cross (10), then valve (5)should be closed.

7. Connect coupling (4) to the circuit-breaker’s gas valve (6).

8. Connect the gas-filled hose (7) to the coupling.

9. Connect the hose to the gas cylinder.

10. Go from the breaker to the protected area and let the gas flow until the reguswitches off.

11. Wait until the gas temperature has reached the circuit-breaker temperaturebefore reading off the gas pressure on the density monitor. Adjust the presif necessary.

12. Dismantle the hose from the coupling on the circuit-breaker.

13. Close the valve to the density monitor.

14. Dismantle the coupling from the circuit-breaker.

15. Release the pressure at the density monitor by opening valve (5) or valve

16. Dismantle the density monitor from the coupling and fit it on the circuit-breaker.

17. Repeat from 4 through to 16 for poles B and C.

N.B. When reading off from the precision gauge, correct the filling pressuredepending on the temperature as set out inTable 6-1.

Table 6-1. Filling pressure

Filling pressure in MPa (abs)stated on the rating plate

0.5 0.7 0.5 0.7

Filling pressure read off the gauge in

Temp. whenfilling ˚C

MPa(abs)

bar(abs)

MPa(abs)

bar(abs)

MPa(a.op)

bar(a.op)

MPa(a.op)

bar(a.op)

+40 0.54 5.4 0.75 7.5 0.44 4.4 0.65 6.5

+30 0.52 5.2 0.72 7.2 0.42 4.2 0.62 6.2

+20 0.50 5.0 0.70 7.0 0.40 4.0 0.60 6.0

+10 0.48 4.8 0.66 6.6 0.38 3.8 0.56 5.6

± 0 0.46 4.6 0.63 6.3 0.36 3.6 0.53 5.3

-10 0.44 4.4 0.61 6.1 0.34 3.4 0.51 5.1

-20 0.42 4.2 0.58 5.8 0.32 3.2 0.48 4.8

-30 0.40 4.0 0.30 3.0

1HSB445410-14 en 33


at the

a

18. Close the valve on the gas cylinder when all poles have been filled.

19. Disconnect the hose from the gas cylinder and release the pressure in theregulator by pressing in the non-return valve.

20. Release the set pressure in the regulator by turning the adjuster valve so thnext circuit-breaker to be assembled is not filled with the wrong pressure.

N.B. When the density monitor (1) is finally fitted, tighten the union nut (2) withtorque of 10 Nm.

Figure 6-2. Density monitor and union nut.

21. Operate the breakerCloseandOpen 3 times from the control room.

22. Connect the cables to the density monitors.

Item

1 Density monitor

2 Union nut

1 2

B10017


34 1HSB445410-14 en


F

ing

6.3 Gas filling with mixed gas

A mixture of SF6 and N2 or CF4 gas is used at low temperatures below -40 ˚C, toprevent condensation of the SF6 gas. See the rating plate if this should be done.

N.B. When filling with mixed gas always fill the SF6 gas first.

The proportions of gas for pressurisation should be 52% SF6 and 48% N2 or CF4.

Example.

For a circuit-breaker with a filling pressure of 0.70 MPa abs (+20 ˚C), first fill S6gas to 0.52 x 0.7 = 0.36 MPa abs (+20 ˚C) and then N2 or CF4 gas to0.70 MPa abs (+20 ˚C).

N.B. When reading off from the precision gauge, correct filling pressure dependon the temperature as set out inTable 6-2.

Gas filling takes place otherwise as set out inChapter 6.2.

Table 6-2. Filling with mixed gas.

Filling pressure in MPa (abs)stated on the rating plate.

SF6 Total fillingpressure

SF6 Total fillingpressure

Filling pressure read off on the gauge in

Temp.whengas filling

˚C

MPa(abs)

bar(abs)

MPa(abs)

bar(abs)

MPa(a.op)

bar(a.op)

MPa(a.op)

bar(a.op)

+40 0.39 3.9 0.75 7.5 0.29 2.9 0.65 6.5

+30 0.37 3.7 0.72 7.2 0.27 2.7 0.62 6.2

+20 0.36 3.6 0.70 7.0 0.26 2.6 0.60 6.0

+10 0.34 3.4 0.66 6.6 0.24 2.4 0.56 5.6

± 0 0.33 3.3 0.63 6.3 0.23 2.3 0.53 5.3

-10 0.32 3.2 0.61 6.1 0.22 2.2 0.51 5.1

-20 0.30 3.0 0.58 5.8 0.20 2.0 0.48 4.8

-30 0,29 2,9 0,57 5,7 0,19 1,9 0,47 4,7

1HSB445410-14 en 35


the

thatut

6.4 Gas monitoring system• Drill a 23 mm diameter hole in flange (1) on the bottom of the operating

mechanism and fit a cable gland (2) with a sealing washer (3) and nut (4) inhole.

• Insert the cable through the cable gland in the operating mechanism andconnect it to the terminal blocks as stated on the applicable operatingmechanism’s circuit diagram.

• Tighten the cable gland (2) to secure the cable.

• Secure the cable to the frame’s leg using pipe clips (5) and nuts, bolts andwashers (6).

• Connect the cable to the density monitor’s terminal blocks.

N.B. The cable ends for the density monitor should be as long as necessary sothe density monitor can be disconnected from the non-return valve withothe need of disconnecting the cable.

Figure 6-3. Gas monitoring.

Item

1 Flange

2 Cable gland

3 Sealing washer

4 Nut

5 Pipe clips 4 pcs.

6 Bolts M5x20

Nuts M5

Washers 5.3x10x1

4 pcs.

4 pcs.

8 pcs.

1

23

5

4

6

B10018

36 1HSB445410-14 en


.

6.5 Leakage test

Perform a leakage test using a leak detector around the density monitor’sconnections.

6.6 Fitting the signs and cover

Fit and tighten all Close and Open signs (1) with a tightening torque of 22,5 Nm

Then fit the cover (2) with a tightening torque of 9 Nm.

Figure 6-4. Fitting the signs and cover.

Item

1 Sign

2 Cover

3 Bolts M8x16

Washers 8.4x16x1.5

9 pcs.

9 pcs.

12

B10012

3

TIGHTENING TORQUES9 and 22,5 Nm

1HSB445410-14 en 37

Assembly Instructions Commissioning

7. CommissioningBefore commissioning the circuit-breaker, carry out all the checks as set out in“Check list for assembling and commissioning 1HSB445410-100”and fill in theoperating values for the installation.

1HSB445410-14 en 39

Assembly Instructions Operating values

8. Operating valuesThe operating values in these instructions apply to SF6 circuit-breakers typeHPL 245-550B2 with operating mechanism type BLG 1002A.

8.1 Times

8.2 Motor and control circuits

8.3 Resistance

Main circuit resistance per breaking unit < 40 µΩ.

8.4 Contact stroke

Main contact stroke is 208±4 mm.

Closing times < 65 ms

Opening time coil I 17 ±2 ms

Opening time coil II 17 ±2 ms

Close-Open time(1)

(1) The Close-Open time refers to the time the maincontacts are closed during a closing operation whena tripping pulse is simultaneously connected via theauxiliary contact.

<47 ms

Charging time for motor max. 20 s

Operating voltage openingcoil I

V (according tothe rating plate)

Operating voltage openingcoil II


Operating voltage closingcoils I and II


1HSB445410-14 en 41

1HSB445410-14 en0204



SF6 Circuit-Breaker Circuit-breakers HPL and LTB

1HSB445410-100 en rev2

Check list, assembly






Date: 2002-02-14

Check list Check list for assembly and commissioning

rcuit-

bled

the

g.

a in

hree

1. Check list for assembly and commissioningThe following checks shall be made and the check list completed before the cibreaker is commissioned. The check list shall be kept in the order binder.

Date:_______________

Installation: ______________________________________________

Serial number:_____________________________

Circuit-breaker pole

1. Check that the circuit-breaker and operating mechanism have been assemin accordance with the assembly instructions.

2. Check that all bolted joints are tightened to the tightening torques stated inassembly instructions.

3. Ensure that all poles are in the open position. The alignment hole in theoperating lever shall align with the predrilled hole in the mechanism housin

Operating mechanism

4. Make an ocular inspection to check that oil from the oil dashpots has notleaked in the operating mechanism.

5. Tighten all screws in terminal blocks involved in the assembly work.

Gas filling

6. Connect the operating mechanism for remote control from a protected areconnection with gas filling and test operations.Set the control switch to remote.

7. Connect the gas filling equipment for gas filling from the protected area.

8. Fill with gas each pole one after the other and perform an operational test ttimes as set out in the assembly instructions.

9. Check the heater element.

10. Make sure the thermostat, if provided, is set to 10°C 1.

1. Other thermostat settings may occur.

1HSB445410-100 en rev2 1

Check list for assembly and commissioning Check list

fores in

n be

Operating values

11. Check the breaker’s operating values with the applicable operating valuesthe breaker in the Assembly Instructions and note down the measured valuthe table below.

CAUTION

The circuit-breaker must not be switched Open - Close without anintermediate delay of 300 ms.

.

12. Check carried out by:________________________________

13. If points 1-11 as set out above have been completed, the circuit-breaker cacommissioned.

Check the followingMeasured values

Pole A Pole B Pole C

Closing time coil I ms ms ms

Closing time coil II ms ms ms

Opening time coil I ms ms ms

Opening time coil II ms ms ms

Close-Open time ms ms ms

Lowest control voltage closing coil I V V V

Lowest control voltage closing coil II V V V

Lowest control voltage opening coil I V V V

Lowest control voltage opening coil II V V V

Main circuit resistance µΩ µΩ µΩ

Filling pressure(1)

(1) Filling pressure in accordance with the rating plate.

MPa (abs) MPa (abs) MPa (abs)

2 1HSB445410-100 en rev2

1HSB445410-100 en rev20202



SF6 Circuit-Breaker Type HPL

1HSB445409-102 en

Operating and MaintenanceInstructions



The document, or parts of it, may not be reproduced or copied without prior permission from ABBPower Technology Products AB. It may not either be imparted to third party or otherwise be used wit-hout authorisation. Infringement hereof will be subject to action in accordance with applicable laws.



Date: 2002-06-10

Operating and Maintenance Instructions

1HSB445409-102 en i

TABLE OF CONTENTS

1. General ................................................................................ 11.1 Warning text ................................................................................... 1

1.2 Warning .......................................................................................... 2

2. Preventive maintenance .................................................... 32.1 Circuit-breaker ............................................................................... 3

2.2 Operating mechanism..................................................................... 5

2.3 Spare parts...................................................................................... 6

3. Inspection intervals............................................................ 73.1 Maintenance summary ................................................................... 8

3.2 Maintenance category A ................................................................ 9

3.3 Maintenance category B............................................................... 10

3.4 Maintenance category C............................................................... 12

3.5 Maintenance category D .............................................................. 18

Operating and Maintenance Instructions

ii 1HSB445409-102 en

FIGURES

Figure 2-1. Arcing contacts and PTFE insulation ............................................. 4

Operating and Maintenance Instructions General

are

ionts. Ife is

ter a

1. GeneralThese operating and maintenance instructions apply to the SF6 circuit-breaker typeHPL with operating mechanism of type BLG 1002A.

The instructions contain recommendations for the care and guidelines for themaintenance of high-voltage circuit-breakers of the HPL type. The instructionsdivided into four parts:

• Inspection intervals

• Instructions for preventive maintenance of circuit-breakers

• Instructions for preventive maintenance of operating mechanisms

• Fault correction maintenance.

Periodic maintenance must be carried out at the time or operation intervalsspecified.

Fault correction maintenance is related to the faults detected. The fault correctmaintenance described in this Manual involves the replacement of defective unithe user chooses to try and repair a defective unit instead, specialist knowledgoften needed. This will not be found in the Manual.

The equipment must be overhauled in accordance with specified criteria, e.g. afcertain number of operations. Overhaul of the equipment must be entrusted toauthorised service personnel.

1.1 Warning textCareful attention must be given to text marked with:

DANGER

indicates an immediate hazardous situation that, if not avoided,will resultin death or serious injury.

WARNING


CAUTION

indicates a hazardous situation thatcan result inminor or moderateinjury.

N.B. is used for hazards thatmay only result indamage to the installation.

1HSB445409-102 en 1

General Operating and Maintenance Instructions

1.2 Warning

WARNING

Circuit-breakers with pressurised porcelain insulators.Mechanical damage to the porcelaincan cause it to explode with thesubsequent risk ofsplintering. Work on the circuit-breaker that bringsabout the risk of mechanical damage to the insulators should be carriedout at a reduced gas pressure, 0.15 MPa (abs.)

2 1HSB445409-102 en

Operating and Maintenance Instructions Preventive maintenance

d theve a

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asr

one

ed

rt-

sE /

2. Preventive maintenance

2.1 Circuit-breaker

2.1.1 Circuit-breaker service life

Assuming that the recommended inspection intervals have been adhered to anappropriate measures have been implemented, the HPL circuit-breaker will haservice life exceeding 30 years or 10,000 operations.

The following points will ensure a long service life:

1. Burning-off of the arcing contacts is limited

2. Each breaking unit is equipped with an absorption agent with a service lifeequivalent to that of the circuit-breaker

3. Bearings in the space filled with gas are maintenance-free

4. The seals have double sealing rings.

Generally speaking, there are only two reasons to open the breaking unit:

– if the number of short-circuits x short-circuit current (kA) is approachinthe curve onFigur 2-1, page 4

or...

– if the number of operations for line-, reactor-, or capacitor- switching, well as switching of the load current1 has reached the level specified undethe heading “Inspection intervals” in the inspection chart.

Other reasons for opening the breaking unit are limited to mechanicalfaults/incorrect adjustment of the drive system that may cause damage tocomponents inside the breaking unit.

N.B. Opening the breaking unit requires special instructions and may only be dby trained and authorised personnel.

The curve that defines the permissible number of short-circuits can be expressapproximately as:

Σ n x I1.8 = 20,000

where

n = number of short-circuitsI = short-circuit current, kA (RMS).

All short-circuit current levels can be included in the total of the number of shocircuits x short-circuit current to the power 1.8,e.g. 20x301.8+30x201.8+40x101.8=18,230.

1. All normal service switched-off and -on load currents are not to be included into thiformula- they are considered only in calculation of total number of mechanical CLOSOPEN operations.

1HSB445409-102 en 3

Preventive maintenance Operating and Maintenance Instructions

ents due

nal,

2.1.2 Service life of arcing contacts with short-circuit interruption

The diagram below shows the number of interruptions versus short-circuit currthat the contacts in an HPL circuit-breaker can manage before the metal losseto burning becomes so great that they must be replaced.

Figure 2-1. Arcing contacts and PTFE insulation

2.1.3 Tightness checking

The circuit-breakers are equipped with density monitors for checking the gasdensity. Each density monitor is equipped with an alarm contact that gives anelectric signal in the event of abnormal leakage. Alarm level 1 gives an alarm sigwhile alarm level 2 blocks.

N.B. A new or overhauled circuit-breaker should be checked for tightness byreading the density monitors afterabout 1 month and then at 1-2 yearintervals in connection with the regular ocular inspection.

5,000

2,000

1,000

20

500

50

100

200

20102 4 53 30 40 50 63

N

kA

Number of interruptions

Short-circuit current

4 1HSB445409-102 en

Operating and Maintenance Instructions Preventive maintenance

tion.of

nter

-1”.

n

”,

s for

2.1.4 Cleaning the outside

The circuit-breaker insulators must be cleaned from salt and other contaminandeposits at the same time as the cleaning of the other insulators in the substatThe time interval for cleaning depends on the local conditions, i.e. the amount atmospheric pollution.

N.B. All HPL circuit-breakers are completely hose-proof, i.e. circuit-breakers ioperation can be cleaned with high-pressure water without any risk of waentering the circuit-breaker and causing damage to essential parts.

2.1.5 Lubricating the circuit-breaker

Use only the lubricants recommended in the document “Lubricants 1HSB445409This is particularly important in cold climates with temperatures below -25˚C.

When supplied, the circuit-breaker bearings are lubricated with Grease “G”1 andwill not normally need lubricating except during major overhauls.

See the Overhaul Instructions applicable for the circuit-breaker, for lubricatingsealing rings.

The worm gear in the drive unit is lubricated with Grease “M”1.

2.2 Operating mechanism

2.2.1 Maintenance

Work on the operating mechanism with the circuit-breaker in the closed positioand with tensioned closing springs always involves a certain risk. It is thereforeimportant that the guidelines in the document “Product Information BLG 1002ASafety regulations, are followed before the work is started.

2.2.2 Cleaning

Clean the operating mechanism when necessary using a vacuum cleaner.

Check that the filters in the valves are clean. Replace them if they are dirty.

1. See the document “Lubricants” 1HSB445409-1 for the names of suppliers and brandgrease and oils.

1HSB445409-102 en 5

Preventive maintenance Operating and Maintenance Instructions

tlys ineased

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2.2.3 Lubrication

The ball, roller and needle bearings in the operating mechanism are permanenlubricated and require no maintenance. Lubrication is therefore limited to shaftthe latch mechanisms and the worm gear in the drive unit. These should be grafter 2,000 operations. In connection with overhauls, the sliding surfaces of thespring fork and dashpot must be lubricated with Grease “G”1and the chains withOil “A” 1.

When supplied, the bearings in the operating mechanism are lubricated with Gr“G” 1 and will not normally need to be lubricated except during major overhauls

When supplied the closing and opening dashpots are filled with Oil “S”1.

2.2.4 Rust protection

Certain steel parts in the operating mechanism have manganese phosphate streatment and are then dipped in a rust inhibiting oil. This applies to latches, gwheels, parts of the link system, etc.

The closing and opening springs are rust inhibited by painting with two-componpaint.

When supplied, the operating mechanism is equipped with anti-corrosion vapophase inhibitors. These inhibitors are only for protection during transport.

Despite the extensive rust inhibitor treatment, minor corrosion can occur after syears especially if the circuit-breaker is located in a strongly corrosive environmRust spots should be cleaned and new rust inhibitor applied with a brush or sp

The recommended rust inhibitor is Grease “G”1or Tectyl 506(ABB Article No. 1241 0011-108).

N.B. Tectyl 506 forms a waxy protective skin when it dries and therefore it munot be sprayed into bearings and latch mechanisms or on to gear-wheelchains.

2.3 Spare parts

Spare parts must be stored indoors in an approved storage space2 and in the originalpackaging. This is particularly important for rubber components (seals etc.), wmust also be protected against sunlight to prevent them drying. Seals have a limshelf life so avoid storing them. Base frames can be stored outdoors.

1. See the document “Lubricants” 1HSB445409-1 for the names of suppliers and brandgreases and oils.

2. Approved storage space:roof, solid foundation, relative humidity less than 50%, temperature +200C(±10°C)

6 1HSB445409-102 en

Operating and Maintenance Instructions Inspection intervals

2A.

ing

e

es.

3. Inspection intervalsInspection of HPL circuit-breakers with operating mechanisms of type BLG 100

Important checkpoints, acceptable tolerances, certain functional values foradjustments, and recommended inspection intervals can be found in the followinspection chart.

In corrosive or polluted air and in climates with a high relative humidity, it can bnecessary to halve the inspection intervals.

The specified inspection intervals should be considered as recommended guidvalues, which can be increased or decreased depending on the local condition

1HSB445409-102 en 7

Inspection intervals Operating and Maintenance Instructions

3.1 Maintenance summary

Explanations:

1. Mech. oper. = Mechanical Close-Open operations.

2. CLOSE/OPEN oper. with el load = Close-Open operations with electricalloading.

3. Special requirements for resistance check of circuit-breakers operated> 100 CLOSE/OPEN operations/year.

Type of measure Inspection intervalExplan-

ation

Condition ofcircuit-breaker

during work

Com-petencerequire-ments

A Ocular inspection 1-2 years a1 a2

B Preventive maintenance

Intermediate check

• Operation test includingtiming test

• Thermovision check

• Greasing of Wormgear

3-6 years or 2,000 mech.CLOSE/OPEN operations.

1) b1 b2

C Preventive maintenance

• General check of circuit-breaker and operatingmechanism

15 years or 5,000 mech.CLOSE/OPEN operations.

1), 3) b1 b2

D Overhaul

• Overhaul of breakingchambers

• Line and transformercircuit-breakers

• Capacitor-reactor and filtercircuit-breakers

• Not synchronized

• Synchronized

• Major overhaul

ΣnxI1.8 =20,000

2,500 CLOSE/OPEN op.with el. load.

5,000 CLOSE/OPEN op.with el. load.


2)

1)

c1

d1

c2

c2

8 1HSB445409-102 en


d. Iffore

d.

d.

s.

Condition of circuit-breaker during work:

a1) Circuit-breaker in service.

b1) Closing springs unloaded, circuit-breaker open, disconnected and earthethermovision measurement is included, it shall be done at normal load bethe circuit-breaker is disconnected.

c1) Closing springs unloaded, circuit-breaker open, disconnected and earthePoles/Breaking units dismounted and transported to workshop.

d1) Closing springs unloaded, circuit-breaker open, disconnected and eartheComplete circuit-breaker including operating mechanism transported toworkshop.

Competence requirements:

a2) Substation personnel with no special training.

b2) Personnel authorised by ABB to carry out assembly, commissioning andmaintenance work.

c2) Personnel authorised by ABB to carry out assembly, commissioning andmaintenance work. Support from ABB may be necessary in certain case

3.2 Maintenance category A

To be inspected Inspection interval Measures / Tools/ Instructions

1.

Ocular inspection 1-2 years. Check external cleanliness, heaterelement function, gas pressure, valvesand drainage holes.

No special tools needed.

See Chapter 2.1.3 and Chapter 2.1.4.

1HSB445409-102 en 9


3.3 Maintenance category B


1.

Ocular inspection 3-6 years or 2,000 mech. CLOSE/OPEN operations.

Check external cleanliness, heaterelement function, gas pressure, valvesand drainage holes.


See Chapter 2.1.3 and Chapter 2.1.4.

2.

Rating plates 3-6 years or 2,000 mech. CLOSE/OPEN operations.

Make a note of the serial number.

3.

Operation counter 3-6 years or 2,000 mech. CLOSE/OPEN operations.

Make a note of the number ofoperations.

4.

Visual inspection inoperating mechanism

3-6 years or 2,000 mech. CLOSE/OPEN operations.

Look for loose bolts and nuts, oil leaksfrom dashpots.

If leakage replace the completedashpot.

No tools necessary.

See Manual 1HSB515409-100.

5.

Corrosion inspection

Rust protection


Visual inspection.

Rust stains polished off and treatedwith rust protection.

See Chapter 2.2.4.

6.

Greasing 15 years or 2,000 mech. CLOSE/OPEN operations.

Circuit-breaker in open position, closingsprings discharged. Greasing of theworm gear and shafts in latches in theoperating mechanism with grease “M”.

See Chapter 2.1.5, Chapter 2.2.3 andManual 1HSB515409-100.

10 1HSB445409-102 en


7.

Thermovisionmeasurements


To be carried out at full load before thecircuit-breaker is taken out of service.

Checking the temperature rise of thethe external parts of the breaking unit.

The maximal allowed temperaturedifference between phases is5 degrees.

Thermovision camera.

The load current must be taken intoconsideration during the measurementsas well as large variations in the loadcurrent 3-4 hours before themeasurements.

See manual for the thermovisioncamera.

8.

Exchange pullrod 2,000 mech. CLOSE/ OPENoperations.

Exchange the pullrod between theoperating mechanism and the breakerpole.

See the Assembly Instruction forapplicable circuit-breaker.

9.

Measurement springcharging


Measure the dimension between thespring bridge and frame foot.


10.

Operating test 3-6 years or 2,000 mech. CLOSE/OPEN operations.

Operating test, if possible incombination with measurement ofoperating times (incl. Close-Opentimes).

See the Assembly Instruction forapplicable circuit-breaker.


1HSB445409-102 en 11


3.4 Maintenance category C


1.

Ocular inspection 15 years or 5,000 mech. CLOSE/OPEN operations.

Check external cleanliness, heaterelement function, gas pressure, valvesand drainage holes.


See Chapter 2.1.3 and Chapter 2.1.4and Manual 1HSB515409-100.

2.

Rating plates 15 years or 5,000 mech. CLOSE/OPEN operations.

Make a note of the serial number.

3.

Operation counter 15 years or 5,000 mech. CLOSE/OPEN operations.

Make a note of the number ofoperations.

4.

SF6-gas

• Filling of gas (ifnecessary)

• Dew point at normalpressure in circuit-breaker.

15 years or 5,000 mech. CLOSE/OPEN operations.

Gas filling equipment.

See Assembly instruction for applicablecircuit-breaker, ch 6.

Dew point maximum - 5 ˚C at ratedfilling pressure and + 20 ˚Ctemperature.

5.

Insulators

• Visual inspection andcleaning.


Spray and rub the insulators clean.Check cementing, bolts and nuts.

Spray equipment, clothes andwrenches.

See Chapter 2.1.4.

12 1HSB445409-102 en


6a.

Main current circuit

• Resistance check. 15 years or 5,000 mech CLOSE/OPEN operations.

Circuit-breakers only operating>100 CLOSE/OPENoperations/year after 6-8 yearsor 2500 mech CLOSE/OPENoperations.

Check resistance of circuit-breaker.

Resistance bridge, test current min.200 A DC.

Resistance value as specified inapplicable Assembly instructions for thecircuit-breaker in question.

Higher values allowed for frequentoperation with small currents (≤400 Α).Calculation of permissible resistance:

7a.

Contact system

• Opening position 15 years or 5,000 mech. CLOSE/OPEN operations.

Inspection of reference holes in outerarm and mechanism housing.

See applicable Assembly instructionsfor the actual circuit-breaker.

7b.

Operatingcharacteristics

• Opening time

• Closing time

• Close-Open time

• Phase discrepancy

• Auxiliary switches

• Contact travel

• Contact damping.


Measurement with electronic timer.

Nominal operating voltage.

For times, see the applicable Assemblyinstructions for the circuit-breaker.

Max phase discrepancy betweenphases:

at closing 4 ms; at opening 3 ms.

max discrepancy between breaks in thesame phase:

at closing 3 ms; At opening 2 ms.



RRn2

------- InI-----

1.65=

R = Permissible increase inresistance

Rn = Max. resistance as specifiedin operating values

In = Rated current as specified onrating plate

I = Current for which maxresistance is calculated.

1HSB445409-102 en 13


8a.

Operation availability

• Pull rod system

• Safety of release ofoperation

• Anti-pumping device.

15 years or 5,000 mechanicalClose-Open operations.



Checking of the tightening torque ofnuts on pull rods.

Wrench size: 36 mm.

Torque: 300 Nm.

See applicable Assembly instruction foractual circuit-breaker.

Measurement of minimum operatingvoltage.

Closing coil: < 85% of nominal voltage.

Opening coil: < 70% of nominal voltage.

Variable D.C. voltage source required.

Checking anti-pumping function:

The circuit-breaker in open position, theoperating mechanism charged, CLOSEand OPEN impulse givensimultaneously (the close button shallbe pressed).

The circuit-breaker will make a CLOSE-OPEN operation and may not closewhen the operating mechanism ischarged.

The pumping device must stay as longas the close impulse remain. Lowestoperating voltage of the relay ismeasured (85% of nominal).

8b.

Motor current 15 years or 5,000 mech. CLOSE/OPEN operations.

The motor current is to be measured atthe end of the charging operation. Maxallowed motor current is 110% of valuemeasured at routine test.

The charging time is allowed to changeup to 30% from value measured atroutine test.

The motor shall be able to charge thesprings at min. 85% of nominal voltage(IEC).

See 1HSB 515409-100.


14 1HSB445409-102 en


8c.

Dash-pots 15 years or 5,000 mech. CLOSE/OPEN operations.

Checking of oil-level or recording ofdamping during operation alternatively.

Recording of damping during operationis made by means of a circuit breakeranalyzer with transducers connected to:

• main shaft of the circuit breakermechanism when checking theopening dash-pot

• main shaft (cam shaft) of theoperating mechanism whenchecking the closing dash-pot.

These measurements are to be carriedout only by specially trained personal.


8d.

Catch-gears. 15 years or 5,000 mech. CLOSE/OPEN operations.

Visual control of the adjustment.

Play of gaps in the catch-gears acc. toManual 1HSB515409-100.

Greasing of shafts and catch surfaceswith Grease “L” acc. to 1HSB445409-1.

Change the signal from coil 1 to coil 2.

8e.

Coils 15 years or 5,000 mech CLOSE/OPEN operations.

The resistances of coils and coilcurrents are allowed to differ +/- 10%from value measured at routine test.

8f.

Mechanical interlocking 15 years or 5,000 mech. CLOSE/OPEN operations.

In OPEN position the distance betweenthe interlocking arm and theinterlocking disc shall be min. 2 mm.

In CLOSE position there must be fullcontact between the arm and disc (Nogap is permitted).


8g.

Heaters

• Operating mechanism 15 years or 5,000 mech. CLOSE/OPEN operations.

Checking of resistance:

If applicable, check signal for loss ofpower.



1HSB445409-102 en 15


8h.

Central control cubicle 15 years or 5,000 mech. CLOSE/OPEN operations.

Checking of resistance.

Small cubicle:

48 W, 110 V R = 330 Ohms +/- 10%

48 W, 220 V R = 1000 Ohms +/- 10%.

Middle or large cubicle:

140 W, 110 V R = 86 Ohm +/-10%

140 W, 220 V R = 346 Ohm +/- 10%.

8i.

Thermostat 15 years or 5,000 mech. CLOSE/OPEN operations.

If applicable, check that the thermostatis adjusted to requested value.


8j.

Terminal blocks 15 years or 5,000 mech. CLOSE/OPEN operations.

Tightening of screws or clamps.

See Manual 1HSB 515409-100.

8k.

Direct on line motorstarter


If applicable, check signal for loss ofpower.

See Manual 1HSB 515409-100.

9.

Tightness of SF 6-gas

• Density monitoring. 15 years or 5,000 mech. CLOSE/OPEN operations.

Check the density switches andsignal/blocking circuits.

Accurancy test of the pressure gaugemust be done at standard referenceatmosphere i.e. +20 ˚C and 101.3 kPa(1013 mbar).

Remove the density switch from thecircuit-breaker for checking of function.

N.B. Min permissible voltage for testof the circuits in the densityswitch (30 V).

See applicable Assembly Instruction forthe circuit-breaker.

10.

Blocking relays 15 years or 5,000 mech. CLOSE/OPEN operations.

The relays shall close when a densityswitch is pulled out from a polepressurized to filling pressure.


16 1HSB445409-102 en


11.

Corrosion 15 years or 5,000 mech. CLOSE/OPEN operations.

Outside:

Visual check, particularly checkprotected components in non heatedcompartments, pull-rod system, cleviscouplings, springs.

Treat with anti-rust oil if necessary.

See Chapter 2.2.4 and Manual1HSB515409-100.

12.

Lubrication 15 years or 5,000 mech. CLOSE/OPEN operations.

Operating mechanism sliding surfacesof spring bridge with Grease “M” andchains with Oil “A”.

See Chapter 2.1.5, Chapter 2.2.3 andManual 1HSB515409-100.

13.

Tightening torque 15 years or 5,000 mech. CLOSE/OPEN operations

Check of tightening torque on screwjoints.

Tightening torques acc. to AssemblyInstruction and Overhaul Instruction.

Tightening torque for earthing 79 Nm.


1HSB445409-102 en 17


3.5 Maintenance category D

To be inspected Inspection intervals Measures / Instructions / Tools

1.

Overhaul of breakingchambers

• Line and transformercircuit-breakers

• Capacitor bank circuit-breakers

• Reactor circuit-breakers

• Filter circuit-breakers

• All kinds of service.

ΣnxI1.8 =20,000

Not synchronized:

2,500 CLOSE/OPEN operationswith el. load.

Synchronized:

5,000 CLOSE/OPEN operation withel. load.

Alarming result at diagnostic test.

Gas evacuated, poles/ breaking unitsdismounted and transported to a cleanworkshop.

Porcelain lift off, contacts and PTFE-parts replaced with new ones.

See Manual Overhaul Instruction foractual circuit-breaker.

Standard tools, close fitting dust mask,long sleeved overall, protective plasticor rubber gloves.

See Manual Overhaul Instruction forapplicable circuit-breaker.

2.

Major overhaul ofcomplete circuit-breaker and operatingmechanism


Circuit-breaker.

Disassembly of the poles andmechanisms. New contacts and PTFE-components are to be mounted.Exchange of outer worn out parts.

If the circuit-breaker and operatingmechanism are overhauled for another2,000 operations, selected worn outparts are to be exchanged.

If the circuit-breaker and operatingmechanism are overhauled for another10,000 operations, in principle allmoving parts are to be exchanged.

Protection against decomposed gas asstandard tools above.

Instructions:

For circuit-breaker, see ManualOverhaul Instructions for actual circuit-breaker.

Operating mechanism undersupervision from ABB.

3.

Capacitor 30 years or 10,000 mech.CLOSE/OPEN operations.

Check of values on:

C = CN+5%,-0%

PD < 5 pC

Tan d < 0,2%.

18 1HSB445409-102 en

1HSB445409-102 en0206



SF6 Circuit-Breaker Circuit-breakers HPL and LTB

1HSB445409-1 en1

Lubricants

The information in this document is subject to alteration without prior notice and should not beregarded as an undertaking from ABB Power Technology Products AB. ABB Power Technology Prod-ucts AB takes no responsibility for errors that can occur in the document.


The document, or parts thereof, may not be reproduced or copied without prior permission from ABBPower Technology Products AB. It may not either be imparted to a third party or otherwise be usedwithout authorisation. Infringement hereof will be subject to action in accordance with applicable laws.


Article number: 1HSB445409-1 en1

Date: 2002-02-14

Lubricants

... 1

LIST OF CONTENTS

1. General ................................................................................ 11.1 Safety instructions.......................................................................

2. Oil........................................................................................ 3

3. Grease ................................................................................. 5

1HSB445409-1 en1 i

Lubricants General

of

ical

1. GeneralAs a guide to the selection of oils and greases for circuit-breakers, Combined,Compact HPL and LTB with operating mechanisms, a description is given belowthe application areas as well as trade names and suppliers.

1.1 Safety instructions

Protective gloves, long-sleeved overalls and eye protection must be worn whenhandling greases and oils.

All spillage shall be covered with an absorption agent and taken care of as chemwaste according to applicable local directives.

1HSB445409-1 en1 1

Lubricants

rs.

LG.il.

2. Oil

Oil “A”

Thin, fully synthetic lubricating oil for precision components in the operatingmechanism and circuit-breaker. Also used for post lubrication of bearings thatcannot be lubricated with grease “G” without dismantling, e.g. links and link gea

Viscosity at 40C: 62-65 cSt

Lowest pour temperature: -52˚C

Oil “D”

Breaker oil with a low viscosity~ 6.0 cSt at 20C. Also used as oil in dashpots.Dashpots with the letter “s” punched on the cover shall be filled with oil “S”.

Oil “S”

Silicone oil intended for dashpots in heavy-duty operating mechanisms, type BOnly dashpots with the letter “s” punched on the cover shall be filled with this o

SUPPLIER Oil “A” Oil “D” Oil “S”

ABB art. No. 1171 2039-1 1171 3011-102 1173 7011-106

ABB spare part No. 1HSB875318-A 1HSB875318-B 1HSB875318-C

MOBIL MOBIL 1 (481127)5W-30

Circuit-breaker oilUnivolt 42 (44)

-

CASTROL FORMULA RS5W-50

- -

SHELL TMO Synthetic5W-30

NYSWITCHO 3NYSWITCHO 3X

DC 200 Fluid 200CS

OK Super-synthetic4W-40

Circuit-breaker oilA65Kälte-Schalteroel X

-

1HSB445409-1 en1 3

Lubricants

ers

ts,ere

rs, Also

g

onals

ted

3. Grease

Grease “G”

Low-temperature grease for all types of bearings, gearing and worm gears andvalves in air-blast circuit-breakers.

Also used for greasing sealing rings and crevice corrosion protection on breaktype HPL and for moving contacts (opening contacts9 for disconnectors.

Grease “K”

Molykote grease for lubricating pins in link gears and in earthquake dampers.

Grease “N”

For lubricating moving contacts and puffer cylinders in SF6 circuit-breakers. Thegrease shall be applied in a very thin layer on the contact’s sliding surfaces.

Grease “L”

Low-temperature grease especially suitable for lubricating precision componenfor example, latch mechanisms in operating mechanisms that shall work in sevcold.

Grease “M”

Low-temperature grease for long-term and permanent lubrication of worm geaand spur gears and other machine elements. Counteracts wear and corrosion.for lubricating moving contacts (opening contacts) for earthing switches.

Grease “P”

Vaseline for coating contact surfaces on fixed joints on the inside of the breakinunit.

Grease “S”

Fluoro-silicone grease for lubricating the EPDM-O-rings and as crevice corrosiprotection on circuit-breakers type ED as well as for lubricating rotating shaft seon circuit-breakers types LTB and HPL.

Grease “SV”

For lubricating moving contacts (opening contacts) for disconnectors, silver-placontacts and brushed aluminium surfaces on fixed joints outdoors

1HSB445409-1 en1 5

Lubricants

.

SUPPLIER Grease “G” Grease “K” Grease “N” Grease “L”

ABB art. No. 1171 4014-407 1263 0011-102 1171 4016-607 1171 4016-606

ABB spare part No. 5316 381-A 5316 381-M 5316 381-L 5316 381-H

ASEOL AG - - ASEOL SYLITEA 4-018

Dow Corning G-rapid plus

GULF 718EP Syntheticgrease

- -

MOBIL Mobil grease 28 - -

Montefluos S.p.A. - Fomblin OT 20 -

SHELL Aero ShellGrease 223

- -

SUPPLIER Grease “M” Grease “P” Grease “S” Grease “SV”

ABB art. No. 1171 4016-612 1171 5011-102 1171 4014-406 1171 4016-610

ABB spare part No. 5316 381-J 5316 381-N 5316 381-G 5316 381-C

Klüber Isoflex Topas NB52

-

Dow Corning - - FS-3451 No. 2

Fluortech AB TP55

SHELL - Shell vaseline8401

Statoil Electrical grease

1HSB445409-1 en1 6

1HSB445409-1 en10202



SF6 Circuit-Breaker Operating Mechanismtype BLG 1002A

1HSB515409-100 en rev3

Maintenance






Date: 2002-10-06

Maintenance Operating Mechanism

1HSB515409-100 en rev3 i

LIST OF CONTENTS

1. General ............................................................................... 1

2. Safety................................................................................... 32.1 Warning text ................................................................................... 3

2.2 Safety directives ............................................................................. 4

3. Maintenance, general ......................................................... 73.1 Tools ............................................................................................... 7

3.2 Cleaning equipment ....................................................................... 7

3.3 Spare parts...................................................................................... 7

3.4 Test equipment ............................................................................... 7

4. Maintenance........................................................................ 94.1 General ........................................................................................... 9

4.2 Preparations for maintenance....................................................... 12

4.3 Cleaning ....................................................................................... 13

4.4 Corrosion...................................................................................... 13

4.5 Lubrication ................................................................................... 14

4.6 Heater element ............................................................................. 15

4.7 Drive unit...................................................................................... 16

4.8 Catch gear..................................................................................... 17

4.9 Dashpots....................................................................................... 18

4.10 Link system and spring battery .................................................... 20

4.11 Auxiliary contact.......................................................................... 20

4.12 Terminal blocks............................................................................ 22

4.13 Slow closing and opening operations........................................... 23

Maintenance Operating Mechanism

ii 1HSB515409-100 en rev3

FIGURES

Figure 4-1. Operating mechanism ..................................................................... 9

Figure 4-2. Interlocking mechanism ............................................................... 10

Figure 4-3. Releasing the interlock ................................................................. 11

Figure 4-4. Check dimension, closing springs. ............................................... 11

Figure 4-5. Control panel ................................................................................ 12

Figure 4-6. Heater element .............................................................................. 15

Figure 4-7. Drive unit ...................................................................................... 16

Figure 4-8. Catch gear ..................................................................................... 17

Figure 4-9. Checking the clearance. ................................................................ 17

Figure 4-10. Closing and Opening dashpots. .................................................... 18

Figure 4-11. Damping curve, Closing dashpot. ................................................ 19

Figure 4-12. Damping curves, Opening dashpot. .............................................. 19

Figure 4-13. Limit switch with auxiliary contact. ............................................. 20

Figure 4-1. Time measurement, contact travel. ............................................... 21

Figure 4-2. Electrical equipment. .................................................................... 22

Figure 4-3. Switch Local/Remote, direct-on-line starter ................................ 23


Figure 4-5. Fitting the blocking beams ........................................................... 24

Figure 4-6. Interlocking, circuit-breaker open and closing springs uncharged. ..25

Figure 4-7. Operating mechanism, slow closing operation. ............................ 26

Figure 4-8. Switch Local/Remote, dirct-on-line starters. ................................ 27


Figure 4-10. Fitting the blocking beams. .......................................................... 28

Figure 4-11. Interlocking, circuit-breaker closed and closing springs uncharged.29

Figure 4-12. Operating mechanism, slow opening operation. .......................... 30

Figure 4-13. Check dimension, closing springs. ............................................... 31

Operating Mechanism Maintenance General

ed

r

1. GeneralThis information applies to the spring operating mechanism BLG 1002A intendfor operating circuit-breakers with integrated opening springs. Informationregarding maintenance is provided in these instructions.

Preventive maintenance and overhaul work on the operating mechanism BLG1002A should be carried out at regular intervals.

• Visual inspection at intervals of 1-2 years.

• Lubrication after 3-6 years or 2,000 mechanical Close-Open operations.

• Preventive maintenance after 15 years or 5,000 mechanical Close-Openoperations.

• Overhaul after 30 years or 10,000 mechanical Close-Open operations.

Overhauling and repair work may only be carried out by authorised ABB PoweTechnology Products AB service personnel.

1HSB515409-100 en rev3 1

Operating Mechanism Maintenance Safety

ld be

2. Safety

2.1 Warning text

Warning text occurs where required and indicates that the text in question shouobserved extra carefully. The warning texts are marked as set out below:

DANGER

indicates an immediate hazardous situation that, if not avoided, will resultin death or serious injury.

WARNING


CAUTION

indicates a hazardous situation thatcan result inminor or moderateinjury.

N.B. used for hazards thatmay only result indamage to the installation.

1HSB515409-100 en rev3 3

Safety Operating Mechanism Maintenance

be

s

d

relay

2.2 Safety directives

On all types of work on high-voltage circuit-breakers, the risks listed below musttaken into consideration and corresponding measures must be taken.

WARNING

Breakers with pressurised insulators.Mechanical damage to the porcelaincan cause it to explode with thefollowing risk ofsplintering.Work on the circuit-breaker that risk mechanical damage to the insulatorshould be carried out at a reduced gas pressure, 0.125 MPa (abs).

WARNING

Do not operate the mechanism unloaded!Operations shall take place only when the mechanism has been connecteand trimmed with the associated circuit-breaker.

The standard operating cycle is O- 0.3 s - CO - 3 min. -CO. The time betweenclosing operations should not be less than 1 minute when circuit-breakers andsystems are tested with more than 3 closing operations.

4 1HSB515409-100 en rev3

Operating Mechanism Maintenance Safety

WARNING

The work requires training and product knowledge and may only becarried out by authorised personnel.

Risk Measure

Working next to high voltage. Isolate and earth next to the workplace. If work must be carried outnext to live installation components,the safety distance applying in thecountry’s applicable safetyregulations must be observed.

Working on ladders and platforms. Work shall be carried out inaccordance with applicable safetyregulations in the country concerned.Difficult weather conditions thatrequire short shifts with a great dealof climbing on ladders and platforms,should be avoided.

Working with low voltage.

Both alternating (AC) and direct (DC)current can be routed to theoperating mechanism.

Switch off the control voltage and ifnecessary the heater voltage.

Risk of crushing in the operatingmechanism and link system.

There is stored energy in both theopening and the closing springs. Themechanism can be tripped by heavyvibrations or by unintentional contactwith the catch components.

Operate the circuit-breaker to theopen position. Isolate and earth thehigh-voltage side. Discharge thesprings by switching off the motorcurrent and perform a Close-Openoperation or move the drive shaft onthe operating mechanism backwardsby hand. For reasons of safety theclosing springs must be unchargedduring transportation as well asduring assembly and storage.

Working next to pressurisedinsulators.

The normal working pressure is up to0.8 MPa. Damage to the porcelaincan result in splintering.

Work next to the circuit-breaker’sinsulators that may result in damageto the porcelain must not be carriedout until the gas has been emptied tomax. 0.125 MPa (abs.) pressure.

1HSB515409-100 en rev3 5

Operating Mechanism Maintenance Maintenance, general

e

3. Maintenance, generalAll requisite equipment should be available before work is started so thatmaintenance work can be carried out in the best way.

The following equipment is required.

3.1 Tools

• A normal set of tools including torque wrenches (10-100 Nm).

3.2 Cleaning equipment

• Vacuum cleaner.

• Drying cloths of a lint-free material.

3.3 Spare parts

• Lubricants and oils, see Lubricants, 1HSB445409-1 for suppliers and tradnames.

Grease “G”: ABB Art. No. 1171 4014-407Grease “M”: ABB Art. No. 1171 4016-612.

Oil “A”: ABB Art. No. 1171 2039-1

• Anti-corrosion agent.

Valvoline Tectyl 506: ABB Art. No. 1241 0011-108Grease “G”: ABB Art. No. 1171 4014-407.

3.4 Test equipment

• Equipment to record attenuation curves and operating values.(e.g. Programma or ABB SA10).

1HSB515409-100 en rev3 7

Operating Mechanism Maintenance Maintenance

in

d

hichhe

ual

4. Maintenance

4.1 General

The Operating and Maintenance Instructions for the circuit-breaker should bestudied and followed before work on circuit-breaker is started and while work isprogress.

WARNING

Do not operate the operating mechanism unloaded!Operations shall take place only after the mechanism has been connecteand trimmed with the associated pressurised circuit-breaker.

The component parts of the operating mechanism are integrated in a cabinet, walso contains a control panel with operating equipment. The top and doors of tcabinet can be removed to facilitate service and overhaul procedures.

Figure 4-1. Operating mechanism

• Measure all operating values and note them down. If the measured valuescorrespond with the specified values for the circuit-breaker, then only a visinspection, cleaning and lubrication are required.

Item

1 Drive unit


3 Control panel

4 Spring battery

5 Heater element

1

2

4

3

5

B20001

1HSB515409-100 en rev3 9

Maintenance Operating Mechanism Maintenance

ism

n the

f the

4.1.1 Mechanical interlock

The mechanical interlock prevents a closing operation if the circuit-breaker isalready in the closed position or if the closing springs in the operating mechanare uncharged or not completely charged, which can occur if, for example, theclosing catch has been opened by hand or if a mechanical fault has occurred iinterlocking mechanism.

• Check the position of the interlocking arm in relation to the outside of theinterlocking disc. The interlocking arm should lie 2 mm above this.

• Check that the closing circuit is closed when the arm rests on the outside ointerlocking disc.

Figure 4-2. Interlocking mechanism

Item

1 Limit switch

2 Interlocking arm

3 Interlocking disc

4 Cam disc

5 Operating rod

1

4

3

2

5B20019

2 m

m

10 1HSB515409-100 en rev3


iblel

on.

ft

wise,e

Releasing the interlock

If the movement of the cam disc is stopped by the interlocking arm, it is not possto carry out a closing operation until the cam disc has been returned to its normaposition.

1. Manual discharging of the closing springs.

a. Turn the switch Local/Remote on the control panel to the “STOP” positi

b. Switch off the motor voltage with the direct-on-line starters.

c. Turn the switch on the drive unit to the “HAND” position so that the shafor manual cranking is released. Put the crank on the shaft.

2. Press the reverse catch button in hard using a screwdriver and crank clockseeFigure 4-3a, until the locking lug on the operating lever (1) is well past throller (2).

3. Rectify the cause of the fault.

4. Crank anticlockwise, seeFigure 4-3b, until the locking lug on the operatinglever (1) rests against the roller (2) in the closing catch gear.

Figure 4-3. Releasing the interlock

4.1.2 Electrical interlock

Check by measuring between the bridge and theframe foot. Dimension according to figure.4.4

Figure 4-4. Check dimension, closing springs.

Item

1 Operating lever

2 Roller, Close

21

B20020a b

294

+2

B20021

1HSB515409-100 en rev3 11


g

4.2 Preparations for maintenance

The following should be done before maintenance is started:

1. Switch the circuit-breaker to the open position.

2. Isolate and earth.

3. Switch off the motor current.

4. Perform a Close-Open operation so that the spring battery in the operatinmechanism is discharged.

5. Switch off the control voltage and, if necessary, also the heater voltage.

Figure 4-5. Control panel

Item

1 Control panel

2 Control switch On/Off

3 Switch Local/Remote

4 Electric counter

5 Spring indicator

1 352

4

B20009

12 1HSB515409-100 en rev3


the

,

ehe

y

eers,

er of

plied

4.2.1 Emptying the gas

Work that involves a risk of damaging the insulators must not be carried out untilgas has been evacuated to a pressure of max. 0.125 MPa (abs).

WARNING

Unused SF6 gas is non-toxic, odourless and colourless. It is heavier thanair and can therefore easily collect in low-lying places, e.g. cable trenchestanks, etc., if released in large volumesWhen large quantities of SF6 gas collect in such places, a risk ofasphyxiation may occur due to a lack of oxygen.

The SF6 gas is evacuated by using gas handling equipment, which cleans andcompresses the gas so that it can be reused or destructed.

N.B. Mixed gas, SF6 mixed with N2 or CF4, must not be reused unless the mixturratio is kept under control. (Can be checked with a meter that indicates tpercentage of SF6.)

4.3 Cleaning

• Clean the inside of the operating mechanism using a vacuum cleaner.

• Check that the filters in the valves are clean. If they are heavily soiled, theshould be replaced.

4.4 Corrosion

Some of the steel mechanism parts have been surface treated with manganesphosphate and then rust protected by dipping in oil. This applies to, among othcatches, gears and components in the link system.

Despite good rust protection, small signs of corrosion can appear after a numbyears, especially on circuit-breakers erected in very aggressive environments.

• Rust spots should be removed and new anti-corrosive agent should be apby brush or spray. Recommended anti-corrosive agents are Grease “G” orTectyl 506.

N.B. After drying, Tectyl 506 forms a protective wax-like film and must not besprayed on bearings, catch gears, gears or chains.

1HSB515409-100 en rev3 13


tlys and

ed

an

4.5 Lubrication

The ball, roller and needle bearings in the operating mechanism are permanenlubricated and require no maintenance. Therefore only the shafts in catch gearworm gear in the drive unit need to be lubricated.

• Check whether the chains in the operating mechanism are dry and corrodand, if necessary, lubricate with Grease “G” or oil “A”.

Sliding surfaces for the spring yoke and dashpots should be lubricated during overhaul with Grease “G” .

14 1HSB515409-100 en rev3


ion

h,

ent

4.6 Heater element

The operating mechanism is fitted with a heater element to prevent condensatand should always be connected.

• Measure the resistance and check the voltage failure signal, if there is sucafter every15 years or 5,000 operations.

Figure 4-6. Heater element

Data

70 W heater element permanently connected , 140 W or 2x140 W heater elem(thermostat controlled) extra for temperatures below -25°C.

Item

1 Heater element

Tabell 4-1. Heater element resistances

-25°C -40°C -55°C

70 W, 220 V, R=691 Ohms ±10% X

140 W, 220 V, R=346 Ohms ±10% X X

2x140 W, 220 V, R=173 Ohms ±10% X X

70 W, 110 V, R=173 Ohms ±10% X

140 W, 110 V, R=86 Ohms ±10% X X

2x140 W, 110 V, R=43 Ohms ±10% X X

13 2

5 46

1B20010

1HSB515409-100 en rev3 15


rive

ns.

tage

4.7 Drive unit

• Check and clean the shafts in the catch gear and the worm gears in the dunit.

• Lubricate these with Grease “M” at intervals of 15 years or 2,000 operatio

• Measure the motor current at the end of the spring charging procedure atintervals of 15 years or 5,000 operations. See the relevant AssemblyInstructions for the circuit-breaker, chapter Operating values.

The motor should be capable of charging the springs at 85% of its nominal vol(IEC).

Figure 4-7. Drive unit

4.7.1 Switch Hand-Motor

Check that the signal for voltage failure functions. If not, replace the switch.

Item

1 Drive unit

1

B20011

16 1HSB515409-100 en rev3


g

e,

uste the

4.8 Catch gear

The operating mechanism is fitted as standard with one closing coil and twoopening coils, but can, on request, be equipped with double coils on the closinside.

Figure 4-8. Catch gear

• Check that the voltage to the coils does not fall below the minimum voltagsee the delivery document for the operating mechanism.

• Check the play between the magnet arm and the auxiliary catch . The play mbe at least 1 mm. If the plays are outside the specified dimensions, replacentire catch gear.

Figure 4-9. Checking the clearance.

Item

1 Catch gear

Item

1 Auxiliary catch

2 Magnet arm

1

Closing catch gear

Opening catch gear

B20012

1 mm

1

2

B20013

1HSB515409-100 en rev3 17


ofg

4.9 Dashpots

The operating mechanism is fitted with a Closing dashpot to brake the rotationthe cam disc and an Opening dashpot to dampen the final phase of the openinmovement.

Figure 4-10. Closing and Opening dashpots.

Item

1 Closing dashpot

2 Opening dashpot

1

2B20014

18 1HSB515409-100 en rev3

Operating Mechanism Maintenance

ion.

ting the

tion.

ord aut in

4.9.1 Closing dashpot

Check the oil level in the dashpot by recording the damping effect during operat

• Connect the circuit-breaker analyser’s sensor to the cam shaft in the operamechanism and record a damping curve. Check the damping distance anddamping time as set out inFigure 4-11. If the measured values for “a” and “b”are outside the specified values, replace the complete dashpot.

Figure 4-11. Damping curve, Closing dashpot.

4.9.2 Opening dashpot

Check the oil level in the dashpot by recording the damping effect during opera

• Connect the circuit-breaker analyser’s sensor to the breaker’s shaft and recdamping curve. Check the damping distance and the damping time as set oFigure 4-12. If the recorded curve differs from the correct curve, replace thecomplete dashpot.

Figure 4-12. Damping curves, Opening dashpot.

“b”

“a”

“a” = damping distance 15-25 mm“b” = damping time 80-300 ms

B20015

Wrong Right WrongB20016

1HSB515409-100 en rev3 19


ing

ker

timesrison

4.10 Link system and spring battery

Perform a visual check of the spring battery, links and bearings. If necessary,lubricate the links and bearings with Grease “M”.

4.11 Auxiliary contact

The operating mechanism is fitted as standard with a 6-pole auxiliary contactconsisting of six opening and six closing contacts. Three closing and one opencontacts are used for the functioning of the operating mechanism.

The auxiliary contact shaft is in direct connection with the operating lever in theoperating mechanism and accordingly follows the movement of the circuit-breacontacts.


After 15 years or 5,000 operations, check the contact travel by measuring the and compare the results with those obtained during commissioning. The compacan then be used to check the condition of:

• Contact travel

• Contact damping

Item

1 Limit switch

2 Auxiliary contact

21B20017

20 1HSB515409-100 en rev3


1. Connect a time-meter across the signal contacts 20, 29, 291 and 292 inaccordance with the circuit diagram.

2. Measure the times t1, t2 and t3

3. Turn the switch “Local/Remote” to the “LOCAL” position.

4. Connect the time-meter across terminals X1:190 and X1:192.

5. Turn the switch “On/Off” to the “OFF” position and then the “ON” position.

6. Note down the times t1, t2 and t3.

7. Disconnect the time-meter.

8. Turn the switch “Local/Remote” to the “REMOTE” position.

Figure 4-1. Time measurement, contact travel.

Contact travel

Arcing contact

Closed

Auxiliary contact

Open

t2

t3t1Time

t1 ms Proportional to the contact’s opening speed.

t2 ms Time that determines contact damping.

t3 ms Proportional to the contact’s closing speed.

B20018

Contact travel

1HSB515409-100 en rev3 21


4.12 Terminal blocks

Check all screws and pins.

Figure 4-2. Electrical equipment.

Item

1 2 limit switches withauxiliary contacts

2 Motors

3 Switch Hand/Motor

4 Relays

5 Contactors

6 Direct-on-line starters

7 Miniature circuit-breakers

8 Plug socket

9 Thermostat

10 Fuses

11 Opening coil

12 Terminal block

13 Closing coil

14 Cover

1

2

4

12

11

4

3

4

7

5

6

8

7

9

10

13

14

B20022

12

22 1HSB515409-100 en rev3


4.13 Slow closing and opening operations

Some service work requires the circuit-breaker to operate slowly. For examplepreparing for overhaul of breaking unit on two chamber breaker.

CAUTION

Slow closing and opening operations may only be carried out by personsthat are well conversant with the operation of the mechanism and circuit-breaker, as there is a risk of personal injury and mechanical damage.

Slow closing of the operating mechanism

May only be carried out if:

1. The circuit-breaker is in the open position.

2. The switch Local/Remote (1) onthe control panel is in the Offposition.

3. The motor voltage is switchedoff with the direct-on-linestarters (2), (3).

4. The switch Motor/Hand (4) is inthe Hand position so that theshaft for manual cranking isreleased.

Figure 4-3. Switch Local/Remote, direct-on-line starter

Item


2 Direct-on-line starter


4 Switch Motor/Hand

2

4

1

B20002

3

1HSB515409-100 en rev3 23


e thering

ng

5. The closing springs are uncharged.

a. Place the crank (1) on the shaft.

b. Press the reverse catch button (2) in hard using a screwdriver to releasreverse catch and discharge the springs. Crank clockwise until the spyoke has reached the bottom position and rests against the foot of theframe.


6. Blocking beams fitted.

a. Fit the blocking beam (1) around the rod so that the fixing hole is faciout towards the cabinet. Fit the bolt (2) in the blocking beam.

b. Fit the other beam in thesame way.

Figure 4-5. Fitting the blocking beams

Item

1 Crank

2 Reverse catch button

3 Switch Motor/Hand

Item

1 Blocking beams 2 pcs.


Direction

Direction

Direction

3

1

2B20003

of rotation

of power of power

12

B20004

12

24 1HSB515409-100 en rev3


.

thecuit-

of aves

mrds5)

sooff-

m

7. The interlocking mechanism is disengaged.

a. Press the operating rod (1) or the interlocking arm (2) upwards.

b. Insert the blocking pin (3) in the hole (4).

Figure 4-6. Interlocking, circuit-breaker open and closing springs uncharged

8. The blocking beams move against the mechanical end stop.

a. Crank anticlockwise, normally 6-8 turns, max. 10 turns.

9. The intermediate catch is released.

a. Press down the armature on the closing coil (1).

The slow closing operation in progress can be interrupted in any position beforelocking lug engages the roller. Press in the reverse catch button, so that the cirbreaker runs slowly towards its open position and stops in the required positionwhen the button is released.

1. Crank anticlockwise 310 turns. The cam disc (2) then rotates approx. 3/4 turn and actuates the stop roller (3) so that the operating lever (4) slowly mothe circuit-breaker towards the closed position. Towards the end of themovement a click is heard when the locking lug (5) on the operating armengages behind the roller (6) in the tripping mechanism.

2. Crank a few more turns anticlockwise, so that the outer most tip on the cadisc (2) leaves the stop roller (3). The operating lever is drawn quickly towathe open position by the power of the opening spring until the locking lug (loudly rests against the roller (6).

3. Crank anticlockwise until the locking lug (7) just rests against the roller (8)that the cam disc returns to its normal position and the blocking beams areloaded.

4. Remove the blocking beams.

5. Check that the locking lug (7) rests against the roller (8). Otherwise the cadisc will come in the wrong position and the operating mechanism can bedamaged during an opening operation.

Item

1 Operating rod

2 Interlocking arm

3 Blocking pin

4 Hole for blocking pin

2

3

4

Open

Closed

B20005

1

position

position

1HSB515409-100 en rev3 25


on

ning

6. Pull the blocking pin out of the hole.

7. Turn the switch Motor/Hand to the Motor position.

8. Switch on the motor voltage with the direct-on -line starters.

9. Set the switch Local/Remote to the Remote position.

The circuit-breaker is now in the closed position and a normal opening operatican be carried out.

N. B. Check that the blocking beams are dismantled before carrying out an opeoperation.

Figure 4-7. Operating mechanism, slow closing operation.

Item

1 Closing coil

2 Cam disc

3 Stop roller

4 Operating lever

5 Locking lug

6 Roller, Open

7 Locking lug

8 Roller, Closed

1

2

3

4

5

68

7

B20006

26 1HSB515409-100 en rev3


Slow opening operation

May only be done if:

1. The circuit-breaker is in the closed position.

2. The switch Local/Remote (1) onthe control panel is in the Offposition.

3. The motor voltage is switchedoff with the direct-on-linestarters (2), (3).

4. The switch Motor/Hand (4) is inthe Hand position so that thehand crank shaft can be released.

Figure 4-8. Switch Local/Remote, dirct-on-line starters.

Item




4 Switch Motor/Hand

2

4

1

B20002

3

1HSB515409-100 en rev3 27


e thering

ng

5. The closing springs are uncharged.

a. Place the crank (1) on the shaft.

b. Press the reverse catch button (2) in hard using a screwdriver to releasreverse catch and discharge the springs. Crank clockwise until the spyoke has reached the bottom position and rests against the foot of theframe.


6. Blocking beams fitted.

a. Fit the blocking beam (1) around the rod so that the fixing hole is faciout towards the cabinet. Fit the bolt (2) in the blocking beam.

b. Fit the other beam in thesame way.

Figure 4-10. Fitting the blocking beams.

Item

1 Crank

2 Reverse catch button

3 Switch Motor/Hand

Item

1 Blocking beams 2 pcs.


Direction of

Direction

Direction of

3

1

2B20003

ofof rotation

power power

12

B20004

12

28 1HSB515409-100 en rev3


l

d.

untilight

anyd

s.

.g. ards

awn

dise.

7. The interlocking arm (1) is locked by the pin (5) and stops in the horizontaposition against the locking disc (4).

a. Press the interlocking arm (1) with force upwards.

b. Insert the blocking pin (2) in the hole (3).

Figure 4-11. Interlocking, circuit-breaker closed and closing springs uncharge

The slow opening operation means that by using the cam disc you “fetch ” thecircuit-breaker and thereafter release the reverse catch and let the operatingmechanism make a slow opening operation.

1. Place the crank in the manual operation position and crank anticlockwise the blocking beams move against the mechanical end stop. It feels like a lresistance on the crank and takes normally 6-8 turns, max. 10 turns.

2. Press down the armature on the closing coil (1),Figure 4-12, so that the lockinglug (2) is disengaged from the roller (3).

3. Turn the crank approx. 300 turns anticlockwise. If the crank is turned too mturns, a clang is heard when the cam disc (4) passes the stop roller (5) anreturns once again to the position shown inFigure 4-12, top diagram. Make anew attempt. Follow the instructions from point 1 and crank a few turns les

4. Press in the reverse catch button in the drive unit.

5. Release the crank and let it rotate until it stops.

6. Release the opening catch gear by tapping the armature (6) lightly with, escrewdriver. The switch’s opening springs draw the operating lever (7) towathe open position. The movement is stopped when the stop roller (5) restsagainst the cam disc (4).

7. Keep the reverse catch button held in until the circuit-breaker has been drinto the open position by the opening springs. If the spring force is notsufficient to move the locking lug (2) so it passes and engages in the lockeposition against the roller (3), press in the button and turn the crank clockw

8. Dismantle the blocking beams.

Item

1 Interlocking arm

2 Blocking pin

3 Hole for blocking pin

4 Locking disc

5 Pin

Closed

Open

1

5

2

4

3

B20007

position

position

1HSB515409-100 en rev3 29


nti-

can

t an

9. Check that the locking lug (2) rests against the roller (3). Otherwise crank aclockwise until the locking lug rests against the roller.

10. Pull the blocking pin out of the hole.

11. Turn the switch Motor/Hand to the Motor position.

12. Switch on the motor voltage with the direct-on-line starters.

13. Turn the switch Local/Remote to the Remote position.

The circuit-breaker is now in the open position and a normal closing operation be carried out.

N.B. Check that the blocking beams have been dismantled before carrying ouopening operation.

Figure 4-12. Operating mechanism, slow opening operation.

Item

1 Closing coil

2 Locking lug

3 Roller, Closed

4 Cam disc

5 Stop roller

6 Armature

7 Operating lever

6

12

3

4

5

7

B20008

30 1HSB515409-100 en rev3


4.13.1 Manual tensioning of the closing springs

1. Crank anticlockwise until the closing springs are fully charged. Check bymeasuring between the bridge and the frame foot.

2. Turn the switch on the drive unit to the“MOTOR” position.

3. Reset the direct-on-line starters.

4. Turn the switch Local/Remote on thecontrol panel to the “REMOTE” position.

5. Make a test operation.

Figure 4-13. Check dimension, closing springs.

294

+2

B20021

1HSB515409-100 en rev3 31

1HSB515409-100 en rev30602




1HSB445409-212 en

Overhaul Instructions


ABB Power Technology Products AB is not responsible for damage incurred due to the misuse ofthis document.

The document, or parts of it, may not be reproduced or copied without prior permission from ABBPower Technology Products AB. It may not either be imparted to a third party or otherwise be usedwithout authorisation. Infringement hereof will be subject to action in accordance with applicablelaws.



Date: 2002-04-05


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LIST OF CONTENTS

1. General ............................................................................... 1

2. Safety................................................................................... 32.1 Warning text ................................................................................

2.2 Safety directives ..........................................................................

3. Overhaul, general ............................................................... 73.1 Tools ............................................................................................

3.2 Gas handling equipment.............................................................

3.3 Personal safety equipment..........................................................

3.4 Cleaning equipment ....................................................................

3.5 Spare parts.................................................................................

3.6 Test equipment ...........................................................................

3.7 Premises .....................................................................................

4. Dismantling the circuit-breaker......................................... 94.1 General .......................................................................................

4.2 Gas..............................................................................................

4.3 Cleaning and waste disposal ......................................................

4.4 Dismantling the breaking unit for transport .................................

4.5 Dismantling the breaking unit......................................................

5. Contact and puffer replacement ..................................... 195.1 Replacing the upper main circuit ................................................

5.2 Replacing the lower current path ................................................

5.3 Replacing the puffer ....................................................................

6. Overhaul of the upper mechanism ................................. 23

7. Assembling the breaking unit ......................................... 257.1 Treatment of contact surfaces ....................................................

7.2 Treatment of sealing surfaces and seals ....................................

7.3 Assembling the breaking unit......................................................

8. Dismantling the post insulator and mechanism fortransport318.1 Dismantling the post insulator ....................................................

8.2 Off-loading the tripping mechanism’s pull-rod............................

8.3 Removing the post insulator........................................................

9. Overhaul of the mechanism ............................................ 35

1HSB445409-212 en i


.. 39

. 40

. 41

10.Assembling the post insulator........................................3710.1 Assembling the tripping mechanism’s pull-rod on the operating

lever ............................................................................................

10.2 Assembly the Opening device “High-speed” ..............................

10.3 Gas filling ....................................................................................

11.Assembling the circuit-breaker and commissioning....43

ii 1HSB445409-212 en


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FIGURES

Figure 4-1. Deassemble Opening device “High-speed” ..............................

Figure 4-2. Off-loading the pull-rod. ............................................................

Figure 4-3. Dismantling the breaking unit. ...................................................

Figure 4-4. Assembling the transport cover. ................................................

Figure 4-5. Breaking unit with assembly tool. ..............................................

Figure 4-6. Dismantling the breaking unit. ...................................................

Figure 5-1. Upper current path. ....................................................................

Figure 5-2. Lower current path. ...................................................................

Figure 5-3. Puffer. ........................................................................................

Figure 6-1. Upper mechanism. ....................................................................

Figure 7-1. Assembling the puffer and lower current path. ..........................

Figure 7-2. Assembling the breaking unit. ...................................................

Figure 7-3. Assembling the absorption agent and cover. ............................

Figure 7-4. Assembling the locking washer. ................................................

Figure 8-1. Dismantling the post insulator. ..................................................

Figure 8-2. Off-loading the pull-rod. ............................................................

Figure 8-3. Dismantling the post insulator. ..................................................

Figure 8-4. Dismantling the operating insulator. ..........................................

Figure 9-1. Mechanism housing. .................................................................

Figure 10-1. Assembling the operating insulator. ..........................................

Figure 10-2. Assembling the post insulator. ..................................................

Figure 10-3. Assembling the tripping mechanism’s pull-rod on the operatinglever ............................................................................................

Figure 10-4. Assembling the Opening device “High-speed” ..........................

1HSB445409-212 en iii

Overhaul Instructions General

air

1. GeneralThis Overhaul Instruction Manual applies to the SF6 circuit- breakerHPL 245-550B2, 1-pole operation. It contains information for overhaul and repwork.

Overhaul and repair work may only be carried out by technicians trained byABB Power Technology Products AB.

1HSB445409-212 en 1

Overhaul Instructions Safety

ld be

2. Safety

2.1 Warning text

Warning text occurs where required and indicates that the text in question shouobserved extra carefully. The warning texts are marked as set out below.

DANGER

indicates an immediate hazardous situation that, if not avoided,will resultin death or serious personal injury.

WARNING

indicates an immediate hazardous situation that, if not avoided,can resultin death or serious personal injury.

CAUTION

indicates a hazardous situation thancan result inminor or moderateinjury.

N.B. used for hazards thatmay only result indamage to the installation.

1HSB445409-212 en 3

Safety Overhaul Instructions

be

e,

d

t-

2.2 Safety directives

On all types of work on high-voltage circuit-breakers, the risks listed below musttaken into consideration and corresponding measures must be taken.

WARNING

Circuit-breakers with pressurised porcelain insulators.Mechanical damage to the porcelaincan cause it to explode with thefollowing risk ofsplintering.Work on the circuit-breaker that brings about the risk of mechanicaldamage to the insulators should be carried out at a reduced gas pressur0.125 MPa (abs).

WARNING

Do not operate the mechanism unloaded!Operations shall take place only after the mechanism has been connecteand trimmed with the associated circuit-breaker.

The standard operating cycle is O- 0.3 s - CO - 3 min.-CO. The time betweenclosing operations should not be less than 1 minute during the testing of circuibreakers and relay systems involving more than 3 closing operations.

4 1HSB445409-212 en

Overhaul Instructions Safety

WARNING

Work requires training and product knowledge and may only be carriedout by authorised personnel.

Risk Measure

Working next to high voltage. Isolate and earth close to the workplace. If work must be carried outclose to live installation components,the safety distance applying in thecountry’s applicable safetyregulations must be observed.

Working on ladders and platforms. Work shall be carried out inaccordance with applicable safetyregulations in the country concerned.Difficult weather conditions thatrequire short shifts with a great dealof climbing on ladders and platforms,should be avoided.

Working with low voltage.

Both alternating (AC) and direct (DC)current can be routed to theoperating mechanism.

Switch off the control voltage and ifnecessary the heating voltage.

Risk of crushing in the operatingmechanism and link system.

There is stored energy in theopening and closing springs. Themechanism can be tripped by heavyvibrations or by unintentional contactwith mechanical latch components.

Operate the circuit-breaker to theopen position. Isolate and earth thehigh-voltage side. Off-load thesprings by switching off the motorcurrent and perform a Close-Openoperation or move the operatingmechanism’s drive shaft backwardsby hand (see the Product Informationfor the operating mechanism). Forreasons of safety the closing springsmust be off-loaded duringtransportation as well as duringassembly and storage.

Working close to pressurisedinsulators.

The normal working pressure is up to0.8 MPa. Damage to the porcelaincan result in splintering.

Work close to the circuit-breaker’sinsulators that may result in damageto the porcelain, must not be carriedout until the gas has been emptied tomax. 0.125 MPa (abs.) pressure.

1HSB445409-212 en 5

Overhaul Instructions Overhaul, general

ent the

be

used

and

3. Overhaul, generalBefore the overhaul work is started, all the necessary equipment and replacemparts should be made available so that the overhaul work can be carried out inbest possible way.

The following equipment is needed.

3.1 Tools

• A normal set of tools and torque wrenches (10-100 Nm).

• Lifting devices and lifting slings. The weights of the circuit-breaker parts tolifted can be found on the applicable dimension drawing for the order.

• Assembly tool, ABB Art. No. 5439 142-E.

3.2 Gas handling equipment

Gas handling equipment for evacuating, cleaning, compressing and storing theSF6 gas as well as instruments for monitoring the pressure and vacuum.

3.3 Personal safety equipment

• Full face mask with filter for fine particles and acid gases.

• Long-sleeved overall.

• Protective gloves of plastic or rubber.

3.4 Cleaning equipment

• Vacuum cleaner with micro-filter and plastic nozzle.

• Drying cloths of a lint-free material.

• Sealed storage containers for waste products and used absorption filters.

• Wire brush for contact surfaces of aluminium.

• Cleaning pad, e.g. Scotch Brite, for contact surfaces of copper.

• Industrial alcohol 95% (vol), C2H5OH, for cleaning inside surfaces.

• Heavy duty plastic sheet and plastic bags to prevent the ingress of moistureto protect cleaned components before assembly.

1HSB445409-212 en 7

Overhaul, general Overhaul Instructions

.

ar tod to

3.5 Spare parts

• Contact kits1

• Set of seals1

• Absorption agent1

• Lubricants, see Lubricants, 1HSB445409-1 for the names of suppliers andbrandsGrease “G”: ABB Art. No. 1171 4014-407Grease “K”: ABB Art. No. 1263 0011-102Grease “M”: ABB Art. No. 1171 4016-612Grease “N”: ABB Art. No. 1171 4016-607Grease “S”: ABB Art. No. 1171 4014-406Grease “P”: ABB Art. No 1171 5011-102.

• Anti-corrosion agentValvoline Tectyl 506, ABB Art. No. 1241 0011-108.

• SF6 gas.

• Nitrogen gas.

• Protective cover, circlip and off-loading tool from the assembly.

– Protective cover for breaking unit ABB Art. No. 1HSB442186-5.

– Protective cover for post insulator, ABB Art. No. 1HSB442158-1.

– Locking ring, ABB Art. No. 2171 835-D.

– Off-loading tool for tripping mechanism, ABB Art. No. 1HSB446381-A

3.6 Test equipment• Equipment to record attenuation curves on the operating mechanism.

(e.g. Programma or ABB SA10)

• Operating time meter.

• Ohmmeter.

• Leak detector.

3.7 Premises

The circuit-breaker or breaking unit must be opened indoors in dry and cleanpremises.

When the weather is good and settled and outdoor working conditions are similindoor conditions, the breaking units can be removed outdoors and transportedry and clean premises for the overhaul.

N.B. Under no circumstances may the breaking unit be removed or dismantledduring rain or other unsettled weather conditions, nor when the relativehumidity is 80% or higher.

1. According to the spare parts lists for the breaker in question.

8 1HSB445409-212 en

Overhaul Instructions Dismantling the circuit-breaker

g

tling.

4. Dismantling the circuit-breaker

4.1 General

Before the circuit-breaker is dismantled and during the course of the dismantlinwork, the directives in the Operating and Maintenance Instructions1HSB445409-100 must be read and followed:

Check and make a note of the circuit-breaker’s operating values before disman

Any deviation from the recommended values indicates that something must becarefully checked during the overhaul.

The overhaul can be carried out separately on:

• The breaking unit.

• The post insulator.

N.B. Removal and assembly of the breaking units must not be done when theweather is such that there is a risk of rain.

WARNING

This work requires trained staff with product knowledge and may only becarried out by authorised personnel.

4.1.1 Preparations for the overhaul

The following must be done before starting the overhaul:

• Operate the circuit-breaker to the Open position.

• Isolate and earth.

• Off-load the spring battery in the operating mechanism by switching off themotor current and performing a Close-Open operation.

• Switch off the control voltage and, if necessary, also the heater power.

1HSB445409-212 en 9

Dismantling the circuit-breaker Overhaul Instructions

nots).

sn.

,

singn be

e

y any

4.2 Gas

Work on the circuit-breaker’s insulators or other live components as well astransport and dismantling of complete circuit-breaker poles from the frame, maybe done until the gas has been evacuated to a pressure of max 0.125 MPa (ab

Gas shall be emptied fully to atmospheric pressure when a normal pressurisedspace, e.g. the breaking unit, shall be opened.

WARNING

When nitrogen gas is used for cleaning inside the circuit-breaker, the gamay be discharged into the atmosphere, but only via a dust and absorptiofilter.The emptying operation must be done outdoors and at ground level

WARNING

Unused SF6 gas is non-toxic, odourless and colourless. It is heavier thanair and can therefore easily collect in low-lying places, e.g. cable trenchestanks, etc., if released in large volumes.When large quantities of SF6 gas collect in such places, a risk ofasphyxiation may occur due to lack of oxygen.

4.2.1 Emptying the gas:

The SF6 gas is evacuated and the circuit-breaker should be vacuum pumped uthe gas handling equipment. This cleans and compresses the gas so that it careused or destructed.

N.B. Mixed gas, SF6 mixed with N2 or CF4, must not be reused unless the mixturratio is under control. (Can be checked with a meter that indicates thepercentage of SF6.)

After vacuum pumping, the circuit-breaker is filled with dry nitrogen gas untilatmospheric pressure is reached and is then vacuum pumped again. In this wafree-floating dust inside the circuit-breaker will be extracted.

Finally the circuit-breaker is filled again with dry nitrogen gas until atmosphericpressure is reached. The breaker is now ready to be dismantled.

10 1HSB445409-212 en


k of

ved

l

ed

4.3 Cleaning and waste disposal

CAUTION

Some decomposition products formed in the breaking unit can, whencoming in contact with moisture, become corrosive and can irritate theskin, eyes and mucous membranes.

Protective gloves of plastic or rubber, long-sleeved overalls and a full face maswith a fine particle and acidic gas filter must be worn when cleaning the insidethe circuit-breaker.

The dust (decomposition products) that forms in the circuit-breaker can be remousing a vacuum cleaner fitted with a micro-filter and wiped off using a soft clothdampened with alcohol.

N.B. All dust, old absorption agent, used cloths, etc., should be collected in asealed vessel and treated as chemical waste according to applicable locadirectives.

Protective gloves must be worn during all waste handling.

N.B. Drying cloths, protective gloves and vacuum cleaner bags should be rinsthoroughly in water after waste handling.

1HSB445409-212 en 11


f

ng

4.4 Dismantling the breaking unit for transport

Before the breaking unit is dismantled, the circuit-breaker must be taken out oservice,see Chapter 4.1.1, and the gas emptied,see Chapter 4.2.1.

1. Deassemble the bolt, washer and pin (1).

2. Loosen the nuts, bolts and washers (2). Deassemble the complete Openidevice “High-speed”(3).

Figure 4-1. Deassemble Opening device “High-speed”

Item

1 Bolt M8x16

Washer

Pin

1 pcs.

1 pcs.

1pcs.

2 Bolt M12x50

Washers 13x24x2.5

Nuts M12

4 pcs.

4 pcs.

4pcs.


3

1

2

12 1HSB445409-212 en


theforhas

(5)

3. Operate the circuit-breaker slowly towards the Closed position by crankingoperating mechanism by hand. This is described in the Product Informationthe operating mechanism. Stop cranking when the dimension L= 180 mm been reached.

4. Remove the tripping mechanism’s bottom cover (1).

5. Remove the bolt (2) and fit tool (3) 1HSB446381-A.

6. Tension the adjuster screw (4) to off-load the tripping mechanism’s pull-rodfrom the operating lever (6) in the mechanism housing.

Figure 4-2. Off-loading the pull-rod.

Item

1 Bottom cover

2 Bolt M16x30

Washer

1 pcs.

1 pcs.

3 Tool 1HSB446381-A

4 Adjuster screw

5 Pull-rod

6 Operating lever

3

4

5 6

B1009821

L

1HSB445409-212 en 13


in

nit

4),

1. Dismantle the cover (3) from the breaking unit (1).

2. Fit the locking washer (5) so that the contacts in the breaking unit are heldthe right position.

3. Dismantle the circlip (6) and pin (7).

4. Place a lifting sling around the breaking unit (1) and prepare to lift it.

5. Undo the bolts (8) against the post insulator and carefully lift the breaking ustraight up.

Figure 4-3. Dismantling the breaking unit.

6. Assemble the cover (3) on the breaking unit using the bolts and washers (tighten by hand.

Item

1 Breaking unit

2 Post insulator

3 Cover with 2 sealing rings

4 Bolts M10x25

Washers 10.5x22x2

4 pcs.

4 pcs.

5 Locking washer

6 Circlip

7 Pin

8 Bolts M12x70

Washers 13x24x2.5

Nuts M12

4 pcs.

8 pcs.

4 pcs.

1

3

5

6, 7

8

B10093

2

4

14 1HSB445409-212 en


r.

aul.

1. Fit the breaking unit’s transport cover (1) with associated sealing ring.

2. Fit the transport cover (3) with associated sealing ring on the post insulato

3. Fill the post insulator with SF6 gas or nitrogen gas to a pressure of0.125 MPa abs.

Figure 4-4. Assembling the transport cover.

4. Place the breaking unit on a suitable transport base so it cannot tip over.

The breaking unit is now ready for transportation to the workshop for an overh

Item


2 Bolts M12x50

Washers 13x28x3

Nuts M12

8 pcs.

16 pcs.

8 pcs.


1

3

B10090

2

1HSB445409-212 en 15


the

ce

der,

ort

the

out.

4.5 Dismantling the breaking unit

Plan the dismantling work so that it can be carried out quickly and without longdelays to prevent moisture in the air coming into lengthy contact with the dust inbreaking unit and on the inside and outside of the breaking chamber insulator.

N.B. Use personal safety equipment such as overalls, protective gloves and famask.

Take care of the decomposition products in the breaking unit, in the form of powas the breaking unit is successively opened. First use a vacuum cleaner andthereafter carefully wipe the dismantled components.

Dismantling and assembly are facilitated by placing the breaking unit on anassembly tool, ABB Art. No. 5439 142-E, with a mechanism for operating thecontacts.

1. Lift the breaking unit (1) from the transport base and dismantle the transpcover (2), but let the sealing ring remain in position.

2. Place the assembly tool (4) on the transport base and position thebreaking unit (1).

3. Connect the mechanism in the assembly tool to the breaking unit by fittingpin (5) and circlip (6).

4. Screw a bolt, M8, into the threaded hole in the locking washer (7) and pull it

5. Remove any capacitors and corona rings.

Figure 4-5. Breaking unit with assembly tool.

Item

1 Breaking unit

2 Transport cover with sealing ring

3 Bolts M12x70

Washers 13x28x3

Nuts M12

4 pcs.

8 pcs.

4 pcs.

4 Assembly tool Art.No. 5439 142-E

5 Pin

6 Circlip

7 Locking washer

2 4

1

5, 6

7

3

B10099

16 1HSB445409-212 en


be re-

(4).e

antle

1. Dismantle the cover (1) and lift out the absorption agent containers (2).

N.B. Place the bags with absorption agent in a vessel for chemical waste.

2. Mark the flanges on the breaking chamber insulators (5) so that they can assembled in the same position.

3. Dismantle the upper current paths (3) with the upper connection flange.

4. Place a lifting sling on the breaking chamber insulators as set out inFigure 4-6and undo the breaking chamber insulators (5) from the mechanism housingCarefully lift straight out so that the puffer (6) and lower current path (7) arnot damaged.

5. Dismantle the lower current paths (7).

6. Operate the puffer (6) outwards using a spanner on the shaft (8) and dismthe puffer by removing the pin (9) on the lower end of the puffer’s pull-rod.

Figure 4-6. Dismantling the breaking unit.

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

Item

1 Cover

2 Absorption agent container

3 Upper current path


5 Breaking chamber insulator

6 Puffer

7 Lower current path

8 Shaft with 24 mm spanner head

9 Pin

1

2

35

7 6

8

9

B10100

4

1HSB445409-212 en 17

Overhaul Instructions Contact and puffer replacement

ning

end

er

s

5. Contact and puffer replacementIf the circuit-breaker is not going to be reassembled immediately after the cleaof the component parts, protect them against contamination and moisture bypacking them in plastic bags with a desiccant to absorb moisture.

The insulators are suitably protected by tying heavy-duty plastic sheet over thesurfaces.

5.1 Replacing the upper main circuit

The entire current path (3) with flange and puffer should be replaced if the uppcurrent path’s fixed arcing contact (4),Figure 5-1, has been burnt so that thedistance to the reference surface is more than 9 mm or if the outside has beenseverely burnt. Replace the upper current path if the silver on the current path’contacts is worn so that the copper is visible.

Tighten the bolts (2). Tightening torque 22.5 Nm.

Figure 5-1. Upper current path.

Item

1 Flange

2 Bolt M8x20

Retaining washer

Washer

3 Current path

4 Arcing contact

max. 9 mm

1

3

4

B10101

Reference

2

surface

TIGHTENING TORQUE22.5 Nm

1HSB445409-212 en 19

Contact and puffer replacement Overhaul Instructions

and.

5.2 Replacing the lower current path

Remove the current path from the upper mechanism housing. Lift off the puffercheck that there is no wear on the pull-rod’s sliding surfaces in the puffer guide

Check that the silver on the lower current path contacts is not worn so that thecopper is visible.

If there are signs of wear, replace the whole lower current path with flange.

Tighten the bolts (2). Tightening torque 22.5 Nm.

Figure 5-2. Lower current path.

Item

1 Upper mechanismhousing

2 Bolt M8x20

Retaining washer

Washer

3 Current path

4 Puffer

5 Puffer guide

6 Teflon band

21 3

5 6 4B10102

2 2


20 1HSB445409-212 en

Overhaul Instructions Contact and puffer replacement

s onhat

act is

5.3 Replacing the puffer

Check that the nozzle (1) is not punctured. Also check that the contact surfacethe puffer cylinder (3) are not burnt or worn so that the copper is visible. Check tthere is no wear on the pull-rod’s sliding surfaces.

N.B. If the upper current path has been replaced because the fixed arcing contburnt, the puffer must also be replaced.

Replace the entire puffer if it has burnt or worn surfaces.

Figure 5-3. Puffer.

Item

1 Nozzle

2 Pull-rod

3 Puffer cylinder

4 Bolt M8x16

12

Contact surface

3

B10025

4


1HSB445409-212 en 21

Overhaul Instructions Overhaul of the upper mechanism

ion

e

6. Overhaul of the upper mechanismCheck that the upper mechanism is not heavily contaminated with decompositproducts.

Replace all sealing rings and coat them with grease “G” and all pins with greas“M”, if the mechanism needs to be dismantled and cleaned.

Figure 6-1. Upper mechanism.

Item

1 Pull-rod, uppersection

2 Support collar

3 Sealing ring

4 Bushing

5 Sealing ring

1

2

4

3

5B10103

1HSB445409-212 en 23

Overhaul Instructions Assembling the breaking unit

rse

lvent

ith a

lydry,”

uld

and

te.

7. Assembling the breaking unitTo re-assemble the breaking unit follow the dismantling instructions in the reveorder,see Chapter 4.5.

N.B. When re-assembling the breaking unit, all sealing rings should be new.Careful cleaning and treatment of sealing surfaces is required.

7.1 Treatment of contact surfaces

Before re-assembling the breaking unit, treat the contact surfaces as follows:

7.1.1 Fixed contact surfaces

• Silver-plated:If necessary, clean silver-plated contact surfaces, using a soft cloth and so(alcohol).

N.B. Polishing using Scotch Brite or grinding mustnot take place.

• Copper surfacesCopper surfaces must be clean and free from oxide. If necessary, clean wcloth and solvent (alcohol) or with Scotch Brite.

N.B. After cleaning with Scotch Brite,always remove all loose particles from thesurfaces using alcohol.

• Aluminium surfacesBrush clean contact surfaces of aluminium, using Scotch Brite. Immediatethereafter carefully clean the surfaces to remove any loose particles with aclean cloth. Then coat the surfaces with a thin layer of Vaseline, grease “P(ABB Art. No. 1171 5011-102).

N.B. Grease should be applied within five minutes of cleaning and the joint shobe fitted within 15 minutes.

7.1.2 Moving contact surfaces

• Silver-plated:If necessary, clean silver-plated moving contact surfaces, using a soft clothsolvent (alcohol).

• Non-silver-plated:Clean moving contact surfaces that are not silver-plated in a similar way tosilver-plated surfaces. However, they may also be cleaned with Scotch BriAfter cleaning with Scotch Brite, always remove all loose particles.

• Greasing:Apply Grease “N” (ABB Art. No. 1171 4016-607) in acovering, but very thinlayer to the male contacts and the puffer cylinder surfaces.Carefully wipe offall excess grease.

1HSB445409-212 en 25

Assembling the breaking unit Overhaul Instructions

sive,

ges in

nti-”

7.2 Treatment of sealing surfaces and seals

Clean, degrease and inspectall sealing surfaces in connection with assembly.

N.B. Sealing grooves and other sealing surfaces mustnot have lateral scratches.Any small scratches on sealing surfaces can be polished with a fine abrae.g. Scotch Brite. Polishing shall take place along the sealing line butneveracross it.

When re-assembling the circuit-breaker replaceall seals with new ones.

Grease sealing surfaces and sealssparingly to facilitate the seal’s union against thesurface and as corrosion protection. Excess grease that can squeeze out on flanthe gas chamber mustnot occur.

Coat flange surfaces outside the outer seal with a thin, well-covering layer of acorrosion agent matched to the flange material in question, usually Grease “G(ABB Art. No. 1171 4014-407).

Degreasing and cleaning material:

• Alcohol.

Greases for seals:

• Grease “G” for static sealsGrease “S” for moving seals, e.g. shaft seals.

26 1HSB445409-212 en


ver

he

7.3 Assembling the breaking unit

1. Fit the puffers (1) on the puffer guides. When the puffer starts to go down othe Teflon band, carefully turn it so that the Teflon band is not damaged.

N.B. Take care so that the Teflon band on the piston is not damaged when thepuffer is moved down.

2. Connect together the puffers’ pull-rods (2) and links (3) with the pins (4).

3. Fit the lower current paths (5) over the puffers and puffer guides. Tighten tbolts (6) to a torque of 22.5 Nm.

Figure 7-1. Assembling the puffer and lower current path.

Item

1 Puffer

2 Pull-rod

3 Link

4 Pin

5 Lower current path

6 Bolts M8x20

Washers 8.4x20x2

Retaining washers

12 pcs.

12 pcs.

12 pcs.

15

24

3

6B10104


1HSB445409-212 en 27


de”.

lts

ce

nner

ators

4. Carefully clean the sealing surfaces for the sealing rings (1) and the outsisurface on the upper mechanism housing (2) and coat well with grease “GPlace the sealing rings (1) on the mechanism housing and carefully lift thebreaking chamber insulators (3) into position. Tighten by hand with the bo(4).

5. Carefully clean the sealing surfaces for the sealing rings (5) and the surfaoutside the lower top flanges (6) and coat well with grease “G”. Place thesealing rings (5) on the lower top flanges (6) and assemble with the uppercurrent path (7). Tighten the upper current path by hand with bolts (8).

Figure 7-2. Assembling the breaking unit.

6. Slowly operate the puffers (9) towards their Closed position using the spa(10). Align the fixed contacts so that they are centred with each other bymoving the upper flanges (6) and, if necessary, the breaking chamber insul(3) too.

7. Tighten the bolts (4) and (8) with a tightening torque of 60 Nm.

Item

1 Sealing ring


3 Breaking chamber insulator

4 Bolts M12x50

Washers 13x28x3

8 pcs.

8 pcs.

5 Sealing ring

6 Upper flange

7 Upper current path

8 Bolts M12x50

Washers 13x28x3

8 pcs.

8 pcs.

9 Puffer

10 Spanner

51

3

8

2

4

9 7 6

10B10105


28 1HSB445409-212 en


e and

ption

bolts

e

st

e

1. Clean the sealing surfaces on the upper flanges (1) and the outside surfaccoat with grease “G”. Place the sealing rings (2) on the upper flanges.

2. Open the new absorption agent package and place the agent in the absoragent containers (3).

3. Fit the absorption agent containers (3) and the covers (4) and tighten the with a torque of 45 Nm.

Figure 7-3. Assembling the absorption agent and cover.

4. Fit the cover (5) with the sealing ring.

5. Operate the breaking unit until it is virtually in the Closed position using thspanner (6).

6. Fill the breaking unit with gas.

a. Vacuum pump down to 100 Pa and let the pumping continue for at leaone hour after this pressure has been reached.

b. Stop the vacuum pumping and fill the circuit-breaker with dry and purnitrogen to atmospheric pressure. Allow to stand for a few hours orovernight.

c. Vacuum pump again down to 100 Pa and fill with pure SF6 gas to apressure of 0.125 MPa (abs).

Store filling hoses so that they are not exposed to moisture or contamination.Theymust not be used other than for their intended purpose.

7. Check, using a detector, around all covers and insulator flanges that thebreaking unit does not leak.

Item

1 Upper flange

2 Sealing ring

3 Absorption agent container

4 Upper cover

5 Cover

6 Spanner


13

4

2

6 5B10106

1HSB445409-212 en 29


tical

).

(6).

1. Turn the shaft with spanner (1) so that the slot on the end of the shaft is verand the breaking unit is in the sealed position.

2. Dismantle the cover (2), circlip (3) and pin (4) and fit the locking washer (5

3. Fit the cover (2).

4. Fit any capacitors.

5. Lift off the breaking unit from the assembly tool and fit the transport cover

6. Place the breaking unit on a suitable transport base.

Figure 7-4. Assembling the locking washer.

The breaking unit is now ready for assembling on the post insulator.

Item

1 Spanner

2 Cover

3 Circlip

4 Pin

5 Locking washer

6 Transport cover with sealing ring

7 Bolts M12x50

Washers 13x28x3

Nuts M12

4 pcs.

8 pcs.

4 pcs.

6

1

4, 3

5

7

1

2

B10099

30 1HSB445409-212 en

Overhaul Instructions Dismantling the post insulator and mechanism for transport

d to

ive

8. Dismantling the post insulator and mechanism for transportBefore the post insulator is dismantled, the gas must be emptied,see Chapter 4.2.1.The density monitor must be dismantled and the sealing cap (1) should be fittethe non-return valve (2).

1. Dismantle the pull-rod between the operating mechanism and the circuit-breaker.

2. Place a lifting sling under the post insulator’s upper flange as shown inFigure8-1 and prepare to lift with a crane. Now loosen the post insulator (5),removing the four bolts (3) on the frame and the four bolts (4) on the protecttube.

3. Lift up the post insulator andcarefully lay it down on atransport carriage. Block up thepost insulator so it lieshorizontal. The blocks (6) underthe post insulator should be ofan elastic material, e.g. wood orrubber.

N.B. If possible, keep the supportssupplied on delivery for thispurpose.

Transport to the workshop or a newsite should take place with care so asnot to damage the post insulator.

Figure 8-1. Dismantling the post insulator.

Item

1 Sealing cap

2 Non-return valve

3 Bolts M20x60

Nuts M20

Washers 21x36x3

4 pcs.

4 pcs.

8 pcs.

4 Bolts M12x40

Nuts M12

Washers 13x24x2.5

4 pcs.

4 pcs.

8 pcs.

5 Post insulator

6 Blocks

1

2

6 6B10110

4

3

5

1HSB445409-212 en 31

Dismantling the post insulator and mechanism for transport Overhaul Instructions

me

of ad to

8.1 Dismantling the post insulator

The post insulator is set up vertically on a suitable frame, e.g. circuit-breaker fraor a frame on the floor of the workshop.

8.2 Off-loading the tripping mechanism’s pull-rod

1. If the tripping mechanism shall be dismantled, measure and make a note reference dimension, e.g. “Y”, so that the opening springs (1) can be refittethe same tension using the nut (2) at some time in the future.

Y=............. mm date................

2. Remove the pin (3).

Figure 8-2. Off-loading the pull-rod.

Item

1 Opening spring

2 Lock nut

3 Pin

1

3

2

Y

B10107

32 1HSB445409-212 en

Overhaul Instructions Dismantling the post insulator and mechanism for transport

cklyact

ce

r is

ing.

is

8.3 Removing the post insulator

Plan the work to remove and clean the insulator so that it can be carried out quiand without long delays to prevent moisture in the air coming into lengthy contwith the dust in the post and on the operating insulators.

N.B. Use personal safety equipment such as overalls, protective gloves and famask.

1. Dismantle the transport cover (1) and the upper guide (2).

2. Fit a lifting sling from the top of the post insulator to the crane or overheadcrane.

3. Remove the upper post insulator unit’s bolts (5) from the lowerpost insulator (7).

4. Lift the upper post insulator unit (4) straight up until the operating insulatoreleased. Hold the operating insulator when lifting the post insulator.

5. Remove the sealing washer (6).

6. Remove the lower post insulator unit’s bolts (8) from the mechanism hous

7. Lift the lower post insulator unit (7) straight up until the operating insulatorreleased. Hold the operating insulator when lifting the post insulator.

N.B. Take care so as not to damage the operating insulator.

Figure 8-3. Dismantling the post insulator.

Item

1 Transport cover

2 Upper guide

3 Bolts M12x40

Washers 13x28x3

4 pcs.

4 pcs.

4 Upper post insulator unit

5 Bolts M16x70

Washers 17x30x3

Nuts M16

8 pcs.

16 pcs.

8 pcs.

6 Sealing washer

7 Lower post insulator unit

8 Bolts M16x50

Washers 17x30x3

8 pcs.

8 pcs.

1 2

4

5

7

6

8

B10108

1HSB445409-212 en 33

Dismantling the post insulator and mechanism for transport Overhaul Instructions

m

8. Mark the operating insulator so that it is positioned correctly when re-assembling. Dismantle the operating insulator by removing the circlip (1),washer (2) and pin (3).

Figure 8-4. Dismantling the operating insulator.

9. Carefully clean the operating insulator and protect it using plastic sheet.

10. Carefully clean the post insulator units, inside and outside, and protect theusing plastic sheet.

Item

1 Circlip

2 Washer

3 Pin

1

3

2

B10109

34 1HSB445409-212 en


t and

ber

iden

ball-

9. Overhaul of the mechanismClean the mechanism housing using a vacuum cleaner and then wipe it. Inspeclubricate the bearings and sealing rings.

Protect untreated or manganese phosphated steel parts outside the gas chamusing Valvoline Tectyl 506, ABB Art. No. 1241 0011-108.

1. The operating shaft (2) is journalled on a large ball-bearing (4) on the outsof the gas chamber. The bearing is accessible for inspection and lubricatiowhen the operating lever (3) and circlip (5) are dismantled.

2. Pull the operating shaft (2) out of the mechanism housing and remove thebearing (4) from the shaft.

3. Lubricate the ball-bearing (4)with grease “G”.

4. Remove the bushing (6) thatholds the sealing rings inposition by means of the twobolts (M5), which are screwedinto the holes at the end of thebushing. Replace the sealingrings (7, 8) in the bushing (6)and coat with grease “S”.

5. Check that the ball-bearing (9)rotates easily.

Figure 9-1. Mechanism housing.

Item

1 Mechanism housing

2 Operating shaft

3 Operating lever

4 Ball-bearing

5 Circlip

6 Bushing

7 X-ring 69.2x5.7

8 O-ring 89.1x5.7

9 Ball-bearing

Inner mechanism

1

2

Outer mechanism

3

Bearings and O-rings

9

7

5

4

8B10027

6

2

1HSB445409-212 en 35


post

10. Assembling the post insulator1. Turn the operating lever (1) and link (2) over the edge of the mechanism

housing and fit the operating insulator (3) using the pin (4), washer (5) andcirclip (6).

N.B. Fit the pin so that the circlip (6) faces towards the large bearing.

2. Place the sealing ring on the mechanism housing (9) and lift on the lower insulator unit (7), tighten the bolts (8) with a torque of 79 Nm.

Figure 10-1. Assembling the operating insulator.

Item

1 Operating lever

2 Link

3 Operating insulator

4 Pin

5 Washer

6 Circlip


8 Bolts M16x50

Washers 17x30x3

8 pcs.

8 pcs.

9 Mechanism housing


6

4

5

1

2

3

9

7

8

B10109

1HSB445409-212 en 37

Assembling the post insulator Overhaul Instructions

atora

3. Place the sealing washer (1) with the sealing rings on the lower post insulunit (2) and lift on the upper post insulator unit (3). Tighten the bolts (4) withtorque of 190 Nm.

4. Fit the upper guide (5) and tighten the bolts (6) with a torque of 60 Nm.

5. Fit the transport cover (7).

Figure 10-2. Assembling the post insulator.

Item

1 Sealing washer


3 Upper post insulator unit

4 Bolts M16x70

Washers 17x30x3

Nuts M16

8 pcs.

16 pcs.

8 pcs.

5 Upper guide

6 Bolts M12x40

Washers 13x28x3

4 pcs.

4 pcs.

7 Transport cover



75

3

4

2

1

6

B10108

38 1HSB445409-212 en


ly.

ver

10.1 Assembling the tripping mechanism’s pull-rod on the operating lever

1. Turn the operating lever (3) anti-clockwise towards the Open position andconnect it to the pull-rod (5) , coat the pin (4) with grease “K” before assemb

2. If the nut (8) has moved out of position, adjust it to the dimension Y,see Chapter 8.2.

Figure 10-3. Assembling the tripping mechanism’s pull-rod on the operating le

3. Set the dimension L= 180 mm using the adjuster screw (10).

Item

1 Bottom cover


3 Operating lever

4 Pin

5 Pull-rod

6 Spring housing

7 Opening spring

8 Lock nut

9 Tool 1HSB446381-A

10 Adjuster screw

7

35

6

10 1

4

8

Y

B10107

9

L

1HSB445409-212 en 39


n the and

(1).

ds

10.2 Assembly the Opening device “High-speed”

Deassemble the bolt, washer and pin (1).

Mount the complete Opening device “High-speed”(2), seal the surface betweeOpening device and the mechanism housing with silicone.Fit the bolts,washersnuts (3) and tighten with tightening torque 79 Nm.

Fit the coupling link (4) from the Opening device and the coupling link from theoperating mechanism (5) in the operating lever (6). Fit the pin,washer and boltTighten with tightening torque 22,5 Nm. Secure with Loctite 270.

Seal the slots (7) in the Opening device with silicone. The slot facing downwarshall be open for drainage.

Figure 10-4. Assembling the Opening device “High-speed”

Item

1 Bolt M8x16

Washer

Pin

1 pcs.

1 pcs.

1pcs.


3 Bolt M12x50

Washers 13x24x2.5

Nuts M12

4 pcs.

4 pcs.

4pcs.

4 Coupling link

5 Coupling link

6 Operating lever

7 Slots


TIGHTENING TORQUE22,5 Nm

2

1

3

4

5

7

6

1HSB445409-212 en 40

Overhaul Instructions Assembling the post insulator

ne

ht.

10.3 Gas filling

• Vacuum pump down to 100 Pa and let the pumping continue for at least ohour after this pressure has been reached.

• Stop the vacuum pumping and fill the circuit-breaker with dry and purenitrogen to atmospheric pressure. Allow to stand for a few hours or overnig

• Vacuum pump again down to 100 Pa and fill with pure SF6 gas to a pressure of0.125 MPa (abs).

Store filling hoses so that they are not exposed to moisture or contamination. Theymust not be used other than for their intended purpose.

The post insulator is now ready for transport.

1HSB445409-212 en 41


ce

es.

11. Assembling the circuit-breaker and commissioningThe circuit-breaker is assembled and commissioning is carried out in accordanwith applicable assembly instructions for the circuit-breaker in question.

After the circuit-breaker is assembled, check and note down the operating valu

Check carried out on the : ________________________________

First overhaul.







Close-Open times(1)

(1) The circuit-breaker must not be operated Open-Close without an intermediate delay of 300 ms.

ms ms ms






Filling pressure(2)

(2) Filling pressure according to rating plate.


1HSB445409-212 en 43


1HSB445409-212 en 44

Check carried out on the : ________________________________

Second overhaul.







Close-Open times(1)

(1) The circuit-breaker must not be operated Open-Close without an intermediate delay of 300 ms.

ms ms ms






Filling pressure(2)

(2) Filling pressure according to rating plate.


1HSB445409-212 en0204




1HSB445409-312 en

Spare Parts


ABB Power Technology ProductsPower Technology Products AB is not responsible for damage incur-red due to the misuse of this document.

The document, or parts thereof, may not be reproduced or copied without prior permission from ABBPower Technology ProductsPower Technology Products AB. It may not either be imparted to a thirdparty or otherwise be used without authorisation. Infringement hereof will be subject to action in accor-dance with applicable laws.



Date: 2002-04-05

Spart Parts

1HSB445409-312 en i

LIST OF CONTENTS

1. General ................................................................................ 11.1 Circuit-breaker pole ....................................................................... 2

2. Breaking unit....................................................................... 32.1 Breaking unit.................................................................................. 3

2.2 Contact set...................................................................................... 4

2.3 Upper mechanism........................................................................... 4

3. Post insulator...................................................................... 5

4. Mechanism.......................................................................... 74.1 Mechanism housing ....................................................................... 7

4.2 Tripping mechanism....................................................................... 7

4.3 Opening device “High-speed”........................................................ 8

5. Accessories ...................................................................... 115.1 Absorption agent container .......................................................... 11

5.2 Density monitor............................................................................ 11

5.3 Sets of seals .................................................................................. 12

5.4 Assembly sets............................................................................... 12

5.5 Non-return valve .......................................................................... 12

5.6 Capacitor ...................................................................................... 13

5.7 Corona ring................................................................................... 13

6. Tools and lubricants......................................................... 156.1 Protective cover............................................................................ 15

6.2 Tool for off-loading the tripping mechanism ............................... 15

6.3 Lubricants..................................................................................... 15

Reservdelar

ii 1HSB445409-312 en

FIGURES

Figure 1-1. Circuit-breaker pole. HPL 245-550B2 ........................................... 1

Figure 1-2. Circuit-breaker pole. ....................................................................... 2

Figure 2-1. Breaking unit. ................................................................................. 3

Figure 2-2. Contact set. ..................................................................................... 4

Figure 2-3. Upper mechanism ........................................................................... 4

Figure 3-1. Post insulator. ................................................................................. 5

Figure 4-1. Mechanism housing. ....................................................................... 7

Figure 4-2. Tripping mechanism. ...................................................................... 7

Figure 4-3. Tripping mechanism. ...................................................................... 8

Figure 5-1. Absorption agent container. .......................................................... 11

Figure 5-2. Density monitor. ........................................................................... 11

Figure 5-3. Non-return valve. .......................................................................... 12

Figure 5-4. Capacitor. ...................................................................................... 13

Figure 5-5. Corona ring ................................................................................... 13

Figure 6-1. Off-loading tool. ........................................................................... 15

Spare Parts General

that

void

ers of

1. GeneralSpare parts for the SF6 circuit-breaker HPL 245-550B2 with operating mechanismBLG 1002A are supplied by:

ABB Power Technology Products ABBox 700SE-771 80 LudvikaSwedenTel: +46 (0) 240-78 20 00

Spare parts recommended to be kept in stock are marked with an R. With moreten circuit-breakers in operation, the spare parts marked with RR are alsorecommended to be kept in stock. To be able to make quick replacements and along periods of downtime, the parts marked by RRR can also be stocked.

Figure 1-1. Circuit-breaker pole. HPL 245-550B2

Please state the type designation and serial number with all enquiries and ordspare parts. Please also state the order number if possible.

Item Designation Note

1 Breaking unit RRR

2 Post insulator RRR

3 Operating mechanism RRR

4 Capacitor

5 Frame

1

3

2

B10111

5

4

1HSB445409-312 en 1

General Spare Parts

ers of

1.1 Circuit-breaker pole

Figure 1-2. Circuit-breaker pole.


Item Designation

1 Breaking unit

2 Post insulator

3 Mechanism

4 Tripping mechanism

2

1

34

B10217

2 1HSB445409-312 en

Spare Parts Breaking unit

ers of

2. Breaking unit

2.1 Breaking unit

Figure 2-1. Breaking unit.


Item Qty Designation Note

1 2 Breaking chamberinsulator

RR

2 1 Upper mechanism

3 2 Upper current path Included incontact set

4 2 Lower current path Included incontact set

5 2 Puffer Included incontact set

B10113

1 4 352

1HSB445409-312 en 3

Breaking unit Spare Parts

ers of

2.2 Contact set

Figure 2-2. Contact set.

2.3 Upper mechanism

Figure 2-3. Upper mechanism


Qty Designation Note

1 Contact set R


1 1 Upper mechanism RR

B10114

1

B10115

4 1HSB445409-312 en

Spare Parts Post insulator

rs of

3. Post insulator

Figure 3-1. Post insulator.

Please state the type designation and serial number with all enquiries and ordespare parts. Please also state the order number if possible.


1 1 Upper post insulatorunit

RR

2 1 Lower post insulatorunit

RR

3 1 Operating insulator RR

4 1 Upper guide

5 1 Sealing ring

1

5

B10116

4

2

3

1HSB445409-312 en 5

Spare Parts Mechanism

ers of

4. Mechanism

4.1 Mechanism housing

Figure 4-1. Mechanism housing.

4.2 Tripping mechanism

Figure 4-2. Tripping mechanism.



1 1 Mechanism RR


1 1 Trippingmechanism

RR

1

B10012

B10107

1

1HSB445409-312 en 7

Mechanism Spare Parts

4.3 Opening device “High-speed”

Figure 4-3. Tripping mechanism.


1 1 Opening device“High-speed”

RR

B10107

1

8 1HSB445409-312 en

Spare Parts Mechanism

ers of
1HSB445409-312 en 9

Spare Parts Accessories

ers of

5. Accessories

5.1 Absorption agent container

Figure 5-1. Absorption agent container.

5.2 Density monitor

Figure 5-2. Density monitor.



1 1 Absorption agentcontainer

2 1 Absorption agent R


1 1 Density monitor,temperature- compensated -reference volume

R

2 1 Density monitor,temperature- compensated -bimetal

R

12

B10117

1

B10052

2

1HSB445409-312 en 11

Accessories Spare Parts

ers of

5.3 Sets of seals

Sets of seals for a complete circuit-breaker pole.

5.4 Assembly sets

Set of bolts for a circuit-breaker pole.

Set of pins for a complete circuit-breaker pole.

5.5 Non-return valve

Figure 5-3. Non-return valve.


Qty Designation Article number Note

1 Set of seals 1HSB446309-D R


1 Set of bolts 1HSB446309-E R


1 Pins with circlips 1HSB446309-F R


1 1 Non-return valve RR

1

B10053

12 1HSB445409-312 en

Spare Parts Accessories

ers of

5.6 Capacitor

Figure 5-4. Capacitor.

5.7 Corona ring

Figure 5-5. Corona ring



1 1 Capacitor

2 2 Bracket

3 1 Spacer washer


1 1 Corona ring

1B10118

2

3

2

1

B10119

1HSB445409-312 en 13

Spare Parts Tools and lubricants

ers of

6. Tools and lubricants

6.1 Protective cover

6.2 Tool for off-loading the tripping mechanism

Figure 6-1. Off-loading tool.

6.3 Lubricants

6.3.1 Oil


Item Qty Designation Article number Note

1 1 Protective cover forbreaking unit

1HSB442186-5 R

2 1 Protective cover forpost insulator

1HSB442158-1 R

Item Qty Designation Article number Note

1 1 Off-loading tool 1HSB446381-A R

Oil Article number Note

“A” 1HSB875318-A

“D” 1HSB875318-B

“S” 1HSB875318-C

1

B10054

1HSB445409-312 en 15

Tools and lubricants Spare Parts

ers of

6.3.2 Grease


Grease Article number Note

“G” 5316 381-A

“K” 5316 381-M

“N” 5316 381-L

“L” 5316 381-H

“M” 5316 381-J

“P” 5316 381-N

“S” 5316 381-G

“SV” 5316 381-C

16 1HSB445409-312 en

1HSB445409-312 en0204



SF6 Circuit-Breaker Operating mechanismtype BLG 1002A

1HSB515409-200 en rev3

Spare Parts






Date: 2002-06-11

Spare Parts

1HSB515409-200 en rev3 i

TABLE OF CONTENTS

1. General ................................................................................ 1

2. Drive unit ............................................................................. 3

3. Dashpots ............................................................................. 53.1 Closing dashpot.............................................................................. 5

3.2 Opening dashpot............................................................................. 6

4. Catch gear ........................................................................... 7

5. Auxiliary contact................................................................. 9

6. Heater element.................................................................. 11

7. Electrical equipment ........................................................ 13

8. Lubricants ......................................................................... 158.1 Oil................................................................................................. 15

8.2 Grease........................................................................................... 15

Spare Parts

ii 1HSB515409-200 en rev3

FIGURES

Figure 1-1. Operating mechanism. .................................................................... 1

Figure 2-1. Drive unit. ....................................................................................... 3

Figure 3-1. Closing dashpot. ............................................................................. 5

Figure 3-2. Opening dashpot ............................................................................. 6

Figure 4-1. Catch gear ....................................................................................... 7

Figure 5-1. Limit switch with auxiliary contact. ............................................... 9

Figure 6-1. Heater element. ............................................................................. 11

Figure 7-1. Electrical equipment. .................................................................... 13

Spare Parts General

ers of

1. GeneralSpare parts for operating mechanism BLG 1002A are supplied by:

ABB Power Technology Products ABSE-711 80 LudvikaSwedenTel: +46 (0) 240-78 20 00

Replacement modules are supplied complete and tested.

Please state the type designation and serial number with all enquiries and ordspare parts or tools. Please also state the order number, if possible.

Figure 1-1. Operating mechanism.

Item

1 Drive unit


3 Control panel

4 Spring battery

5 Heater element

1

2

4

3

5

B20001

1HSB515409-200 en rev3 1

Spare Parts Drive unit

are

2. Drive unit

Figure 2-1. Drive unit.

Please state the type designation and serial number with all enquiries and orders of spparts or tools. Please also state the order number, if possible.

Type of drive unit (1)

(1) See wiring diagram

Article number

1 Motor, 220 V 0-60Hz 2361 113-AU

2 Motors, 220 V 0-60 Hz 2361 113-AV

1 Motor, 110 V 0-60Hz 2361 113-AS

2 Motors, 110 V 0-60 Hz 2361 113-AT

B20031

1HSB515409-200 en rev3 3

Spare Parts Dashpots

are

3. Dashpots

3.1 Closing dashpot

Figure 3-1. Closing dashpot.


Designation Article number

Closing dashpot 5256 707-BN

B20032

1HSB515409-200 en rev3 5

Dashpots Spare Parts

are

3.2 Opening dashpot

Figure 3-2. Opening dashpot



Opening dashpot HPLxxxA1, 3-pole 5256 707-BP

HPLxxxB1, 3-pole

HPLxxxA4

HPLxxxB4

HPLxxxB2 5256 707-BH

HPLxxxA1, xxxB1, xxxA2,1-pole

5256 707-BR

HPL B1, 1-pole 5256 707-BS

HPL B1, 1-pole, HI-speed 5256 707-BY

HPL B2, B4 5256 707-BT

HPL B1, 3-pole 5256 707-BV

LTB E1, 3-pole 5256 707-BX

LTB E2 5256 707-BU

B20033

6 1HSB515409-200 en rev3

Spare Parts Catch gear

are

4. Catch gear

Figure 4-1. Catch gear



Closing catchgear

STD 1-coil 5436 009-V

1-coil, interlock 5436 009-AB

2-coils 5436 009-X

2-coils, interlock 5436 009-AC

Opening catchgear

STD 5436 009-Z

Manual opening 5436 009-AD

Manual opening69 device

5436 009-AFB20034

1HSB515409-200 en rev3 7

Spare Parts Auxiliary contact

are

5. Auxiliary contact




Auxiliary contact 6- or 12-pole 5751 805-F

18-pole 5751 805-H

B20035

1HSB515409-200 en rev3 9

Spare Parts Heater element

are

6. Heater element

Figure 6-1. Heater element.


Designation Voltage range Article number

Heater element 110-127 V AC, 70 W 5291 800-R

220-254 V AC, 70 W 5291 800-S

110-127 V AC, 70+140 W 5291 800-U

220-254 V AC, 70+140 W 5291 800-V

110-127 V AC,70+140+140 W

5291 800-X

220-254 V AC,70+140+140 W

5291 800-Y

13 2

5 46

B20036

1HSB515409-200 en rev3 11

Spare Parts Electrical equipment

are

7. Electrical equipmentSpare parts for electrical equipment BLG 1002A.

Figure 7-1. Electrical equipment.

Please state the type designation and serial number with all enquiries and orders of spparts or tools. Please also state the order number if possible.

Item Designation Voltage rangeArticlenumber

1 Contactors 110-125 V DC 5351 749-2

110-130V, 50/60 HZ 5351 749-4

220-250 V DC 5351 749-1

220-250 V, 50/60 Hz 5351 749-3

2 Direct-on-linemotor starters

110-125 V, 4-6 A 5576 0760-2

220-250 V, 2.4-4A 5576 0760-1

3 Relay, 3-pole 42-48 V DC 5619 758-4

110 V DC 5619 758-2

125 V DC 5619 758-8

220 V DC 5619 758-1

250 V DC 5619 758-7

Relay, 4-pole 42-48 V DC 5619 750-4

110 V DC 5619 750-2

125 V DC 5619 750-8

220 V DC 5619 750-1

250 V DC 5619 750-10

4 Counter 42-48 V DC 5692 965-3

110-125 V DC 5692 965-2

220-250 V DC 5692 965-1

B20002

2

3

1

4

1HSB515409-200 en rev3 13

Spare Parts Lubricants

are

8. Lubricants

8.1 Oil

8.2 Grease


Oil Article number

“A” 1HSB875318-A

“D” 1HSB875318-B

“S” 1HSB875318-C

Grease Article number

“G” 5316 381-A

“K” 5316 381-M

“N” 5316 381-L

“L” 5316 381-H

“M” 5316 381-J

“P” 5316 381-N

“S” 5316 381-G

“SV” 5316 381-C

1HSB515409-200 en rev3 15

1HSB515409-200 en rev30602


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