Instructions for Erection, SF6 Circuit-Breakers

Operation and Maintenance

Type HE. .1...6

Operating Mechanism

Publication No. CH-HS 1495 87 E

Supersedes CH-A 466 296 E Rev. D

Contents

1 General
2 Construction
3 Function
4 Erection
5 Commissioning
6 Troubleshooting
7 Maintenance
8 Spare parts
11 Appendix

ABB Switzerland Ltd

 Note:
The operation, i.e. the manipulation and maintenance of
an SF6 gas-insulated high-voltage circuit breaker must be
performed by certified specialized personnel and in ob-
servation of the regulations applicable for high-voltage
switchgear installations and equipment. ABB stipulates
the availability of appropriate specialized personnel and
the prerequisite knowledge of the regulations.
The operating instructions describes only one component
of the high-voltage circuit breaker and provide information
on the operation and maintenance thereof. They do not
substitute either for appropriate specialized personnel
nor the applicable regulations.
The operator of the high-voltage circuit breaker is respon-
sible for the employment of adequately trained special-
ized personnel, as well as for the adherence to all appli-
cable regulations.

Copyright:
Without our written consent the disclosure, reprinting,
copying and reproduction of this publication, whether in
full or in part, are prohibited.

Printed in Switzerland (9704-50-1) Rev. D

Classification No. 040403
Contents Page Page

1 General 2 7.4.5 Solenoid valve 10

1.1 Validity 2 7.4.6 Guide tube 10
1.2 Type designation 2 7.4.7 Control mechanism 11
1.3 Specifications 2 7.4.8 Control air connection 11
1.4 Mass 2 7.4.9 Heater compl. 11
1.5 Optional features 2 7.4.10 Operating mechanism in operating
1.6 Storage instructions 2 mechanism mounting assembly 11
1.7 Pertaining operating instructions 2
8 Spare parts 12
2 Construction 2 8.1 General 12
2.1 Cylinder 2 8.1.1 Spare parts to the operating mechanism 12
2.2 Main control valves 2 8.1.2 Ordering of spare parts 12
2.3 Pilot valves 2 8.1.3 Important data 12
2.4 Solenoid valve 3 8.2 Definitions of spare parts 12
2.5 Control mechanism 3 8.2.1 Reserve parts set A 12
2.6 Catch 3 8.2.2 Reserve parts set B 12
2.7 Silencer hood 3 8.2.3 Overhaul parts sets 12
2.8 Control air connection - pneumatic OPEN 3 8.3 Spare parts list 12
2.9 Heater compl. 3 8.3.1 Reserve parts sets A and B 12
8.3.2 Overhaul parts sets 12
3 Function 4
3.1 Operating mechanism 4 11 Appendix 13
3.1.1 Limit position damping 4 11.1 Figures 13
3.1.2 Limit position catch 4
3.2 Pneumatic OPEN switching operation 4
3.3 Heater compl. 5

4 Erection 5

5 Commissioning 5

6 Troubleshooting 6
6.1 Electrical control 6
6.2 Pressure loss 6

7 Maintenance (Overhaul) 6
7.1 General 6
7.1.1 Important notes 6
7.2 Tools and working materials 6
7.2.1 Standard tools to be made available 6
7.2.2 Special tools, jigs and fixtures to be made
available 6
7.2.3 Working materials 7
7.3 Disassembly 7
7.3.1 Prerequisites 7
7.3.2 Guide tube 7
7.3.3 Catch 7
7.3.4 Cylinder and valve hoods 7
7.3.5 Pilot valves 8
7.3.6 Solenoid valve 8
7.3.7 Control air connection 8
7.3.8 Heater compl. 8
7.4 Assembly 8
7.4.1 Cylinder 8
7.4.2 Catch 9
7.4.3 Main control valves 9
7.4.4 Pilot valves 10

CH-HS 1495 87 E 1
1 General 2 Construction

1.1 Validity The operating mechanism 10760, 13400 to the circuit

breaker comprises essentially (Fig. 2/1):
These operating instructions are applicable for operating
- Cylinder 10773
mechanism 10760, 13400 of circuit breaker type
- Main control valve OPEN and CLOSE 10567, 10774
HE . . 1/2/3/4/5/6 in the version described in chapter 2.
- Pilot valve OPEN and CLOSE 10569, 10568
- Solenoid valve 10525
1.2 Type designation - Control mechanism 10770
Operating mechanism SADHE 160/200. - Catch 10771
- Silencer hood 10772.

1.3 Specifications Additional equipment:

- Control air connection for pneumatic OPEN switching
- Service pressure depending on breaker type 690 - 960 operations (section 2.8)
kPa (abs) ( = 100 - 140 lbf / in2) - Heater compl. 13418 or heater compl. 13418 for pneu-
- Piston Ø 160 mm ( = 6.3 in) matic OPEN switching operations to circuit breaker
- Piston stroke 200 mm ( = 7.9 in) type HEF (section 2.9).
- Further specifications such as voltage of control coils
see order documentation.
2.1 Cylinder (Fig. 7/1)

1.4 Mass The cylinder 10773 comprises essentially:

- Cylindrical tube 10440
The operating mechanism weighs 54 kg ( = 119 lb). - Damping ring retainer 10442 with diaphragms 10446
and damping rings 10445
1.5 Optional features - Cylinder head 10438
- Guide head 10439
The circuit breaker or operating mechanism can be - Piston rod 10441 with piston 10448 and damping
equipped with a pneumatic control for OPEN switching pistons 25699, 25699/1
operations (pneumatic OPEN) if expressly ordered (sec- - Tiebar tube 10443, 10443/1
tions 2.8 and 3.2). - Tiebar 10444.
For the circuit breaker type HEF (outdoor) the operating Cylinder 10773 is bolted together with 2 tiebars 10444 and
mechanism 13400 is equipped with a heater. two tiebar tubes 10443. The tiebar tubes 10443 and
10443/1 installed on the main control valves 10567, 10774
1.6 Storage instructions are constructed as air channels (tubes " e " and " f " in Fig.
3/1).
See Treatment and Storage Instructions, chapters 21, 22,
23.
2.2 Main control valves (Fig. 7/1)
1.7 Pertaining operating instructions The main control valve OPEN and CLOSE 10567, 10774
comprises essentially:
- Circuit breaker system HE . . 1/2/3/4/5/6
- Left and right valve hoods 10469, 10468 with sealing
- Treatment and Storage Instructions HE.
washer 10472
- Valve piston 10470 with piston seal 10538 and sealing
ring 10474
- Compression spring 25676.
Cylinder head 10438 or guide head 10439 make up the
lower parts of the main control valves OPEN and CLOSE
10567, 10774.
Valve hoods left and right 10469, 10468 are fastened on
cylinder head 10438 or guide head 10439.
Valve pistons 10470 are sealed with rod seals 10476 and
sealing rings 10477 and piston seals 10538 and sealing
rings 10474 in valve hoods 10469, 10468 and guided in
guide strip 10459.

2.3 Pilot valves (Fig. 2/1, 7/1, 7/3)

The pilot valves OPEN and CLOSE 10569, 10568 com-
prise essentially:
- Valve body 10520
- Plug screw 10521

2 CH-HS 1495 87 E
- Compression spring 10532 " d2 " (see Fig. 3/1). With control tube 25693 fully extend-
- Valve plunger 25673 ed (position OPEN) the bores " d1 " are located in the vent
- Piston 25682 duct of pilot valve OPEN 10569 as a connection (vent) to
- Piston seal 10528 silencer 25696 (Fig. 2/1).
- Sealing ring 10529
- Thrust disk 10524 2.6 Catch (Fig. 2/1, 7/1)
- Sealing disk 10531.
Valve bodies 10520 of the pilot valves are flanged directly Catch 10771 comprises essentially:
to valve hoods left and right 10469, 10468 (Fig. 7/1). - Tapered stops 10503
Valve cover 25689 is fastened to valve body 10520, - Tubes 10497, 10498 and 10499
simultaneously accommodates solenoid valves 10525 - Plate assembly 10500 with 6 sleeves 10502, in each of
and serves as a support for control tube 25693. The ducts which a steel ball 10506 with 11 Belleville springs
to solenoid valves 10525 are drilled in valve cover 25689. 10505 are prestressed in series.
The control air discharged to the atmosphere on switching Tapered stops 10503 are positively connected with piston
operations passes through the filters 10517, 10557. rod 10441. Plate assembly 10500 is spaced at a distance
The pilot valves OPEN and CLOSE 10569, 10568 differ by tube 10497 and fastened with tiebar 10509 to guide
from one other in the following characteristics: head 10439. In the end positions of piston 10448 steel
- Pilot valve OPEN 10569 for OPEN switching opera- balls 10506 rest against the steeper bevel of the respec-
tions is fitted with filter 10517, two solenoid valves tive tapered stop 10503.
10525 and an air flow restrictor 10554. The piston 10448 is thereby mechanically fixed in position.
- Pilot valve CLOSE 10568 for CLOSE switching opera-
tions is fitted with filter 10557 and a solenoid valve 2.7 Silencer hood (Fig. 2/1)
10525.
Installed in silencer hood 10772 is silencer 10515 with
- Half-moon ring 10518
2.4 Solenoid valve (Fig. 2/1, 7/4) - Retaining ring 10513
The solenoid valve 10525 comprises essentially: - Sleeve 10514
- Coil 10540, 10630 - Hose clamp 25686.
- Coil carrier 10549 Silencer hood 10772 is clamped between cylinder head
- Armature 10541 with spring-loaded valve disk 10544 10438 or guide head 10439 and left and right valve hood
- Base 10543. 10469, 10468 (Fig. 7/1).
Coil carrier 10549 is screwed into base 10543. Coil 10540,
10630 is secured on coil carrier 10549 with nut 10493 and 2.8 Control air connection - pneumatic OPEN
spring lockwasher 10494. (Fig. 7/5b, c)
Armature 10541 is forced all the way down into base
10543 by spring 10564. Valve disk 10544 is spring-loaded Control air connection 25671 is provided for the connec-
and closes nozzle 10550. tion of control line " B " (pneumatic OPEN) (see sections
1.5 and 3.2) and consists of a valve plate 25685 with
- Coupling 25692
2.5 Control mechanism (Fig. 2/1, 7/2, 7/3) - Recoil disk 25454
The control mechanism 10770 comprises essentially: Control air connection 25671 is fastened between sole-
- Control tube 25693 noid valves 10525 and valve cover 25689 of pilot valve
- Guide tube 25690 OPEN 10569. Coupling 25692, to which the air hose " B "
- Silencer 25696 is connected for the control, is screwed into valve plate
- Sleeves 10561, 10562 with compression springs 10507 25685. The recoil disk 25454, which is forced against the
- Lever 25694 valve seat by spring 25453, is located inside valve plate
- Thrust disk 10485 25685.
- Two-piece snap-in ring 10488 Control air connection for pneumatic OPEN switching
- Sleeves 10486 operations with heater compl. see fig. 7/5c.
- Sleeves 25672 and 25698 with cotter pin 10556.
Control tube 25693 is positively connected to piston rod 2.9 Heater compl. (Fig. 7/5a, c)
10441 with lever 25694 by thrust disk 10485, sleeves
10486, two-piece snap-in rings 10488 and sleeves 25672, The heater compl. 13418, 13414 for operating mecha-
25698. nism 13400 to circuit breaker type HEF consists of:
Guide tube 25690 together with guide bushes 25691 is - Heating plate 13419
locked in valve covers 25689 (Fig. 7/2, 7/3) and sealed - Valve plate 13420
with sealing rings 10536. Fixing screws 25674 anchor - Insulating plate 13421 or blind insulating plate 13422.
both guide tube 25690 and guide bushes 25691.
Control tube 25693 runs in guide bushes 25691; the
movable connection is sealed by sealing rings 10566.
Sleeve 10561 (Fig. 2/1) is movably mounted on control
tube 25693. Held by the two springs 10507, with control
tube 25693 extended sleeve 10561 covers the bores
CH-HS 1495 87 E 3
3 Function atmosphere. The corresponding pilot valve is vented
and closes. If in this position solenoid valve 10525 is still
actuated, the pressure will escape via the path de-
3.1 Operating mechanism (Fig. 3/1) scribed above.
- The pressure acting on the surface of valve piston
- The air compressed by a compressed air supply unit is 10470 escapes to the atmosphere via duct " b ". Valve
stored in the compressed air receiver mounted on the piston 10470 is forced by spring 25676 against seal
circuit breaker. The compressed air is supplied to the 10472. Vent duct " h " opens. The pressure in cylinder
valve seats (air supply " a ") of solenoid valves CLOSE 10773 is conducted to hood 10722 (Fig. 2/1) and
and OPEN 10525, as well as to valve pistons 10470 of escapes through silencer 10515 arranged in the hood
main control valves 10774, 10567 CLOSE and OPEN (Fig. 2/1). In the end positions cylinder 10773 is always
via connection 10491. pressureless.
In Fig. 3/1 a CLOSE switching operation is shown - With slight leakage of solenoid valve 10525 the leakage
schematically. air can escape via bore " g " in piston 25682 through
- When solenoid valves 10525 are electrically actuated, duct " b " to the atmosphere.
they will open.
On CLOSE switching operations air is admitted to pilot 3.1.1 Limit position damping (Fig. 3/1, 7/1)
valve CLOSE 10568, and on OPEN switching opera-
tions to pilot valve OPEN 10569. Before piston 10448 reaches an end position, damping
- Example: Breaker operating mechanism in position piston 25699 immerses into damping ring 10445. The gap
OPEN (starting position shown in Fig. 3/1). In this between the damping ring and the damping piston, as well
position the vent bores " d2 " are not connected with as the bores in damping piston 25699, are dimensioned
pilot valve CLOSE 10568. Pressure can build up in pilot such that a counterpressure will build up between piston
valve CLOSE 10568. At the same time the discharge 10448, damping piston 25699 and damping ring retainer
" d1 " in control tube 25693 is connected with the 10442. This pressure brakes piston 10448. Immediately
actuation compartment in pilot valve OPEN 10569. An before the limit position is reached, damping piston 25699
OPEN switching command is not forwarded because runs through the damping ring 10445, so that the pressure
with this pilot valve in the OPEN position, operating can escape through the opened flow area. When the
pressure cannot build up. piston starts to move, diaphragm 10446 opens flow areas
- With solenoid valve 10525 actuated armature 10541 is in damping ring retainer 10442 so that the air can flow
pulled against spring 10546, the compressed air flows freely to piston 10448.
through base 10543 (Fig. 7/4) under piston 25682 of the
pilot valve, and valve plunger 25673 is forced off the 3.1.2 Limit position catch (Fig. 7/1)
valve seat. Catch 10771
- The air flows through the opened radial bores in valve Piston rod 10441 is locked mechanically in its two limit
plunger 25673 beneath piston 25682 and augments the positions by 6 spring-loaded steel balls 10506 against a
air flow from solenoid valve 10525 (self-holding). The beveled abutment surface (tapered stop 10503). In the
pilot valve 10568, 10569, to which compressed air is end positions cylinder 10773 is always pressureless, i.e.
admitted, thereby remains open by this self-holding, in the end positions the circuit breaker is mechanically
even if solenoid valve 10525 closes. Compressed air locked independent of the pressure of the compressed air.
flows through the pilot valve into the associated main
control valve.
3.2 Pneumatic OPEN switching operation
- In main control valve 10567, 10774 the corresponding
(Fig. 7/5b, c)
valve piston 10470 is forced downward, thereby closing
the vent duct " h ". A direct connection ensues between If (by order) the circuit breaker or the operating mecha-
connection 10491 and cylinder 10773 or piston 10448. nism is equipped with a control connection for the pneu-
On a CLOSE switching operation the spring chamber matic OPEN switching operation according to section 1.5
underneath valve piston 10470 is connected with the or 2.8, with the compressed air present an OPEN switch-
vented chamber of cylinder 10773 by the tiebar tube ing operation of the operating mechanism 10760, 13400
" f ", or the spring chamber beneath valve piston 10470 (Fig. 2/1) or of the circuit breaker can be executed via the
(OPEN) is connected by tiebar tube " e " to the pressu- control air connection 25671 independent of the electrical
rized chamber of cylinder 10773. By this measure, on control of solenoid valves 10525.
a CLOSE switching operation main control valve OPEN Control air connection 25671 is installed between the
10567 or on an OPEN switching operation main control valve cover 25689 of pilot valve OPEN 10569 and the
valve CLOSE 10774 is pneumatically blocked in the solenoid valves 10525. Control air connection 25671 has
vented position. the same function as solenoid valves 10525, but is actu-
For example, on a CLOSE switching movement an ated with compressed air via hose " B " (the associated
eventual OPEN command must wait until the drive has pneumatic command valves are installed separately, or
reached the CLOSED position and is vented. depending on construction they are mounted on the circuit
- If piston rod 10441 is in limit position CLOSED or breaker).
OPEN, the corresponding bores " d2 ", " d1 " in control In the idle condition recoil disk 25454 is forced by com-
tube 25693 discharge the pressure from the actuated pression spring 25453 against the valve seat in valve plate
pilot valve through silencers 25696 (Fig. 2/1) to the 25685. When the control air is admitted, recoil disk 25454
4 CH-HS 1495 87 E
is forced off the valve seat and the inflowing compressed 4 Erection
air initiates the OPEN switching operation analogous to
the solenoid valves 10525.
In the case of solenoid valves 10525 being actuated The operating mechanism is assembled and tested in the
electrically, the recoil disk 25454 prevents the air from factory together with the circuit breaker system HE . . .
escaping to the pneumatic actuation channel (hose " B "). If an operating mechanism is supplied separately (re-
placement unit), chapters 21, 22 and 23 of the Treatment
3.3 Heater compl. (Fig. 7/5a, c) and Storage Instructions are to be observed.
Installation of an operating mechanism into the circuit
For the outdoor version (type HEF) the operating mecha- breaker system, as well as the connections and adjust-
nism 13400 is equipped with a heater compl. 13418 ments, together with the circuit breaker operating linkage,
(sections 1.5, 2.9). are described in the pertaining instructions for erection,
Check! operation and maintenance of the circuit breaker system
If the ambient temperature drops below 0 °C ( = 32 °F), the HE . . 1...6.
heater compl. must be turned on by a thermostat (electri-
cal control and switching points see pertaining control
diagram).

5 Commissioning

The operating mechanism can only be commissioned

(inspected) together with the circuit breaker system. See
pertaining instructions for erection, operation and mainte-
nance of circuit breaker system HE . . 1...6.

CH-HS 1495 87 E 5
6 Troubleshooting 7 Maintenance (Overhaul)

In an operating manual it is impossible to account for every 7.1 General

eventuality in the use of technical objects. We therefore
For an overview of maintenance work, maintenance
request that you contact ABB or our responsible repre-
cycles and admissible loadings see pertaining instruc-
sentative in the event of any and all irregularities, and in
tions for erection, operation and maintenance of the circuit
such cases for which these instructions do not provide
breaker system HE . . 1...6.
detailed data.
Overhaul work should only be carried out in closed and
clean rooms (see pertaining Treatment Instructions,
6.1 Electrical control chapter 1).
In the event that the operating mechanism does not switch Before starting an overhaul it is imperative that the manu-
at nominal pressure, the following checks are to be made: facturer be contacted well in advance. Our advice and
- Electrical control (see pertaining control diagram) information will help you to realize a fast and trouble-free
- Solenoid valves 10525 (Fig. 7/5b, c). overhaul.

7.1.1 Important notes

6.2 Pressure loss
- Locking of screws
In the event of pressure loss in the position CLOSED or In the figures the tightening torque is indicated at
OPEN, first establish whether the compressed air system screwed connections.
is leaking: However, for safety reasons it is imperative that individ-
- Compressed air supply unit ual screws additionally be treated with locking agent
- Pressure switch (LOCTITE) according to *), chapter 4. For which screw
- Fittings connections this treatment is necessary is described in
- Air receiver the text section covering the individual assembly oper-
- Hoses etc.. ations, and also marked with (U) in the figure section.
If after the above investigations no leaks were found in the - Lubrication
compressed air system, the following checks are to be Which surfaces (sliding and sealing surfaces) must be
made on the operating mechanism. lubricated (treated with lubricant) is described in the
- Where compressed air is present in the operating text section covering the individual assembly opera-
mechanism is described in the beginning of chapter 3. tions and marked with (B) in the figure section.
Check the respective seals of - On disassembly replace all cotter pins, pins, spring
- Main control valve 10567, 10774 washers and securing elements.
- Pilot valve 10569, 10568 - The data in the pertaining operating instructions are to
- Solenoid valve 10525. be observed before the maintenance work is started.
- For further steps to locate the leakage first remove They constitute an integral part of these instructions.
solenoid valves 10525 and close the bores with cover - When maintenance work is being carried out, the local
plate 10559. safety regulations are to be observed.
If after a pressure test with compressed air the operat- - When performing overhaul work, as a general rule
ing mechanism is not leaking, replace solenoid valve observe utmost cleanness.
10525.
If the leak is inside the operating mechanism, the operat- 7.2 Tools and working materials
ing mechanism must be disassembled and overhauled
according to chapter 7. 7.2.1 Standard tools to be made available
- Torque wrenches for a range of 3...300 Nm with:
( = 2.2...221 ft.lbf) with:
- Hex sockets WS 13 mm, WS 17 mm
WS 22 mm, WS 36 mm
- Hex key wrenches WS 3...WS 10 mm
- Standard tools, such as open end and hex key wren-
ches, hook wrenches, circlip pliers, punches, screw-
drivers etc.

7.2.2 Special tools, jigs and fixtures to be made availa-

ble (Fig. 7/2a)
For disassembly and assembly of pilot valves (sections
7.3.5 and 7.4.4)
- Pin wrench 01021
- Spanner wrench (pin Ø 3 mm) 01022.

6 CH-HS 1495 87 E
7.2.3 Working materials tube 10498 off piston rod 10441. Pull snap-in ring
10511 off piston rod 10441.
See *), section 11.1.
- Drive spring pin 10510 out of plate 10769 and disas-
semble plate assembly 10500 (spring retainer 10504,
7.3 Disassembly sleeve 10502, Belleville springs 10505, spherical bear-
ing washers 10508 and steel balls 10506).
7.3.1 Prerequisites
- When maintenance work is performed the local safety 7.3.4 Cylinder and valve hoods (Fig. 2/1, 7/1)
regulations are to be observed. Cylinder 10773, valve hoods left and right 10468, 10469
- The electrical control of the operating mechanism 10760/ - Force retaining ring 10492 out of groove of connection
13400 must be turned off. 10491 and push back together with ring 10425 so that
- When maintenance work is being carried out, it must connection 10491 can be moved into right valve hood
not be possible to execute any switching operations. 10468 until connection 10491 no longer engages in left
Especially the compressed air to the operating mech- valve hood 10469. First disassemble right valve hood
anism 10760/13400 must be released. For this purpose 10468 with connection 10491.
open the ball valve on the compressed air receiver; see Screw nuts 10467/1 (Fig. 2/1) off studs 10465.
pertaining instructions for erection, operation and main- Attention! left and right valve hoods 10468, 104698
tenance of the circuit breaker system HE . . 1...6. will be forced off by compression springs 25676
- For detachment of (Fig. 7/1).
- pressure hose between compressed air receiver, First remove the two nuts 10467/1 of the short studs
and 10465. Then uniformly unscrew nuts 10467/1 of the
- operating mechanism from operating mechanism long studs 10466 (Fig. 2/1) of both valve hoods 10468,
mounting assembly see pertaining instructions for 10469 diagonally opposed so that the valve hoods do
erection, operation and maintenance of the circuit not cant. Before nuts 10467/1 are removed entirely,
breaker system HE . . 1...6. check whether compression springs 25676 can be held
- Observe principle data given in section 7.1.1. under pressure by pressing on valve hoods 10468,
10469 by hand. When the valve hoods are disassem-
7.3.2 Guide tube (Fig. 2/1, 7/2, 7/3) bled, silencer hood 10772 can be removed. (Attention!
Guide tube 25690 Make sure not to damage rubber hose 10516).
- Carefully release slotted nut 10489 (Fig. 2/1) (hold lever - Remove silencer 10515 (if necessary) out of silencer
25694 against turning) and remove together with lock- hood 10772.
ing plate 10490. Drive out half-moon rings 10518, release hose clamp
Take lever 25694 off piston rod 10441, pulling control 25686 and pull out fixing rings 10513. If sleeve 10514
tube 25693 out of guide bushes 25691 of the pilot and silencer 10515 are not in good condition, replace
valves (Fig. 7/2, 7/3). sleeve and silencer.
Pull sleeves 10561, 10562 and compression springs - Take valve piston 10470, compression spring 25676,
10507 off control tube 25693 (Fig. 2/1). guide strip 10459, rod seal 10476, sealing ring 10477,
- Remove valve cover 25689 piston seal 10538 and sealing ring 10474 out of left and
Unscrew socket head screws 10526 of pilot valves right valve hoods 10469, 10468 or cylinder head 10438
10569 and 10568 so that guide tube 25690 can be and guide head 10439 and replace if not in good
disassembled together with the two valve covers 25689. condition.
- Unscrew fixing screws 25674 in valve covers 25689 - Replacement of sealing washer 10472
and pull guide tube 25690 out of valve covers 25689. Release socket head screw 10475 in left and right valve
Change sealing rings 10536 in valve covers 25689. Pull hoods 10469, 10468, remove clamping disk 10471 and
guide bushes 25691 out of guide tube 25690 and sealing washer 10472.
replace sealing rings 10566. - Screw screws 10454 out of tiebar 10444 and tiebar
- Replace silencer 25696 if necessary (Fig. 2/1). tubes 10443 and 10443/1, remove damping ring retain-
For this purpose detach a retaining ring 10478 and a er 10442 and cylindrical tube 10440. Release locknut
washer 10565 from guide tube 25690. 10460, remove ring 10450 and withdraw piston rod
- Replacement of sleeve 10486 10441.
Drive cotter pins 10556 out of control tube 25693. - Piston 10448 (replace after 5,000 CO switching op-
Pull sleeve 26672, two-piece snap-in ring 10488, sleeve erations)
10486, thrust disk 10485, lever 25694 and sleeve Disassemble and replace guide strips 25681, piston
25698 off control tube 25693. seal 10463 and sealing ring 10464.
- Replace guide strip 10458 in guide head 10439.
7.3.3 Catch (Fig. 7/1) - In damping ring retainer 10442 release retaining ring
10457 and check condition of damping ring 10445.
Catch 10771 - Check condition of diaphragm 10446 and damping
- Pull out tiebar 10509, take off plate assembly 10500 piston 25966.
and tube 10497.
- Take ring 10501, tube 10499, tapered stops 10503 and
*) Treatment and Storage Instructions

CH-HS 1495 87 E 7
7.3.5 Pilot valves (Fig. 7/2, 7/3) - Release nuts 10493 and pull out coil 10540, 10630
(Fig. 7/4).
Pilot valves OPEN and CLOSE 10569, 10568
- Release socket head screws 12469 and 25687
- Unscrew socket head screws 10535, remove pilot
(details X and Y). Remove solenoid valves 10525,
valves from valve hood 10469, 10468 (Fig. 7/1).
insulating plates 13421 and blind insulating plates
- Unscrew plug screw 10521 with spanner wrench 01022
13422.
(Fig. 7/2a).
- Replace sealing rings 10533.
Replace sealing ring 10527 and sealing washer 10531.
- Only if absolutely necessary disassemble solenoid
- Using pin wrench 01021 (Fig. 7/2a) or a hex key wrench
valve 10525 (Fig. 7/4):
(WS 5 mm) screw valve plunger 25673 out of piston
- Screw coil carrier 10549 out of base 10543 and
25682 (hold against turning with spanner wrench 01022).
clean all internal parts of solenoid valve 10525.
Replace piston seal 10528 and sealing ring 10529.
Attention! Make sure not to damage nozzle 10550
- If necessary, remove and replace filter 10517 of pilot
and valve disk 10544.
valve OPEN 10569.
- After releasing socket head screw 10558 and removing
cover 10563 remove filter 10557 from pilot valve CLOSE 7.4 Assembly
10568 and replace if necessary.
Prior to assembly
- Clean all parts and make sure that they are in good
7.3.6 Solenoid valve (Fig. 7/4)
condition.
Dismount solenoid valve 10525 from valve covers 25689 - Observe the principle data given in section 7.1.1.
(Fig. 7/2, 7/3). The assembly can be done in the sequence given below.
- Unscrew nuts 10493 and pull out coil 10540, 10630.
- Release socket head screws 10537 (Fig. 7/2, 7/3) and 7.4.1 Cylinder (Fig. 2/1, 7/1)
remove solenoid valve 10525.
Cylinder 10773
- Replace sealing rings 10533.
- After 5,000 C-O switching operations change piston
- Only if absolutely necessary, disassemble solenoid
10448.
valve 10525:
- Change piston seal 10463 and sealing ring 10464 (Fig.
- Screw coil carrier 10549 out of base 10543 and clean
7/1), install new rings, grease according to *), section
all internal parts of solenoid valve 10525.
2.10.
Attention! Make sure not to damage nozzle 10550
- Replace guide strips 25681 on piston 10448 and lubri-
and valve disk 10544.
cate according to *), section 2.9.
Remove cover plate 10559 from valve covers 25689 (Fig.
- Replace guide strips 10459 in cylinder head 10438 and
7/3)
guide head 10439 and lubricate according to *), section
- Unscrew socket head screws 10537 and remove cover
2.9.
plate 10559.
Change guide strips 10458 in guide head 10439 and
- Replace sealing rings 10533.
lubricate according to *), section 2.9.
- Slide damping piston 25699, 25699/1, rings 10450 and
7.3.7 Control air connection (Fig. 7/5b, c)
new piston 10448 onto piston rod 10441.
This optional equipment is not installed as standard equip- Tighten new locknuts 10460, secure according to *),
ment in every case (see sections 1.5, 2.8 and 3.2). section 4.1.2 (observe torque).
Control air connection 25671 (pneumatic OPEN) - Lubricate outer surfaces of damping piston 25699,
- Detach hose B from connection 25692. 25699/1 according to *), section 2.9.
- After releasing socket head screws 25687, remove - Lubricate running surface of piston in cylindrical tube
solenoid valves 10525 and valve plate 25685. 10440 according to *), section 2.9.
Attention! When removing valve plate 25685 from - Insert piston rod 10441 with piston 10448 into cylindri-
valve cover 25689 hold spring-loaded plug 25684 cal tube 10440. When inserting make sure that piston
against moving. Remove valve plate 25685. Replace 10448 does not cant to prevent guide strips 25681 and
sealing rings 10533 and 25703. piston seal 10463 from being damaged. Replace damp-
- Remove plug 25684 together with sealing ring 25678, ing rings 10445 if necessary and install in damping ring
take out recoil disk 25454 with the attendant parts. retainer 10442 with retaining ring 10457. Lubricate
Replace washer 25452, compression spring 25453, damping rings 10445 according to *), section 2.9.
gasket 25451 and sealing ring 25678. Check condition and function of diaphragms 10446
with fastening parts, replace if necessary.
7.3.8 Heater compl. (Fig. 7/5a, c) Insert damping ring retainer 10442 in cylindrical tube
Heater compl. 13418, 13414 is only for operating mecha- 10440 .
nism 13400 to circuit breaker HEF (see sections 1.5, 2.9 Attention: Diaphragms 10446 must be installed
and 3.3). facing piston 10448.
- Release screws 10736 from heating plate 13419 and - Replace sealing rings 25683 (Fig. 2/1) in tiebar tube
remove. 10443 and grease according to *), section 2.10. Insert
- Detach solenoid valve 10525 and valve plates 13420, tiebar tube 10443 and 10443/1 with sealing ring 25683
14424 from valve covers 25689.
*) Treatment and Storage Instructions

8 CH-HS 1495 87 E
 into upper bores in guide head 10439 (making sure that with socket head screws 10475, secure according to *),
they are positioned correctly, see details E and F). section 4.1.1 (observe torque).
Place cylinder head 10438 and guide head 10439 on - Replace guide strips 10459 in left and right valve hoods
damping ring retainer 10442, for which tiebar tubes 10469, 10468 and lubricate according to *), section 2.9.
10443 with sealing rings 25683 must be inserted into - Attention!
the corresponding bores in cylinder head 10438. Install the following 3 seals carefully and without injuring
Insert tiebar 10444. their surface (compressed air is available during the
Uniformly tighten down cylinder 10773 with fasteners entire operation).
10454, 10455, 10456 diametrically opposed, secure - Replace sealing rings 10477 in left and right valve
according to section 4.1.2 (observe torque). hoods 10469, 10468, grease according to *), section
Attention! washers 10456 must be against cylinder 2.10 and carefully install.
head 10438 or guide head 10439. Lubricate rod seals 10476 according to *), section 2.9,
and carefully fit in the same groove as sealing rings
7.4.2 Catch (Fig. 7/1) 10477.
Catch 10771 - Replace sealing rings 25679 in left and right valve
Attention! catch 10771 should be installed with piston hoods 10469, 10468 and grease according to *), sec-
rod 10441 inserted. tion 2.10.
- Plate compl. 10500 - If necessary replace valve piston 10470.
- Fill sleeves 10502 (replace after 5,000 CO) with new Replace and grease sealing ring 10474 and piston seal
steel balls 10506 and Belleville springs 10505. 10538 according to *), section 2.10. and fit on valve
Grease steel balls 10506, spherical bearing washers piston 10470.
10508 and Belleville springs 10505 well according - Lubricate running surfaces in left and right valve hoods
to *), section 2.11. 10469, 10468, as well as running surfaces on valve
- Place steel ball 10506 and then spherical bearing piston 10470 according to *), section 2.9.
washer 10508 with spherical surface facing down- Carefully insert valve piston 10470 in left and right valve
ward in sleeve 10502. Place the first Belleville spring hoods 10469, 10468.
on spherical bearing washer 10508 such that the Attention! Do not cant valve piston 10470.
large diameter of the Belleville spring 10505 is rest- - Complete assembly of silencer hood 10772 (Fig. 2/1).
ing on spherical bearing washer 10508. - Install silencer 10515 (replace if necessary) and
- Continue to stack Belleville springs 10505 (total of 11 sleeves 10514.
springs) according to Fig. 7/1 such that the spring Insert retaining rings 10513 in silencer hood 10772
retainer 10504 presses against the smaller diameter and assemble silencer 10515 with sleeve 10514 and
of the top Belleville spring 10505. hose clamp 25696 in between.
Press spring retainer 10504 (with > S up) into sleeve Secure retaining rings 10513 by means of half-moon
10502 and secure with a prepared pin Ø 6 x 24 mm rings 10518.
(on final assembly pin Ø 6 x 24 mm will be driven out - Check:
by spring pin 10510). Rubber hoses 10516, replace if necessary.
Check! - Place silencer hood 10772 with silencers 10515 on
Spring retainer 10504 must be seated flush with cylinder head 10438 and on guide head 10439.
sleeve 10502; otherwise turn spring retainer 180°. - Grease new compression springs 25676 according
- Slide plate 10769 onto tube 10497. to *), section 2.10, and insert in cylinder head 10438
- Insert the prepared, filled up sleeves 10502 with and guide head 10439.
Belleville springs 10505 and steel balls 10506 one - Place left valve hood 10469 with inserted valve piston
after the other into the bores in plate 10769 and 10470 on compression springs 25676 or cylinder head
fasten with new spring pin (Ø 6 x 36 mm) 10510 (in 10438.
the process of which pin Ø 6 x 24 mm is forced out). - Fasten valve hood with new nuts 10467/1 (Fig. 2/1).
- Insert snap-in ring 10511 into groove on piston rod - Using the 2 long studs 10466 force left valve hood
10441. 10469 against compression spring 25676 onto cylin-
- Lubricate new tapered stops 10503 according to *), der head 10438.
section 2.11. Slide tapered stop 10503 (making sure Attention!
that it is positioned correctly) , tube 10498, second Valve piston 10470 must slide into guide strip 10459
tapered stop 10503, tube 10499 and ring 10501 onto without canting.
piston rod 10441. - Uniformly tighten down fasteners 10467/1, 10466,
- Fasten plate assembly 10500 and tube 10497 with 10548 diagonally opposed such that left valve hood
tiebar 10509 to guide head 10439 with screws uniform- 10469 and silencer hood 10772 abut against cylinder
ly tightened down diagonally opposed (secure accord- head 10438.
ing to *), section 4.1.2 (observe torque). - Lubricate connection 10491 on both ends according
to *), section 2.9.
7.4.3 Main control valves (Fig. 7/1) Fit retaining ring 10492 on connection 10491 past the
groove. Insert connection 10491 together with ring
Main control valves OPEN and CLOSE 10567, 10774
10495 all the way into right valve hood 10468.
- Install new sealing washers 10472 and new clamping
disks 10471 in left and right valve hoods 10469, 10468 *) Treatment and Storage Instructions
CH-HS 1495 87 E 9
- Place right valve hood 10468 with inserted valve piston screws 10537 (Fig. 7/3), secure according to section
10470 and connection 10491 on compression springs 4.1.1 (observe torque).
25676 or guide head 10439. - Slide coil 10540, 10630 and spring lockwasher 10494
- Fasten valve hood with new nuts 10467/1 (Fig. 2/1). onto coil carrier 10549 and fasten with nut 10493.
- Force right valve hood 10468 against compression
Operating mechanism 13400 to circuit breaker system
springs 25676 onto guide head 10439 with the 2 long
type HEF 1...6
studs 10466.
- Replace and grease sealing rings 10533 (Fig. 7/4)
Attention!
according to *), section 2.10.
Valve piston 10470 must slide into guide strip 10459
- Replace and grease sealing rings 10533 (Fig. 7/5a)
without canting.
according to *), section 2.10.
- Uniformly tighten down fasteners 10467/1, 10466,
- Fit solenoid valves 10525, 2 insulating plates 13421
10548 until right valve hood 10468 and silencer
and valve plate OPEN 13420 (making sure that they
10772 are against guide head 10439.
are positioned correctly) with socket head screws
- Carefully insert connection 10491 (Fig. 7/1) into left
12469 (Fig. 7/5a, detail X) on valve cover 25689/1,
valve hood 10469 until retaining ring 10492 snaps into
secure according to *), section 4.1.1 (observe torque).
the groove.
- Fit solenoid valve 10525 with insulating plate 13421,
- Definitively tighten down fasteners 10465, 10466,
blind insulating plate 13422 and valve plate CLOSE
10467/1, 10548 uniformly diagonally opposed (ob-
13424 (making sure that they are positioned correctly)
serve torque).
with socket head screws 12469, 25687 (Fig. 7/5a,
detail Y) on valve cover 25689/2, secure according to
7.4.4 Pilot valves (Fig. 7/2, 7/3)
*), section 4.1.1 (observe torque).
Pilot valves OPEN and CLOSE 10569, 10568 - Place coil 10540, 10630 and spring lockwasher 10494
- Replace sealing ring 10529 and piston seal 10528 and (Fig. 7/4) on coil carrier 10549 and fasten with nut
grease according to *), section 2.10. 10493.
Lubricate piston running surface in valve body 10520
according to *), section 2.9. 7.4.6 Guide tube (Fig. 2/1, 7/2, 7/3)
- Using pin wrench 01021 (Fig. 7/2a) or a hex key wrench
Guide tube 25690
(WS 5 mm) screw new valve plunger 25673 into valve
- Fit silencer 25696 (replace if necessary) and lock with
body 10520 with piston 25682 (holding against turning
ring 10565 and retaining ring 10478 (Fig. 2/1).
with spanner wrench 01022), secure according to *),
- Replace sealing rings 10536 in valve cover 25689 and
section 4.1.2 (observe torque).
grease according to *), section 2.10.
Lubricate new sealing washer 10531, thrust disk 10524
- Replace sealing rings 10566, grease according to *),
and new compression spring 10532 according to *),
section 2.10, and install in new guide bushes 25691.
section 2.10 and place on valve plunger 25673.
Insert guide bushes 25691 in pairs in guide tube 25690.
- Replace and grease sealing ring 10527 according to *),
Attention! Make sure that the guide bushes 25691
section 2.10.
are positioned correctly (Fig. 7/2 and 7/3). The
- Lubricate running surface of valve plunger 25673 in
bores for the fixing screws 25674 must also align.
plug screw 10521 according to *), section 2.10.
- Pilot valve OPEN 10569 with flow restrictor 10554 and
- Screw plug screw 10521 with fitted new sealing ring
2 solenoid valves 10525.
10527 into valve body 10520 with spanner wrench
Place valve cover 25689/1 on guide tube 25690 (mak-
01022 (observe torque).
ing sure that it is positioned correctly). Turn valve cover
25689/1 and move until the fixing screws 25674 can be
7.4.5 Solenoid valve (Fig. 7/4)
installed as shown in Fig. 7/2, secure according to *),
In the event of leakage, use new solenoid valve 10525; section 4.1.1) (observe torque).
only if absolutely necessary disassemble and reassem- - Pilot valve CLOSE 10568 with one solenoid valve
ble (disassembly see section 7.3.6). 10525. Fit valve cover 25689/2 on guide tube (making
- Assemble the cleaned internal parts of the solenoid sure that it is positioned correctly). Turn valve cover
valve without lubricating grease. 25689/2 and shift around until fixing screws 25674 can
Attention! Make sure not to damage nozzle 10550 and be inserted as shown in Fig. 7/3; secure according to *),
valve disk 10544. section 4.1.1 (observe torque).
Using coil carrier 10549 and base 10543 screw togeth- - Screw screws 25675 into both valve covers 25689,
er solenoid valve 10525. secure according to *), section 4.1.2 (observe torque).
Operating mechanism 10760 to circuit breaker system - Replace seal 25703, apply grease according to *),
type HE . . 1...6 section 2.10, and place in valve covers 25689/1 and
25689/2.
- Replace sealing rings 10533 and grease according
- Fasten valve cover 25689/1 with guide tube 25690 to
to *), section 2.10.
valve body 10520/1 (with flow restrictor 10554) by
- Fit solenoid valve 10525 with socket head screws
means of socket head screws 10526, secure accord-
10537 (Fig. 7/2, 7/3) on valve cover 25689, secure
ing to *), section 4.1.1 (observe torque).
according to *), section 4.1.1 (observe torque).
- Fasten valve cover 25689/2 with guide tube 25690 to
Fit cover plate on valve cover 25689 with socket head
*) Treatment and Storage Instructions
10 CH-HS 1495 87 E
 valve body 10520/2 by means of socket head screws - Replace gasket 25451, grease according to *), section
10526, secure according to *), section 4.1.1 (observe 2.10 and place on recoil disk 25454. Place washer
torque). 25452, compression spring 25453 and aperture wash-
er 25455 on recoil disk 25454 and insert in valve plate
7.4.7 Control mechanism (Fig. 2/1, 7/2, 7/3) 25685.
- Replace sealing ring 25678, grease according to *),
Control mechanism 10770
section 2.10, and place on plug 25684.
- Piston rod 10441 should be in the extended position.
- Control air connection 25671 (pneumatic OPEN)
Carefully insert control tube 25693 into guide bushes
(Fig. 7/5b)
25691 (Fig. 7/2, 7/3). Place following parts in following
- Place socket head screws 25687 together with
sequence on control tube 25693 (Fig. 2/1):
solenoid valves 10525 in readiness for assembly.
- Sleeve 10562
The sealing rings 10533 of solenoid valves 10525
- Compression spring 10507
must be replaced and greased according to *),
- Sleeve 10561
section 2.10.
- Compression spring 10507
- Insert plug 25684 with new sealing ring 25678 in
- Sleeve 10562, and
valve plate 25685 and hold valve plate 25685 on
- Sleeve 25698.
valve cover 25689. Fasten valve plate 25685 and
- Place two-piece snap-in ring 10488 into the groove of
solenoid valves 10525 on valve cover 25689 with
control tube 25693, place sleeve 25698 over it and
socket head screw 25687 (secure according to *),
secure with cotter pin 10556.
section 4.1.1, observe torque).
- Slide new sleeve 10486, thrust disk 10485 and lever
- Control air connection (pneumatic OPEN) with heat-
25694 onto control tube 25693. At this time simultane-
er 13414 (Fig. 7/5c)
ously place lever 25694 on piston rod 10441. Then
- Place insulating plates 13421 and socket head
install second thrust disk 10485, new sleeve 10486
screws 12469 together with solenoid valves 10525
and two-piece snap-in ring 10488. Put on sleeve 25672
in readiness for assembly. The sealing rings 10533
and secure with cotter pin 10556.
of solenoid valves 10525 must be replaced and
- Bolt lever 25694 to piston rod 10441.
greased according to *), section 2.10.
Definitely make sure that the groove " N " in piston
- Insert plug 25684 with new sealing ring 25678 in
rod 10441 is positioned exactly as shown in Fig.
valve plate 25685 and hold valve plate 25685, insu-
2/1.
lating plate 13421 on valve cover 25689. Fasten
If necessary, turn piston rod 10441.
valve plate 25685 and solenoid valves 10525 on
Place locking plate 10490 on piston rod 10441, screw
valve cover 25689 with socket head screw 12469
on slotted nut 10489 (installation position see Fig.
(secure according to *), section 4.1.1, observe
2/1) and carefully tighten (control tube 25693 may not
torque).
be bent, i.e. lever 25694 must be appropriately sup-
- Screw hose " B " onto connection 25692.
ported). Secure slotted nut 10489 with locking plate
10490.
7.4.9 Heater compl. (Fig. 7/5a)
- For finel erection see the erection instruction of "Gen-
erator swichgear system". Heater compl. 13418, 13414 is only for operating mech-
- Pilot valve OPEN 10569 with flow restrictor 10554 anism 13400 to circuit breaker HEF (see sections 1.5, 2.9
If necessary, replace installed (short) filter 10517. and 3.3).
- Pilot valve CLOSE 10568. - Fit heating plate 13419 with screw fasteners 10736,
If necessary replace filter 10557 (long). 10340, 12732 (observe torque).
Fit cover 10563 together with spacer tube 25704 and
filter 10557 with socket head screw 10558, secure 7.4.10 Operating mechanism in operating mechanism
according to *), section 4.1.1 (observe torque). mounting assembly
- Replace sealing ring 10534, grease according to *), Further mounting steps of the operating mechanism
section 2.10 and install in valve body 10520. 10760, 13400 which is now completely pre-assembled:
- Fasten control mechanism 10770 with pilot valve OPEN - Mounting in operating mechanism mounting assembly
10569 (with flow restrictor 10554) to left valve hood - Fitting of pressure hose.
10469 (Fig. 7/1) and pilot valve CLOSE 10468 to right Compressed air connection between operating mech-
valve hood 10468 by means of socket head screws anism 10760, 13400 and compressed air supply unit
10535 (secure according to *), section 4.1.2, observe - Coupling and adjustment of operating linkage to the
torque). circuit breaker.
- Check for tightness
7.4.8 Control air connection (Fig. 7/5b, c)
- Function test
Control air connection 25671 (pneumatic OPEN) or con- shall be conducted according to the pertaining instruc-
trol air connection for pneumatic OPEN switching opera- tions for erection, operation and maintenance of the
tions with heater compl.13414. circuit breaker system HE . . 1...6.
This optional equipment is not installed in every case as
standard equipment (see sections 1.5, 2.8, 3.2)
- Replace sealing ring 25703, grease according to *),
section 2.10, and place in valve plate 25685. *) Treatment and Storage Instructions
CH-HS 1495 87 E 11
8 Spare parts After the overhaul criteria are reached (see section 8.1.1),
for the purpose of restoring the operational capability
replacement of the parts of the overhaul parts sets is
8.1 General mandatory.
Contents of overhaul parts sets for
8.1.1 Spare parts to the operating mechanism - Overhaul criterion 5,000 C-O:
Wearing parts and seals.
On request, the following will be supplied by the manufac-
- Overhaul criterion 10 years:
turer for the circuit breaker operating mechanism:
Plastic parts and seals (subject to ageing).
- Reserve parts sets A and B
- Overhaul parts sets for the respective overhaul criteri-
on (see also section 7.1). 8.3 Spare parts list
Overhaul criteria are listed in the pertaining instruction for
erection, operation and maintenance of the circuit break- 8.3.1 Reserve parts sets A and B
er system HE . . 1...6, chapter 7. Reserve parts sets A and B are identical.
Order overhaul parts sets only shortly before the overhaul
criteria are reached (observe procurement time). Part No. Part designation Qty. Fig.
Due to the plastic parts (storage time see Treatment and
Storage Instructions, chapter 7) storage of the overhaul 10525 Solenoid valve 1 7/2...7/4
part sets for periods extending over several years is not 10540 Coil CLOSE, OPEN I 1 7/5b
recommended. 10630 Coil OPEN II 1 7/5b
25701 Small parts set,
8.1.2 Ordering of spare parts consisting of:
various screws and
For ordering, the following data are essential:
securing materials 1 -
- Order number 1-...... See order documentation
25702 Set of seals
- Type designation See nameplate
consisting of all seals 1 -
- Serial number See nameplate
- Publication number See cover sheet
- Reserve parts set number See operating instructions 8.3.2 Overhaul parts sets
- Overhaul parts set number See operating instruc- Overhaul parts sets
tions. - Overhaul parts set No. 1
5,000 C-O (CLOSE-OPEN switching operations)
8.1.3 Important data - Overhaul parts set No. 2
The data on the treatment and storage of the spare parts 10 years in operation
are definitely to be adhered to. Combinations of overhaul parts sets
- Storage, see Treatment and Storage Instructions, - Overhaul parts set No. 3
chapters 21, 22, 23. 5,000 C-O + 10 years in operation.
- Unpacking: shortly before use. The overhaul parts set No. 3 is not the sum of overhaul
parts sets 1 + 2.

8.2 Definitions of spare parts

8.2.1 Reserve parts set A

Reserve parts set A contains spare parts which are not
required for a routine, periodic maintenance, the stocking
of which is however recommended.

8.2.2 Reserve parts set B

Reserve parts set B contains spare parts which are not
required for a routine, periodic maintenance, the stocking
of which is however recommended for
- installations with several circuit breakers
- installation with a high number of switching cycles, and
- installations with a long spare part procurement time
(geographical location).

8.2.3 Overhaul parts sets

On request, the manufacturer will quote and supply
assembly-specific overhaul parts sets for the individual
overhaul criteria, see section 8.3.2.

12 CH-HS 1495 87 E
11 Appendix

11.1 Figures
Fig. Title
2/1 Operating mechanism (construction)
3/1 Operating mechanism schematically
7/1 Cylinder, piston (in CLOSED position), catch and main control valves
7/2 Pilot valve OPEN
7/2a Special tools (pilot valves)
7/3 Pilot valve CLOSE
7/4 Solenoid valve
7/5a Operating mechanism (construction) with heater
7/5b Pneumatic OPEN (control air connection)
7/5c Operating mechanism (construction) with heater and pneumatic OPEN

CH-HS 1495 87 E 13
 Legende zu Fig. 2/1 Legend to fig. 2/1
10441 Kolbenstange Piston rod
10443 Zugankerrohr Tiebar tube
10444 Zuganker Tiebar
10447 Schwenkzapfen Trunnion
10454 Sechskantschraube M14x25 Hex screw M14x25 mm
10455 Spannscheibe 14,4/32x3,4 Spring washer 14.4/32x3.4 mm
10456 Unterlagscheibe 15/35x3 Washer 15/35x3 mm
10465 Gewinde-Stift M10x60 Stud M10x60 mm
10466 Gewinde-Stift M10x80 Stud M10x80 mm
10467 Sicherungsmutter M10 Nut M10
10478 Sicherungsring A36 Retaining ring A36
10485 Druckscheibe Thrust disk
10486 Hülse Sleeve
10488 Zweiteiliger Sprengring Two-piece snap-in ring
10489 Nutmutter M35x1,6 Slotted nut M35x1.6 mm
10490 Sicherungsblech Locking plate
10491 Anschluss Connection
10492 Sicherungsring A50 Retaining ring A50
10495 Ring Ring
10507 Druckfeder Compression spring
10513 Haltering Retaining ring
10514 Haltehülse Sleeve
10515 Schalldämpfer Silencer
10516 Gummischlauch Rubber hose
10517 Filter (kurz) Filter (short)
10518 Halbmondring 48 Half-moon ring 48 mm
10525 Magnetventil Solenoid valve
10540 Spule EIN + AUS I Coil CLOSE + OPEN I
10548 Unterlagscheibe 10,5/20 Washer 10.5/20 mm
10554 Drossel Air flow restrictor
10556 Splint Cotter pin
10557 Filter (lang) Filter (long)
10559 Abdeckplatte Cover plate
10561 Hülse Sleeve
10562 Hülse Sleeve
10564 Deckel Cover
10565 Scheibe Ring
10567 Hauptsteuerventil AUS Main control valve OPEN
10568 Vorsteuerventil EIN Pilot valve CLOSE
10569 Vorsteuerventil AUS Pilot valve OPEN
10630 Spule AUS II Coil OPEN II
10760 Antrieb Leistungsschalter Circuit breaker operating mechanism
10770 Steuermechanismus Control mechanism
10771 Rastrierung Catch
10772 Schalldämmhaube Silencer hood
10773 Zylinder Cylinder
10774 Hauptsteuerventil EIN Main control valve CLOSE
25672 Haltehülse Sleeve
25683 Runddichtring Sealing ring
25686 Schlauchbride Hose clamp Nm ft . lbf
25689 Ventildeckel Valve cover 3 2.5
25690 Führungsrohr Guide tube 27 20.0
41 30.0
25693 Steuerrohr Control tube 95 70.0
25694 Hebel Lever
25696 Schalldämpfer Silencer
25698 Haltehülse Sleeve
N Nut ( Kolbenstange 10441) Groove (piston rod 10441)
(B) Schmieren, siehe 7.1.1 Lubrication, see 7.1.1
(U) Kleben / sichern (LOCTITE), siehe 7.1.1 Adhesives / securing (LOCTITE), see 7.1.1
MD Drehmoment Torque

CH-HS 1495 87 D, E
CH-HS 1495 87

10525 10525 10525

10630 10491 10540 10492 10495 10540 10559
10567 10774

10466
10465 10569 10568
10467/1
10548
MD= 41Nm 10443
10770 F
E
10443/1
10467 F
MD= 27Nm E
10772 10772
10516 10516

(U) 10454
10455 10447
10447
MD= 95Nm
10773

10456 10771
10444 10517 10554 10557 25694

10760
(B) (B)
10456 25683 10443 10772 10514 10515 10513 10518 25686 25683 10456

10454 (U)
(U) 10454 N
10455
10455
MD= 95Nm
MD= 95Nm

10466 10441 25698 10486 25672

10465 10556
10556
10489
10490
10564 25693
10488
10485 10488
25694
25693 25690 10466 25689/1 10478 10565 25696 10565 10478 10770 25689/2 10562 10507 10561 10507 10562 10485
Fig. 2/1

Fig. 2/1
 Legende zu Fig. 3/1 Legend to fig. 3/1
10441 Kolbenstange Piston rod
10442 Dämpfungsringhalter Damping ring retainer
10445 Dämpfungsring Damping ring
10446 Membrane Diaphragm
10448 Kolben Piston
10470 Ventilkolben Valve piston
10472 Dichtscheibe Sealing washer
10491 Anschluss Connection
10525 Magnetventil Solenoid valve
10540 Spule EIN + AUS I Coil CLOSE + OPEN I
10541 Anker Armature
10546 Feder Spring
10561 Hülse Sleeve
10567 Hauptsteuerventil AUS Main control valve OPEN
10568 Vorsteuerventil EIN Pilot valve CLOSE
10569 Vorsteuerventil AUS Pilot valve OPEN
10630 Spule AUS II Coil OPEN II
10773 Zylinder Cylinder
10774 Hauptsteuerventil EIN Main control valve CLOSE
25673 Ventilstössel Valve plunger
25676 Druckfeder Compression spring
25682 Kolben Piston
25693 Steuerrohr Control tube
25696 Schalldämpfer Silencer
25699 Dämpfungskolben Damping piston
a Luftzuführung Magnetventil Air supply-solenoid valve
b Auslass Haupsteuerventil Main control valve outlet
d1, d2 Auslass Vorsteuerventil Pilot valve outlet
e Zugankerrohr 10443 (siehe Fig. 2/1) Tiebar tube 10443 (see fig. 2/1)
f Zugankerrohr 10443/1 (siehe Fig. 2/1) Tiebar tube 10443/1 (see fig. 2/1)
g Entlüftung bei Leckage Magnetventil Vent for solenoid valve leak
h Entlüftungskanal Vent duct
O AUS OPEN
I EIN CLOSED

CH-HS 1495 87 D, E
 CH-HS 1495 87

10567 25673 10569 10491 10472 10774

25673 10568

a b g
25682 b
10541
10472
10546 10470 25682 10561 25693
10470 10525 25676
10540 25696
25676
10525
10630
10541
a d2
e f h d1 g h 10525 10546
10540

10445 10442 10446 25699 10448 10773 25699 10446 10442 10445 10441

I O
Fig. 3/1

Fig. 3/1
 Legende zu Fig. 7/1 Legend to fig. 7/1
10438 Zylinderkopf Cylinder head
10439 Führungskopf Guide head
10440 Zylinderrohr Cylindrical tube
10441 Kolbenstange Piston rod
10442 Dämpfungsringhalter Damping ring retainer
10443 Zugankerrohr Tiebar tube
10444 Zuganker Tiebar
10445 Dämpfungsring Damping ring
10446 Membrane Diaphragm
10448 Kolben Piston
10450 Scheibe Ring
10451 Membranstift Diaphragm pin
10454 Sechskantschraube M14x25 Hex screw M14x25 mm
10455 Spannscheibe 14,4/32x3,4 Spring washer 14.4/32x3.4 mm
10456 Unterlagscheibe 15/35x3 Washer 15/35x3 mm
10457 Sicherungsring A80 Retaining ring A80
10458 Führungsband Guide strip
10459 Führungsband Guide strip
10460 Sicherungsmutter M24x1, 5 Locknut M24x1. 5 mm
10461 Scheibe 7,4/14 Washer 7.4/14 mm
10462 Splint 2,5x16 Cotter pin 2.5x16 mm
10463 Kolbendichtung 160 Piston seal 160 mm
10464 Runddichtring 142,2x7 Sealing ring 142.2x7 mm
10468 Ventilhaube rechts Right valve hood
10469 Ventilhaube links Left valve hood
10470 Ventilkolben Valve piston
10471 Klemmscheibe Clamping disk
10472 Dichtscheibe Sealing washer
10474 Runddichtring 85,09x5,34 Sealing ring 85.09x5.34 mm
10475 Zylinderkopfschraube M5x20 Socket head screw M5x20 mm
10476 Stangendichtung 45 Rod seal 45 mm
10477 Runddichtring 47,22x 3,53 Sealing ring 47.22x 3.53 mm
10489 Nutmutter M35x1,6 Slotted nut M35x1.6 mm
10490 Sicherungsblech Locking plate
10491 Anschluss Connection
10492 Sicherungsring A50 Retaining ring A50
10495 Ring Ring
10497 Rohr Tube
10498 Rohr Tube
10499 Rohr Tube
10500 Platte kpl. Plate assembly
10501 Scheibe Ring
10502 Hülse Sleeve
10503 Raste Tapered stop
10504 Federhalter Spring retainer
10505 Tellerfeder Belleville spring
10506 Kugel Ball
10508 Kugelteller Spherical bearing washer
10509 Zuganker Tiebar
10510 Spannstift 6x36 Locking pin 6x36 mm
10511 Sprengring 40 Snap-in ring 40 mm
10538 Kolbendichtung 100 Piston seal 100 mm
10567 Hauptsteuerventil AUS Main control valve OPEN
10769 Platte Plate
10771 Rastrierung Catch
10773 Zylinder Cylinder
10774 Hauptsteuerventil EIN Main control valve CLOSE
Nm ft . lbf
25676 Druckfeder Compression spring
25679 Runddichtring 47,3x2,62 Sealing ring 47.3x2.62 mm 7 5.2
25681 Führungsband Guide strip 80 59.0
95 70.0
25694 Hebel Lever 300 221.0
25699 Dämpfungskolben Damping piston
> S, < S Siehe 7.4.2 See 7.4.2
(B) Schmieren, siehe 7.1.1 Lubrication, see 7.1.1
(U) Kleben / sichern (LOCTITE), siehe 7.1.1 Adhesives / securing (LOCTITE), see 7.1.1
MD Drehmoment Torque

CH-HS 1495 87 D, E
 CH-HS 1495 87

(B) (B) (B)

10469 25679 10491 10492 10495 25679 10468

10567 10774

10500

(B) (B) (B) (B) (B)

(U) 10475 (U) 10475 10769 10506 10510 10504 10505 10508 10502
10471 10471
10472 10472
MD= 7 Nm MD=7 Nm >S
(B) 10459 (B) 10459 <S
(B) 10477 (B) 10477
(B) 10476 (B) 10476
(B) 10474 (B) (B) 10474
(B)
(B) 10538 (B) 10538
(B) 10470 (B) 10470
(B) 25676 (B) 25676
10773

(B) 10771
10464
(B) 10459 (B) (B) 10443/1 10459 (B)
10463 25681 10448 25699 10450 10443 10441
(B)
25681 (B) (B) (B) 10489
10458 10511 10503 10498 10503 10499 10501 10490

25699/1
(B) (B)
10450
(U) 10460
MD= 300Nm

(B)
10438 (B)

(B)
(U) 10454
10455
MD= 95Nm
10454 (U) 10497 10500 10509 (U) 25694
10456
10455 MD= 80Nm
MD= 95Nm
Fig. 7/1

10445 10457 10442 10462 10461 10451 10446 10444 10440 10445 10446 10451 10442 10461 10462 10457 10439 10456
Fig. 7/1
 Legende zu Fig. 7/2, 7/3, 7/4 Legend to fig. 7/2, 7/3, 7/4
01021 Stirnlochschlüssel Pin wrench
01022 Gelenk-Stirnlochschlüssel Spanner wrench
10493 Sechskantmutter Hex nut
10494 Federscheibe Spring lockwasher
10517 Filter (kurz) Filter (short)
10520 Ventilkörper Valve body
10521 Verschlussschraube Plug screw
10524 Druckscheibe Thrust disk
10525 Magnetventil Solenoid valve
10526 Zylinderkopfschraube M6x75 Socket head screw M6x75 mm
10527 Runddichtring Sealing ring
10528 Kolbendichtung 60 Piston seal 60 mm
10529 Runddichtring 47x5,34 Sealing ring 47x5.34 mm
10531 Dichtscheibe Sealing disk
10532 Druckfeder Spring
10533 Runddichtring 6,07x1,78 Sealing ring 6.07x1.78 mm
10534 Runddichtring 14x1,78 Sealing ring 14x1.78 mm
10535 Zylinderkopfschraube M8x85 Socket head screw M8x85 mm
10536 Runddichtring Sealing ring
10537 Zylinderkopfschraube M4x12 Socket head screw M4x12 mm
10539 Elektrischer Anschluss Electrical connection
10540 Spule EIN + AUS I Coil CLOSE + OPEN I
10541 Anker Armature
10543 Sockel Base
10544 Ventilteller Valve disk
10545 Feder Spring
10546 Feder Spring
10549 Spulenträger Coil carrier
10550 Düse Nozzle
10554 Drossel Air flow restrictor
10557 Filter (lang) Filter (long)
10558 Zylinderkopfschraube M5x35 Socket head screw M5x35 mm
10559 Abdeckplatte Cover plate
10563 Deckel Cover
10566 Runddichtring 28,25x2,62 Sealing ring 28.25x2.62 mm
10568 Vorsteuerventil EIN Pilot valve CLOSE
10569 Vorsteuerventil AUS Pilot valve OPEN
10630 Spule AUS II Coil OPEN II
25673 Ventilstössel Valve plunger
25674 Fixierschraube Fixing screw
25675 Schraube Screw
25682 Kolben Piston
25689 Ventildeckel Valve cover
25690 Führungsrohr Guide tube
25691 Führungsbüchse Guide bush
25693 Steuerrohr Control tube
25703 Runddichtring 5,28x1,78 Sealing ring 5.28x1.78 mm
25704 Distanzrohr Spacer tube
*) Lufteinlass Air inlet
2*) Luftauslass Air outlet
3*) Sechskant-Stiftschlüssel SW 5 Hex key wrench WS 5 mm
(B) Schmieren, siehe 7.1.1 Lubrication, see 7.1.1
(U) Kleben / sichern (LOCTITE), siehe 7.1.1 Adhesives / securing (LOCTITE), see 7.1.1
MD Drehmoment Torque

Nm ft . lbf
3 2.5
7 5.2
10 7.4
15 11.0
20 15.0

CH-HS 1495 87 D, E
 CH-HS 1495 87
(B) (B) MD= 15Nm MD= 20Nm MD= 10Nm (B) (B) MD= 15Nm MD= 20Nm MD= 10Nm
10532 10527 25673 (U) 10521 10554 10517 10520/1 10526 (U) 10532 10527 25673 (U) 10521 25704 10557 10520/2 10526 (U)
(B) (B)
10520/1 10520/2
10563
(B) 10534 (B) 10534
MD= 3Nm
10524 10524 (U) 10558
(B) 10531 10535 (U) (B) 10531 10535 (U)
MD= 20Nm MD= 20Nm

25682 (B) 25682 (B)

(B) 25703 (B) 25703

(B) 10536 (U) 10529 10528 (B) 10536 (U) 10529 10528
(B) (B) (B) (B)
(B) 10566 (B) 10566
25693 25693 10559
25691 25691

25690 25690

25675 (U) 25674 (U) 25689/1 10537 (U) 10525 25675 (U) 25674 (U) 25689/2 10537 (U) 10525 10537 (U)
MD= 20Nm MD= 7Nm MD= 3Nm MD= 20Nm MD= 7Nm MD= 3Nm MD= 3Nm

Fig.7/2 (10569) Fig.7/3 (10568)

(B) (B)
20 10533 2*) *) 10533
01021 01022 10543
mm in

2,5 0.098 10550

3 0.118 10546 10544
4 0.157
150

Ø10
10 0.394 10545
13,1 0.516
18 0.709 10541
20

Ø3

20 0.787
40 1.575 10540
Ø2,5 10630
3*) 150 5.906 10539
4

13,1
Fig. 7/2, 7/3, 7/4

18...40
10549

25673 10494
10493

Fig.7/2a Fig.7/4 (10525)

Fig. 7/2, 7/3, 7/4
 Legende zu Fig. 7/5a, b, c Legend to fig. 7/5a, b, c
10340 Spannscheibe 10,5/23 Spring washer 10.5/23 mm
10525 Magnetventil Solenoid valve
10533 Runddichtring 6,07x1,78 Sealing ring 6.07x1.78 mm
10540 Spule EIN + AUS I Coil CLOSE + OPEN I
10569 Vorsteuerventil AUS Pilot valve OPEN
10630 Spule AUS II Coil OPEN II
10736 Sechskantschraube M10x25 Hex screw M10x25 mm
12469 Zylinderkopfschraube M4x40 Socket head screw M4x40 mm
12732 Unterlagscheibe 10,5/21 Washer 10.5/21 mm
13400 Antrieb Leistungsschalter Circuit breaker operating mechanism
13414 Heizung kpl. und pneumatisches AUS Heater compl. and pneumatic OPEN
13418 Heizung kpl. Heater compl.
13419 Heizplatte Heating plate
13420 Ventilplatte AUS Valve plate OPEN
13421 Isolierplatte Insulating plate
13422 Isolierplatte blind Blind insulating plate
13424 Ventilplatte EIN Valve plate CLOSE
25410 Rückschlagventil Non-return valve
25451 Flachdichtung Gasket
25452 Scheibe Washer
25453 Druckfeder Compression spring
25454 Rückschlagkegel Recoil disk
25455 Durchlassscheibe Aperture washer
25671 Steueranschluss Control air connection
25678 Runddichtung 8x2 Sealing ring 8x2 mm
25684 Stopfen Plug
25685 Ventilplatte Valve plate
25687 Zylinderkopfschraube M4x32 Socket head screw M4x32 mm
25689 Ventildeckel Valve cover
25692 Stutzen Connection
25703 Runddichtring 5,28x1,78 Sealing ring 5.28x1.78 mm
B Luftschlauch (pneumatisches AUS, siehe 2.8) Air hose (pneumatic OPEN, see 2.8)
(B) Schmieren, siehe 7.1.1 Lubrication, see 7.1.1
(U) Kleben / sichern (LOCTITE), siehe 7.1.1 Adhesives / securing (LOCTITE), see 7.1.1
MD Drehmoment Torque

Nm ft . lbf
3 2.2
45 33.0

CH-HS 1495 87 D, E
 CH-HS 1495 87
13400 13421 25689/1 13424 25689/2 13421

X Y

10525
10540
13418
X Y
10525 10525 13420 13419 10736
10630 10540 10340
12732
(B) 10533 MD= 45Nm

13421 12469 (U) 13420 10533 13424 13421 12469 (U) 25687 (U) 13422 10533
MD= 3Nm (B) MD= 3Nm MD= 3Nm (B)

Fig. 7/5a -13418

B K - 25410

(B)
A-A 25678 (B) (B)
A 25684 25453 25703 25451 25685 25689

25689 10569 25689

25692 10533
25689
(B)
K 25703 (B)
13421
25685
25703
(B)
10533 (B) 10533
25685 (B) 25685
25687 (U) 12469 (U)
MD = 3Nm MD= 3Nm
25455 10533 25452 25454 10525
Fig. 7/5a, b, c

10525 (B)
10525
10540
10525
10630 A
Fig. 7/5b - 25671 Fig. 7/5c -13414
Fig. 7/5a, b, c

ABB Switzerland Ltd
Division PTHG, High Current Systems
P.O. Box 5023
CH-8050 Zurich/Switzerland

Hotline
24 Hour Call Center: +41/(0)844 845 845
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