1HSB439954-2en 20171101

PRODU C T M A N U A L
LTB 72.5-245E1
Operating Mechanism BLG1002A
3-Pole Operation
1HSB439954-2en
The information contained in this document may be subject to change without prior warning and should not be considered as binding on
ABB AB's behalf. ABB AB accepts no liability for any errors that may appear in this document. ABB AB is not liable for any damage resulting
from the incorrect interpretation of this document. This document, or parts thereof, must not be reproduced or copied without ABB AB's
consent. It must not be distributed to others, or used by unauthorized parties. Any breaches to the above will be penalized with the support
of applicable laws.
© Copyright 2017 ABB All rights reserved.

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

Telefax: +46(0) 240 782320
www.abb.com
Table of contents
1 Safety 7
1.1 Levels of Safety Risks ......................................................................................................................................... 7
1.2 Hazardous Working Situations ........................................................................................................................... 8
1.3 Discharge the Springs......................................................................................................................................... 9

1.3.1 Discharge the Springs Electrically ......................................................................................................... 9
2 Product Description 11
2.1 Description ......................................................................................................................................................... 11
2.2 Gas System ........................................................................................................................................................ 14
2.3 Breaking Principle ............................................................................................................................................. 15
3 Reference Information 17
3.1 Oil Types ............................................................................................................................................................. 17
3.2 Types of Grease ................................................................................................................................................. 18
3.3 Locking Fluid...................................................................................................................................................... 20
3.4 Tightening Torque.............................................................................................................................................. 21
3.5 Operating Values................................................................................................................................................ 22
4 Delivery 23
4.1 Delivery Inspection ............................................................................................................................................ 23
4.2 Storage Prior to Assembly................................................................................................................................ 24
5 Installation 27
5.1 Installation in Short Steps................................................................................................................................. 27
5.2 Required Equipment .......................................................................................................................................... 29
5.3 Foundations ....................................................................................................................................................... 30
5.4 Assembly of Support Structure ........................................................................................................................ 31
5.5 Installation of an Earthquake Damper on the Foundation (Option) .............................................................. 33
5.6 Assembly of Support Structure on the Foundation ....................................................................................... 36
5.7 Lifting the Circuit Breaker Poles ...................................................................................................................... 38
5.8 Assembly of Circuit Breaker Pole .................................................................................................................... 40
5.9 Installation of Corona Rings on the Post Insulator (Option) ......................................................................... 42
5.10 Lifting the Operating Mechanism ..................................................................................................................... 43
5.11 Installation of Operating Mechanism ............................................................................................................... 45
5.12 Assembly of Protective Tube ............................................................................................................................ 47
5.13 Final Assembly of the Circuit Breaker Pole. ................................................................................................... 48
5.14 Fitting of Rod System ........................................................................................................................................ 50

5.14.1 Preparations for Fitting of Rod System ................................................................................................ 50
5.14.2 Fitting the Pull-Rod Between the Operating Mechanism and the Circuit Breaker Pole ....................... 51
5.14.3 Fitting the Pull-Rod Between the Poles ............................................................................................... 54
5.15 Assembly of Gas Monitoring System .............................................................................................................. 56
5.16 Fitting the Distribution Block (Option)............................................................................................................. 58
5.17 Electrical Connections ...................................................................................................................................... 60

5.17.1 Connecting the Circuit Breaker's Operating Mechanism ..................................................................... 60
5.17.2 Fitting the High-Voltage Terminals ....................................................................................................... 61
1HSB439954-2en 2017-11-01 3
Table of contents
5.18 Pressurizing of Circuit Breaker Poles.............................................................................................................. 62

5.18.1 Preparations for Gas Filling ................................................................................................................. 62
5.18.2 Gas Filling Equipment.......................................................................................................................... 64
5.18.3 Gas Filling with SF6 Gas ..................................................................................................................... 65
5.18.4 Filling of Mixed Gas ............................................................................................................................. 69
5.19 Inspection of Bolt Joints ................................................................................................................................... 74
5.20 Assembling the Indicator Sign and Cover....................................................................................................... 75
5.21 Inspection Prior to Commissioning ................................................................................................................. 77

5.21.1 Gas System Tightness Check.............................................................................................................. 77
5.21.2 Final Inspection of Rod System ........................................................................................................... 78
6 Commissioning 81
6.1 Introduction ........................................................................................................................................................ 81
6.2 Pre-Commissioning Checklist .......................................................................................................................... 82
6.3 Operating Values and Signature....................................................................................................................... 84
7 Maintenance 85
7.1 Introduction ........................................................................................................................................................ 85
7.2 Required Equipment .......................................................................................................................................... 86
7.3 Description of Maintenance Categories .......................................................................................................... 87
7.4 Maintenance Schedule ...................................................................................................................................... 89

7.4.1 Category A ........................................................................................................................................... 89
7.4.2 Category B ........................................................................................................................................... 90
7.4.3 Category C........................................................................................................................................... 93
7.4.4 Category D........................................................................................................................................... 94
7.5 Maintenance, Circuit Breaker Pole................................................................................................................... 95

7.5.1 The Service Life of the Circuit Breaker ................................................................................................ 95
7.5.2 The Service Life of the Arcing Contacts in the Event of Short Circuit Breaking................................... 96
7.5.3 Cleaning and Lubrication of Circuit Breakers....................................................................................... 97
7.6 Maintenance, Operating Mechanism and Link System .................................................................................. 98

7.6.1 Preparatory Measures and Overview of the Operating Mechanism .................................................... 98
7.6.2 Cleaning, Lubrication, and Rust Protection of Operating Mechanism ............................................... 100
7.6.3 Locking and Unlocking of the Mechanical Interlocking Device .......................................................... 101
7.6.4 Inspection of Heating Element ........................................................................................................... 103
7.6.5 Inspection of Drive Unit...................................................................................................................... 104
7.6.6 Inspection of Latch Devices ............................................................................................................... 106
7.6.7 Check of Oil Level in Damper ............................................................................................................ 108
7.6.8 Check of Limit Switch and Auxiliary Contact...................................................................................... 110
7.6.9 Check of Link System and Spring Assembly ..................................................................................... 112
7.6.10 Inspection of Connection Terminals ................................................................................................... 113
7.7 Slow Manual Closing and Tripping Operation .............................................................................................. 114

7.7.1 Introduction ........................................................................................................................................ 114
7.7.2 Preparations for the Operating Mechanism for Manual Closing Operation ....................................... 115
7.7.3 Slow Manual Closing Operation......................................................................................................... 117
7.7.4 Cancel the Slow Closing Operation in Progress ................................................................................ 119
7.7.5 Preparing the Operating Mechanism for Slow Manual Opening Operation ....................................... 120
7.7.6 Slow Manual Tripping Operation........................................................................................................ 122
7.8 Maintenance of Rust Protection ..................................................................................................................... 124
4 2017-11-01 1HSB439954-2en
Table of contents
8 Overhaul 125
8.1 Preparations ..................................................................................................................................................... 125
8.1.1 Preparations for Overhaul.................................................................................................................. 125
8.1.2 Evacuation of SF6 Gas ...................................................................................................................... 126
8.1.3 Cleaning and Waste Treatment ......................................................................................................... 127
8.2 Required Equipment ........................................................................................................................................ 128
8.3 Removal of Circuit Breaker Pole for Transport ............................................................................................. 130
8.4 Overhaul of Circuit Breaker Pole.................................................................................................................... 132

8.4.1 Relieving the Trip Mechanism's Pull-Rod. ......................................................................................... 132
8.4.2 Removal of the Trip Mechanism's Pull-Rod ....................................................................................... 133
8.4.3 Removal of Interrupter Unit................................................................................................................ 135
8.4.4 Removal of Post Insulator.................................................................................................................. 137
8.4.5 Overhaul of Interrupter Unit ............................................................................................................... 139
8.4.6 Inspection and Replacement of Contacts and Self-Blast................................................................... 141
8.4.7 Overhaul of Mechanism ..................................................................................................................... 144
8.5 Assembling the Circuit Breaker Pole Following Overhaul .......................................................................... 146
8.5.1 Treatment of Contact Surfaces .......................................................................................................... 146
8.5.2 Treatment of Sealing Surfaces and Seals.......................................................................................... 147
8.5.3 Assembly of Post Insulator ................................................................................................................ 148
8.5.4 Assembly of Interrupter Unit Following Overhaul............................................................................... 150
8.5.5 Assembly of Interrupter Unit on the Post Insulator ............................................................................ 153
8.5.6 Assembly of Trip Mechanism's Pull-Rod to the Operating Lever ....................................................... 155
8.5.7 Filling Gas Before Transport .............................................................................................................. 157
8.6 Replacement of breaking unit......................................................................................................................... 158

8.6.1 Dismantling of Interrupter Unit for Transport...................................................................................... 158
8.6.2 Assembly of Interrupter Unit on the Post Insulator on Site ................................................................ 161
8.7 Installation of Circuit Breaker Poles and Commissioning ........................................................................... 164
9 Disposal and Environmental Information 167

9.1 Disposal and Recycling................................................................................................................................... 167
9.2 Environment Information, SF6 Gas ................................................................................................................ 169
10 Spare parts 171

10.1 Introduction ...................................................................................................................................................... 171
10.2 Circuit Breaker Pole......................................................................................................................................... 174

10.2.1 Circuit Breaker Pole ........................................................................................................................... 174
10.2.2 Interrupter Unit ................................................................................................................................... 175
10.2.3 Contact Set ........................................................................................................................................ 176
10.2.4 Post Insulator and Insulating Pull-Rod............................................................................................... 177
10.2.5 Mechanism......................................................................................................................................... 178
10.2.6 Trip Mechanism.................................................................................................................................. 179
10.2.7 Accessories........................................................................................................................................ 180
10.3 Operating Mechanism ..................................................................................................................................... 182

10.3.1 Drive Unit, Complete With Motor ....................................................................................................... 182
10.3.2 Damper .............................................................................................................................................. 183
10.3.3 Latch Device ...................................................................................................................................... 184
10.3.4 Auxiliary Contact ................................................................................................................................ 185
10.3.5 Heating Element ................................................................................................................................ 186
10.3.6 Electrical Equipment .......................................................................................................................... 187
1HSB439954-2en 2017-11-01 5
Table of contents
6 2017-11-01 1HSB439954-2en
1 Safety
1 Safety
1.1 Levels of Safety Risks
Description
Throughout the manual, various types of safety risks are indicated. These are divided into five different
levels, depending on the degree of danger. The most serious level on this scale provides a warning about
serious personal injury or possible death, or major damage to a product, if the instructions are not observed.
The least serious is simply a comment on important facts and conditions. The levels are indicated using
symbols.
Safety Risks - Symbols and Their Meanings.
DANGER!
The yellow, filled warning triangle warns that an accident will occur if the instructions are not
complied with and that it will result in serious personal injury or death and/or major damage to the
product.
It is used, for example, to warn such of dangers as: contact with high-voltage, explosion or fire
risk, risk for toxic gases, risk of crushing, impacts, falls from high places, etc.
WARNING!
The red, unfilled warning triangle warns that an accident can occur if the instructions are not
complied with, resulting in serious injury or death and/or major damage to the product.
It is used, for example, to warn such of dangers as: contact with high-voltage, explosion or fire
risk, risk for toxic gases, risk of crushing, impacts, falls from high places, etc.
ELECTRIC SHOCK!
The symbol for electric shocks warns about electrical dangers that could cause serious personal
injury or death.
IMPORTANT!
The round warning symbol warns that an accident could occur if the instructions are not observed,
and that this could result in personal injury and/or damage to the product.
It is also used to warn of risks that entail burns, eye injuries, skin damage, impaired hearing,
crushing or slipping injuries, tripping, impacts, falls from high places, etc.
In addition, it is used to warn about functional requirements when assembling or removing
equipment where there is a risk of damage to the product or that it might cause downtime.
NOTE!
The comment symbols identify important facts and conditions.
Also used for any danger that could lead to damage to the plant only.
1HSB439954-2en 2017-11-01 7
1 Safety
1.2 Hazardous Working Situations
General
For all work on high-voltage circuit breakers and other high-voltage devices, the risks below must be
observed and corresponding measures taken.
Comply with local regulations and requirements.
Hazardous Working Situations
Risk Action/information
Working close to high-voltage Disconnect and earth around the workplace. If work must be
carried out next to live plant components, the safety distance
must satisfy the applicable safety regulations.
Working with low voltage Switch off the control voltage and where necessary the heater
voltage as well.
Both AC and DC can be connected to the operating
mechanism and control cabinet.
Working with circuit breakers or in operating For overhaul or maintenance work that requires work on the
mechanisms circuit breaker or operating mechanism, it is important that both
the close and trip springs are discharged.
Working on ladders and platforms Work must be executed in accordance with applicable safety
regulations. Avoid climbing ladders and platforms in poor
weather conditions.
Working next to pressurized insulators Work close to the circuit breaker's insulators, entailing risk for
damage to an insulator, must not be carried out until the gas
pressure has been lowered to max. 0.125 MPa (abs.) pressure.
Porcelain insulators: At normal gas pressure, damage to the
porcelain could cause it to shatter.
Handling gas Comply with local regulations while handling gas.
8 2017-11-01 1HSB439954-2en
1 Safety
1.3 Discharge the Springs
1.3.1 Discharge the Springs Electrically
General
WARNING!
For maintenance work that requires work on the circuit breaker or operating mechanism, it is
important that both the close and trip springs are discharged.
IMPORTANT!
The contactor must NOT be manually operated as this would cause the limit switch to malfunction.
Consequently causing mechanical damage to the operating mechanism.
NOTE!
This type of work must only be executed by personnel trained by ABB.
Example of Component Placement
NOTE!
The placing of components as shown in the illustration is an example. See the circuit diagram for
exact component placing.
1 Protective motor switch

2 Switch Local/Remote/Disconnected (S4)
3 Close springs indicator
4 Control switch, Close/Open (S1)
Discharge the Springs Electrically
1. Switch off the motor current by switching off the motor protection (1) (Stop/Off).
2. Set the "Local/Remote/Disconnected" switch (2) to "Local".
3. Execute an Open-Close-Open operation.
1HSB439954-2en 2017-11-01 9
1 Safety
4. Check that the springs are discharged. The indicator (3) shows discharged spring.
5. Check that the circuit breaker is in its open position.
6.
NOTE!
Following completion of work the motor protection (1) (Start/On) must be reset.
End of instruction
10 2017-11-01 1HSB439954-2en
2 Product Description
2.1 Description
Standards
The circuit breaker complies in applicable parts with the requirements of the IEC or ANSI/IEEE standards.
Assembly
Each circuit breaker pole consists of:

• a mechanism housing with a mechanism.
• a hollow post insulator with insulating pull-rod
• a interrupter unit that consists of a breaking chamber insulator with attendant flanges and adapter plates.
The interior of the interrupter unit consists of a fixed upper and lower current path with integrated
contact system and a moving puffer unit.
The circuit breaker poles are fitted to separate column support structures. The support structures are hot-dip
galvanized and consists of two welded halves that are interconnected using bolted cross-bracings.
The circuit breaker poles are linked using pull-rods that are sealed in protective tubes.
1HSB439954-2en 2017-11-01 11
The Circuit Breaker's Main Components
Item Part Weight, kg
1 Circuit Breaker Pole See outline drawing for applicable order

2 Interrupter Unit See outline drawing for applicable order
3 Post Insulator See outline drawing for applicable order
4 Mechanism See outline drawing for applicable order
5 Operating Mechanism 465 kg
6 Support structure 86-200 kg
7 Protective tube See outline drawing for applicable order
12 2017-11-01 1HSB439954-2en
Summary, Operating Mechanism
1 Drive Unit
2 Mechanism
3 Control Panel
4 Spring assembly
5 Heating Element
6 Latch Device
7 Auxiliary Contact
1HSB439954-2en 2017-11-01 13
2.2 Gas System
Gas Pressure
The circuit breaker poles are delivered vacuum processed and filled with gas at transport pressure.
When commissioning, the gas must be filled to the pressure specified on the rating plate. Different gas
pressures may occur depending on the different requirements with respect to the lowest ambient temperature.
Density Monitor
The circuit breaker is equipped with a density monitor for checking the density of the gas. All density
monitors are equipped with a set of contacts that must be connected to give an alarm in the event of abnormal
gas pressure.
The density monitor is a calibrated monitoring instrument. It must be treated with care and protected from
careless handling and all types of mechanical damage. Open the density monitor packaging just before it will
be installed.
SF6
Sulfur hexafluoride SF6 is a synthetic gas, which is colorless, odorless and non-combustible.
The gas is chemically very stable and at room temperature, it does not react with any other substance.
The stability of the gas is the basis for it being used in electrical devices as it provides very high electrical
insulation and can effectively extinguish arcs. These SF6 properties enable the construction of devices and
equipment with small footprints, using less material, that are safe and have long service lives. In an electrical
context, the SF6 gas is only used in closed and sealed systems, e.g. as insulation gas in substations and
insulation and extinguishing medium in circuit breakers for high and medium voltage.
14 2017-11-01 1HSB439954-2en
2.3 Breaking Principle
Self-Blast Principle
The interrupter unit functions in accordance with the self-blast (auto-puffer) principle, with a puffer cylinder
that is divided into two chambers; a self-blast section and a compression section.
When normal operating currents are interrupted, the gas in the compression section is compressed to an
overpressure. When the arcing contacts separate, the gas in the compression section flows out and
extinguishes the arc at a current zero passage.
When short-circuit currents are interrupted, the required extinguishing pressure is built up in the self-blast
section by heat from the arc. The pressure increase is achieved with energy from the arc and no extra energy
is required from the operating mechanism.
On close operation, the puffer cylinder slides upwards, the contacts engage and the puffer cylinder is refilled
with gas.
Interrupter Unit with Self-Blast
1 Puffer cylinder
2 Self-blast chamber
3 Compression section
1HSB439954-2en 2017-11-01 15
3 Reference Information
3.1 Oil Types
General
This section deals with the applications, type names, and suppliers of oil.
IMPORTANT!
All lubricant and oil spills must be covered using absorbent material and be handled as chemical
waste in accordance with locally applicable regulations.
IMPORTANT!
When handling oil and lubricants, long-sleeved overalls, protective gloves and protective goggles
must be worn at all times.
Oil A
Thin all-synthetic lubricant for precision mechanical components in the operating mechanism and circuit
breakers. Also used when lubricating bearings that cannot be lubricated with grease “G” without removing,
e.g. links and link gears.
Property Value
Viscosity at 40 °C 62-65 cSt

Lowest pour temperature point -52°C
Supplier Designation Part number
ABB 1171 2039-1 1HSB875318-A

MOBIL MOBIL 1 (481127)5W-30 -
CASTROL FORMULA RS5W-50 -
SHELL TMO Synthetic 5W-30 -
OK Super-Synthetic 5W-40 -
Oil S
Silicone oil designed for dampers in operating mechanisms, such as BLG, BLK and MSD models.
ABB 1173 7011-106 1HSB875318-C

SHELL DC 200 Fluid 200 CS -
1HSB439954-2en 2017-11-01 17
3.2 Types of Grease
General
This section deals with the applications, type names, and suppliers of grease.
IMPORTANT!
All lubricant and oil spills must be covered using absorbent material and be handled as chemical
waste in accordance with locally applicable regulations.
IMPORTANT!
When handling oil and lubricants, long-sleeved overalls, protective gloves and protective goggles
must be worn at all times.
Grease G
Low temperature grease for all types of bearings, gear drives and worm gears as well as valves in air-blast
circuit breakers. Also used for greasing O-rings and as crevice corrosion protection for circuit breakers, and
for movable contacts (opening contacts) in disconnectors.
ABB 1171 4014-407 5316 381-A

GULF 718EP Synthetic grease -
MOBIL Mobil grease 28 -
SHELL Aero Shell Grease 22 -
Grease K
Molycote lubricant for lubricating pins in link gears and in earthquake dampers.
ABB 1263 0011-102 5316 381-M

Dow Corning G-rapid plus -
Grease L
Low temperature grease specially designed for lubricating precision-engineered equipment parts, such as
latching mechanisms in operating mechanisms that are to work in very cold conditions.
ABB 1171 4016-606 5316 381-H

Maagtechnic Glattol 4103982 -
ASEOL AG ASEOL SYLITEA 4-018 (No longer -
manufactured)
Shell Shell Alvania 0982 (No longer manufactured) -
18 2017-11-01 1HSB439954-2en
Grease M
Low temperature grease for long-term and permanent lubrication of worm gears, gear drives and other
machine elements. Counteracts wear and corrosion.
Also reduces electrical resistance at the lubrication point, therefore making it suitable for electrical
connections and for lubrication of contacts in disconnectors and earthing switches. The grease should be
rubbed on in a very thin layer on the sliding surfaces of the contacts.
ABB 1171 4016-612 5316 381-X

Klüber Isoflex Topas NB 52 -
Grease N
For lubrication of movable contacts and puffer cylinders in SF6 circuit breakers. The grease should be rubbed
on in a very thin layer on the sliding surfaces of the contacts.
ABB 1171 4016-607 5316 381-L

Montefluos S.p.A Fomblin OT20 -
Grease P
Vaseline for treatment of contact surfaces in fixed joints internally in the interrupter unit.
ABB 1171 5011-102 5316 381-N

SHELL Shell Vaseline 8401 -
Grease "S"
Fluorosilicone grease for lubrication of EPDM O-rings and as crevice corrosion protection for ED type circuit
breakers, as well as greasing of rotating shaft seals in circuit breaker types LTB and HPL.

ABB 1171 4014-406 5316 381-G
Dow Corning FS-3451 No. 2 -
Fluortech AB TP55 -
Grease SV
For lubrication of movable contacts (opening contacts) in disconnectors, silver-plated contacts and brushed
aluminum surfaces in fixed joints outdoors.
ABB 1171 4016-610 5316 381-C

Statoil Electrical grease -
1HSB439954-2en 2017-11-01 19
3.3 Locking Fluid
General
This section deals with the applications, names and suppliers of locking fluid.
Preliminary Treatment of Surfaces
The surfaces must be free from oil, grease, wax, paint and anti-rust agent.
Locking Fluid B
Medium strength locking fluid used to lock threads. Removable.
ABB 1269 0014-429 -

Locking fluid Thread locker, grade 43 -
Locking Fluid C
Strong locking fluid used to lock threads. Difficult to remove.

ABB 1269 0014-408 -
Locking Fluid D
A thin fluid that penetrates quickly. Used for locking brackets following assembly or adjustment. The fluid
can also impregnate porous welded joints, castings and sintered material. The interlocking has a high
resistance against pressure, solvents and chemicals.
Fluid can only be used on clean and dry surfaces. Oily material must be washed with ethanol.
Spray the fluid on the surface in question or apply with a brush.

ABB 1269 0014-409 -
Locking Fluid F
Extra strong locking fluid for cylindrical attachment. Recommended for joints with sliding or forced fit. Must
be heated in order to be removed (temperature resistance 175º C).
ABB 1234 0011-126 -

20 2017-11-01 1HSB439954-2en
3.4 Tightening Torque
General
NOTE!
The listed tightening torques are general values for installation, maintenance and overhaul. Use the
tightening torques that are specified in the respective instructions.
NOTE!
Torque and lubrication of threads unless otherwise stated. Thread size M8 or larger must be
lubricated with "G" grease. Joints where locking fluid is used are excepted. In such instances, the
thread must be dry and free of oil and grease.
Tightening Torque, General
Size Tightening torque (Nm)
M6 10
M8 22,5
M10 45
M12 79
M16 190
M20 420
1HSB439954-2en 2017-11-01 21
3.5 Operating Values
Times
Events Times
Closing time < 55 ms

Opening time 17 ± 2 ms
Close-Open time 1 < 42 ms
NOTE!
Close-Open time stated refers to the time the arcing contacts are closed during a closing operation
when the trip impulse is connected at the same time via the auxiliary contact.
Motor and Control Circuits
Events Values
Charging time for motor < 20 s

Control voltage trip coil I V (according to rating plate)
Control voltage trip coil II V (according to rating plate)
Control voltage close coil I (and II) V (according to rating plate)
Resistance
The main circuit resistance for breaking chamber length L=2094 mm is less than 49 µΩ per pole.
The main circuit resistance for breaking chamber length L=1472 mm is less than 39 µΩ per pole.
Stroke
The stroke is 160 ± 3 mm.
22 2017-11-01 1HSB439954-2en
4 Delivery
4 Delivery
4.1 Delivery Inspection
General
The material is packed in boxes and on pallets. The boxes are marked with package numbers and gross
weights. Other information is printed on a plate/label attached to two sides of the boxes.
When unpacking the boxed delivery, just lift off the cover from the package and lift the contents out.
All packaging material is recyclable.
Damaged Goods
Check on arrival that the delivery matches the order and delivery documents and that no transportation
damage has occurred. If damage is found or suspected, the boxes must be opened and the damage
photographed and documented.
In the event of missing material or if transportation damage has occurred, this must be reported immediately
to ABB.
1HSB439954-2en 2017-11-01 23
4 Delivery
4.2 Storage Prior to Assembly
Storage Requirements
All components that are to be stored in an approved storage environment (conditions equivalent to indoors)
must comply with the following storage requirements.
An approved storage environment must have:
a roof
solid ground
air humidity below 50%
a temperature of 20°C (±10°C).
Dust, smoke, abrasive or flammable gas, steam or salt must not be present in close proximity to the products.
If this is the case, the equipment must be cleaned prior to assembly.
Storage in a Moist Environment
Storage in moist environments without ventilation can cause discoloring of zinc-coated surfaces. This
discoloring is known as “white rust” and primarily consists of zinc oxide and zinc hydroxide. It is the result of
a chemical reaction between the pure zinc on the surface and moisture.
The long-term rust protection will not be affected by the "white rust", and the steel-zinc layer under the
surface will remain unaffected. In accordance with current practice "white rust" is not a reason for returning
the goods.
NOTE!
Operating mechanisms must not be stored in damp environments as phosphatized surfaces can be
attacked by corrosion.
Stacking of Packaging Boxes
Packaging boxes of different sizes must never be stacked on top of each other (the pressure could damage the
lids of the lower boxes). If different sized boxes need stacking, a frame must be used between the boxes to
distribute the pressure.
WARNING!
Never stack more than three boxes on top of each other. Due to instability and the risk of collapse
the boxes need to be secured.
Circuit Breaker Poles
The circuit breaker poles must be stored in their original packaging, where they are protected from damage.
The packaging must not stand in water and must primarily be kept in a horizontal position indoors and above
ground level, so as to avoid cracking or water damage.
The circuit breakers may also be stored outdoors, but in that case in an area protected from rain on a dry,
well-drained surface. If a tarpaulin is used, it must not be wrapped too tightly; air circulation to the
zinc-plated surfaces must not be hindered. Any moisture must be easy to drain off.
Support Structure
Support structures can be stored outdoors.
Operating Mechanism/Control Cabinet
Operating mechanisms and control cabinets must be stored in their original packaging to protect them against
damage. For periods of storage greater than 3 months, the storage area must be protected from rain and
consist of a dry, well-drained surface, with the heating element electrically connected to prevent corrosion on
the sensitive equipment.
24 2017-11-01 1HSB439954-2en
4 Delivery
Spare Parts
Spares must be stocked indoors in their original packing. This is particularly important for rubber
components, (such as seals) which also need protecting from sunlight to avoid drying up. Gaskets have a
limited service life, you should therefore avoid stocking them.
1HSB439954-2en 2017-11-01 25
4 Delivery
5 Installation
5 Installation
5.1 Installation in Short Steps
General
This section provides a summary of the installation procedure, encompassing the steps required for installing
the complete circuit breaker with the support structure and operating mechanism.
WARNING!
Before assembling, check that the serial numbers on the circuit breaker pole and operating
mechanism match.
NOTE!
Read the section on safety before commencing installation work. See Safety, page 7.
Overview
1 Circuit Breaker Pole

2 Interrupter Unit
3 Post Insulator
4 Mechanism
5 Operating Mechanism
6 Support structure
7 Protective tube
1HSB439954-2en 2017-11-01 27
5 Installation
Summary of the Installation
1. Check the delivery. Delivery Inspection, page 23.
2. Check that all the required tools are on hand. Required Equipment, page 29.
3. Check that the foundations meet all requirements Foundations, page 30.
for the installation.
4. Assemble the support structure Assembly of Support Structure, page 31.
5. Fit the earthquake damper (option). Installation of an Earthquake Damper on the

Foundation (Option), page 33.
6. Mount the support structure on the foundation. Assembly of Support Structure on the Foundation,
page 36.
7. Lift circuit breaker pole. Lifting the Circuit Breaker Poles, page 38.
8. Fit all circuit breakers to their support structures. Assembly of Circuit Breaker Pole, page 40.
9. Assemble the corona rings (option) Installation of Corona Rings on the Post Insulator
(Option), page 42.
10. Lifting the Operating Mechanism.
11. Fit the operating mechanism. Installation of Operating Mechanism, page 45.
12. Fit the protective tubes. Assembly of Protective Tube, page 47.
13. Fit the pull-rods. Fitting of Rod System, page 50.
14. Final assembly of the circuit breaker pole. Final Assembly of the Circuit Breaker Pole.,
page 48.
15. Fit the gas monitoring system. Assembly of Gas Monitoring System, page 56.
16. Fit the Distribution Block (Option). Fitting the Distribution Block (Option), page 58.
17. Install all electrical connections: Electrical Connections, page 60.

• Connect the operating mechanism.
• Fit the rails or lines.
18. Pressurize the circuit breaker poles. Pressurizing of Circuit Breaker Poles, page 62.
19. Check the bolt joints. Inspection of Bolt Joints, page 74.
20. Fit indicator signs and covers. Assembling the Indicator Sign and Cover, page 75.
21. Prepare for commissioning. Inspection Prior to Commissioning, page 77.

• Perform a gas system tightness check.
• Inspect the pull-rod system.
End of instruction
28 2017-11-01 1HSB439954-2en
5 Installation
5.2 Required Equipment
General
This section specifies the equipment needed for installing the circuit breaker.
Required Tools
Tool ABB part no. Note
MK toolbox 6880 768-7 Torque wrenches 10-550 Nm.

Note: The MK toolbox is not included in the
delivery; it must be ordered separately.
Alternatively, the existing tool equipment may be
used.
Lifting device and slings
Gas filling equipment
Leak spray
Fine abrasive material or emery cloth
Lubricant
Agent ABB part no. Note
Grease "G" See sections Types of Grease, page 18 and Oil

Types, page 17 for ABB part numbers, suppliers
Grease "SV"
and trade names.
Contact paste -
Other Documentation
Document ABB part no. Note
Outline drawing and diagram -

applicable to the order
1HSB439954-2en 2017-11-01 29
5 Installation
5.3 Foundations
General
The foundation for the circuit breaker must be flat and horizontal. The figure shows the permitted tolerances
in millimeters for the position of the foundation bolts and for the phase spacing.
Any deviations should be adjusted using spacers; see section Assembly of Support Structure on the
Foundation, page 36. The nominal dimensions, as well as the dimensions for the foundation bolts and nuts
are specified in the outline drawing that is applicable to the order.
Tolerances
1 Foundation for support structure 1

4 Foundation bolt, L>130 mm
30 2017-11-01 1HSB439954-2en
5 Installation
5.4 Assembly of Support Structure
Example of Fitting the Support Structure
The support structure is delivered as welded halves together with cross-bracings, and bolts, nuts and washers.
1 Support structure halves

2 Cross-bracing
3 Bolt M20x60, nut M20, washer 21x37x3
Required Equipment
Equipment Part number Note

MK toolbox 6880 768-7
1HSB439954-2en 2017-11-01 31
5 Installation
Assembly Instructions
NOTE!
Ensure you follow the order of assembly.
1. Fit the cross-bracings in the order of assembly

(1-4) shown in the illustration, with bolts, nuts and
washers.
2. Tighten all bolts finger-tight.

NOTE!
Final torque tightening takes place at a
later stage of the installation.
End of instruction
32 2017-11-01 1HSB439954-2en
5 Installation
5.5 Installation of an Earthquake Damper on the Foundation (Option)
General
These installation instructions describe the installation of the earthquake damper for circuit breakers.
The earthquake damper is intended to protect circuit breakers and operating mechanism, and are used
particularly in the areas where there is a significant risk of earthquakes.
NOTE!
The earthquake damper does not require any maintenance during its service life.
Required Equipment
Grease "K" 1263 0011-102

Torque wrench Torque range 79-350 Nm.
Wooden block - about 70 mm high
Assembly
1. Adjust the nuts (1) to the same level using

spacers (2).
1: Nut M24, (not included).

2: Spacer, (not included).
3: Adapter plate
4: Guide cone, (4 pcs)
5: Guide, (4 pcs)
6: Damper element, (4 pcs)
7: Bolt M12x60 (24 pcs),

Washer 13x24x2.5 (24 pcs)
8: Support structure
9: Bolt M30x90 (4 pcs), Washer 31x56x4 (8 pcs),
Nut M30 (4 pcs)
2. Tighten the nut (1).

Torque
350 Nm
1HSB439954-2en 2017-11-01 33
5 Installation
3. Place the adapter plate (3) over the foundation

bolt (1). Use a wooden block (2) as a support.
4. Fit the guide cone (4) and guide (5) on the

foundation bolt.
5. Check that the guide (5) is correctly oriented.
6. Apply grease "K" to the surface between the guide cone (4) and the guide (5).
7. Tighten the guide cone.

Torque
NOTE! 350 Nm
Check that the foundation bolt is not
higher than the guide cone.
8. Fit the damper element (6) to the adapter plate (3)

with the bolts (7).
NOTE!
Check that the guide (5) is correctly
positioned in relation to the lower
section of the damper element (6).
34 2017-11-01 1HSB439954-2en
5 Installation
9. Tighten the bolts (7) crosswise by hand to ensure that the damper element is flat against the adapter
plate.
10. Tighten the bolts (7).

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

NOTE!
and tighten the bolts (9) finger-tight.
End of instruction
1HSB439954-2en 2017-11-01 35
5 Installation
5.6 Assembly of Support Structure on the Foundation
General
This section describes how the support structure is fitted to the foundation.
If an earthquake damper is to be fitted, see Installation of an Earthquake Damper on the Foundation
(Option), page 33.
Assembly
1 Foundation bolt, L>130 mm

2 Nut
3 Washer for M24 (26.5x50x10)
3 Washer for M30 (32x65x10)
4 Spacing washer
5 Foundations
6 Support structure
NOTE!
Foundation bolt, nuts and spacers are not included in the delivery.
Required Equipment

Torque wrench - Torque 300-350 Nm for M24.
Torque 500-550 Nm for M30.
36 2017-11-01 1HSB439954-2en
5 Installation
Assembly
DANGER!
Use a lifting tackle that is designed for the weight!
1. Fit the lower nuts (2) and washers (3) to the foundation bolt (1) and position the support structure (6)
as illustrated.
2. Check that the support structure is vertical and level it by adjusting the lower nuts (2).
3. Fill the spaces between the lower nuts (2) and the foundation using spacers (4).
NOTE!
The space should be as small as possible.
4. Torque tighten the lower nuts (2) to the spacers

Torque
(4).
M24: tightening torque 300-350 Nm.
M30: tightening torque 500-550 Nm.
5. Fit the washers (3) and upper nuts (2) as

NOTE!
illustrated. Tighten finger tight.
6. Check that the top of the support structure is flat.
NOTE!
The top of the support structure must
be level within 1 mm, otherwise it must
be adjusted.
End of instruction
1HSB439954-2en 2017-11-01 37
5 Installation
5.7 Lifting the Circuit Breaker Poles
Safety
WARNING!
So that the correct lifting tackle will be used, it is extremely important to check the weight of the
circuit breaker pole. The weight of the circuit breaker pole is specified on the outline drawing
applicable to the order.
IMPORTANT!
Please note the positioning of the lifting sling! In respect of polymer insulators, the lifting sling
must be placed as close as possible to the connecting flange and not on the rubber surface.
NOTE!
The circuit breaker pole/poles should be stored in transport boxes until immediately before
assembly.
Required Equipment
Torque wrench 60-79 Nm

Lifting device and slings
Lifting Illustration
1 Bolt joint
38 2017-11-01 1HSB439954-2en
5 Installation
Lifting Instructions
DANGER!
The breaker pole must be lifted with lifting equipment that is designed for the weight!
See outline drawing for the exact weights.
1. Place a lifting sling around the top of the circuit

IMPORTANT!
breaker pole.
Please note the positioning of the lifting
sling! In respect of polymer insulators,
the lifting sling must be placed as close
as possible to the connecting flange
and not on the rubber surface.
2. Check that the bolts (1), have the correct

Torque
tightening torque.
60 Nm
3. Lift the circuit breaker pole from its horizontal position in the transport packaging.
Start with the pole that will be installed at the center.
4. Check that the circuit breaker pole is pressurized

NOTE!
to the transport pressure.
Should the pressure be incorrect, this
must be rectified before the circuit
breaker pole is fitted.
End of instruction
1HSB439954-2en 2017-11-01 39
5 Installation
5.8 Assembly of Circuit Breaker Pole
Overview
The figure below shows the circuit breaker pole's retaining bolts and nuts.
1 Bolt M20x70 (4 pcs), nut M20 (4 pcs), and washer 21x37x3 (8 pcs)
Required Equipment
Lifting equipment -
Lifting tackle -
Torque wrench - 300-550 Nm
1. Lift one circuit breaker pole at a time onto the Lifting the circuit breaker pole is described in
support structure and attach them using bolts, Lifting the Circuit Breaker Poles, page 38.
washers and nuts (1). Tighten finger-tight.
NOTE!
Final tightening is performed when the
operating mechanism and the
protective tube have been fitted.
40 2017-11-01 1HSB439954-2en
5 Installation
2. Torque tighten the upper nuts securing the support

Torque
structure to the foundation.
M24: 300-350 Nm
M30: 500-550 Nm
3. Torque tighten the cross-bracings on the support

Torque
structure.
420 Nm.
4. Torque tighten the post insulator unit to the

Torque
support structure.
420 Nm.
End of instruction
1HSB439954-2en 2017-11-01 41
5 Installation
5.9 Installation of Corona Rings on the Post Insulator (Option)
Corona ring
1 Corona ring
2 Bracket
3 Bolt M10x20 (4 pcs), Washer 10.5x20x2 (4 pcs)
4 Bolt M10x25 (4 pcs), Washer 10.5x20x2 (4 pcs), Nut M10 (4 pcs)
Required Equipment

Torque wrench 45 Nm
Assembly
1. Fit the corona ring (1).
2. Tighten the bolts.

Torque
45 Nm
End of instruction
42 2017-11-01 1HSB439954-2en
5 Installation
5.10 Lifting the Operating Mechanism
Required Equipment
Lifting tackle
Lifting device
Lifting Following Delivery in Box
Lifting Following Delivery on Pallet
1HSB439954-2en 2017-11-01 43
5 Installation
Lifting Instructions
DANGER!
Use a lifting tackle that is designed for the weight!
NOTE!
The lifting slings must not be placed around the cabinet when lifting.
1. Check that the retaining bolts for the lifting rails are securely tightened.
2. Attach the lifting slings to the lifting brackets on

the operating mechanism. NOTE!
If the operating mechanism is to be
lifted out of a box, one of the slings
needs to be attached to a bracket and
the other sling around the bottom of the
mechanism.
3. Lifting the operating mechanism.
End of instruction
44 2017-11-01 1HSB439954-2en
5 Installation
5.11 Installation of Operating Mechanism
General
The operating mechanism is adjusted on delivery, i.e. the close spring is correctly set to the corresponding
circuit breaker pole.
WARNING!
Before assembling, check that the serial numbers on the circuit breaker pole and operating
mechanism match.
Operating Mechanism
1 Bolts M12x50 (10 pcs), nuts M12 (10 pcs), washers 13x24x2.5 (20 pcs)
2 Spring washer 13x29x3 (4 pcs)
Safety
WARNING!
The operating mechanism must not be closed, operated nor have charged close springs until all
tasks related to installation and adjustment of the circuit breaker have been completed.
Required Equipment

Torque wrench 79 Nm
1HSB439954-2en 2017-11-01 45
5 Installation
1. Dismantle all covers (1) on the poles and indicator

signs (2).
2. Lifting the operating mechanism. Described in section Lifting the Operating

Mechanism, page 43
3. Position the operating mechanism and secure See illustration in Operating Mechanism, page 45.
using bolts, washers and nuts (1, 2). Tighten
finger-tight.
4. Finally tighten the bolted joints using a torque See illustration in Operating Mechanism, page 45.
wrench.
Torque
Tightening torque item 1 = 79 Nm
End of instruction
46 2017-11-01 1HSB439954-2en
5 Installation
5.12 Assembly of Protective Tube
Overview
1 Bolt M12x50 (16 pcs), nut M12 (16 pcs),washer 13x24x2.5 (32 pcs)
Required Equipment

Torque wrench 79 Nm
1. Fit the pull-rods in the protective tubes and then fit the protective tubes.
2. Tighten the bolted joints (1) using a torque

NOTE!
wrench.
Tightening torque 79 Nm.
End of instruction
1HSB439954-2en 2017-11-01 47
5 Installation
5.13 Final Assembly of the Circuit Breaker Pole.
General
This section describes the final assembly of the circuit breaker poles, and should be carried out when the
operating mechanism is fitted.
Overview
Required Equipment
MK toolbox 6880 768-7 -

Torque wrench - 300-550 Nm
Instructions
1. Tighten the support structure to the foundation See section Assembly of Support Structure,
using the upper nuts. page 31.
Torque
300-350 Nm (M24).
500-550 Nm (M30).
48 2017-11-01 1HSB439954-2en
5 Installation
2. Tighten the cross-bracings on support structure.

Torque
420 Nm
3. Tighten the circuit breaker poles to the support

Torque
structure.
420 Nm
End of instruction
1HSB439954-2en 2017-11-01 49
5 Installation
5.14 Fitting of Rod System
5.14.1 Preparations for Fitting of Rod System
General
Each circuit breaker pole is adjusted on delivery as per basic settings. The circuit breaker poles must be
adjusted to the correct open position when the pull-rods are fitted between the operating mechanism and the
circuit breaker poles.
The pull-rods are fitted in several steps,which must be conducted in the correct order:
• Preparatory measures as per this section.
• The pull-rod between the operating mechanism and circuit breaker pole A1 is fitted as specified in
section Fitting the Pull-Rod Between the Operating Mechanism and the Circuit Breaker Pole, page 51.
• The pull-rods between the circuit breaker poles are fitted as specified in section Fitting the Pull-Rod
Between the Poles, page 54.
Required Equipment
Preparatory Measures
1. Check that the latch pawl on the closing lever (1)

rests against the roller in the close catch.
2. Adjust the operating mechanism (shown in figure

to the right):
• Press the latch pawl (1) down onto the
operating lever by inserting a tool, e.g. a
large screwdriver, into the hole (2).
• Now move the operating lever to the right,
past the trip latch assembly.
End of instruction
50 2017-11-01 1HSB439954-2en
5 Installation
5.14.2 Fitting the Pull-Rod Between the Operating Mechanism and the Circuit Breaker
Pole
General
Each pole has a basic setting on delivery and its open position is preset. Adjustments are made as shown in
this section.
Pull-Rod
1 Mechanism housing
2 Pull-rod from operating mechanism
3 Operating lever (operating mechanism)
4 Linkage joint (circuit breaker pole)
5 Turnbuckle screw
6 Spring washers (2 pcs)
7 Control hole in lever
8 Lock nut
9 Control hole, pull-rod
10 Control hole, linkage joint
11 Operating lever (mechanism housing)
1HSB439954-2en 2017-11-01 51
5 Installation
Required Equipment
Equipment ABB part no. Note
Pin with Ø 6 mm - Used to check the position as per instructions.

Torque wrench - 330 Nm
Instructions
NOTE!
Each pole has a basic setting on delivery and its open position is preset.
1. The turnbuckle screw (5) is supplied for the

operating mechanism. Possible placement (12) of
the turnbuckle screw (5) in the operating
mechanism.
12. Possible placement of turnbuckle screw in

operating mechanism.
2. Move the operating lever (3) and pull-rod from the

NOTE!
operating mechanism (2) out by hand far enough
to ensure that the turnbuckle screw (5) can be The operating mechanism's pull-rod
placed between the linkage joint (4) and the must not be pushed in too far causing it
pull-rod from the operating mechanism. to be locked in its inner closed position.
3. Turn the turnbuckle screw (5) into the operating

NOTE!
mechanism's pull-rod (2) (right-hand thread) and
the pole's linkage joint (4) (left-hand thread) at the Remember to fit two spring washers (6)
same time. under each lock nut (8).
4. Turn the turnbuckle screw (5) inward to reduce its

NOTE!
length, at the same time as the operating lever (3)
moves to its open position. The turnbuckle screw (5) has the
correct length when the operating lever
(3) is in its open position and the
control hole (7) is aligned with the
drilled hole in the mechanism housing
(1).
5. Check the position of the hole (7) using a pin with a diameter of 6 mm.
6. Check that the pull-rod (2) is threaded past the control holes (9 and 10).
52 2017-11-01 1HSB439954-2en
5 Installation
7. Torque-tighten the lock nuts (8).

Torque
IMPORTANT! 330 Nm
Make sure that the connector (4) is
parallel to the legs of the operating
lever (11) and not rotated when
tightening.
End of instruction
1HSB439954-2en 2017-11-01 53
5 Installation
5.14.3 Fitting the Pull-Rod Between the Poles
General
This section describes the installation of the pull-rod between poles. Assembly presupposes that the pull-rod
between the operating mechanism and the closest pole has been fitted, see section Fitting the Pull-Rod
Between the Operating Mechanism and the Circuit Breaker Pole, page 51 .
Overview
1 Linkage joints (right-hand thread)

2 Lock nut (right thread)
3 Lock nut (left thread)
4 Pull-rod
5 Linkage joints (left-hand thread)
6 Operating lever
7 Locking bolt with square washer
8 Cylindrical pin
9 Spring washer
10 Control hole in operating lever
54 2017-11-01 1HSB439954-2en
5 Installation
Required Equipment

Locking fluid Loctite 270
Instructions
1. Fully thread the lock nuts (2 and 3) onto the

NOTE!
pull-rod (4) ends. This is particularly important for
the lock nut (3). Double nuts (3)!
2. Fit two spring washers (9) on the pull-rod's right end (4) and thread on the linkage joint (1) with two
turns of the pull-rod (4).
3. Remove the locking bolt with square washer (7), pin (8) and linkage joint (5) from the operating lever
(6) in pole B and thread on the linkage joint with two turns of the pull-rod (4). Push the linkage joint
down between the operating lever's (6) shanks.
4. Turn the pull-rod using the counter-tightened nuts (3) to ensure that the rod is threaded into the linkage
joints in both poles B1 and A1, and in doing so reducing the gap between the linkage joints.
5. Fit the cylindrical pin (8) and locking bolt with

Torque
square washer (7), when the gap is shorten so
that the holes, Ø 25, in the lever (6) and the 22.5 Nm.
linkage joint (5) are aligned.
Tighten the locking bolt and secure with locking
fluid, 70.
6. After the cylindrical pin has been fitted and secured with the locking bolt, washer and Loctite: continue
turning the pull-rod in the same direction.
The resistance will increase as the operating lever (6) is pulled towards closed position (to the right)
and the B1 pole's trip spring is pressed together.
7. Lock the pull-rod using the lock nuts (2, 3) when

Torque
the control hole (10) is aligned with the
corresponding control hole in the mechanism 330 Nm
housing. Tighten the lock nuts.
8. Fit the pull-rod between poles B1 and C1 in the same way.
End of instruction
1HSB439954-2en 2017-11-01 55
5 Installation
5.15 Assembly of Gas Monitoring System
Cable Wiring
1 Protective tube
2 Pipe clamps
3 Bolt M6x25 (5 pcs), nut M6 (5 pcs), washer 6.4x15x1.5 (10 pcs), retaining plate (5 pcs)
4 Bushing
5 Flange
6 Cable gland
7 Sealing ring
8 Nut
9 Pipe clamps (4 pcs)
10 Bolt M5x20 (4 pcs), nut M5 (4 pcs), washers 5.3x10x1 (8 pcs)
Safety
NOTE!
When fitting the gas monitoring system, the greatest possible cleanliness must be observed.
56 2017-11-01 1HSB439954-2en
5 Installation
Required Equipment

23-mm drill bit
Assembly
1. Secure the protective tubes (1) to the support structure using pipe clamps (2), and bolts, nuts and
washers (3).
2. Fit a bushing (4) to each cable which is to be run through the protective tubes and through the cable.
3. Also fit bushings to the other ends of the protective tubes.
4. Connect the cable to the density monitor's terminal blocks.
5. Drill three holes with Ø 23 mm in the flange (5) in the bottom of the operating mechanism and fit the
cable glands (6) in the holes using grommets (7) and nuts (8).
6. Push the cables through the cable glands in the operating mechanism and connect them to the
terminal blocks specified in the applicable diagram for the device.
7. Tighten the cable glands (6) for attaching the cable.
8. Secure the cables to the support structure leg

NOTE!
using pipe clamps (9), and bolts, nuts and
washers (10). The cable end to the density monitor
should be sufficiently long to ensure the
density monitor can be removed from
the non-return valve without having to
disconnect the cable.
End of instruction
1HSB439954-2en 2017-11-01 57
5 Installation
5.16 Fitting the Distribution Block (Option)
Overview
For easier access when filling with gas, the device can be equipped with a distribution block (valve block)
with several gas valves. The distribution block is fitted on to the support structure.
1 Gas tube
2 Pipe clamps (the quantity depending on the height of the support structure)
3 Bolt M5x20, nut M5, washer 5.3x10x1 (the quantity depending on the height of the support
structure)
4 Bracket
5 Bolt M8x25 (4 pcs), washer M8 (4 pcs), nut 8.4x16x1.6 (8 pcs)
6 Clamp washer (2 pcs)
7 Bolt M8x35 (2 pcs), nut M8 (2 pcs), washer 8.4x16x1.6 (4 pcs)
8 Valve block
9 Bolt M8x25 (4 pcs), washer 8.4x16x1.6 (4 pcs)
10 Rain protection
11 Stay (2 pcs)
12 Bolt M6x20 (2 pcs), nut M6 (2 pcs), washer 6.4x12x1.6 (4 pcs)
13 Gas valve, mechanism housing
58 2017-11-01 1HSB439954-2en
5 Installation
Safety
NOTE!
When fitting the gas monitoring system, the greatest possible cleanliness must be observed.
WARNING!
The gas tube assembly sequence must be followed, otherwise there is a risk of gas leakage.
Required Equipment

23-mm drill bit
Torque wrench 10 Nm
Assembly
1. Bracket (4) secured to the support structure using clamp washers (6) along with bolts, nuts and
washers (7).
2. Fit the valve block (8) to the bracket (4) with bolts and washers (9).
3. Secure the rain protection (10) and stay (11) to the bracket (4) with bolts, nuts and washers (5).
4. Secure the stay (11) to the rain protection (10) with bolts, nuts and washers (12).
5. The gas tube (1) is secured to the support

Torque
structure using pipe clamps (2) bolts, nuts and
washers (3). Drill a Ø5.5 mm hole for each pipe 10 Nm
clamp when installing.
Fit the lower nut to the gas tube (1) against the
valve block's gas valve (8) and tighten it to its
bottom position.
6. Fit the upper nut to the gas tube (1) against the
Torque
mechanism housing's gas valve (13) and tighten it
to its bottom position. 10 Nm
WARNING!
In order to avoid gas leakage, the gas
tube must first be connected to the gas
valve on the valve block.
End of instruction
1HSB439954-2en 2017-11-01 59
5 Installation
5.17 Electrical Connections
5.17.1 Connecting the Circuit Breaker's Operating Mechanism
General
This section describes the connection of the external cabling to the operating mechanism.
Required Equipment

Torque wrench 10 Nm
Connection
1. Connect the earth cable to the earth terminal (1)

on the side of the cabinet.
1. Earthing terminal
2. Run the cables for the operating and signal conductors through the flange at the bottom of the cabinet.
3. Fit the flange with an appropriate seal for the cable in question.
4. Connect the cables to the coupling terminals as

NOTE!
per the applicable connection diagram.
As standard the terminals are of the
plug-in type for multicore cable and are
in conduit or disconnectable designs.
The through-wiring design is for the
connection of max 4 mm2 conductor
area and the disconnectable design for
the connection of max. 6 mm2
conductor cross-sectional area. The
disconnectable design is intended for
motor, AC and power supply circuits.
End of instruction
60 2017-11-01 1HSB439954-2en
5 Installation
5.17.2 Fitting the High-Voltage Terminals
General
This section describes the fitting of the rails and lines.
Safety
WARNING!
Work must not be performed on pressurized circuit breakers.
NOTE!
Bimetal washers are positioned so that their aluminum sides face the aluminum surfaces. The
copper sides are turned towards the copper- or silver-plated surfaces.
NOTE!
Contact paste must only be used on fixed joints. It must not be used inside the interrupter units.
Remember:
High voltage lines, which consist of aluminum rails or aluminum attachments for lines, can, after treatment
with contact paste, be connected directly to the interrupter unit's adapter plates, which are made of aluminum.
However, if copper bars or copper attachments are used for conductors, grease must be used and a bimetallic
washer fitted to the connection. Bimetallic washers can be supplied from ABB on request.
Connect all support structures to the existing grounded net
Required Equipment
Fine abrasive material or emery cloth - e.g. Scotch Brite no 7447

Grease "SV" 1171 4016-610 See section Types of Grease,
page 18 for details.
Treatment with Grease
1. Clean the contact surfaces of grease or old paste.
2. Polish the surfaces with a fine abrasive material, e.g. Scotch Brite no. 7447 or using an emery cloth.
3. Apply grease to the aluminum and copper surfaces immediately after polishing.
4. Assemble the joint
5. Wipe off any unnecessary grease.
End of instruction
1HSB439954-2en 2017-11-01 61
5 Installation
5.18 Pressurizing of Circuit Breaker Poles
5.18.1 Preparations for Gas Filling
General
The circuit breaker poles are delivered vacuum processed and filled with SF6 gas to a pressure of 0.12-0.13
MPa abs at 20°C.
NOTE!
If gas tubes and gas blocks are stored outside of room temperature, we recommend that they
should be flushed with nitrogen (N2). Allow gas flush to continue for 4-5 minutes, to make sure
the gas system is free from moist.
Safety
WARNING!
When commissioning, the gas must be filled to the pressure specified on the rating plate. The
filling pressure has to be compensated for, depending on the temperature, in accordance with the
table.
WARNING!
Any transport damage to the insulators means there will be a safety risk when filling with gas. To
avoid personal injury when filling, installation personnel must exercise caution, staying in a
protected and safe area away from the circuit-breaker. The gas cylinder is placed at the same
location as the filling device.
Local safety regulations must be applied.
Preparations
WARNING!
Check that the protective motor switch is set to Off and that all the springs are discharged.
1. Connect the cables to the operating mechanism's

WARNING!
connection blocks for close and open operations.
The cables must be run from the circuit
breaker to a protected location. For
personal safety, the circuit breaker
must be remotely operated from the
protected location. Local safety
regulations must be applied.
2. Connect the cables to suitable test equipment.
3. Set the operating mechanism Local/Remote

WARNING!
switch to the "Remote" position.
The circuit breaker must be filled with
gas before it can be operated. Local
safety regulations must be applied.
62 2017-11-01 1HSB439954-2en
5 Installation
4. If the operating values are to be measured,

WARNING!
connect the performance testing device with
variable control voltage and time measurement. For the sake of personal safety, the
performance testing device must be
connected before gas filling takes
place.
End of instruction
1HSB439954-2en 2017-11-01 63
5 Installation
5.18.2 Gas Filling Equipment
Gas Filling Components
1 Density monitor (without indicator) 8 Hose

2 Density monitor (with indicator) 9 Valve
3 Gas bottle 10 Cross-connection
4 Valve 11 SF6 regulator
5 Nipple with clamp nut 12 Circuit breaker non-return valve

6 Coupling link 13 N2 (CF4) regulator
7 Plug-in nipple
64 2017-11-01 1HSB439954-2en
5 Installation
5.18.3 Gas Filling with SF6 Gas
General
This section describes how the circuit breaker is filled with SF6 gas. For instructions on filling mixed gas, see
page Filling of Mixed Gas, page 69.
WARNING!
If the density monitor is turned immediately AFTER tightening, there is a risk of damaging the
capillary tube inside the density monitor, resulting in gas leakage, incorrect indication and/or
alarms not triggering.
All warranty obligations are invalidated by incorrect operation.
Required Equipment
Gas filling equipment 1HSB 445439-A Only used for SF6 gas.
When delivered, the hose included in the

equipment is vacuum-pumped and filled with SF6
gas.
Grease "G" 1171 4014-407 More information in section Types of Grease,
page 18.
Torque wrench 10 Nm
Filling Pressure (SF6 Gas)
NOTE!
When reading the pressure gauge, the filling pressure must be corrected depending on the
temperature.
The filling pressure in MPa (abs) is stated on the rating plate

0,5 0,7 0,8 0,95
Read the filling pressure on the manometer in
Temperature MPa MPa MPa MPa MPa MPa MPa MPa
at gas filling (abs) (abs) (abs) (abs) (abs) (abs) (abs) (abs)
°C
+40 0,54 0,44 0,76 0,66 0,87 0,77 1,04 0,94
+30 0,52 0,42 0,73 0,63 0,84 0,74 1,00 0,90
+20 0,50 0,40 0,70 0,60 0,80 0,70 0,95 0,85
+10 0,48 0,38 0,67 0,57 0,76 0,66 0,90 0,80
0 0,46 0,36 0,64 0,54 0,72 0,62 0,86 0,76
-10 0,44 0,34 0,60 0,50 0,69 0,59 0,81 0,71
-20 0,42 0,32 0,57 0,47 0,65 0,55 - -
-30 0,39 0,29 - - - - - -
bar = MPa x 10
1HSB439954-2en 2017-11-01 65
5 Installation
Gas Filling Instructions
NOTE!
Do not use any sharp tools!
1. Put the gas bottle (3) in a protected place.
2. Check the filling pressure on the circuit-breaker's rating plate
3. Fit the regulator (11) to the gas cylinder (3).
4. Connect the coupling (6) to the circuit breaker's The circuit breaker's non-return valve (12) may be
non-return valve (12). located on the mechanism housing or on the gas
block.
Gas filling takes place via the gas block, which
then distributes the gas to the pole(s).
5. Connect the gas filled hose (8) to the coupling link (6).
6. Connect the gas filled hose (8) to the gas bottle (3) via the regulator (11).
7. Connect a density monitor (1, 2) or a precision Precision pressure gauges are not included in the
manometer to the cross-connection outlet (4). delivery.
WARNING!
If the density monitor is turned
immediately AFTER tightening, there is
a risk of damaging the capillary tube
inside the density monitor, resulting in
gas leakage, incorrect indication and/or
All warranty obligations are invalidated
by incorrect operation.
8. Open the valve (9).
9. Close the motor protection switch to tension the

1. The close spring is fully discharged. NOTE! The
close spring.
trip spring is charged if the circuit breaker is
closed.
NOTE!
Check that the indicator shows charged 2. The driver is in contact with the closing catch.
springs The close spring has started to charge. NOTE: No
work must be performed on the operating
mechanism. The spring should be considered as
charged.
3. The closing spring is fully charged.
10. Switch off the protective motor switch.
11. Open the tap to the gas bottle (3).
66 2017-11-01 1HSB439954-2en
5 Installation
12. Gradually fill the circuit breaker with gas via the
NOTE!
regulator, in steps of 0.5 bar up to full pressure (to
avoid ice build-up). When reading a manometer that is not
temperature compensated, the filling
WARNING! pressure must be corrected depending
on the ambient temperature, in
For personal safety, the circuit breaker
accordance with the table Filling
must be filled with gas from a protected
Pressure (SF6 Gas), page 65.
location. Local safety regulations must
be applied.
13. Wait until the gas temperature has reached the circuit breaker's temperature level and then read the
pressure on the density monitor/precision manometer.
14. Adjust the pressure where necessary.

NOTE!
When reading a manometer that is not
pressure must be corrected depending
15. Shut off the tap to the gas bottle (3).
16. Test the operation of the circuit breaker by

WARNING!
Close-Open switching three times from a
protected location. For personal safety, the circuit breaker
must be remotely operated from a
17. Remove the hose (8) from the coupling link (6).
18. Remove the coupling (6) from the circuit breaker's non-return valve (12).
19. Unload the regulator's pressure so that an incorrect pressure is not obtained before the next fill.
20. Install the density monitor with new O-rings that have been smeared with grease "G", on to the circuit
breaker's non-return valve.
21. Torque tighten the clamp nut on the density

monitor.
WARNING!
Torque
10 Nm
1HSB439954-2en 2017-11-01 67
5 Installation
22. Perform a gas system tightness check. See section Gas System Tightness Check, page 77.
NOTE!
A new or overhauled circuit breaker
should have its gas system tightness
checked by reading the density monitor
after 1 month and then as specified in
the maintenance schedule.
End of instruction
68 2017-11-01 1HSB439954-2en
5 Installation
5.18.4 Filling of Mixed Gas
General
The breaker shall be filled with blended gas (SF6 - and N2 - or CF4 gas) at lower temperatures to avoid
condensation of SF6 gas. See the rating plate if this should be done or not.
Follow the information on the rating plate for the gas mixture proportions. Example: For a circuit breakers
with filling pressure of 0.70 MPa abs (+20ºC), fill first with 0.52 x 0.7 = 0,36 MPa abs (+20ºC) SF6 gas and
then N2 - or CF4 gas to 0.70 MPa abs (+20ºC).
WARNING!
If the density monitor is turned immediately AFTER tightening, there is a risk of damaging the
capillary tube inside the density monitor, resulting in gas leakage, incorrect indication and/or
All warranty obligations are invalidated by incorrect operation.
Remember:
NOTE!
When filling with mixed gas, the SF6 gas must always be filled first.
NOTE!
When reading the precision measuring instrument, the filling pressure must be corrected
depending on the temperature in accordance with the table.
Filling Pressure (Mixed Gas)
The filling pressure in MPa (abs) is stated on the rating plate

Total filling Total filling Total filling
SF6 SF6 SF6
pressure pressure pressure
Read the filling pressure on the manometer in
Temperature at MPa (abs) MPa (abs) MPa (abs) MPa (abs) MPa (abs) MPa (abs)
gas filling °C
+40 0,39 0,75 0,39 0,87 0,39 1,04
+30 0,37 0,72 0,38 0,84 0,38 1,00
+20 0,36 0,70 0,36 0,80 0,36 0,95
+10 0,35 0,66 0,34 0,76 0,34 0,90
0 0,33 0,63 0,32 0,72 0,33 0,86
-10 0,32 0,61 0,31 0,69 0,31 0,81
-20 0,30 0,58 0,29 0,65 - -
-30 0,29 0,57 - - - -
bar = MPa x 10
MPa (atö) = MPa (abs) -0.1
1HSB439954-2en 2017-11-01 69
5 Installation
Required Equipment
Gas filling equipment 1HSB445439-B Only used for mixed gas.

When delivered, the hose included in the
equipment is vacuum-pumped and filled with
SF6 gas.

Grease "G" 1171 4014-407 More information in section Types of Grease,
page 18.
Gas Filling
NOTE!
Do not use any sharp tools!
1. Put the gas bottle (3) in a protected place.
2. Check the filling pressure on the circuit-breaker's rating plate
3. Fit SF6 regulator (11) to the gas cylinder (3) with

WARNING!
SF6 gas.
When filling with mixed gas, the SF6
gas must be filled first !
4. Connect the coupling (6) to the circuit breaker's The circuit breaker's non-return valve (12) may be
non-return valve (12). located on the mechanism housing or on the gas
block.
Gas filling takes place via the gas block, which
then distributes the gas to the pole(s).
5. Connect the gas filled hose (8) to the coupling link (6).
WARNING!
70 2017-11-01 1HSB439954-2en
5 Installation
9. Close the motor protection switch to tension the

1. The close spring is fully discharged. NOTE! The
close spring.
trip spring is charged if the circuit breaker is
closed.
NOTE!
Check that the indicator shows charged 2. The driver is in contact with the closing catch.
springs The close spring has started to charge. NOTE: No
work must be performed on the operating
mechanism. The spring should be considered as
charged.
3. The closing spring is fully charged.
10. Switch off the protective motor switch.
NOTE!
be applied.

NOTE!
16. Remove the hose (8) from the regulator (11).
17. When all circuit breakers are filled with SF6 gas,
NOTE!
discharge the regulator (11) by pressing in the
Fill all the circuit breakers with SF6 gas
non-return valve and detaching the regulator (11)
from the gas cylinder (3). first.
18. Fit N2 regulator (13) on the CF4 gas bottle (3).

NOTE!
N2 - and CF4 gas uses the same
regulator.
1HSB439954-2en 2017-11-01 71
5 Installation
WARNING!
NOTE!
be applied.

NOTE!
27. Test the operation of the circuit breaker by

WARNING!
Close-Open switching three times from a
protected location. For personal safety, the circuit breaker
must be remotely operated from a
28. Remove the hose (8) from the coupling link (6).
29. Remove the coupling (6) from the circuit breaker's non-return valve (12).
30. Unload the regulator's pressure so that an incorrect pressure is not obtained before the next fill.
31. Install the density monitor with new O-rings that have been smeared with grease "G", on to the circuit
breaker's non-return valve.
72 2017-11-01 1HSB439954-2en
5 Installation
32. Torque tighten the clamp nut on the density

monitor.
WARNING!
Torque
10 Nm
33. Perform a gas system tightness check. See section Gas System Tightness Check, page 77.
NOTE!
A new or overhauled circuit breaker
should have its gas system tightness
checked by reading the density monitor
after 1 month and then as specified in
the maintenance schedule.
34. Install the gas monitoring system when all poles See Assembly of Gas Monitoring System, page 56 .
are filled with gas.
NOTE!
The circuit breaker must not be
operated until the gas monitoring
system has been installed!
End of instruction
1HSB439954-2en 2017-11-01 73
5 Installation
5.19 Inspection of Bolt Joints
General
WARNING!
Check that the operating mechanism's close spring is fully discharged before commencing work. If
the close spring is not discharged, discharge as specified in section Discharge the Springs
Electrically, page 9 .
Inspection
Before the circuit breaker is put into service, the following must be inspected.
• Use a pin, Ø 6 mm, to check that the outer lever’s control hole is aligned with the predrilled hole in the
mechanism housing.
• Ensure that all bolted joints are tightened to the right torque.
74 2017-11-01 1HSB439954-2en
5 Installation
5.20 Assembling the Indicator Sign and Cover
Instructions
WARNING!
Required Equipment
1. Fit the end cover (1) to the mechanism housing

and torque tighten the bolts, washers and nuts (2).
Torque
79 Nm (M12).
2. Fit the indicator sign (2) on the pole nearest to the

operating mechanism and torque tighten the bolts
and washers.
1. Cover
2. Indicator sign
Torque
22.5 Nm.
1HSB439954-2en 2017-11-01 75
5 Installation
3. Fit all covers (1) using bolts torque tighten the

Torque
bolts and washers.
9,5 Nm
End of instruction
76 2017-11-01 1HSB439954-2en
5 Installation
5.21 Inspection Prior to Commissioning
5.21.1 Gas System Tightness Check
General
This section describes how you perform a tightness check with leak spray around the density monitor and the
gas tube's connections.
Connections
1 Density Monitor
2 Connections
Required Equipment
Equipment Description
Leak spray -
Instructions
1. If the connections are not tight:

• disconnect the connections.
• check the O-rings and contact surfaces.
• replace the seals where necessary.
2. Perform a new gas system tightness check.
End of instruction
1HSB439954-2en 2017-11-01 77
5 Installation
5.21.2 Final Inspection of Rod System
General
Before final inspection of the rod system, you must fill the circuit breaker with gas to nominal filling pressure
(in order to be able to operate the circuit breaker). See Pressurizing of Circuit Breaker Poles, page 62.
Overview
1 Pole nearest to operating mechanism

2 Center pole
3 Outer pole
4 Lock nut (right thread)
5 Control hole in operating lever
6 Lock nut (left thread)
7 circuit breaker in "CLOSED" position
8 circuit breaker in "OPEN" position
Required Equipment

Cylindrical pin Diameter 6 mm
78 2017-11-01 1HSB439954-2en
5 Installation
Final Inspection of Rod System
The instructions below describe how the rod system is checked prior to commissioning.
1. Close the circuit breaker from a protected location.
2. Tighten the lock nuts (4) moderately.
3. OPEN the circuit breaker from a protected location.
4. Use a cylindrical pin, Ø 6 mm, to check that the

Torque
control hole (5) is aligned with the hole in the
mechanism housing. Any necessary adjustment is 300 Nm
made by undoing the lock nuts and turning the
pull-rod. Tighten the lock nuts (4) for all poles.
5. Check that the pull-rods are threaded past the coupling link's control hole (5).
6. Close the circuit breaker from a protected location.
7. Tighten all lock nuts (4).

Torque
300 Nm
8. Perform another OPENCLOSE and an OPEN operation from a protected location.
9. Finish by setting the control switch in the operating mechanism in OPEN position.
End of instruction
1HSB439954-2en 2017-11-01 79
5 Installation
6 Commissioning
6 Commissioning
6.1 Introduction
General
Before the circuit breaker is put into service, all the inspections in accordance with Pre-Commissioning
Checklist, page 82 for installation and commissioning must have been carried out and the operating values
for the installation completed, see Operating Values and Signature, page 84.
Reset all connection circuits as per the applicable circuit diagram and verify the tightening torque for the
affected coupling terminals.
Put the help tools back in their holders.
1HSB439954-2en 2017-11-01 81
6 Commissioning
6.2 Pre-Commissioning Checklist
General
WARNING!
Before the circuit breaker is put into service

• all checks for circuit breaker poles, operating mechanism and gas filling must have been conducted as
described in this section.
• the checklist is completed and filed.
Identification
Date:
Installation:
Serial number (circuit breaker manufacturing number):
Inspection of Circuit Breaker Pole
1. Check that the circuit breaker and the operating mechanism have been assembled as per the
installation instructions.
2. Ensure that all bolted joints are tightened to the correct torque.
3. Check that all circuit breaker poles are in open position. The control hole in the outer lever should be
aligned with the predrilled hole in the mechanism housing. The pull-rods must be threaded past the
control holes on the linkage joints.
End of instruction
Check of Operating Mechanism
1. Make a visual inspection to check if the damper has leaked oil into the operating mechanism.
2. Verify the torque of the bolts in the connection blocks that have been affected by the assembly.
3. Check the functionality of the heating element.
4. Check that the thermostat, if any, is set to 10 °C. Other settings may occur in accordance with
customer specifications.
End of instruction
82 2017-11-01 1HSB439954-2en
6 Commissioning
Check of Gas Filling
1. Check the gas filling and test run as per See Gas Filling with SF6 Gas, page 65 or Filling
instructions of Mixed Gas, page 69.
End of instruction
1HSB439954-2en 2017-11-01 83
6 Commissioning
6.3 Operating Values and Signature
Check of Operating Values.
Check the operating values for the circuit breaker against data applicable to the circuit breaker in Operating
Values, page 22 and note the measured values in the table below.
Check Below Measured values Measured values Measured values

Pole A Pole B Pole C
Closing time (close coil I) ms ms ms

Closing time (close coil II) ms ms ms
Opening time (trip coil I) ms ms ms
Opening time (trip coil II) ms ms ms
Close-Open time ms ms ms
Lowest control voltage close coil I V V V
Lowest control voltage close coil II V V V
Lowest control voltage trip coil I V V V
Lowest control voltage trip coil II V V V
Main circuit resistance μΩ μΩ μΩ
Filling pressure (2) MPa (abs) MPa (abs) MPa (abs)
(2) Filling pressure is as specified on the rating plate.
IMPORTANT!
The circuit breaker must not be operated Open-Close without an intermediate delay of 300 ms.
Signing
After the inspections have been completed, this document must be signed. If all the inspections in this section
have been carried out, the circuit breaker can be put into service.
Inspection conducted by: ___________________________________________________
84 2017-11-01 1HSB439954-2en
7 Maintenance
7 Maintenance
7.1 Introduction
General
These maintenance instructions give recommendations for care and guidelines for maintenance of
high-voltage circuit breakers.
WARNING!
For maintenance work that requires work on the circuit breaker or operating mechanism, it is
important that both the on and off springs are discharged. See Discharge the Springs, page 9 .
Instructions
The instructions are divided into:

• Inspection intervals
• Instructions for preventive maintenance of circuit breakers
• Instructions for preventive maintenance of operating mechanisms
The periodic maintenance should be carried out at specified time intervals or number of operations.
Equipment should be overhauled in line with specified criteria such as a certain number of operations.
Overhauls should be made by authorized service personnel.
1HSB439954-2en 2017-11-01 85
7 Maintenance
General
This section specifies the equipment needed for routine maintenance of the circuit breaker.
Tool

Alternatively, the existing tool equipment may
be used.
Feeler gauge -
Multimeter -
Cleaning Equipment
Vacuum cleaner -
Lint-free drying cloths -
Lubricant
Grease "G" 1171 4014-407 See sections Types of Grease, page 18 and Oil
Types, page 17 for ABB part numbers,
Grease "M" 1171 4014-406
suppliers and trade names.
Oil "A" 1171 4016-606
1171 4016-612
1171 2039-1
1171 7011-106
Anti-rust agent, Valvoline Tectyl 506 1241 0011-108
86 2017-11-01 1HSB439954-2en
7 Maintenance
7.3 Description of Maintenance Categories
Maintenance Categories
The following inspection schedule includes important checking points, acceptable tolerances, functional
values for certain adjustments and recommended inspection intervals, along with competence requirements.
In corrosive or polluted air environments and in climates with high humidity, it may be necessary to halve the
inspection interval. The specified inspection intervals should be regarded as recommended guidelines that can
either be extended or shortened depending on local conditions.
Category A
Action/explanation Interval Condition of Requirement

Circuit Breaker
Visual inspection 1-2 years a1 a2
Category B

Circuit Breaker
Preventive Maintenance 15 years or 5,000 b1 b2
operations 2)
General overhaul of circuit breaker and
operating mechanism
Thermography
Category C

Circuit Breaker
Overhaul of breaking chamber c1 c2
Overhaul of line and transformer circuit ΣnxI2=20,000 c1 c2
breakers
Overhaul of capacitor bank circuit breakers, 2,500 operations c1 c2
reactor circuit breakers and filter circuit
breakers without point-on-wave control
Overhaul of capacitor bank circuit breakers, 5,000 operations 1) c1 c2
reactor circuit breakers and filter circuit
breakers with point-on-wave control
Category D

Circuit Breaker
Overhaul of complete circuit breaker and After 30 years or d1 c2
operating mechanism. 10,000 operations2)
Explanations
1)The load currents from normal Close and Trip operations should not be included in the calculation. These
are only included in the calculations when counting the total number of mechanical Close and Open
operations.
2)Special requirements for resistance checks for circuit breakers; >100 close and tripping operations executed
per year.
1HSB439954-2en 2017-11-01 87
7 Maintenance
Condition of Circuit Breaker
The following specifies the condition in which the circuit breaker should be for the various maintenance
activities.
a1 Circuit breaker in operation.

b1 Close spring discharged, circuit breaker open, disconnected and grounded. If thermography (heat
measurement) is part of the maintenance activity, this should be done during normal load before
the circuit breaker trips
c1 Close spring discharged, circuit breaker open, disconnected and grounded. The circuit breaker
poles/interrupter units are dismantled and transported to the workshop.
d1 Close spring discharged, circuit breaker open, disconnected and grounded. The entire circuit
breaker with operating mechanism is transported to the workshop
Competence Requirements
The following describes the necessary requirements for personnel carrying out maintenance work.
a2 Substation personnel without special training

b2 Personnel authorized by ABB to carry out assembly, commissioning and maintenance work
c2 Personnel authorized by ABB to carry out assembly, commissioning and maintenance work. In
some cases support may be required from ABB
88 2017-11-01 1HSB439954-2en
7 Maintenance
7.4 Maintenance Schedule
7.4.1 Category A
Inspected in respect of: Instructions/Tools
Circuit breaker and External cleanliness Exterior Cleaning, page 97, Inspection
operating mechanism of Heating Element, page 103.
Heating element function
Gas pressure
Valves and draining holes
1HSB439954-2en 2017-11-01 89
7 Maintenance
7.4.2 Category B
Maintenance category B takes place at an interval of 15 years or 5,000 mechanical closing/trip operations.
Rating plates Note serial number

Operation counter Note the number of operations
SF6 gas Gas level (filling if required) Gas-filling equipment.
Dew point, for normal gas pressure See Gas Filling with SF6 Gas, page 65.
in the circuit breaker
Dew point meter.
Dew point max. -5 °C at specified
filling pressure and +20 °C
Porcelain insulators External cleanliness Wash and dry the insulators.
Bolts and nuts Rinsing equipment, drying cloths, torque
wrenches.
This is described in Exterior Cleaning,
page 97.
Composite insulators Damage to the insulator
Main circuit Resistance Measurement Resistance values as specified in section
Operating Values, page 22.
Resistance bridge, using a test current of
200-400 A DC.
In the case of circuit breakers with a load
current of less than 400 A, a resistance value
of up to 1000 µOhm is permitted per
interrupter unit.
Thermography The temperature increase in the Carried out at full load prior to shutting down.
outer parts of the interrupter unit
The highest permitted temperature difference
between the phases is 5 °C.
Thermal camera.
Consideration must be taken to the load
current during measurement, both to the
larger variations of the load current 3-4 hours
prior to measurement. See the manual for the
thermal camera.
Mechanism Control hole in outer lever and See Fitting the Pull-Rod Between the Operating
mechanism housing Mechanism and the Circuit Breaker Pole,
page 51.
Function times Opening time Measuring with electronic timing.
Closing time Nominal control voltage
Close-Open time For times, see Operating Values, page 22.
Deviations between phases Maximum time deviation between phases, 4
ms at closing and 3 ms at trip.
Auxiliary switch
Travel curve
Contact damping
Rod system Tightening torque Check of tightening torque for nuts in the rod
system
90 2017-11-01 1HSB439954-2en
7 Maintenance

Anti-pumping relay Function With the circuit breaker in Open position and
the operating mechanism charged, a
simultaneous Close and Open operation is
produced (Close button pressed in).
The circuit breaker carries out a Close/Open
operation and must not Close when the
operating mechanism is charged.
The anti-pump function must be activated as
long as the close impulse lasts. The lowest
control voltage should be measured for the
relay (85% of nominal).
Motor Motor brushes Check the carbon in the motor/motors. If they
are below 10 mm, replace the carbon!
Motor current
The motor current must be measured
towards the end of the charging process. The
maximum permitted motor current is 110 % of
the measurement values received during
routine tests.
The permitted variation in charge time is 30%
of the measurement value obtained during
routine tests.
Damper Oil level If there is an oil leak, replace the whole
damper. Single drops are not to be
considered signs of leakage.
The oil level check can take place during
testing. See Check of Oil Level in Damper,
page 108.
Latch Device Visual inspection of settings For setting the gap in the latch assembly, see
Inspection of Latch Devices, page 106.
Surfaces on shafts and latches are lubricated
using Grease "L". See section Types of Grease,
page 18.
Move the signal from coil 1 to coil 2.
Coils (latch device) Coil resistance and current The coil resistance and current is allowed to
vary ±10% of the measurement value
obtained during routine tests.
Mechanical Play In Open position the interlocking arm must be
Interlocking lifted at least 2 mm above the periphery of
the latch disc.
In Closed position there must be full contact
between the interlocking arm and latch disc
(no play permitted).
Heating Element Resistance Measurement Check the signal for voltage drop, if
applicable.
See Inspection of Heating Element, page 103.
Thermostat (if Adjusted value Check that the thermostat is adjusted to
applicable) comply with the set value.
See Pre-Commissioning Checklist, page 82.
Terminal blocks Bolts and clamps Check that bolts and clamps are properly
tightened.
Protective motor switch Signal for voltage drop Check the signal for voltage drop, if any.
1HSB439954-2en 2017-11-01 91
7 Maintenance

Gas-tight seals Density monitoring Check the density monitors as regards
pressure indicator and signal/break contacts.
NOTE!
The test must take place in normal
air conditions, +20 °C and
101.3 kPa (1,013 mbar).
Remove the density monitor from the circuit

breaker to check the function.
Minimum permitted voltage when
checking: 30 V
See Assembly of Gas Monitoring System,
page 56.
Blocking relays Relays The relays must switch off when a density
monitor is removed from a circuit breaker
pole, pressurized at filling pressure.
WARNING!
May only be carried out when the
circuit breaker is out of service.
Corrosion Operating Mechanism Make a special check of the protected

components in the unheated areas, pull-rod
system, forks and springs.
Treat with anti-rust agent where necessary.
See Cleaning, Lubrication, and Rust Protection
of Operating Mechanism, page 100.
Lubrication Latches Check and lubricate the latches using grease
"L".
Worm gear
Check and lubricate the worm gear using
Spring bridge
grease "M".
Close damper
Lubricate the slide surface of the spring
bridge to the operating mechanism's drive
unit with grease"M" and chains with oil "A".
See Cleaning, Lubrication, and Rust Protection
of Operating Mechanism, page 100.
Tightening Torque Bolt joint Check the tightening torque on all bolt joints.
Operation Test and measurement Operation tests in combination (if possible)
with operating time measurement (incl.
open/close operation time).
92 2017-11-01 1HSB439954-2en
7 Maintenance
7.4.3 Category C
Inspected Interval Instructions/Tools
- Line and transformer circuit Σn x I1.9 = 20 000 Evacuate the gas, dismantle the circuit
breaker breaker poles and transport to a clean
workshop.
Capacitor, reactor and filter 2,500 operations
circuit breakers without Dismantle the breaking chamber
point-on-wave control insulator, fit a new contact set and new
PTFE components.
Capacitor, reactor and filter 5,000 Operations
circuit breakers with Equipment:
point-on-wave control
Standard equipment, tight fitting face
All types of maintenance. During diagnostic mask for dust protection, long-sleeved
testing with overalls, protective gloves of plastic or
non-conformities. rubber.
See Overhaul of Interrupter Unit,
page 139 .
1HSB439954-2en 2017-11-01 93
7 Maintenance
7.4.4 Category D
Inspected Interval Instructions/Tools
Overhaul of complete circuit 30 years or 10,000 Dismantling of circuit breaker pole and
breaker and operating mechanical mechanism. Assembly of new contact set.
mechanism. Close/Open Replacement of other worn components.
operations
If the circuit breaker and the operating
mechanism are being overhauled for a further
2,000 operations, all wear parts must be
replaced.
If the circuit breaker and the operating
mechanism are overhauled for a further 10,000
operations, the entire circuit breaker should be
reconditioned.
Protection against by-products as per standard
equipment above
Instructions:
See chapter Overhaul, page 125.
For operating mechanism, with instructions and
guidance from ABB
Capacitor (if fitted) 30 years or 10,000 Check the values for:
mechanical
C = CN +5%, -0%
Close/Open
operations PD < 5 pC
Tan d < 0.2%
94 2017-11-01 1HSB439954-2en
7 Maintenance
7.5 Maintenance, Circuit Breaker Pole
7.5.1 The Service Life of the Circuit Breaker
General
Assuming that the recommended inspection intervals and actions have been observed, the circuit breaker will
have a service life greater than 30 years or 10,000 mechanical operations.
Maintenance Points
The following points ensure a long service life.

• Contact wear of the arcing contacts is small
• Bearings in the gas space are maintenance-free.
• The seals are designed to have O-rings with double sealing surfaces.
• Each interrupter unit is equipped with a desiccant equivalent to at least the service life of the circuit
breaker.
Replacement of Interrupter Unit
In general there are only three reasons for changing the interrupter units:
Reasons
1 If the number of short-circuits x short-circuit current (kA) approaches the curve, see figure No. of
Operations, page 96The Service Life of the Arcing Contacts in the Event of Short Circuit Breaking,
page 96 .
2 If the number of operations at the line, reactor or capacitor connection, as well as the switching of load
current1) has reached the number under the heading "Interval" in Description of Maintenance Categories,
page 87 .
3 A mechanical fault or incorrect adjustment of the drive system has damaged components in the
interrupter unit.
1)The load currents from normal Close and Open operations are not calculated in the formula. These are only
calculated when counting the total number of mechanical Close and Open operations.
NOTE!
Changing the interrupter unit calls for special instructions and must only be carried out by
qualified and authorized personnel.
Calculations
The graph that shows the restriction to the number of permitted short circuits can be given roughly as:
Formula Explanation
Σn x I2 = 20 000 n = number of short circuits

I = short-circuit current kA (RMS)
In the formula, all levels of short-circuit current are included. E.g. 10x302+20x202+20x102 = 19,000.
1HSB439954-2en 2017-11-01 95
7 Maintenance
7.5.2 The Service Life of the Arcing Contacts in the Event of Short Circuit Breaking
General
The table shows the number of breaks as a function of the breaking current that the contacts in a circuit
breaker can undergo before burn-off is so great that they must be replaced.
Wear on the interrupter unit depends largely on the actual loading and frequency. These values are only a
rough guideline in order to determine when maintenance needs to be carried out.
No. of Operations
n Number of short-circuit current breaks

kA Short-circuit current/Commutation current
96 2017-11-01 1HSB439954-2en
7 Maintenance
7.5.3 Cleaning and Lubrication of Circuit Breakers
Exterior Cleaning
The circuit breaker's porcelain insulators should be cleaned of salt and dirt deposits in conjunction with the
cleaning of other insulators in the substation. The time interval for this cleaning depends on local conditions,
i.e. the degree of air pollution.
Wash and dry the insulators using rinsing equipment and drying cloths.
WARNING!
Work on the circuit breaker when there is a risk for mechanical damage to the insulators should be
executed at reduced gas pressure, 0.125 MPa (abs).
NOTE!
All circuit breakers with porcelain insulators are completely waterproof, i.e. the circuit breakers in
use can be cleaned using water without any risk of moisture penetrating and damaging important
parts.
Composite insulators do not normally require cleaning. Solvents or water rinsing with high
pressure could damage the silicone surface on the insulator.
Cleaning the Mechanism Housing
Clean the mechanism housing where necessary through vacuuming. The time interval for this cleaning
depends on local conditions, i.e. the degree of air pollution.
Lubricant
Only use lubricants recommended in section Types of Grease, page 18. This is particularly important at
temperatures below -25 °C.
Lubrication of Circuit Breakers
The circuit breaker bearings are lubricated with grease on delivery and do not normally need to be lubricated
other than for larger overhauls.
See Treatment of Sealing Surfaces and Seals, page 147.
Rust Protection
The close and trip springs are anti-rust protected with two-component paint.
Some levers, pull-rods and links are manganese phosphatized and oiled. Treat with anti-rust agent where
necessary. See Cleaning, Lubrication, and Rust Protection of Operating Mechanism, page 100.
See Maintenance of Rust Protection, page 124.
1HSB439954-2en 2017-11-01 97
7 Maintenance
7.6 Maintenance, Operating Mechanism and Link System
7.6.1 Preparatory Measures and Overview of the Operating Mechanism
General
This section describes the actions that must/can be made prior to commencing maintenance work.
WARNING!
Do not operate the operating mechanism without a load! Operation must not be conducted until the
device has been connected and adjusted as appropriate for the associated pressurized circuit
breaker.
Operating Mechanism
1 Drive Unit
2 Operating Mechanism
3 Control Panel
4 Spring assembly
5 Heating element (behind protective cover)
98 2017-11-01 1HSB439954-2en
7 Maintenance
Control Panel
1 Control Panel
2 Control switch, Close/Open
3 Switch, Local/Remote/Disconnected
4 Electric counter
5 Spring indicator
Before Commencing Maintenance the Following Must Be Done:
1. Operate the circuit breaker to the open position.
2. Switch off the motor current using the protective motor switch.
3. Perform a close-and-open operation in order to discharge the operating mechanism springs.
4. Switch off the control voltage and where necessary the heater voltage as well.
5. Disconnect and earth.
End of instruction
To Facilitate Maintenance, the Following Can Be Performed:
1. Remove the top of the operating cabinet to facilitate the maintenance work.
2. Open the control panel.
End of instruction
1HSB439954-2en 2017-11-01 99
7 Maintenance
7.6.2 Cleaning, Lubrication, and Rust Protection of Operating Mechanism
Safety
WARNING!
Work on the operating mechanism with the circuit breaker in closed position and charged springs
always represents a risk.
It is therefore important to observe the safety instructions before commencing work. See
Hazardous Working Situations, page 8.
Lubricant
The table below shows the greases and oils that are needed for this maintenance. For suppliers and trade
names of oils and greases, see sections Oil Types, page 17 and Types of Grease, page 18.
Lubricant Part number Note
Grease "M" 5316 381-J

Oil "S" 1173 7011-106
Oil "A" 1HSB875318-A
Grease "G" 1171 4014-407
Cleaning
Clean the operating mechanism and mechanism housing where necessary through vacuuming. The time
interval for this cleaning depends on local conditions, i.e. the degree of air pollution.
Check that the filters in the valves are clean. Replace them if they are overly dirty.
Lubrication
The operating mechanism's ball, roller and needle bearings are permanently lubricated and require no
maintenance. Lubrication is therefore limited to apply only to the shafts in the latch device and worm gear in
the drive unit, as per the interval given in the maintenance schedule. As part of the overhaul, the slide surfaces
for the interleaved joint and damper should also be lubricated with grease "G" and the chains lubricated with
oil "A".
The bearings in the operating mechanism are lubricated with grease "G" and normally need lubricating
following major overhauls.
The open and close dampers are filled with "S" oil on delivery.
Rust Protection
On delivery, the operating mechanism is treated with desiccant as transport protection against moisture.
Despite good anti-rust treatment, minor corrosion may occur, particularly if the circuit breaker is installed in a
highly corrosive environment.
Rust spots must be polished off and new anti-rust agent applied, see Maintenance of Rust Protection,
page 124
Spare Parts
Spare parts must be stored indoors in an approved storage area1) and in original packaging. This applies
especially to rubber components (seals etc.) that must also be protected against sunlight to prevent drying out.
Gaskets can be stored only for a limited period, so avoid stocking them. Support structures can be stored
outdoors.
1) Approved storage areas: Roof, solid ground, air humidity below 50%, temperature +20 oC (±10 oC).
100 2017-11-01 1HSB439954-2en

7 Maintenance
7.6.3 Locking and Unlocking of the Mechanical Interlocking Device
General
This section describes how to use the mechanical interlocking device.
Interlocking Device
The figure below shows the component parts in the mechanical interlocking device.
1 Limit Switch
2 Interlocking arm
3 Latch disc
4 Cam disc
5 Pull-rod
6 Shaft for operating lever
Required Equipment
Crank
Driver
Mechanical Interlocking
The interlocking device prevents a closing operation from being executed if the circuit breaker is already
closed or if the operating mechanism's close springs are discharged or not fully charged, which may arise if
for example, the close catch is opened manually or if any mechanical fault arises in the latch mechanism.
1. Check the position of interlocking arm (2) in

NOTE!
relation to the periphery of the latch disc (3).
The interlocking arm should be 2 mm
above.
2. Check that the closing circuit is closed when the arm (2) is on the periphery of the latch disc (3).
End of instruction
1HSB439954-2en 2017-11-01 101

7 Maintenance
Overriding of Interlocking
The instructions below describe how to override the interlocking device.
NOTE!
If the movement of the cam disc is stopped by the interlocking arm, you cannot perform a closing
operation until the cam disc returns to normal position.
1. Discharge springs manually by:

1. Set the Local/Remote control switch in position. DISCONNECTED.
2. Switching off the motor voltage using the protective motor switch.
3. Turn the switch on the drive unit to MANUAL so that the shaft for the hand crank is exposed.
4. Place the crank on the shaft
2. Firmly press the button for the safety latch with a screwdriver.
3. Crank clockwise until the latch flap on the

operating lever (1) has passed the roller (2) by a
good margin.
• 1: Operating lever
• 2: Roller, closing latch device
4. Correct any faults.
5. Wind counter clockwise until the latch flap on the

operating lever (1) is resting against the roller (2)
in the closing latch device.
End of instruction
102 2017-11-01 1HSB439954-2en

7 Maintenance
7.6.4 Inspection of Heating Element
General
Cabinets containing equipment that is sensitive to damp are equipped with a heating element to prevent
condensation.
Heating Element
1 Heating Element
Data
Voltage Resistance ±15 % Power
220 V 691 ohm 70 W

346 ohm 140 W
110 V 173 ohm 70 W
86 ohm 140 W
Instructions
1. Measure the resistance of the element, and compare with the value in the table above to ensure that
the element is intact.
2. Measure the power supply voltage to the element
End of instruction
1HSB439954-2en 2017-11-01 103

7 Maintenance
7.6.5 Inspection of Drive Unit
General
This section describes how to check the drive unit.
Drive Unit
1 Drive Unit
Required Equipment

Grease "M" 1171 4016-612 Detailed information can be found in Types of
Grease, page 18.
Data IEC
48 VDC 110 VDC 220 VDC 120 VAC 230 VAC
85 % - 110 % 85 % - 110 % 85 % - 110 % 85 % - 110 % 85 % - 110 %
The value is a percentage of the nominal IEC voltage.
Data IEEE
48 VDC 125 VDC 250 VDC 120 VAC 240 VAC
36 V - 56 V 90 V - 140 V 180 V - 280 V 104 V - 127 V 208 V - 254 V
Inspection of Drive Unit
1. Check and clean the worm transmission in the drive unit. Lubricate with grease "M".
104 2017-11-01 1HSB439954-2en

7 Maintenance
2. Measure the motor current at the end of the

NOTE!
charging process.
The motor must be able to charge the
springs at the nominal voltage.
3. Check that the signal for tripped motor protection

NOTE!
is working.
If this is not the case, replace the
protective motor switch.
End of instruction
1HSB439954-2en 2017-11-01 105

7 Maintenance
7.6.6 Inspection of Latch Devices
Latch Device
1 Closing latch device

2 Trip latch device
Required Equipment
Grease "L" 1171 4016-606 See section Types of Grease, page 18 for details.
Multimeter
Feeler gauge
Data IEC
48 VDC 110 VDC 220 VDC
Trip coil 70 % - 110 % 70 % - 110 % 70 % - 110 %

Close coil 85 % - 110 % 85 % - 110 % 85 % - 110 %
The value is a percentage of the nominal IEC voltage.
Data IEEE
48 VDC 125 VDC 250 VDC
Trip coil 28 V - 56 V 70 V - 140 V 140 V - 280 V

Close coil 36 V - 56 V 90 V - 140 V 180 V - 280 V
106 2017-11-01 1HSB439954-2en

7 Maintenance
Check of Play
1. Check and clean the arms (1) in the latch devices.
2. Lubricate these with grease “L”.
3. Check that the voltage to the coils is not lower See the operating mechanism's delivery
than the nominal voltage. document.
End of instruction
1HSB439954-2en 2017-11-01 107

7 Maintenance
7.6.7 Check of Oil Level in Damper
General
This section describes how to check the oil level in the damper.
Required Equipment
Oil "S" 1173 7011-106 The oil is specified in section Oil Types, page 17.
Breaker analyser sensor - Used for registration of damping.
Damper
1 Close damper
2 Opening damper
108 2017-11-01 1HSB439954-2en

7 Maintenance
Instructions
Check the dampers' oil level by registering damping during operation as described in the instructions below.
1. Close damper:
Connect a breaker analyser sensor to the
operating mechanism's camshaft and record a
damping curve. Check the damping reach and
damping time as specified in the figure to the right.
If the measured values for “A” and “B” are outside
the specified values, the entire damper must be
replaced.
A. Damping reach: 15-25 ms

B. Damping time: 80-300 ms
2. Opening damper: Correct curve:

Connect a breaker analyser sensor to the circuit
breaker's shaft and record a damping curve.
Check the damping reach and damping time as
specified in the figure to the right.
If the recorded curve deviates from the correct
curve, replace the entire damper.
Incorrect curves:
End of instruction
1HSB439954-2en 2017-11-01 109

7 Maintenance
7.6.8 Check of Limit Switch and Auxiliary Contact
General
The shaft of the auxiliary contact is in direct connection to the operating mechanism's operating lever and
therefore follows the travel of the circuit breaker contacts.
Auxiliary Contact
1 Limit Switch
2 Auxiliary Contact
110 2017-11-01 1HSB439954-2en

7 Maintenance
Time Measurement Contact Movement
y Contact movement
x Time
1 Arcing contact
2 Closed position
3 Auxiliary Contact
4 Open position
5 Contact movement
t1 Proportional to the contact's opening speed.
t2 Time that determines the contact damping.
t3 Proportional to the contact's closing speed.
Instructions
Check the contact movement using time measurement after 15 years or 5,000 operations and compare with
the times obtained when commissioning. The comparison can then be used as condition checks for contact
movement and damping. The measurement must be performed on a disconnected circuit breaker with
connected timing equipment.
1. Connect the timing equipment to the respective terminals in accordance with the wiring diagram.
2. Perform the operation.
3. Measure and note the times t1, t2 och t3
4. Disconnect the timing equipment.
End of instruction
1HSB439954-2en 2017-11-01 111

7 Maintenance
7.6.9 Check of Link System and Spring Assembly
General
These instructions describe the checking of the link system and spring assembly.
Required Equipment
Grease "M" 1171 4016-612
Instructions
1. Check the spring assembly visually.
2. Check the links and bearings visually.
3. Lubricate as necessary with grease "M".
End of instruction
112 2017-11-01 1HSB439954-2en

7 Maintenance
7.6.10 Inspection of Connection Terminals
Coupling Terminals
1 Auxiliary Contact
2 Motor
3 Switch Manual/Motor
4 Relays
5 Contactors
6 Protective motor switch
7 Miniature circuit breaker
8 Plug contact
9 Thermostat
10 Fuses
11 Trip coil
12 Coupling terminal
13 Close coil
14 Cover
Instructions
1. Make a visual inspection to ensure that everything is intact and that all connections are fitted.
End of instruction
1HSB439954-2en 2017-11-01 113

7 Maintenance
7.7 Slow Manual Closing and Tripping Operation
7.7.1 Introduction
General
Some service work requires manual operation of the circuit breaker, e.g. for preparations of overhaul of the
interrupter units on a circuit breaker with two breaking chambers.
Safety
IMPORTANT!
Slow manual closing and tripping operations must only be performed by personnel specially
trained and very familiar with the functionality of the device and the circuit breaker due to the risk
of both personal injury and mechanical damage. The circuit breaker must be disconnected from the
power system during slow operation. Incorrect operation INVALIDATES all guarantees.
Required Equipment
Hand crank
114 2017-11-01 1HSB439954-2en

7 Maintenance
7.7.2 Preparations for the Operating Mechanism for Manual Closing Operation
1. • The circuit breaker is in tripped position.

• The "Local/Remote/Disconnected" switch (1)
on the control panel is in the "Disconnected"
position.
• The motor voltage is switched off with the
protective motor switches (2), (3).
• The "Manual/Motor" switch (4) is in the
"Manual" position, releasing the shaft for
hand cranking.
2. The close springs are discharged.

• Place the crank (1) on the shaft.
• Use a driver to press in the button (2) to the
safety latch firmly in order to release the
safety latch ensuring the springs are
discharged. Wind clockwise until the
interleaved joint has reached its bottom
position and is resting against the support
structure foot.
3. The blocking beams are fitted.

• Fit the red painted blocking beams (1)
around the pull-rod so that the mounting hole
faces the cabinet. Attach the bolts (2) in the
blocking beams.
1HSB439954-2en 2017-11-01 115

7 Maintenance
4. The interlocking device is overridden.

• Press the pull-rod (1) or interlocking arm (2)
upwards.
• Press in the locking pin (3) into the hole (4).
5. The blocking beams run against the mechanical end stop.

• Wind counter clockwise, normally 6-8 turns, max 10 turns.
6. The middle latch is released. See the illustration in section Slow Manual Closing
Operation, page 117.
• Press the anchor down on the close coil (1).
End of instruction
116 2017-11-01 1HSB439954-2en

7 Maintenance
7.7.3 Slow Manual Closing Operation

A slow closing operation in progress can be interrupted at any position before the latch pawl (5) engages with
the roller (6). See section Cancel the Slow Closing Operation in Progress, page 119.
1. Wind 310 turns counter clockwise The cam disc Towards the end of its movement, a click is heard
(2) then rotates around a 3/4 turn and actuates the when the operating lever's safety flap (5) engages
limit stop roller (3) ensuring the operating lever (4) behind the roller (6) in the trip mechanism.
slowly moves the circuit breaker to closed
position.
2. Wind a few more turns counter clockwise, The operating lever is pulled quickly to open
ensuring the outermost point of the cam disc (2) position by the force of the trip spring until the
leaves the limit stop roller (3). safety flap (5) makes contact with the roller (6).
3. Wind counter clockwise until the safety flap (7) is resting precisely against the roller (8) so the cam
disc returns to normal position and the blocking beams are relieved.
4. Remove the blocking beams.
5. Check that the safety flap (7) is resting against the Otherwise the cam disc will be in the wrong
roller (8). position and the operating mechanism may be
damaged in the event of a tripping operation
6. Pull out the locking pin (3) from the hole (4).
7. Turn the "Manual/Motor" switch to the "Motor" position.
1HSB439954-2en 2017-11-01 117

7 Maintenance
8. Connect the motor voltage with the motor protection.
9. Set the "Local/Remote/Disconnected" control switch to the "Remote" position.
10. The circuit breaker is now in closed position and a

NOTE!
normal tripping operation can be made.
Check that the blocking beams are
removed before performing the tripping
operation.
End of instruction
118 2017-11-01 1HSB439954-2en

7 Maintenance
7.7.4 Cancel the Slow Closing Operation in Progress
1. Press the button (2) to the safety latch.
2. The circuit breaker moves slowly to open position.
3. Release the button (2) when the circuit breaker is in the required position.
End of instruction
1HSB439954-2en 2017-11-01 119

7 Maintenance
7.7.5 Preparing the Operating Mechanism for Slow Manual Opening Operation
IMPORTANT!
Slow manual closing and tripping operations must only be performed by personnel specially
trained and very familiar with the functionality of the device and the circuit breaker due to the risk
of both personal injury and mechanical damage. The circuit breaker must be disconnected from the
power system during slow operation. Incorrect operation INVALIDATES all guarantees.
1. • The circuit breaker is in the closed position.

• The "Local/Remote/Disconnected" switch (1)
on the control panel is in the "Disconnected"
position.
• The motor voltage is switched off with the
protective motor switches (2), (3).
• The "Manual/Motor" switch (4) is in the
"Manual" position, releasing the shaft for
hand cranking.
2. The close springs are discharged.

• Place the crank (1) on the shaft.
• Use a driver to press in the button (2) to the
safety latch firmly in order to release the
safety latch ensuring the springs are
discharged. Wind clockwise until the
interleaved joint has reached its bottom
position and is resting against the support
structure foot.
120 2017-11-01 1HSB439954-2en

7 Maintenance
3. The blocking beams are fitted.

• Fit the red painted blocking beams (1)
around the pull-rod so that the mounting hole
faces the cabinet. Attach the bolts (2) in the
blocking beams.
4. Press the pull-rod (1) or interlocking arm (2)

upwards.
Press in the locking pin (3) into the hole (4).
The Inter-locking device is overridden.
1. Pull-rod
2. Interlocking arm
3. Blocking pin
4. Hole for blocking pin
5. Turn counter clockwise, normally 6-8 turns The blocking beams move towards the
(maximum 10 turns). mechanical end stop.
6. Press the anchor down on the close coil. The middle latch is released.
End of instruction
1HSB439954-2en 2017-11-01 121

7 Maintenance
7.7.6 Slow Manual Tripping Operation

A slow manual tripping operation requires the cam disc (4) to "retrieve" the operating lever (7); see figure.
The safety latch is then released, and the operating mechanism is ready to perform a slow manual tripping
operation.
1. Crank about 300 turns counter clockwise. If too Try again: Repeat points 5 and 6 in the
many turns are made, a bumping noise will be preparatory instruction (see Preparing the Operating
heard when the cam disc (4) passes the limit stop Mechanism for Slow Manual Opening Operation,
roller (5) and returns to the position shown in the page 120.) and then follow the instructions (from
figure. point 1) to the left, but crank a few turns less.
2. Release the crank and let it rotate until its stops.
3. Release the trip latch device with a light knock to The circuit breaker's trip springs pull the operating
the anchor (6) using a screwdriver, for example. lever (7) to tripped position. The movement is
stopped when the limit stop roller (5) is resting
against the cam disc (4).
4. Keep the safety latch button pressed until the circuit breaker is pulled to open position by the trip
springs.
5. If the force of the spring is insufficient to get the safety flap (2) to pass and assume locked position to
the roller (3), press in the button to the safety latch and wind clockwise.
6. Remove the blocking beams.
7. Check that the safety flap (2) is resting against the Otherwise wind counter clockwise until the safety
roller (3) in the closing latch device. flap is resting against the roller (3).
122 2017-11-01 1HSB439954-2en

7 Maintenance
8. Pull out the locking pin (3) from the hole (4).
9. Turn the "Manual/Motor" switch to the "Motor" position.
10. Connect the motor voltage with the motor protection.
11. Set the "Local/Remote/Disconnected" control switch to the "Remote" position.
12. The circuit breaker is now in the tripped position

NOTE!
and a normal closing operation can be made.
Check that the blocking beams are
removed before performing the closing
operation.
End of instruction
1HSB439954-2en 2017-11-01 123

7 Maintenance
7.8 Maintenance of Rust Protection
General
Despite good anti-rust treatment, minor corrosion may occur, particularly if the circuit breaker is installed in a
highly corrosive environment.
Many steel mechanical components in the operating mechanism are surface treated through manganese
phosphating agent and protected by being dipped in oil. Components, such as the chassis, are painted as a
means of protection against corrosion. The close and trip springs can be protected against corrosion with
two-component paint or manganese phosphating.
The support structure, pole beam and protective tube are hot dip galvanized.
Phosphated Surface
1. Polish out rust stains.
2. Brush or spray on new rust protection. Grease “G” or Tectyl 506 is recommended as a
rust inhibitor; see section Types of Grease,
page 18.
NOTE!
Tectyl 506 forms a wax-like protective
coat after drying and must not be
applied to bearings or latch
mechanisms.
End of instruction
Hot Dip Galvanized/Electroplated Surface
1. Polish out rust stains.
2. Brush or spray on new rust protection, in the form The thickness of the new surface must be at least
of zinc-rich paint. double the original zinc thickness.
End of instruction
124 2017-11-01 1HSB439954-2en

8 Overhaul
8 Overhaul
8.1 Preparations
8.1.1 Preparations for Overhaul
General
This section describes the preparations that are required prior to an overhaul of the circuit breaker.
The overhaul can be carried out according to two methods:
• The recommended method is to remove the entire circuit breaker pole for transport to the service
workshop where it can be fully dismantled for the overhaul; see sections Removal of Circuit Breaker
Pole for Transport, page 130 .
• The alternative method is to only dismantle the interrupter unit; see sections Dismantling of Interrupter
Unit for Transport, page 158.
The latter method does not require as much work, but must only be applied in clement weather that resembles
indoor working conditions.
WARNING!
The following points must be observed before beginning the overhaul.
• The springs must be discharged, see Discharge the Springs Electrically, page 9
• The gas must be evacuated; see Evacuation of SF6 Gas, page 126.
NOTE!
Under no circumstances may the interrupter unit be opened during rainy or unstable weather, or
when the humidity is 80% or higher.
Preparations
1. Before dismantling the circuit breaker, and during the course of the work, the instructions in Safety,
page 7 must be read and followed.
2. Check and note the circuit breaker's operating values prior to dismantling.
• Deviations from the recommended values indicate that something needs to be checked with extra
care for the overhaul.
3. Switch off the motor current by switching off the motor protection.
4. Set the "Local/Remote/Disconnected" switch on the control panel to the "Local" position.
5. Execute an Open-Close-Open operation.
6. Check that the springs are discharged.
7. Check that the circuit breaker is in open position.
8. Switch off the control voltage and where necessary the heater voltage as well.
9. Disconnect and earth.
End of instruction
1HSB439954-2en 2017-11-01 125

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

Percentage meter for SF6 gas
Evacuation of SF6 Gas
1. Connect the gas treatment equipment.
2. The SF6 gas is evacuated and the circuit breaker is vacuum pumped.
3. The gas is cleaned and compressed to ensure it The mixing ratio between the gases can be
can be reused or destroyed. checked using a percentage meter for SF6 gas.
NOTE!
Mixed gas, SF6 mixed with N2 or CF4,
must not be reused unless the mixing
ratio is controlled.
4. After vacuum-pumping, the circuit breaker is filled with dry nitrogen at atmospheric pressure. It is then
vacuum-pumped once again.
5. Finally the circuit breaker is again filled with dry nitrogen at atmospheric pressure.
6. The circuit breaker is now ready for dismantling
End of instruction
126 2017-11-01 1HSB439954-2en

8 Overhaul
8.1.3 Cleaning and Waste Treatment
General
This section describes cleaning and waste treatment.
Safety
IMPORTANT!
Certain by-products formed in the interrupter unit, in combination with moisture, are corrosive and
can irritate the skin, eyes and mucous membranes. For internal cleaning of the circuit breaker,
protective gloves of plastic or rubber, long-sleeved overalls and a close-fitting facemask with
filtration to counteract fine dust and acidic gases must therefore be worn.
NOTE!
All material and old adsorption media should be collected in a tight container and managed as
chemical waste according to applicable local regulations.
NOTE!
Drying cloths, protective gloves and vacuum cleaner bags should be thoroughly rinsed using
plenty of water.
Required Equipment
Equipment Note
Protective equipment Protective gloves of plastic or rubber.

Long-sleeved overalls.
Facemask With filter to counter act fine dust and acidic gases.
Vacuum cleaner With fine dust filter and plastic nozzle.
Drying cloths Of non-lint material.
Sealed storage vessels For waste products and used adsorption filters.
Steel brush For contact surfaces of aluminum.
Fine abrasive material E.g. Scotch-Brite, for contact copper surfaces
Ethanol >95% ethanol, for cleaning internal surfaces
Thick plastic foil and plastic bags To prevent moisture penetration and to protect cleaned parts prior to
assembly.
Cleaning
• The dust (by-products) formed in the circuit breaker must be removed by a vacuum cleaner fitted with a
fine dust filter and wiped off using drying cloths moistened with ethanol.
1HSB439954-2en 2017-11-01 127

8 Overhaul
General
This section specifies the equipment needed for overhauling the circuit breaker.
Tool

Alternatively, the existing tool equipment may
be used.
Lifting devices and slings. Weights for the current circuit breaker are
specified on the outline drawing applicable to
the order.
Cleaning Equipment
Gas treatment equipment For evacuation, cleaning, compression and
storage of used gas and instruments for
monitoring pressure and vacuums.
Test equipment for recording damping For example Programma or ABB SA10.
curves and operating values
Multimeter
Feeler gauge
Leak spray
Thick plastic foil/plastic bags
Cleaning and drying cloths
Lubricants and Locking Fluids
Grease "G" 1171 4014-407 See sections Types of Grease, page 18 for ABB
part numbers, suppliers and trade names.
Grease "N" 1171 4016-612
Grease "P" 1171 5011-102
Grease "S" 1171 4014-406
Anti-rust agent, Valvoline Tectyl 506 1241 0011-108
Locking fluid "C" 1269 0014-408 See sections Locking Fluid, page 20 for ABB
part numbers, suppliers and trade names.
128 2017-11-01 1HSB439954-2en

8 Overhaul
Spare Parts
Spare ABB part no. Note
Set of contacts - As per spare parts list for current circuit breaker.
Gasket sets - As per spare parts list for current circuit breaker.
Absorbent - As per spare parts list for current circuit breaker.
SF6 gas -
N2 gas -
Protective cover for interrupter 5237 736-R

unit
Protective cover for post insulator 5439 142-A
1HSB439954-2en 2017-11-01 129

8 Overhaul
8.3 Removal of Circuit Breaker Pole for Transport
General
The circuit breaker must be taken out of service before the circuit breaker pole is dismantled, see section
Preparations for Overhaul, page 125 and the gas evacuated, see section Evacuation of SF6 Gas, page 126.
Pole Order
The circuit breaker poles are described in the following instructions, at pos.1, pos. 2 and pos. 3 in accordance
with the illustration.
Preconditions
NOTE!
Required Equipment

Lifting device
Lifting tackle
Dismantling
1. Remove the density monitor from the non-return

valve (1) and fit the sealing cap (2).
2. Remove the pull-rod between the operating mechanism and the circuit breaker.
3. Put a lifting sling under the interrupter unit's upper

NOTE!
flange.
For composite insulators: Place the
lifting sling as close as possible to the
end flange and not on the rubber
surface.
4. Remove the pull-rods between the circuit breaker poles.
130 2017-11-01 1HSB439954-2en

8 Overhaul
5. Now loosen the circuit breaker pole (5) at the four

bolts (3) in the support structure and the four bolts
(4) to the protective tube.
3. Bolt M20x70, nut M20, washer 21x37x3

4. Bolt M12x50, nut M12, washer 13x24x2.5
6. Lift up the circuit breaker pole and carefully lay it on a handling trolley.
7. Support the circuit breaker on blocks (6).
NOTE!
The blocks must be of an deformable
material, e.g., wood or rubber. If
possible. Use the same support as
used on delivery.
End of instruction
1HSB439954-2en 2017-11-01 131

8 Overhaul
8.4 Overhaul of Circuit Breaker Pole
8.4.1 Relieving the Trip Mechanism's Pull-Rod.
General
This section describes how to relieve the trip mechanism

The circuit breaker must be taken out of service before starting work, see section Preparations for Overhaul,
page 125, and the gas evacuated, see section Evacuation of SF6 Gas, page 126.
Trip Mechanism
Safety
NOTE!
Under no circumstances may the interrupter unit be dismantled or opened during rainy or unstable
weather.
Preconditions
NOTE!
Required Equipment

Discharge tool 1HSB446381-A
132 2017-11-01 1HSB439954-2en

8 Overhaul
8.4.2 Removal of the Trip Mechanism's Pull-Rod
General
This section describes the removal of the trip mechanism pull-rod, after the circuit breaker pole has been
transported to a workshop.
Trip Mechanism
1 Operating lever
2 Joint pin
3 Spring pull-rod
4 Spring Housing
5 Trip spring
6 Nut
7 Lock nut
8 Protective Cover
9 Bolt M10x25, 4 pcs
Required Equipment

Instructions
1. Remove the protective cover (8).
2. Measure and note a reference dimension, e.g. “Y”, so that the trip spring (5) has the same charge with
the nut (6) when refitting.
3. Discharge springs by undoing the nuts (6, 7).
1HSB439954-2en 2017-11-01 133

8 Overhaul
4. Remove the pin (2).
End of instruction
134 2017-11-01 1HSB439954-2en

8 Overhaul
8.4.3 Removal of Interrupter Unit
General
This section describes the removal of a interrupter unit, after the circuit breaker pole has been dismantled and
transported to a workshop.
NOTE!
The circuit breaker pole is fitted vertically on a suitable support structure, e.g. a circuit breaker
support or a frame of the floor of the workshop.
Circuit Breaker Pole
1 Bolts M12x35 (8 pcs), washers 13x28x3 (8 pcs)

2 Post insulator
3 Interrupter unit
4 Split pin, 2 pcs
5 Washer, 2 pcs
6 Joint pin
Required Equipment

Lifting device -
Lifting tackle -
1HSB439954-2en 2017-11-01 135

8 Overhaul
Instructions
1. Fit the lifting devices from the top of the interrupter

NOTE!
unit to the hoist or overhead crane.
Stretch the lifting device moderately. lifting strap as close as possible to the
surface.
2.
DANGER!
The circuit breaker pole weighs up to 600 kg. Use lifting tackle that is dimensioned for the
weight.
3. Remove the bolts (1) between post insulator (2) and interrupter unit (3).
4. Lift the interrupter unit 75-100 mm.
5. Remove the split pin (4) washer (5) and pin (6).
NOTE!
Ensure that no lock rings or washers
fall down in the post insulator when
dismantling.
Cover the opening by e.g. a cloth rag.
6. Lift off the interrupter unit completely and place it vertically on an appropriate surface, e.g. on two
cross bars to ensure it does not tip over and that the bottom of the bolts are accessible.
End of instruction
136 2017-11-01 1HSB439954-2en

8 Overhaul
8.4.4 Removal of Post Insulator
General
This section describes the removal of post insulators, after the interrupter unit has been removed from a
dismantled circuit breaker pole.
To prevent moisture in the air coming into long-term contact with dust in the post and insulating pull-rods, the
work on removal and cleaning must be planned to ensure it can be executed quickly and without long breaks.
Overview
1 Post insulator
3 Mechanism housing
4 Cotter key
5 Washer
6 Joint pin
7 Insulating pull-rod
Safety
NOTE!
Use personal safety equipment:
• long-sleeved overalls
• protective gloves of plastic or rubber
• tight fitting facemask for dust protection
1HSB439954-2en 2017-11-01 137

8 Overhaul
Required Equipment

Lifting device
Lifting tackle
Vacuum cleaner With fine dust filter and plastic nozzle
Drying cloths Of non-lint material
Sealed storage vessels For waste products and used absorption filters
Steel brush For contact surfaces of aluminum
Fine abrasive material For contact surfaces of copper
(Scotch Brite)
Ethanol 95% ethanol, for cleaning internal surfaces
Thick plastic foil/plastic To prevent moisture penetration and to protect cleaned parts
bags prior to assembly
Instructions
DANGER!
Use lifting equipment that is designed for the post insulator.
1.
2. Fit the lifting devices from the top of the post

NOTE!
insulator to the hoist or overhead crane.
lifting sling as close as possible to the
surface.
3. Remove the post insulator bolts (2) from the mechanism housing (3).
4. Lift the post insulator straight up until the

NOTE!
insulating pull-rod (7) runs free. Hold the insulating
pull-rod when lifting. Be careful not to damage the insulating
pull-rod.
5. Remove the insulating pull-rod (7) by removing the split pin (4) washer (5) and pin (6).
6. Clean the insulating pull-rod with care and protect it with plastic foil.
7. Clean the post insulator with care internally and externally and protect it with plastic foil.
End of instruction
138 2017-11-01 1HSB439954-2en

8 Overhaul
8.4.5 Overhaul of Interrupter Unit
General
This section describes how the interrupter unit is opened in order to allow for inspection, cleaning and/or
replacement of the internal parts.
Interrupter Unit

2 Cover
3 Absorbent container
5 Upper adapter plate
6 Upper current path
7 Breaking chamber insulator
8 Lower adapter plate
1HSB439954-2en 2017-11-01 139

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

Lifting device -
Lifting tackle -
Vacuum cleaner - With fine dust filter and plastic nozzle.
Drying cloths - Of non-lint material.
Sealed storage vessels - For waste products and used absorption filters.
Steel brush - For contact surfaces of aluminum.
Fine abrasive material - For contact surfaces of copper.
(Scotch Brite)
Ethanol - 95% ethanol, for cleaning internal surfaces
Thick plastic foil/plastic bags - To prevent moisture penetration and to protect cleaned parts
prior to assembly.
Instructions
NOTE!
As and when the interrupter unit is opened, the by-products that are present in the interrupter unit
in powder form, must be taken care of. Primarily by using a vacuum cleaner and then through
careful drying of the removed components.
1. Remove the bolts (1 ) and the cover (2) and lift out
NOTE!
the container for absorbent (3).
Place the bag with absorbent in a
vessel for chemical waste.
2. Remove the bolts (4) and upper adapter plate (5) with the upper current path (6).
3. Remove the bolts (4) and breaking chamber insulator (7) from the lower adapter plate (8).
4. Clean the breaking chamber insulator internally with ethanol.
End of instruction
140 2017-11-01 1HSB439954-2en

8 Overhaul
8.4.6 Inspection and Replacement of Contacts and Self-Blast
General
This section describes changing the Auto-PufferTMand the upper current path.
Remember:
NOTE!
Unless the circuit breaker is to be refitted immediately after cleaning of the component parts, these
should be protected against contamination and moisture by being packed in plastic bags with
desiccant that absorbs moisture.
Insulators are protected preferably by using thick plastic film wrapped over the end surfaces.
NOTE!
All contact surfaces should be treated prior to installation; see Treatment of Contact Surfaces,
page 146.
Required Equipment

Torque wrench Torque 22,5 Nm
Vernier calliper
Plastic film
Mounting plate 1HSB630030-R Not supplied.
Inspection and Replacement of Upper Current Path
1. The entire current path must be replaced if:

• The upper current path's fixed arcing contact
(4) has burnt off so that the gap to the
reference surface (5) is more than 6 mm.
• It is severely burnt at the external diameter.
• If the silver on the current path contacts is
worn so that the copper shines through.
1. Upper adapter plate

2. Bolt M8x16, washer 8.4x16x1.6
3. Upper current path
4. Arcing contact
5. Reference surface
2. Loosen the bolts (2) and remove the upper current path (3) from the upper adapter plate (1).
1HSB439954-2en 2017-11-01 141

8 Overhaul
3. Fit the new upper current path. Tighten the bolts Treat contacts; see Treatment of Contact Surfaces,
(2). page 146.
Torque
22.5 Nm
End of instruction
Inspection of Self-Blast
1. For contact springs upwards from position a to b.
1. Nozzle (PTFE)
2. Puffer pull-rod
3. Self-blast cylinder
4. Bolt M8x16 (8 pcs), washer 8.4x16x1.6 (8 pcs)
5. Contact surface
6. Contact surface
2. Lift off the puffer and check that there is no wear to the pull-rod slide surfaces.
3. Check that the nozzle does not have any punctures.
4. Check that the puffer cylinder's contact position does not have burnt or worn surfaces making the
copper visible.
5. Replace the whole self-blast if there are burnt or worn surfaces.
End of instruction
142 2017-11-01 1HSB439954-2en

8 Overhaul
Inspection and Replacement of Lower Current Path
1. Check that the following components are not

worn.
• sealing ring (5)
• Tape (4)
• Guide bushing (6)
1. Adapter plate
2. Bolt M8x20, spring washer, washer
3. Lower current path
4. Tape (PTFE)
5. Sealing ring
6. Guide bushing
7. Valve washer
2. Check that the valve washer (7) is flat and seals.
3. Check that the silver on the lower current path If there is wear, the whole lower current path and
contacts is not worn so that the copper shines flange must be replaced.
through.
End of instruction
1HSB439954-2en 2017-11-01 143

8 Overhaul
8.4.7 Overhaul of Mechanism
General
This section describes overhaul of the mechanism
Mechanism
1 Mechanism housing
2 Operating shaft
3 Operating lever
4 Ball bearings
5 Circlip
6 Bushing
7 X-ring 69.2 x 5.7
8 O-ring 89.1x5.7
9 Ball bearings
10 Washer
Remember:
NOTE!
Clean the mechanism housing by vacuuming and drying. Check for corrosion, the bearings and
replace all sealing rings.
Apply anti-rusting agent to untreated or manganese phosphated steel outside the gas space using
Valvoline Tectyl.
144 2017-11-01 1HSB439954-2en

8 Overhaul
Required Equipment
Grease "S" 1171 4014-406 Detailed information is specified in section Types of Grease,
page 18.
Grease "G" 1171 4014-407 Detailed information is specified in section Types of Grease,
page 18.
Tectyl 1241 0011-108 Valvoline Tectyl
Instructions
1. Remove the operating lever (3) and the lock ring

NOTE!
(5).
The operating shaft (2) is outside the
gas space stored in a large ball bearing
(4) that is accessible for inspection and
lubrication if the operating lever and
lock ring are removed.
2. Pull out the operating lever (2) from the mechanism housing (1) and remove the ball bearing (4) from
the shaft.
3. Lubricate the ball bearing (4) using grease “G”.
4. Remove the bushing (6) holding the sealing rings in place, using two bolts (M5) that are threaded in
the holes in the end area of the bushing.
5. Replace the sealing rings (7, 8) in the bushing behind the ball bearing and lubricate with grease "S".
6. Check that the ball bearing (9) rotates easily.
End of instruction
1HSB439954-2en 2017-11-01 145

8 Overhaul
8.5 Assembling the Circuit Breaker Pole Following Overhaul
8.5.1 Treatment of Contact Surfaces
General
Contact surfaces should be treated as follows.
Required Equipment
Grease "N" 1171 4016-607 See section Types of Grease, page 18 for more
information on the grease.
Grease "P" 1171 5011-102 See section Types of Grease, page 18 for more
information on the grease.
Fine abrasive material, e.g.
Scotch Brite
Drying cloths
Fixed Contact Surfaces
Surfaces Treatment Note

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

Silver plated Silver plated contact surfaces are Polishing with a fine abrasive
cleaned where necessary with soft material (Scotch Brite) or grinding
drying cloths and ethanol. must not occur.
Non-silver plated Non-silver plated moving contact After cleaning with a fine abrasive
surfaces are cleaned as if they material (Scotch Brite) loose
were silver plated, but even using particles must always be cleaned
a fine abrasive material (Scotch off the surface with ethanol.
Brite).
Lubrication The lubricant grease “N” is applied All surplus grease should be
as a covering layer, but very thin carefully dried.
on the silver-plated section of the
lower current path, the upper
current path and the puffer
cylinder's contact surfaces.
146 2017-11-01 1HSB439954-2en

8 Overhaul
8.5.2 Treatment of Sealing Surfaces and Seals
General
In conjunction with installation, all sealing surfaces should be cleaned, degreased and checked.
Required Equipment
Ethanol >95% ethanol, for cleaning internal

surfaces
Grease "G" 1171 4014-407 For static seals, see Grease G,
page 18.
Grease "S" 1171 4014-406 For moving seals, e.g. shaft seals,
see Grease "S", page 19.
Remember:
NOTE!
Be careful of the sealing surfaces. Place the parts on a suitable surface, such as wooden blocks, so
that the sealing surfaces will not be damaged.
NOTE!
The sealing grooves and other sealing surfaces must not have transverse scratches. Any minor
scratches on the sealing surfaces can be removed using a fine abrasive material, such as
Scotch-Brite. Polish along the sealing line and never across it.
Instructions
1. Replace all seals with new ones when reassembling the circuit breaker.
2. Sparingly lubricate the sealing surfaces and seals. Surfaces and seals are lubricated to facilitate the
seal's fitting to the surface and as corrosion
protection.
Excess grease that could be pressed out of the
flanges inside the gas space must not occur.
3. Coat the flange surfaces outside the external seals with a thin, fully covering layer of corrosion
protective agent adapted to suit the pertinent flange material.
End of instruction
1HSB439954-2en 2017-11-01 147

8 Overhaul
8.5.3 Assembly of Post Insulator
General
This section describes the assembly of post insulators.
DANGER!
Use lifting equipment that is designed for the post insulator.
Overview
1 Operating lever
2 Link
4 Joint pin
5 Washer
6 Cotter key
7 Post insulator
9 Mechanism housing
10 Sealing rings
Required Equipment

Grease "G" 1171 4014-407 More information about grease is specified in Types of
Grease, page 18.
Grease "M" 1171 4016-612 More information about grease is specified in Types of
Grease, page 18.
148 2017-11-01 1HSB439954-2en

8 Overhaul
Instructions
NOTE!
Be careful not to damage the insulating pull-rod.
1. Turn the operating lever (1) and link (2) over the mechanism housing edge.
2. Place the sealing ring (10) on the mechanism Treat the sealing surfaces; see Treatment of Sealing
housing (9) and lift on the post insulator (7). Surfaces and Seals, page 147.

Torque
79 Nm
End of instruction
1HSB439954-2en 2017-11-01 149

8 Overhaul
8.5.4 Assembly of Interrupter Unit Following Overhaul
General
This section describes how the interrupter unit is fitted together again after the overhaul.
Interrupter Unit
1 Puffer
2 Lower current path
3 Bolt M8x20 (16 pcs), Spring washer 8.4x18x2 (16 pcs), Washer 8.4x20x2 (16 pcs)
4 Contact spring (2 pcs)
5 Lower flange
6 Breaking chamber insulator
7 Bolt M12x60 (16 pcs), Washer 13x28x3 (16 pcs)
8 Upper current path
Required Equipment

Grease "G" 1171 4014-407 Information on the grease is provided in Types of
Grease, page 18.
150 2017-11-01 1HSB439954-2en

8 Overhaul

Grease "N" 1171 4016-607 Information on the grease is provided in Types of
Grease, page 18.
Torque wrench 22,5-79 Nm
1HSB439954-2en 2017-11-01 151

8 Overhaul
Instructions
1. Treat contacts. See Treatment of Contact Surfaces, page 146.
2. Fit puffer (1) on the lower current path (2).

IMPORTANT!
When the puffer moves down over the
Teflon strap, turn the puffer carefully to
ensure the Teflon strap and the puffer
cylinder's fingers are not damaged.
3. Roll down the contact springs (4) over the contact fingers from position a to position b.
4. Place the sealing ring on the lower flange (5) and Treat sealing surfaces and seals.
lift on the breaking chamber insulator (6).
See Treatment of Sealing Surfaces and Seals,
page 147
5. Centre the breaking chamber insulator and tighten

Torque
the bolts (7).
60 Nm
6. Fit the upper current path (8) with the sealing ring Treat sealing surfaces and seals.
in the breaking chamber insulator (6).
See Treatment of Sealing Surfaces and Seals,
page 147
7. Centre the current path's plug contact in relation to the nozzle in the puffer (1).

Torque
60 Nm
9. A new absorbent container is fitted initially in See section Assembly of Interrupter Unit on the Post
conjunction with the assembly of the unit on the Insulator on Site, page 161.
post insulator.
End of instruction
152 2017-11-01 1HSB439954-2en

8 Overhaul
8.5.5 Assembly of Interrupter Unit on the Post Insulator
General
This section describes how the interrupter unit is refitted to the post insulator.
Overview
1 Puffer pull-rod
2 Post Insulator
3 Lower adapter plate
4 Joint pin
5 Washer
6 Cotter key
7 Bolt M12x35, washer 13x28x3
9 Cover
12 Sealing ring
Required Equipment
Lifting device
Lifting tackle
Torque wrench 45 - 79 Nm
Grease "G" 1171 4014-407 See detailed information in section Types of Grease,
page 18.
1HSB439954-2en 2017-11-01 153

8 Overhaul
Instructions
DANGER!
Use lifting equipment that is designed for the weight of the interrupter unit. See outline drawing
for the exact weights.
1. Suspend the interrupter unit in the lifting device and pull down the puffer pull-rod (1) to fully extended
position making it accessible for assembly.
2. Clean the sealing surface on the sealing ring (2) on the post insulator (2) carefully.
3. Also clean the lower flange and adapter plate (3) and lubricate generously with grease "G" to ensure
that the sealing ring is kept in place during assembly.
4. Place the sealing ring in its groove.
5. Slowly lower the interrupter unit so that it comes into position for fitting the pin (4), around 75-100 mm
above the post insulator.
6. Connect the puffer's pull-rod (1) to the insulating

NOTE!
pull-rod (11) with the pin (4) and secure with the
washer (5) and split pin (6). Ensure that no lock rings or washers
fall down in the post insulator when
dismantling.
Cover the opening by e.g. a cloth rag.
7. When the pin is fitted, lower the interrupter unit carefully towards the post insulator and centre.
8. Secure the interrupter unit with bolts, washers and

Torque
nuts (7).
60 Nm
9. Clean the sealing surface on the upper flange and adapter plate (8) and lubricate with grease "G".
11. Open the packaging to new absorbent and apply this in the container (10).
12. Fit the container (10) and cover (9).

NOTE!
Fit the cover on the container
immediately after fitting the container.

Torque
60 Nm
End of instruction
154 2017-11-01 1HSB439954-2en

8 Overhaul
8.5.6 Assembly of Trip Mechanism's Pull-Rod to the Operating Lever
General
This section describes fitting of the trip mechanism's pull-rod in the operating lever.
Trip Mechanism
1 Bottom cover
2 Bolt M8x20 (4 pcs)
3 Operating lever
4 Joint pin
5 Pull-rod
6 Spring Housing
7 Trip spring
8 Lock nut
Required Equipment
Locking fluid 12690014-410 Loctite 270

Grease "M" 1263 0011-102
Torque wrench 22,5-45 Nm
1HSB439954-2en 2017-11-01 155

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

Torque
22.5 Nm
4. If the nut (8) has moved out of position Adjust until The measurement Y according to Removal of the
measurement Y is reached. Trip Mechanism's Pull-Rod, page 133.
NOTE!
The lock nut must be replaced when
reassembling.
5. Tighten the lock nut (8).

Torque
45 Nm
6. Relieve the spring force using the bolt before removing the discharge tool.
7. Clean the bottom cover's (1) draining groove and refit the cover.
End of instruction
156 2017-11-01 1HSB439954-2en

8 Overhaul
8.5.7 Filling Gas Before Transport
General
Before the circuit breaker pole can be moved, it must be treated with gas as per this section.
Instructions
1. Vacuum-pump down to a pressure of 100 Pa and let the vacuum-pumping continue for at least one
hour after this pressure has been reached.
2. Stop the vacuum-pumping and fill the circuit breaker with dry and clean nitrogen to atmospheric
pressure. Let it stand a couple of hours or overnight.
3. Vacuum pump back down to a pressure of 100 Pa The filling hoses should be stored to ensure that
and fill with clean SF6 gas to 0.125 MPa (abs). they are not exposed to moisture and
contamination. They must not be used for
anything other than their intended purpose.
4. The circuit breaker pole is now ready for transport.
End of instruction
1HSB439954-2en 2017-11-01 157

8 Overhaul
8.6 Replacement of breaking unit
8.6.1 Dismantling of Interrupter Unit for Transport
General
This section describes the dismantling of the interrupter unit for transport. Dismantling the interrupter unit on
site is an option to the recommendation (removing the whole circuit breaker, and then dismantling the
interrupter unit in a workshop) and should only be applied in stable weather which gives indoor-like working
conditions.
The circuit breaker must be taken out of service before the circuit breaker pole is dismantled, see section
Preparations for Overhaul, page 125 and the gas evacuated, see section Evacuation of SF6 Gas, page 126.
Pole Order
The poles on the circuit breaker are described in the following instructions.
Overview
1 Joint pin
2 Washer
3 Cotter key
5 Bolt M12x35, washer 13x28x3
6 Interrupter Unit
7 Puffer pull-rod
8 Post Insulator
158 2017-11-01 1HSB439954-2en

8 Overhaul
Safety
NOTE!
Under no circumstances may the interrupter unit be dismantled or opened during rainy or unstable
weather.
Preconditions
NOTE!
If the post insulator or interrupter unit is left for a long period without the unit being refitted, the
post insulator, or interrupter unit, should be vacuum-pumped and filled with nitrogen.
NOTE!
If large amounts of moisture enter the post insulator, this must be immediately sealed and filled
with nitrogen to be transported as soon as possible to the workshop for dismantling and careful
cleaning.
NOTE!
Required Equipment

Lifting device
Lifting tackle
Protective Cover 5439 142-A
Protective cover for interrupter 1HSB445237-1
unit
Dismantling
1. Before removing the circuit breaker pole the circuit See section Preparations for Overhaul, page 125
breaker should be taken out of service. and Evacuation of SF6 Gas, page 126
2. Operate the breaker slowly to the closed position See section Slow Manual Closing and Tripping
by cranking the operating mechanism by hand. Operation, page 114.
1HSB439954-2en 2017-11-01 159

8 Overhaul
3. Stop cranking when the measurement 230-235 mm

is reached.
The puffer pull-rod (7) with the pin (1) on the

insulating pull-rod (4) is now in the correct position
for removal.
4. Add a lifting sling around the top section of the interrupter unit and prepare for lifting.
DANGER!
Use lifting equipment that is designed for the weight of the interrupter unit. See outline
drawing for the exact weights.
5. Remove the bolts (5) and very carefully lift up the

NOTE!
interrupter unit (6) max 70 mm.
The interrupter unit must not be lifted
more than 70 mm to avoid damage to
the inside of the circuit breaker.
6. Disconnect the interrupter unit (6) by removing the

NOTE!
split pin (3), washer (2) and pin (1).
Ensure that no split pins or washers fall
down in the post insulator when
dismantling. Cover the opening by e.g.
a cloth rag.
7. Fit the protective cover, ABB part no. 5439142-A,

NOTE!
with the sealing ring above the post insulator (8).
When the cover has been mounted, the
nitrogen pressure in the post insulator
is raised to 0.125 MPa abs.
8. Push the puffer pull-rod (7) into the interrupter unit (6) and fit the protective cover with a sealing ring.
9. The interrupter unit is now ready for transport.
End of instruction
160 2017-11-01 1HSB439954-2en

8 Overhaul
8.6.2 Assembly of Interrupter Unit on the Post Insulator on Site
General
This section describes the assembly of the interrupter unit following an overhaul, when the interrupter unit
has been dismantled on site, i.e. not in the workshop.
Circuit Breaker Pole
1 Joint pin
2 Washer, 2 pcs
3 Split pin, 2 pcs
5 Bolts M12x35, (8 pcs), washers 13x28x3 (8 pcs)
6 Interrupter Unit
7 Puffer pull-rod
8 Post Insulator
10 Cover
Required Equipment

Protective Cover 5237 736-R
1HSB439954-2en 2017-11-01 161

8 Overhaul
Assembly
1. Suspend the interrupter unit in the lifting device.
2. Remove the post insulator's protective cover.
3. Pull out the puffer to ensure the puffer pull-rod (7) is accessible for assembly.
4. Reduce the nitrogen pressure in the post insulator (8) to atmospheric pressure and remove the
protective cover
5. Clean the sealing surface for the sealing ring on

NOTE!
the post insulator (8) carefully.
Also clean the sealing surface in the
lower flange (3) and lubricate
generously with grease "G" to ensure
that the sealing ring is kept in place
during assembly.
7. Slowly lower the interrupter unit (6) so that it comes into position for fitting the pin (1), about 75 mm
above the post insulator.
8. Connect the puffer's pull-rod (7) to the insulating

NOTE!
pull-rod with the pin (1), washer (2) and split pin
(3). Protect the opening to the post
insulator with a rag or similar in order to
avoid the split pin or washers from
falling down into the post insulator.
9. When the pin is fitted, lower the interrupter unit (6) carefully towards the post insulator (8) and centre.
10. Secure the interrupter unit with the bolts (5).

Torque
60 Nm
11. Clean the sealing surface on the upper adapter plate (9) and lubricate with grease "G".
12. Place the sealing ring on top of the upper flange.
13. Open the new adsorbent packaging and put the adsorbent into the absorbent container (11).
14. Fit the absorbent container (11) and cover (10)

Torque
and tighten the bolts (5).
60 Nm
NOTE!
Fit the cover immediately after fitting
the absorbent container.
162 2017-11-01 1HSB439954-2en

8 Overhaul
15. Fill the circuit breaker pole with gas. See sections Preparations for Gas Filling,
page 62 and Gas Filling with SF6 Gas,
1. Vacuum pump down to a pressure of 100 Pa
page 65.
and let the vacuum pumping continue for at
least one hour after this pressure has been The filling hoses should be stored to ensure that
reached. they are not exposed to moisture and
2. Stop the vacuum-pumping and fill the circuit contamination.
breaker with dry and clean nitrogen to They must not be used for anything other than
atmospheric pressure. Let it stand a couple their intended purpose.
of hours or overnight.
3. Vacuum-pump back down to a pressure of
100 Pa and fill with clean SF6 gas to
0.125 MPa (abs).
16. Operate the breaker slowly to its open position by

winding the operating mechanism by hand and
checking that the control hole A, D=6 mm, for the
open position in the operating lever is centered
with the hole B in the mechanism housing.
IMPORTANT!
Stop hand cranking according to Slow
Manual Closing and Tripping Operation,
page 114.
17. The circuit breaker is now ready for gas filling as per the assembly instructions for the current circuit
breaker.
End of instruction
1HSB439954-2en 2017-11-01 163

8 Overhaul
8.7 Installation of Circuit Breaker Poles and Commissioning
General
Installation of circuit breaker poles and commissioning are carried out in accordance with the installation
instructions and commissioning instructions applicable to the circuit breaker. See chapters and
Commissioning, page 81 .
Following assembly the operating values of the circuit breaker must be checked and recorded.
First Overhaul
IMPORTANT!
Check Below
Control Points Measured values Measured values Measured values


Inspection conducted on (date): ______________________________________
Inspection conducted by (name): ________________________________________
164 2017-11-01 1HSB439954-2en

8 Overhaul
Second Overhaul
IMPORTANT!
Check Below
Control Points Measured values Measured values Measured values


Inspection conducted on (date): ______________________________________
Inspection conducted by (name): ________________________________________
1HSB439954-2en 2017-11-01 165

8 Overhaul
9 Disposal and Environmental Information
9.1 Disposal and Recycling
General
ABB strives to minimize the product’s impact on the environment throughout its entire life cycle. Technical
and product development focuses on environmental aspects. The ecocycle approach is strived for and
consideration is taken to the materials' environmental impact and recycling alternatives. The manufacturing
processes are selected to be as safe to the environment as possible.
Disposing of Worn-Out Equipment
Worn-out equipment must be phased out in an environmentally sound manner.

When disposing of used equipment, much of the material, or energy content in the material, can be recycled
following sorting and cleaning. The amount that is recycled varies depending on the technical resources and
experience in each country. Non-recyclable components should be sent to an approved environmental waste
treatment plant for destruction or disposal.
Gas
The SF6 gas must be evacuated prior to disposal of a circuit breaker. All handling of SF6 gas must be
conducted with care and according to the applicable regulations to ensure that there are no gas leaks. The gas
can be handled in different ways, depending on the circumstances:
• Regenerated onsite, and reused in other equipment.
• Sent to the gas supplier for regeneration.
• Sent for destruction at a special waste treatment plant.
In cases where the circuit breaker is filled with mixed gas, the SF6 gas is separated from the mixture for
further processing according to the above. Alternatively the gas mixture can be sent for destruction without
being separated. On request, ABB may provide a quote for final disposal of used gas in conjunc tion with the
scrapping of a circuit breaker.
Porcelain
After cleaning, the porcelain can be sent for disposal or used for other purposes, such as for use as filling
material.
Electronics
Electronic equipment should be sent to an approved recycling company or sorted into different component
materials for appropriate treatment.
Metals
Metals should be sorted according to type and surface treatment and sent to an approved recycling company.
Following the removal of any paint or other surface treatment, clean metal can as a rule, be melted down and
used in new products. Many metal components of iron, steel and aluminum are large and easy to identify, e.g.
support structures and mechanism housings.
ABB strives to reduce the use of precious metals and the release of environmentally hazardous metals.
Recycling of these is particularly important. Precious metals such as copper and silver are expensive and are
only present in small amounts in the earth’s crust. Copper is primarily used in current paths, puffers, contacts
and cables. Silver plating of contacts may occur. Emissions from certain metals may cause damage. This
applies to copper, but also zinc and nickel, which are used sparingly as surface treatments.
1HSB439954-2en 2017-11-01 167

Plastics
The different types of plastic should be separated and sent to an approved environmental waste treatment
plant or recycling company. The energy content in thermoplastics and thermosetting plastics can often be
recovered through combustion at a plant designed for the purpose. Thermoplastics can as a rule, be melted
down and reused without any major loss of quality. Composites can be fractioned and used as filling materials
in other materials or be disposed of.
There are various amounts of composites in the insulators and piping. The cable entries are made of a
thermosetting plastic. Thermoplastic is present in components such as guide rings, tape, bushings and support
rings. Thermoplastic in sleeves, nozzles, piping and collars contains fluoride and is not suitable for recycling.
However, it can be disposed of without the risk of leaking hazardous substances.
Oils and Greases
Before disposal, oil, grease and similar products must be removed and sent to an approved environmental
waste treatment plant or recycling company. By utilizing gravimetric forces, oil waste can be separated into
oil, water and a range of contaminants. In many cases, the oil can then be reused. Alternatively, the energy
content in oil can be recovered through combustion at a plant designed for the purpose.
Oil occurs in dampers where grease is used as a lubricant.
Rubber
Rubber can be sent to an approved environmental waste treatment plant, either for disposal or reused for
various purposes.
Rubber is present in various seals.
Other Materials
Other materials are sorted and sent to an approved environmental waste treatment plant.
168 2017-11-01 1HSB439954-2en

9.2 Environment Information, SF6 Gas
Gas Handling
Electrical equipment with SF6 gas has been used for many years with good results. In cases where a device or
substation needs to be opened, the SF6 gas is collected and reused. ABB's policy is that no SF6 should be
released during installation, service or disposal of equipment.
SF6 Gas
Pure SF6 gas is non-toxic and is harmless to inhale if the oxygen content is at least 20%. SF6 gas is
approximately five times heavier than air. This means that gas may collect in, e.g. cable trenches or at the
bottom of tanks.
Greenhouse Effect
The SF6 molecule contributes to the greenhouse effect, but does not contain any chlorine and thereby has no
impact on the ozone layer. Since SF6 gas began to be used 50 years ago, a small amount of gas has leaked into
the atmosphere and contributed less than a tenth of a percent of the total greenhouse effect.
Decomposition
The SF6 gas partially decomposes in conjunction with discharges. This takes place in the temperature range
where arcing is extinguished, 1500-5000 K, and provides an efficient cooling effect. Here both gaseous and
solid by-products are formed. All by-products are reactive, which means that they are quickly decomposed
and disappear.
During normal operation, the level of gaseous by-products is kept low by means of built-in adsorbers. The
solid by-products are primarily metal fluorides in the form of a powder. The powder can be easily processed
as separate waste and represents no long-term threat to the environment. For service and maintenance there
are special procedures as the large concentrations of by-products are corrosive and toxic.
1HSB439954-2en 2017-11-01 169

10 Spare parts
10 Spare parts
10.1 Introduction
General
The replacement modules for the operating mechanism are delivered complete and tested.
Spare parts that are recommended for storage are marked with R. Where there are more than ten circuit
breakers in operation we also recommend the spares marked with RR. RRR parts can be held in stock in order
to be able to replace parts quickly and avoid prolonged stoppages.
State the type designation and serial number for any inquiries and when ordering parts or tools. Specify the
order number also where possible.
LTB 72.5-245E1US is designed for controlled connection of capacitor banks with non-directly earthed
neutral.
LTB 72.5-245E1GS is designed for controlled connection of capacitor banks with directly earthed neutral.
1HSB439954-2en 2017-11-01 171

10 Spare parts
Summary, Circuit Breaker
1 Circuit breaker pole, RRR

2 Interrupter Unit
3 Post Insulator
4 Mechanism
5 Operating mechanism, RRR
6 Support structure
7 Protective tube/pull-rod
172 2017-11-01 1HSB439954-2en

10 Spare parts
Summary, Operating Mechanism
1 Drive Unit
2 Mechanism
3 Control Panel
4 Spring assembly
5 Heating element (Behind protective cover)
1HSB439954-2en 2017-11-01 173

10 Spare parts
10.2 Circuit Breaker Pole
10.2.1 Circuit Breaker Pole
Component Parts
Item Designation Note
1 Interrupter Unit
2 Post Insulator
3 Mechanism
4 Trip Mechanism
174 2017-11-01 1HSB439954-2en

10 Spare parts
10.2.2 Interrupter Unit
Component Parts

1 Breaking chamber insulator RR
2 Upper current path Included in contact set
3 Puffer Included in contact set
4 Lower current path Included in contact set
1HSB439954-2en 2017-11-01 175

10 Spare parts
10.2.3 Contact Set
Component Parts
Quantity Component Parts Part number

1 Contact set R
176 2017-11-01 1HSB439954-2en

10 Spare parts
10.2.4 Post Insulator and Insulating Pull-Rod
Component Parts

1 Post insulator RR
2 Insulating pull-rod RR
1HSB439954-2en 2017-11-01 177

10 Spare parts
10.2.5 Mechanism
Component Parts

1 Mechanism RR
178 2017-11-01 1HSB439954-2en

10 Spare parts
10.2.6 Trip Mechanism
Component Parts

1 Trip mechanism RR
1HSB439954-2en 2017-11-01 179

10 Spare parts
10.2.7 Accessories
Adsorbent

1 Adsorption container
2 Adsorbent R
Density Monitor

1 Density monitor (temperature R
compensated reference volume)
2 Density monitor (temperature R
compensated bimetal)
Gasket Set
Gasket set for full circuit breaker.
Designation Part number Note

Gasket Set 1HSB436309-A R
Assembly Kits
180 2017-11-01 1HSB439954-2en

10 Spare parts

Bolt set 1HSB436309-B R
Pins with locking 1HSB436309-C R
Non-return valve

Non-return valve 1HSB442541-C RR
Protective Cover

Protective cover for interrupter unit 1HSB445237-1 R
Protective cover for post insulator 5439 142-A R
Discharge tool

Discharge tool 1HSB446381-A R
1HSB439954-2en 2017-11-01 181

10 Spare parts
10.3 Operating Mechanism
10.3.1 Drive Unit, Complete With Motor
Component Parts
For type of drive unit, see wiring diagram.
Item Drive unit model Part number

- 1 Motor, 220 V, 0-60 Hz 2361 113-AU
2 Motors, 220 V, 0-60 Hz 2361 113-AV
1 Motor, 110 V, 0-60 Hz 2361 113-AS
2 Motors, 110 V, 0-60 Hz 2361 113-AT
182 2017-11-01 1HSB439954-2en

10 Spare parts
10.3.2 Damper
Damper
Item Designation Part number

1 Close damper 5256 707-BN
2 Opening damper State the serial number on the
operating mechanism when
ordering.
1HSB439954-2en 2017-11-01 183

10 Spare parts
10.3.3 Latch Device
Latch Device
Closing Latch Device

1-coil 5436 009-V
1-coil, with interlocking device 5436 009-AB
2-coil 5436 009-X
2-coils, with interlocking device 5436 009-AC
Trip Latch Device

Standard 5436 009-Z
With manual trip 5436 009-AD
With manual tripping operation and 5436 009-AF
69-device
184 2017-11-01 1HSB439954-2en

10 Spare parts
10.3.4 Auxiliary Contact
Component Parts
State the serial number when ordering.
Component Description Part number

Auxiliary Contact 6- or 12-pole
18-pole
1HSB439954-2en 2017-11-01 185

10 Spare parts
10.3.5 Heating Element
Component Parts

1 110-127 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
186 2017-11-01 1HSB439954-2en

10 Spare parts
10.3.6 Electrical Equipment
Component Parts

1 Contactors:
220-250 V DC 5351 749-1
110-125 V DC 5351 749-2
220-250 V 50/60 Hz AC 5351 749-3
110-130 V 50/60 Hz AC 5351 749-4
2 Protective motor switch:
110-125 V, 4-6 A 5576 0760-2
220-250 V, 2.4-4 A 5576 0760-1
3 Relay, 3 pole
250 V DC 5619 758-7
220 V DC 5619 758-1
125 V DC 5619 758-8
110 V DC 5619 758-2
42-48 V DC 5619 758-4
1HSB439954-2en 2017-11-01 187

10 Spare parts
3 Relay, 4 pole
250 V DC 5619 750-7
220 V DC 5619 750-1
125 V DC 5619 750-8
110 V DC 5619 750-2
42-48 V DC 5619 750-4
4 Counter:
220-250 V DC 5692 965-11
110-125 V DC 5692 965-12
42-48 V DC 5692 965-13
188 2017-11-01 1HSB439954-2en

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

BLK 222 BLG 1002A FSA MD MSD SM 800
Circuit breaker type:

LTB D LTB E LTA D HPL
Disconnector/option:
WCB DCB Truck Spareparts Other
Specification of problem:
Delayed delivery Incomplete delivery Wrong delivery Torque
Documentation Poor packing Corrosion Wiring
Not according to spec Transport damage Functional values Mechanical failure
Quality of material Storage of material Leakage gas/oil/water
Other
Who discovered the problem:

End customer ABB representative Other
When was the problem discovered

Before Installation During Installation During Commissioning After Energizing
Description of problem:
Contact information:
ABB AB Telephone: +46(0) 240 782000
CustomerComplaints Telefax: +46(0) 240 782320 Click here to send!
SE‐771 80 Ludvika, Sweden [email protected]
ABB High Voltage Products
SE-771 80 Ludvika
Sweden
new.abb.com/high-voltage

1HSB439954-2en 20171101

Uploaded by

Copyright:

Available Formats

1HSB439954-2en 20171101

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1HSB439954-2en 20171101

Uploaded by

Copyright:

Available Formats

PRODU C T M A N U A L

© Copyright 2017 ABB All rights reserved.

Telephone: +46(0) 240 782000

1.2 Hazardous Working Situations ........................................................................................................................... 8

1.3 Discharge the Springs......................................................................................................................................... 9

2.2 Gas System ........................................................................................................................................................ 14

2.3 Breaking Principle ............................................................................................................................................. 15

3.2 Types of Grease ................................................................................................................................................. 18

3.3 Locking Fluid...................................................................................................................................................... 20

3.4 Tightening Torque.............................................................................................................................................. 21

3.5 Operating Values................................................................................................................................................ 22

4.2 Storage Prior to Assembly................................................................................................................................ 24

5.2 Required Equipment .......................................................................................................................................... 29

5.3 Foundations ....................................................................................................................................................... 30

5.4 Assembly of Support Structure ........................................................................................................................ 31

5.5 Installation of an Earthquake Damper on the Foundation (Option) .............................................................. 33

5.6 Assembly of Support Structure on the Foundation ....................................................................................... 36

5.7 Lifting the Circuit Breaker Poles ...................................................................................................................... 38

5.8 Assembly of Circuit Breaker Pole .................................................................................................................... 40

5.9 Installation of Corona Rings on the Post Insulator (Option) ......................................................................... 42

5.10 Lifting the Operating Mechanism ..................................................................................................................... 43

5.11 Installation of Operating Mechanism ............................................................................................................... 45

5.12 Assembly of Protective Tube ............................................................................................................................ 47

5.13 Final Assembly of the Circuit Breaker Pole. ................................................................................................... 48

5.14 Fitting of Rod System ........................................................................................................................................ 50

5.15 Assembly of Gas Monitoring System .............................................................................................................. 56

5.16 Fitting the Distribution Block (Option)............................................................................................................. 58

5.17 Electrical Connections ...................................................................................................................................... 60

5.18 Pressurizing of Circuit Breaker Poles.............................................................................................................. 62

5.19 Inspection of Bolt Joints ................................................................................................................................... 74

5.20 Assembling the Indicator Sign and Cover....................................................................................................... 75

5.21 Inspection Prior to Commissioning ................................................................................................................. 77

6.2 Pre-Commissioning Checklist .......................................................................................................................... 82

6.3 Operating Values and Signature....................................................................................................................... 84

7.2 Required Equipment .......................................................................................................................................... 86

7.3 Description of Maintenance Categories .......................................................................................................... 87

7.4 Maintenance Schedule ...................................................................................................................................... 89

7.5 Maintenance, Circuit Breaker Pole................................................................................................................... 95

7.6 Maintenance, Operating Mechanism and Link System .................................................................................. 98

7.7 Slow Manual Closing and Tripping Operation .............................................................................................. 114

7.8 Maintenance of Rust Protection ..................................................................................................................... 124

8.2 Required Equipment ........................................................................................................................................ 128

8.3 Removal of Circuit Breaker Pole for Transport ............................................................................................. 130

8.4 Overhaul of Circuit Breaker Pole.................................................................................................................... 132

8.6 Replacement of breaking unit......................................................................................................................... 158

8.7 Installation of Circuit Breaker Poles and Commissioning ........................................................................... 164

9 Disposal and Environmental Information 167

9.2 Environment Information, SF6 Gas ................................................................................................................ 169

10 Spare parts 171

10.2 Circuit Breaker Pole......................................................................................................................................... 174

10.3 Operating Mechanism ..................................................................................................................................... 182

1.1 Levels of Safety Risks

Safety Risks - Symbols and Their Meanings.

1.2 Hazardous Working Situations

Hazardous Working Situations

1.3 Discharge the Springs

1.3.1 Discharge the Springs Electrically

Example of Component Placement

1 Protective motor switch