1HYB800001-042A-OM Manual (1-Pole) PDF

Product Manual
1HYB800001-042 Rev.A
LTB 245E1
BLK 222
1-pole operation
PRODUCT MANUAL
PRODUCT DESCRIPTION
- Circuit-Breaker 1
PRODUCT DESCRIPTION
- Operating Mechanism 2
ASSEMBLY INSTRUCTIONS
3
CHECKLIST
4
OPERATING AND MAINTENANCE
INSTRUCTIONS 5
LUBRICANTS
6
MAINTENANCE INSTRUCTIONS
OVERHAUL INSTRUCTIONS
- Circuit-Breaker 8
SPARE PARTS
- Circuit-Breaker 9
ABB HV Switchgear
P.O.Box 124,Vadodara-390013,India
SPARE PARTS
11
SF6 Circuit-Breaker LTB 245E1 with operating
mechanism BLK 222
1-pole operation
Product Description
1HYB800001-043 Rev.A
ABB Switchgear
The information in this document is subject to alteration without prior notice and should not be regar-
ded as an undertaking from ABB HV Switchgear . ABB HV Switchgear takes no responsibility for errors
that can occur in the documentation.
ABB HV Switchgear is not responsible for damage incurred due to the misuse of this document.
The document, or parts thereof, may not be reproduced or copied without prior permission from ABB
HV Switchgear . It may not either be imparted to third party or otherwise be used without authorisation.
Infringement hereof will be subject to action in accordance with applicable laws.
© ABB HV Switchgear
Article number: 1HYB800001-043 Rev.A
Date: 01-01-2005
Product Description
LIST OF CONTENTS
1. Description.......................................................................... 1
1.1 Design of the circuit-breaker.......................................................... 1
1.2 The circuit-breaker’s gas system .................................................... 2
1.3 Operating mechanism..................................................................... 3
1.4 Standards ........................................................................................ 3
1HYB800001-043 Rev.A i
Product Description Description
1. Description
High voltage circuit-breaker LTB 245E1, with three operating mechanisms type
BLK 222.
1.1 Design of the circuit-breaker

The circuit-breaker is made up of three separate poles. These consist of three main
parts. At the bottom is an operating mechanism in an alloy housing, above this are
hollow post insulators through which the operating insulator runs and at the top is
the breaking unit.
Each breaking unit consists of a breaking chamber insulator, which together with an
upper and lower flange makes up the enclosure, and upper and lower current paths
and puffer. The puffer, which is designed with the lower operating current contacts
integrated, runs on the outside of the lower current path. The upper operating
current contacts are integrated in the upper current path.
The poles are mounted on separate hot-dipped galvanised column frames. The
frame consists of two welded formed plate halves, which are interconnected with
bolted cross stays.
The weights of component parts:
Item Part Weight, kg
1 Circuit-breaker See
pole dimension
drawing
2 Operating 210
mechanism
3 Frame 86-275 1
B10034
Figure 1-1. Circuit-breaker type LTB 245E1
1HYB800001-043 Rev.A 1
Description Product Description
1.2 The circuit-breaker’s gas system

The circuit-breaker poles are permanently filled with SF6 gas at a pressure of
0.7 MPa abs at 20°C on circuit-breakers whose performance is limited by a lowest
ambient temperature of ≥ -30°C.
On circuit-breakers whose ambient temperature is ≥ -40°C the circuit-breaker is
filled to a pressure of 0.5 MPa abs at 20°C. On breakers whose ambient temperature
is ≥ -55°C the breaker is filled with a mixture of SF6 gas and N2 gas or CF4 gas at a
pressure of 0.7 MPa abs at 20°C. The poles are fitted with density monitors to
monitor the pressure.
1.2.1 Opening and closing

The circuit-breaker poles work according to the Auto-PufferTM- principle with the
puffer cylinder (1) divided into two chambers. An Auto-PufferTM section (2) and a
compression section (3).
When the normal operating currents are
cut, the SF6 gas is compressed in the
compression section to an over-pressure.
When the arcing contacts part, the gas in
the compression section flows out and
extinguishes the arc at the passage trough
zero.
When the short-circuit currents are cut the
requisite extinguishing pressure is built-up 1
in the Auto-PufferTM section by heating the 2
arc. In this way a pressure increase is
achieved with energy from the arc and no 3
extra energy is required from the operating
mechanism.
On closing, the puffer cylinder slides
upwards, the contacts engage one another
and the puffer cylinder is refilled with gas.
Figure 1-2. Circuit-breaker pole in Close position
2 1HYB800001-043 Rev.A
1.3 Operating mechanism

LTB circuit-breaker is operated by a motor-charged spring operating mechanism
type BLK 222.
The operating mechanism is connected to the poles’ mechanism via a pull-rod
system.
The circuit-breaker is closed by the operating mechanism, which houses the closing
springs. On closing, the opening springs are tensioned, which are permanently
coupled to the poles’ operating mechanisms. The trip latch in the operating
mechanism keeps the circuit-breaker in the closed position. Opening of the circuit-
breaker only requires the release of the trip latch.
The normal operating cycle is:
O-0.3s-CO-3 min-CO (according to IEC) or CO-15s-CO (according to ANSI).
1.4 Standards
The circuit-breakers comply with the requirements according to IEC Publication
62271-100 and in most cases also ANSI C37.
1HYB800001-043 Rev.A 3
SF6 Circuit-Breaker Operating mechanism
type BLK 222
Product Description
1HYB800001-013 Rev.A
ABB Switchgear
ded as an undertaking from ABB HV Switchgear. ABB HV Switchgear takes no responsibility for errors
HV Switchgear. It may not either be imparted to third party or otherwise be used without authorisation.
Date: 2003-10-01
Product Description
LIST OF CONTENTS
1. Description.......................................................................... 1
1.1 Delivery...........................................................................................2
1.2 Unpacking .......................................................................................2
1.3 Storage ............................................................................................3
2. Assembly and connection ................................................. 5

2.1 Mechanical connection ...................................................................5
2.2 Electrical connection.......................................................................6
2.3 Loading the closing springs ............................................................7
2.4 Normal operations, the circuit-breaker closed ................................8
2.5 Open, the circuit-breaker is open ....................................................8
2.6 Closed, the circuit-breaker is closed ...............................................9
3. Operations .........................................................................11
3.1 Remote/local operations................................................................11
3.2 Close operation ............................................................................. 11
3.3 Open operation..............................................................................12
3.4 Rapid reconnection .......................................................................12
4. Component parts.............................................................. 13
4.1 Drive mechanism ..........................................................................13
4.2 Catch gear .....................................................................................13
4.3 Dashpot .........................................................................................14
4.4 Limit switch with auxiliary contact ..............................................14
4.5 Heater element ..............................................................................15
1HYB800001-013 Rev.A i
Product Description
FIGURES
Figure 1-1. Operating mechanism BLK 222. .................................................... 1

Figure 1-2. Lifting the operating mechanism. ................................................... 2
Figure 2-1. Operating mechanism. .................................................................... 5
Figure 2-2. Earth clamp connection. ................................................................. 6
Figure 2-3. Electrical loading of the closing spring. ......................................... 7
Figure 2-4. Normal operating position. ............................................................. 8
Figure 2-5. Opening operation. ......................................................................... 8
Figure 2-6. Closing operation. .......................................................................... 9
Figure 3-1. Remote/local operations. ...............................................................11
Figure 3-2. Close operation. .............................................................................11
Figure 3-3. Open operation. ............................................................................ 12
Figure 4-1. Motor. ........................................................................................... 13
Figure 4-2. Catch gear. .................................................................................... 13
Figure 4-3. Dashpot. ........................................................................................ 14
Figure 4-4. Limit switch with auxiliary contact. ............................................. 14
Figure 4-5. Heater element. ............................................................................. 15
ii 1HYB800001-013 Rev.A
1. Description
The operating mechanism BLK 222 is intended for operating circuit-breakers with
integrated opening springs. Under no circumstances may the operating mechanism
be operated without first being mounted and adjusted for a circuit-breaker.
The operating mechanism consists of an closing spring with associated motor
charging device that automatically charge the closing spring after each closing
operation. A closing interlock holds the tensioned closing spring prepared for the
Closing of the circuit-breaker and the re-tensioning of the opening springs. A
opening interlock holds a closed circuit-breaker prepared for immediate Opening.
The component parts of the operating mechanism are integrated in a cabinet which
also accommodates an operating panel and operating equipment. The cabinet’s
cover can be removed and the operating panel opened to facilitate service and
overhauling.
The standard operating cycle is O - 0.3 s - CO - 3 min - CO (IEC) or CO - 15s - CO
(ANSI). The time between closing operations should not be less than 1 minute
during the testing of the circuit-breaker and relay systems involving more than 3
closing operations.
2 1
5
3
B30200
Item
1 Drive unit
2 Operating mechanism
3 Operating panel
4 Closing spring
5 Heater element
Figure 1-1. Operating mechanism BLK 222.
1HYB800001-013 Rev.A 1
1.1 Delivery
Check on arrival that the delivery corresponds with the order and delivery
documents and that no transport damage has occurred.
If any material is missing or if transport damage has occurred, please report this
immediately to ABB Switchgear AB, Circuit Breaker Division.
1.2 Unpacking
The operating mechanism is packed in a crate. The crate is marked with a case
number and the gross weight. Other information is written on a plywood
board/label, which is attached to two of the crate’s sides.
The operating mechanism must be lifted using the lifting eyes on top of the cabinet,
see Figure 1-2. Slings must not be placed around the cabinet when lifting.
All packing material can be recycled.
B30079
Figure 1-2. Lifting the operating mechanism.
2 1HYB800001-013 Rev.A
1.3 Storage
Avoid storage. If storage is necessary, this must be done indoors or under cover.
The operating mechanism shall preferably be stored indoors in a dry building. When
stored outdoors, the crate should be opened to promote the exchange of air and a
heater should be used to prevent condensation.
An approved storage area is a store consisting of:
roof
a solid floor
humidity less than 50%
temperature +20 °C (±10 °C)
1HYB800001-013 Rev.A 3
4 1HYB800001-013 Rev.A
Product Description Assembly and connection
2. Assembly and connection

The operating mechanism should be positioned in accordance with the circuit-
breaker’s measurement diagram.
2.1 Mechanical connection

The connection of the pull-rods between the operating mechanism and the circuit-
breaker should be carried out in accordance with the instructions for the circuit-
breaker to be connected to the operating mechanism.
WARNING
Do not operate the mechanism unloaded!
Operations shall take place only after the mechanism has been connected
and adjusted to the associated pressurised circuit-breaker.
On delivery the operating mechanism’s closing spring is uncharged.

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0LGGOHSRVLWLRQ<HOORZILHOG
0D[*UHHQILHOG
B30161
0LQSRV 1RWHQVLRQRQFORVLQJVSULQJ
,WHP 1% 7KHRSHQLQJVSULQJLVWHQVLRQHGLIWKH

FLUFXLWEUHDNHULVFORVHG
1 Indication disk
0LGSRV 'RJDJDLQVWFORVLQJFDWFKJHDU
2 Indication pin
<HOORZILHOG &ORVLQJVSULQJWHQVLRQLQJKDVEHJXQ
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6SULQJVKDOOEHFRQVLGHUHGWHQVLRQHG
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*UHHQILHOG
Figure 2-1. Operating mechanism.
1HYB800001-013 Rev.A 5
Assembly and connection Product Description
2.2 Electrical connection

Operation and signal cables are routed through the connection flange at the bottom
of the cabinet. Fit the flange with a suitable cable gland for the cable in question.
Connect the cables to the terminal blocks in accordance with the applicable wiring
diagram. The terminal blocks are of a snap-in type and are designed both for
through wiring with termination of a stranded conductor with a cross-section of
max. 4 mm2, and as disconnectable blocks with termination of a stranded conductor
with a cross-section of max. 6 mm2 intended for motor circuits, AC circuits and
supply circuits.
Connect the earth wire to the earth terminal (1) on the side of the cabinet.
N.B. Cables must not be routed so that they obstruct manual cranking.
B30079 1
Figure 2-2. Earth clamp connection.
6 1HYB800001-013 Rev.A
2.3 Loading the closing springs
2.3.1 Electrical loading

Make the motor protection switch (1) so that the motor (2) starts and drives the
spring drum (3) to the tensioned position. The limit switch (4) breaks the contactor
(5) and the motor circuit.
CAUTION
The contactor must not be operated manually so that the limit switch
is bypassed.
2
3
B30200 1 5
Item
1 Motor protection switch
2 Motor
3 Spring drum
4 Limit switch
5 Contactor
Figure 2-3. Electrical loading of the closing spring.
1HYB800001-013 Rev.A 7
2.4 Normal operations, the circuit-breaker closed

The open spring on the circuit-breaker and the closed spring on the operating
mechanism are tensioned. The circuit-breaker remains in the closed position by the
operating mechanism’s opening interlock (1).
Item
1 Open interlock
2 Closed interlock
B30054
Figure 2-4. Normal operating position.
2.5 Open, the circuit-breaker is open

When the circuit-breaker is open the interlock is released from the catch gear (1). In
the end position the movement is dampened by the dashpot (2), which makes up an
end position stop in the OPEN position. The closing spring is tensioned.
Item 2
1 Closing catch gear
2 Dashpot
3 Tripping arm
3
B30057
Figure 2-5. Opening operation.
8 1HYB800001-013 Rev.A
2.6 Closed, the circuit-breaker is closed

When closed the closing arm (1) is released from the tripping arm (3) and the
interlock heel (2). The dashpot piston (4) is extended and is prepared once again for
an opening operation. The motor starts and charges the closing spring again so that
the circuit-breaker returns to normal operations.
The operating mechanism is prepared for a new closing operation after opening
(O-CO).
3
2
Item
1 Closing arm 4
2 Interlock heel
3 Tripping arm with interlock heel
4 Dashpot piston
B30054
1
Figure 2-6. Closing operation.
1HYB800001-013 Rev.A 9
10 1HYB800001-013 Rev.A
Product Description Operations
3. Operations
3.1 Remote/local operations

With normal operations the switch (1) is in the Remote position for electrical remote
operations. In the LOCAL position, operations can only be carried out using the
operating switch (2).
The switch (1) has one position for the Shutdown function.
2 1
Item
1 Switch, Local/Remote
2 Operating switch, On/Off
B30207
Figure 3-1. Remote/local operations.
3.2 Close operation

A Close operation using the operating switch (2) or electrical remote pulses can
only take place if:
• Switch (1) is in the Remote or Local position.
• The closing spring is tensioned with a closed ON circuit via the limit switch
(3).
• The circuit-breaker is in the open position with a closed ON circuit via auxiliary
contact (4).
• The gas density is greater than the blocking level with closed ON circuit via the
density monitor.
Item
3 Limit contact
4 Auxiliary contact 3
B30200 2 1
Figure 3-2. Close operation.
1HYB800001-013 Rev.A 11
Operations Product Description
3.3 Open operation

An Open operation with a closed circuit-breaker can be made with the switch (1) in
the LOCAL position and the operating switch (2) in the ON position.
2 1
Item
B30208
Figure 3-3. Open operation.
3.4 Rapid reconnection

Automatic rapid reconnection, Open-0.3s-Closed-Open can be made if:
• The circuit-breaker is closed.
• The switch is in the Remote position.
• The mechanism’s closing spring is fully loaded when the operating cycle is
started.
With automatic rapid reconnection the switchgear’s relay equipment can give an
immediate Open impulse if the short-circuit still remains in the network. As the
operating circuits are electrically interlocked via the auxiliary contact an Close
operation will always be completed before an Open operation is started. Even if the
Close pulse has been given during a current Open operation.
12 1HYB800001-013 Rev.A
Product Description Component parts
4. Component parts
4.1 Drive mechanism

The drive mechanism is supplied with a motor for 110 or 220 V DC and
50, 60 Hz AC.
The motor should be capable of loading the spring at 85% of the nominal voltage
(IEC).
1
Item
1 Motor
B30068
Figure 4-1. Motor.
4.2 Catch gear

The operating mechanism has a Closing and an Opening catch gear.
The standard voltage of the magnets is 110 or 220 V DC.
The coils rated power is 200 W.
1 2
Item
1 Opening catch gear
B30062
Figure 4-2. Catch gear.
1HYB800001-013 Rev.A 13
Component parts Product Description
4.3 Dashpot
The operating mechanism is fitted with a dashpot to slow the final phase of the
opening movement.
Item
1 Dashpot
B30063
Figure 4-3. Dashpot.
4.4 Limit switch with auxiliary contact

The operating mechanism is fitted as standard with a 12 way auxiliary contact
consisting of twelve normally open and twelve normally closed contacts. Three
normally closing and three normally opening contacts are used for the operating
mechanism’s own function. There is also the possibility of supplementing with
twelve extra contacts.
The auxiliary contact’s shaft is in direct connection with the operating mechanism’s
operating lever and accordingly follows the circuit-breaker contact’s movement.
2 1
Item
1 Limit switch
2 Auxiliary contact
B30200
Figure 4-4. Limit switch with auxiliary contact.
14 1HYB800001-013 Rev.A
Product Description Component parts
4.5 Heater element

The operating mechanism is equipped with a heater element to prevent
condensation and should always be connected.
Item
1 Heater element
B30058
Figure 4-5. Heater element.
1HYB800001-013 Rev.A 15
SF6 Circuit-Breaker LTB 245E1 with three operating
mechanisms BLK 222
1-pole operation
Assembly Instructions
1HYB800001-044 Rev.A
ABB Switchgear
HV Switchgear . It may not either be imparted to a third party or otherwise be used without authorisa-
tion. Infringement hereof will be subject to action in accordance with applicable laws.
Article number:1HYB800001-044 Rev.A
Date: 01-01-2005
LIST OF CONTENTS
1. General ................................................................................ 1
2. Safety................................................................................... 3
2.1 Warning text ................................................................................... 3
2.2 Safety, general ................................................................................ 4
3. Delivery ............................................................................... 5
3.1 Weights........................................................................................... 5
3.2 Unpacking ...................................................................................... 6
3.3 Storage before assembly ................................................................ 7
4. Assembly............................................................................. 9
4.1 Preparations.................................................................................... 9
4.2 Frame assembly............................................................................ 11
4.3 Assembling the frame on the foundation ..................................... 12
4.4 Assembling the circuit-breaker pole on the frame ....................... 13
4.5 Assembling the operating mechanism ......................................... 15
4.6 Final assembly of the circuit-breaker pole ................................... 16
4.7 Assembling the pull-rods ............................................................. 17
4.8 Inspecting the bolted joints, etc.................................................... 19
5. Electrical connections ..................................................... 21

5.1 Connection of the operating mechanism...................................... 21
5.2 Assembly of busbars or overhead lines........................................ 21
6. Pressurising the poles ..................................................... 23

6.1 Preparations.................................................................................. 23
6.2 Gas filling with SF6 gas ............................................................... 24
6.3 Gas monitoring system................................................................. 27
6.4 Leakage test.................................................................................. 28
6.5 Fitting the signs and cover ........................................................... 28
7. Commissioning................................................................. 29
8. Operating values .............................................................. 31

8.1 Times............................................................................................ 31
8.2 Motor and control circuits............................................................ 31
8.3 Resistance..................................................................................... 31
8.4 Contact stroke............................................................................... 31
1HYB800001-044 Rev.A i
FIGURES
Figure 3-1. Component parts ............................................................................. 5

Figure 3-2. Lifting the operating mechanism .................................................... 6
Figure 4-1. Assembly markings ........................................................................ 9
Figure 4-2. Foundation .................................................................................... 10
Figure 4-3. Frame assembly ............................................................................ 11
Figure 4-4. Frame assembly on the foundation ............................................... 12
Figure 4-5. Lifting the circuit-breaker pole ..................................................... 13
Figure 4-6. The circuit-breaker pole’s non-return valve ................................. 13
Figure 4-7. Fitting the circuit-breaker pole on the frame ................................ 14
Figure 4-8. Assembly of the operating mechanism ........................................ 15
Figure 4-9. Circuit-breaker poles on the frame ............................................... 16
Figure 4-10. Dismantling the signs and cover ................................................... 17
Figure 4-11. Assembling the pull-rod ............................................................... 18
Figure 5-1. Operating mechanism ................................................................... 21
Figure 6-1. Gas filling ..................................................................................... 24
Figure 6-2. Density monitor and union nut ..................................................... 26
Figure 6-3. Gas monitoring ............................................................................. 27
Figure 6-4. Fitting the signs and cover ............................................................ 28
ii 1HYB800001-044 Rev.A
Assembly Instructions General
1. General
This assembly instruction applies to the SF6 circuit-breaker type LTB 245E1 with
three operating mechanisms type BLK 222 for 1-pole operation and contain all
essential information for assembly and commissioning.
Read through the entire Assembly Manual before starting the assembly work.
1HYB800001-044 Rev.A 1
Assembly Instructions Safety
2. Safety
2.1 Warning text

Warning text occurs where required and indicates that the text in question should be
observed extra carefully. The warning texts are marked as set out below:
DANGER
indicates an immediate hazardous situation that, if not avoided, will result
in death or serious injury.
WARNING
indicates an immediate hazardous situation that, if not avoided, can result
CAUTION
indicates a hazardous situation that can result in minor or moderate
injury.
N.B. is used for hazards that may only result in damage to the installation.
1HYB800001-044 Rev.A 3
Safety Assembly Instructions
2.2 Safety, general
WARNING
Circuit-breaker with pressurised porcelain insulators.
Mechanical damage on the porcelain can cause it to explode with the
following risk of splintering.
Work on the circuit-breaker that brings about the risk of a mechanical
damage to the insulators should be carried out at a reduced gas pressure,
0.125 MPa (abs).
WARNING
Do not operate the operating mechanism unloaded!
and trimmed with the associated pressurised circuit-breaker.
The standard operating cycle is O - 0.3 s - CO - 3 min.-CO. The time between

closing operations should not be under 1 minute during the testing of circuit-
breakers and relay systems involving more than 3 closing operations.
4 1HYB800001-044 Rev.A
Assembly Instructions Delivery
3. Delivery
Check on arrival that the delivery corresponds with the order and delivery
documents and that no transport damage has occurred.
If any material is missing or if transport damage has occurred, please report this
immediately to ABB HV Switchgear, Circuit Breaker Division.
3.1 Weights
The weights of component parts are as follows:
Weight,
Item Part
kg
1 Circuit-breaker stated on
pole the
applicable
dimension
drawing
1
for the
order..
2 Operating 210
mechanism
2
3 Frame 86-275
B10034
Figure 3-1. Component parts
1HYB800001-044 Rev.A 5
Delivery Assembly Instructions
3.2 Unpacking
The material is packed in crates and on pallets. The crates are marked with a case
number and the gross weight. Other information is written on a plywood
board/label, which is attached to two of the crate’s sides.
The operating mechanism must be lifted using the lifting eyes on top of the cabinet,
see Figure 3-2. Slings must not be placed around the cabinet when lifting.
The circuit-breakers must be kept in the transport packaging until just before
assembly.
All packing material can be recycled.
B10036
Figure 3-2. Lifting the operating mechanism
6 1HYB800001-044 Rev.A
Assembly Instructions Delivery
3.3 Storage before assembly
3.3.1 General
The circuit-breakers are normally delivered in units adapted for transport.
Intermediate storage of these units should be avoided. If intermediate storage can
not be avoided the units should be stored indoors or under a roof. They should also
be stored horizontally above ground level to avoid cracking or water damage. Upon
arrival it is important that the plastic cover is removed in order to prevent corrosion
due to condensation (except for spare parts, see chapter 3.3.5, Spare parts).
Storage in a humid climate, without proper ventilation, can lead to discolouring of
zinc coated surfaces. This discolouring is known as white rust, and consists mainly
of zinc oxide and zinc hydroxide and is a result of a chemical process between pure
zinc on the surface and moisture.
The long term rust protection is not affected because the steel-zinc layer under the
surface remains unaffected. The presence of white rust is no reason to reject the
goods.
Upon arrival each unit should be checked regarding the following:
The delivery corresponds with the order and shipping documents
Damage due to transport and missing parts
If damage is discovered or suspected the case should be opened and photos taken.
Report damage as well as missing parts.
All components should be rationally stored for easy access. All material should be
stored in an approved store1, exceptions are stated below. Dust, smoke, corrosive or
inflammable gas, steam or salt must not pollute the surrounding air otherwise the
equipment must be cleaned before construction.
The original cases can be used for storage, but the plastic covering should be
removed. The assembly units’ coupling pieces as well as connections are provided
with transport covers or protective covers which must not be removed until shortly
before the circuit-breakers are assembled.
3.3.2 Stacking of cases

Cases of different widths shall normally not be stacked (the pressure may destroy
the covers of the lower cases). If cases of different widths need to be stacked, a
framework must be used between the cases in order to distribute the pressure evenly.
Stacking of more than three cases is not allowed. It must be noted that stacking
causes instability sidewise and therefore the cases must be secured, i.e., prevented
from tumbling down or rolling over.
1. An approved store is defined as consisting of:

roof
firm base
humidity below 50%
temperature 20˚C (±10˚C)
1HYB800001-044 Rev.A 7
Delivery Assembly Instructions
3.3.3 Operating mechanism

The operating mechanism should be unpacked on arrival. If it is not kept in an
approved store, the heating element must be connected and permanently switched
on to prevent the control equipment from corrosion or damage due to freezing.
3.3.4 Circuit-breakers
The circuit-breakers should be stored in their original cases where they are properly
protected from damage. The units shall not stand in water. The circuit-breakers can
be stored outdoors. If this happens they should be protected by at least a tarpaulin.
The tarpaulin must not be so tight that air circulation to zinc coated surfaces is
prevented. Any condense should easily drip off.
The lowest permitted ambient temperature for storage is -30˚C.
3.3.5 Spare parts

Spare parts shall be kept indoors in an approved store and in their original packing.
This is especially important for rubber components (seals etc.), which must also be
protected from sunlight to avoid drying. Gaskets have a limited storage life, so avoid
storing them. Frames can be stored outdoors.
8 1HYB800001-044 Rev.A
Assembly Instructions Assembly
4. Assembly
4.1 Preparations
Before starting the assembly, make certain that all requisite tools and documents are
on hand.
• Standard tools with torque wrenches (10 - 430 Nm).
• Lifting devices and lifting slings.
• Lubricant, see Lubricants 1HYB800001-017 for suppliers and brand names.
Grease “G”: ABB article number1171 4014-407
Grease “SV”: ABB article number 1171 4016-610.
• Contact grease.
• Applicable dimension drawings and diagrams for the order.
4.1.1 Assembly markings

On delivery the circuit-breakers are supplied dismantled in transport units. The
component parts are marked to facilitate assembly. The circuit-breaker poles and
operating mechanisms have been tested together.
Check that the assembly markings correspond with Figure 4-1 and that the serial
number on the operating mechanism corresponds with the serial number of the
circuit-breaker.
6 5 4
Item
1 Operating
mechanism A
2 Operating
mechanism B
3 Operating
mechanism C
4 Circuit-breaker
pole A1
5 Circuit-breaker
pole B1
6 Circuit-breaker
pole C1
3 2 1
B10037
Figure 4-1. Assembly markings
1HYB800001-044 Rev.A 9
Assembly Assembly Instructions
4.1.2 Foundation
The circuit-breaker’s foundation must be flat and level. Adjust any deviations using
spacer washers, see “Chapter 4.3, Assembling the frame on the foundation”. Figure
4-2 shows the permitted deviations in mm for the position of the foundation bolts.
The nominal dimensions are stated on the applicable dimension drawing for the
order.
±1
±1
Length = >110
B10038
Figure 4-2. Foundation
10 1HYB800001-044 Rev.A
4.2 Frame assembly

The frame is supplied in welded halves with six cross stays and nuts, bolts and
washers.
Bolt the halves together as shown in Figure 4-3. Fit the cross stays according to
the numbering 1-4, using the supplied nuts, bolts and washers.
N.B. Make sure the stays are fitted as set out in Figure 4-3 and to the intended
operating mechanism.
Tighten the bolted joints to a torque of 430 Nm.
Item
1 Frame halves 2 pcs. 1
2 Stays 6 pcs.
3 Bolts M20x60 8 pcs.

Nuts M20 8 pcs.
Washers 21x37x3 16 pcs.
3
2
TIGHTENING TORQUE
430 Nm
1
B10039
Figure 4-3. Frame assembly
1HYB800001-044 Rev.A 11
4.3 Assembling the frame on the foundation

Check that the frames are upright and adjust them to the same level using the nuts
(2).
Fill with spacer washers the gap between the lower nut and the foundation, which
should be as small as possible.
Thighten the lower nut against the spacer washers (4). For the final tightening of the
frame, use the upper nut, which is tightened to a torque of 300-350 Nm for M24 nut
and 500-550 Nm for M30 nut.
Foundation bolts and spacer washers are not supplied.
1 2 3 Item
1 Foundation bolts,
L> 110 mm
(Not supplied)
2 Nuts (Not supplied) 8 pcs.
3 Washers 8 pcs.
10
6
4 Spacer washers (Not supplied)
>110
20
5 Foundations
4
6 Frame foot
10
TIGTHENINING TORQUE
300-350 Nm
B10006 2 or
500-550 Nm
Figure 4-4. Frame assembly on the foundation
12 1HYB800001-044 Rev.A
4.4 Assembling the circuit-breaker pole on the frame

Place a lifting sling around the breaking unit’s top as shown in Figure 4-5 and, using
this method, lift the circuit-breaker pole from its horizontal position in the transport
packaging.
Check that the bolts (1) are tightened with tightening torque 60 Nm before lifting
the pole to vertical position
B10040
Figure 4-5. Lifting the circuit-breaker pole
Check that the circuit-breaker

pole does not leak before
assembly on the frame.
1. Undo the sealing cap (1).
2. Press the non-return
valve’s disk (2) inwards
using a rod with a
diameter of about 5 mm. 1
A clear hissing noise
should be heard from the
pole. If no hissing noise
is heard, the pole leaks.
This must be rectified 2
B10008
before assembly.
3. Fit the sealing cap (1).
Figure 4-6. The circuit-breaker pole’s non-return valve
1HYB800001-044 Rev.A 13
A circuit-breaker pole is fitted to each frame according to Figure 4-7. Fit the bolts
(1) and tighten by hand.
N.B. Final tightening is carried out when the operating mechanism has been fitted.
Item

Nuts M20 4 pcs.
B10041
Figure 4-7. Fitting the circuit-breaker pole on the frame
14 1HYB800001-044 Rev.A
4.5 Assembling the operating mechanism

On delivery the operating mechanism has been set and is supplied with the closing
springs correctly adjusted.
Fit the operating mechanism as set out in Figure 4-8.
Fit all bolts and tighten them by hand. Then tighten the bolted joints (1) with a
tightening torque of 79 Nm and the bolted joints (2) with a tightening torque of
190 Nm
Dismantle the operating mechanism’s lifting beams (2x2 bolts M8x25) and store
these.
Item
1 Bolts M12x40 8 pcs

Nuts M12 8 pcs
Washers 13x24x2.5 16 pcs

Nuts M16 4 pcs.
3 Spring washer 4 pcs.
3 1
TIGHTENING TORQUE
79 and 190 Nm
B10042
Figure 4-8. Assembly of the operating mechanism
1HYB800001-044 Rev.A 15
4.6 Final assembly of the circuit-breaker pole

Tighten the poles to the frame with a tightening torque of 300 Nm.
TIGHTENING TORQUE
300 Nm
B10043
Figure 4-9. Circuit-breaker poles on the frame
16 1HYB800001-044 Rev.A
4.7 Assembling the pull-rods

Each pole is supplied set to a basic setting. Adjust the poles to the correct open
position when fitting the operating rods between the operating mechanism and the
pole.
Pull-rod assembly takes place in stages:
• Preparations for assembling the pull-rods.
• Assembling the pull-rods between the operating mechanisms and the poles.
4.7.1 Preparations for assembling the pull-rods

Remove all the pole covers (1)
and the Close-Open signs (2), to
gain the best possible access to
the pole mechanisms.
Item
1 Cover
2 Sign
3 Coupling link
B10012 1 2 3
Figure 4-10. Dismantling the signs and cover
1HYB800001-044 Rev.A 17
4.7.2 Assembling the pull-rod between operating mechanism A and pole A1.
Each pole is supplied set to a basic setting and its Close and Open positions are
determined. Adjustment is made as set out in Figure 4-11.
• Move by hand the pull-rod from the operating mechanism (2) to the side, as far
that the turnbuckle screw (5) can be placed between the coupling link (4) and
the pull-rod from the operating mechanism. The operating mechanism’s pull-
rod must not be slide out so far that it locks in its inner Closed position.
• Simultaneously screw the turnbuckle screw (5) in the operating mechanism’s
pull-rod (2) (left-hand thread) and the pole’s coupling link (4) (right-hand
thread).
N.B. Remember the two spring washers (6) under each locking nut (8).
• Turn the turnbuckle screw (5) so its length decreases at the same time as
operating lever (3) moves towards its Open position. The turnbuckle screw
(5) is the right length when the operating lever (3) is in its Open position
and the alignment check hole (7) is directly aligned with the predrilled
hole in the mechanism housing (1). Check the position of the hole using a rod
with a 6 mm diameter. Check that the turnbuckle screw (5) is screwed past the
alignment check holes (9 and 10). The tightening torque for the locking nuts is
190 Nm
5 2 3
Item
1 Mechanism housing
1
2 Pull-rod from operating
mechanism
3 Operating lever
4 6
10
4 Coupling link, pole
5 Turnbuckle screw
6 Spring washers
7 Alignment check hole

in arm
9
8 Locking nuts
9 Alignment check hole

in pull-rod
10 Alignment check hole 7 8

in coupling link B10044
TIGHTENING TORQUE
190 Nm
Figure 4-11. Assembling the pull-rod
18 1HYB800001-044 Rev.A
Repeat the procedure to assemble the pull-rods between operating mechanism B

and pole B1 and between operating mechanism C and pole C1.
4.8 Inspecting the bolted joints, etc.

• Check using a 6 mm diameter rod that the arm’s alignment check hole is
aligned with the predrilled hole in the mechanism housing.
• Check that all bolted joints are tightened to the correct torque in accordance
with the table below.
Bolted joint Tightening torque (Nm)
Frame 430
Foundation 300-350 or 500-550
Circuit-breaker pole 300
Operating 79 and 190

mechanism
Pull-rod 190
Density monitor 10
Protective tube 79
Plates 22,5
Cover 9
1HYB800001-044 Rev.A 19
Assembly Instructions Electrical connections
5. Electrical connections
5.1 Connection of the operating mechanism

Operation and signal cables are routed through the connection flange at the bottom
of the cabinet. Fit the flange with a suitable cable gland for the cable in question.
Connect the cables to terminal blocks in accordance with the applicable wiring
diagram. The terminal blocks are of a snap-in type and are designed both for
through wiring with termination of a stranded conductor with a cross section of
max. 4 mm2, and disconnectable block with termination of a stranded conductor
with a cross section of max. 6 mm2 intended for motor circuits, AC circuits and
supply circuits.
Connect the earth wire to the earth terminal (1) on the side of the cabinet.
B10045
1
Figure 5-1. Operating mechanism
5.2 Assembly of busbars or overhead lines
WARNING
Work must not be carried out on a pressurised circuit-breaker.
High-voltage conductors consisting of aluminium busbars or aluminium connectors

for overhead lines can, after being treated with contact paste, be directly connected
to the breaking unit’s terminal flags which are also made of aluminium.
However, if copper busbars or copper connectors are used for the overhead lines,
grease should be used and a bimetallic washer fitted in the joint. Bimetallic washers
can be supplied by ABB on request.
1HYB800001-044 Rev.A 21
Electrical connections Assembly Instructions
Using contact paste or grease

1. Clean all grease and old paste from the contact surfaces.
2. Rub down the surfaces using an abrasive cloth, e.g. Scotch Brite No. 7447 or
emery cloth.
3. Apply immediately:
- Contact grease on aluminium surfaces.
- Grease “SV”, ABB’s article number 1171 4016-610, on copper surfaces.
4. Fit together the joint with the paste or grease still applied.
5. Wipe off any excess paste or grease.
N.B. Position the bimetallic washers so that the aluminium sides face the
aluminium surfaces and the copper sides are turned towards the copper
surfaces or the silver-plated surfaces.
N.B. The contact paste may only be used on fixed joints. It must not be used
inside the breaking unit.
22 1HYB800001-044 Rev.A
Assembly Instructions Pressurising the poles
6. Pressurising the poles

The circuit-breaker poles are supplied vacuum-processed and filled with SF6 gas at
a pressure of 0.12- 0.13 MPa abs at 20˚C.
6.1 Preparations
WARNING
When commissioning, the SF6 gas needs to be refilled to the pressure
stated on the rating plate.
Pressurisation takes place directly from a gas cylinder using the gas filling
equipment, ABB article number 1HSB 445439-A.
The gas hose for the filling equipment is supplied vacuum-pumped and filled with
SF6 gas.
WARNING
To avoid personal injury while refilling, due to possible transport damage
to the porcelain, assembly personnel must exercise great care and stay in a
protected and safe area (with regard to splintering) away from the circuit-
breaker. The gas cylinder and refilling equipment should be placed in the
same area.
• Connect the control cables to the operating mechanism’s terminal blocks for
opening and closing. The cables are routed to the control room or protected
area away from the circuit-breaker.
• Connect the cables to appropriate pushbutton switches.
• Set the operating mechanism’s control switch in the remote position.
• Switch on the motor starter so the closing springs are tensioned.
• Open the terminal blocks to which the density monitor cables are connected
and interrupt the circuit to the interlocking relays.
1HYB800001-044 Rev.A 23
Pressurising the poles Assembly Instructions
6.2 Gas filling with SF6 gas
3
Item
6 1 Gas cylinder
9
5 4 8 7 2 Regulator
3 Density monitor
4 Coupling
5 Valve
6 The circuit-breaker’s gas valve
7 Hose
8 Adaptor
9 Nipple with union nut
10 Equal union cross
11 Valve
1
2
B10016 10 11
Figure 6-1. Gas filling
1. Place the gas cylinder (1) in a protected area.

2. Check the filling pressure on the circuit-breaker’s rating plate.
3. Fit the regulator (2) on the gas cylinder. Set the right filling pressure,
compensated for the temperature as set out in Table 6-1 on the regulator.
4. Pull the sealing rings off the density monitor (3) with your fingers.
N.B. Do not use a sharp tool.

5. Lubricate the sealing rings thoroughly with grease “G” and refit them on the
density monitor.
24 1HYB800001-044 Rev.A
6. Connect the density monitor (3) to the coupling (4) or the equal union cross
(10). Open valve (5) or alternatively, valve (11). If the density monitor is
connected to coupling (4), then valve (11) must be closed. However, if the
density monitor is connected to the equal union cross (10), then valve (5) must
be closed.
7. Connect coupling (4) to the circuit-breaker’s gas valve (6).
8. Connect the gas-filled hose (7) to the coupling.
9. Connect the hose to the gas cylinder.
10. Go from the circuit-breaker to the protected area and let the gas flow until the
regulator switches off.
11. Wait until the gas temperature has reached the circuit-breaker temperature level
before reading off the gas pressure on the density monitor. Adjust the pressure
if necessary
12. Dismantle the hose from the coupling on the circuit-breaker.
13. Close the valve to the density monitor.
14. Dismantle the coupling from the circuit-breaker.
15. Release the pressure on the density monitor by opening valve (5) or valve (11).
16. Dismantle the density monitor from the coupling and fit it on the circuit-
breaker.
17. Repeat from 4 through to 16 for poles B and C.
N.B. When reading from the precision gauge, correct the filling pressure
depending on the temperature as set out in Table 6-1.
Table 6-1. Filling pressure
Filling pressure in MPa (abs)

stated on the rating plate 0.7
Filling pressure read off on the gauge in
Temp. when
MPa (abs) bar (abs) MPa (gauge bar (gauge)
filling ˚C
+40 0.75 7.5 0.65 6.5
+30 0.72 7.2 0.62 6.2
+20 0.70 7.0 0.60 6.0
+10 0.66 6.6 0.56 5.6
±0 0.63 6.3 0.53 5.3
-10 0.61 6.1 0.51 5.1
-20 0.58 5.8 0.48 4.8
1HYB800001-044 Rev.A 25
18. Close the valve on the gas cylinder when all poles have been filled.
19. Disconnect the hose from the gas cylinder and release the pressure in the
regulator by pressing in the non-return valve.
20. Release the regulator’s adjustment pressure by turning the adjuster valve so
that the wrong pressure is not filled in the next circuit-breaker to be fitted.
N.B. When the density monitor (1) is finally fitted, tighten the union nut (2) is with
a torque of 10 Nm.
TIGHTENING TORQUE
10 Nm
Item
1 Density monitpr
2 Union nut
1 2
B10017
Figure 6-2. Density monitor and union nut
21. Operate the circuit-breaker Close and Open 3 times from the control room.
22. Connect the cables to the density monitors.
23. Reset the circuits for the interlocking relays.
26 1HYB800001-044 Rev.A
6.3 Gas monitoring system

• Drill a 23 mm diameter hole in flange (1) on the bottom of the operating
mechanism and fit cable gland (2) with a sealing washer (3) and nut in the hole.
• Insert the cable through the cable gland in the operating mechanism and
connect it to the terminal blocks as stated on the applicable operating
mechanism’s circuit diagram.
• Tighten the cable gland (2) to secure the cable.
• Secure the cables to the frame’s leg using pipe clips (5) and nuts, bolts and
washers (6).
• Connect the cable to the density monitor’s terminal block.
N.B. The cable ends for the density monitor should be as long as necessary so that
the density monitor can be disconnected from the non-return valve without
the need of disconnecting the cable.
Item
1 Flange
2 Cable gland
3 Sealing washer
1
4 Pipe clips 4 pcs.
3
2 Nuts M5 4 pcs.
Washers 5.3x10x1 8 pcs.
B10046
Figure 6-3. Gas monitoring
1HYB800001-044 Rev.A 27
6.4 Leakage test

Perform a leakage test using a leak detector around the density monitor’s
connections.
6.5 Fitting the signs and cover

Fit and thighten all Close and Open signs (1) with a torque of 22,5 Nm.
Then fit the cover (2) with a tightening torque of 9 Nm.
Item
1 Sign
2 Cover

Washers 8.4x16x1.5 9 pcs.
TIGHTENING TORQUE
9 and 22,5 Nm 1
2 3
B10012
Figure 6-4. Fitting the signs and cover
28 1HYB800001-044 Rev.A
Assembly Instructions Commissioning
7. Commissioning
Before commissioning the circuit-breaker carry out all checks as set out in “Check
list for assembling and commissioning 1HYB800001-015” and fill in the
operating values for the installation.
1HYB800001-044 Rev.A 29
Assembly Instructions Operating values
8. Operating values
The operating values in these instruction apply to SF6 circuit-breakers type
LTB 245E1 with operating mechanism type BLK 222.
8.1 Times
Closing times < 28 ms
Opening time coil I 17 ± 2 ms
Opening time coil II 17 ± 2 ms
Close-Open time(1) 26 ± 3 ms
(1) The Close-Open time refers to the time the main

contacts are closed during a closing operation when
a tripping pulse is simultaneously connected via the
auxiliary contact.
8.2 Motor and control circuits
Charging time for motor max 15 s
Operating voltage opening V (according to the rated data plate)

coil I
Operating voltage opening V (according to the rated data plate)

coil II
Operating voltage closing coil V (according to the rated data plate)

I and II
8.3 Resistance
Main circuit resistance per pole max 49 µΩ.
8.4 Contact stroke

Main contact stroke is 160 ±3 mm.
1HYB800001-044 Rev.A 31
SF6 Circuit-Breaker Circuit-breakers HPL and LTB
Check list, assembly

1HYB800001-015 Rev.A
ABB Switchgear
ded as an undertaking from ABB H V Switchgear. ABB H V Switchgear takes no responsibility for errors
that can occur in the document.
HV Switchgear. It may not either be imparted to a third party or otherwise be used without authorisa-
Date: 2003-10-0
Check list Check list for assembly and commissioning
1. Check list for assembly and commissioning

The following checks shall be made and the check list completed before the circuit-
breaker is commissioned. The check list shall be kept in the order binder.
Date:_______________
Installation:______________________________________________
Serial number:_____________________________
Circuit-breaker pole
1. Check that the circuit-breaker and operating mechanism have been assembled
in accordance with the assembly instructions.
2. Check that all bolted joints are tightened to the tightening torques stated in the
assembly instructions.
3. Ensure that all poles are in the open position. The alignment hole in the
operating lever shall align with the predrilled hole in the mechanism housing.
Operating mechanism
4. Make an ocular inspection to check that oil from the oil dashpots has not
leaked in the operating mechanism.
5. Tighten all screws in terminal blocks involved in the assembly work.
Gas filling
6. Connect the operating mechanism for remote control from a protected area in
connection with gas filling and test operations.
Set the control switch to remote.
7. Connect the gas filling equipment for gas filling from the protected area.
8. Fill with gas each pole one after the other and perform an operational test three
times as set out in the assembly instructions.
9. Check the heater element.
10. Make sure the thermostat, if provided, is set to 10°C 1.
1. Other thermostat settings may occur.
1HYB800001-015 Rev.A 1
Check list for assembly and commissioning Check list
Operating values
11. Check the breaker’s operating values with the applicable operating values for
the breaker in the Assembly Instructions and note down the measured values in
the table below.
CAUTION
The circuit-breaker must not be switched Open - Close without an
intermediate delay of 300 ms.
Measured values
Check the following
Pole A Pole B Pole C
Closing time coil I ms ms ms
Closing time coil II ms ms ms
Opening time coil I ms ms ms
Opening time coil II ms ms ms
Close-Open time ms ms ms
Lowest control voltage closing coil I V V V
Lowest control voltage closing coil II V V V
Lowest control voltage opening coil I V V V
Lowest control voltage opening coil II V V V
Main circuit resistance µΩ µΩ µΩ
Filling pressure(1) MPa (abs) MPa (abs) MPa (abs)
(1) Filling pressure in accordance with the rating plate.
12. Check carried out by:________________________________

13. If points 1-11 as set out above have been completed, the circuit-breaker can be
commissioned.
2 1HYB800001-015 Rev.A
SF6 Circuit-Breaker Type LTB E
Operating and Maintenance

Instructions
1HYB800001-045 Rev.A
ABB Switchgear
Date: 01-01-2005
Operating and Maintenance Instructions
LIST OF CONTENTS
1. General ................................................................................ 1
1.1 Warning text ................................................................................... 1
1.2 Warning .......................................................................................... 2
2. Preventative maintenance ................................................. 3

2.1 Circuit-breaker ............................................................................... 3
2.2 Operating mechanism..................................................................... 5
2.3 Spare parts...................................................................................... 6
3. Inspection intervals............................................................ 7
3.1 Maintenance summary ................................................................... 8
3.2 Maintenance category A ................................................................ 9
3.3 Maintenance category B............................................................... 10
3.4 Maintenance category C............................................................... 12
3.5 Maintenance category D .............................................................. 19
1HYB800001-045 Rev.A i
Operating and Maintenance Instructions
FIGURES
Figure 2-1. Number of operations with short-circuit current. ........................... 4
ii 1HYB800001-045 Rev.A
Operating and Maintenance Instructions General
1. General
These Operating and Maintenance Instructions apply to the SF6 circuit-breaker type
LTB E.
The instructions contain recommendations for the care and guidelines for the
maintenance of high-voltage circuit-breakers the LTB E type. The instructions are
divided into four parts:
• Inspection intervals
• Instructions for preventive maintenance of circuit-breakers
• Instructions for preventive maintenance of operating mechanism
• Fault correction maintenance
Periodic maintenance must be carried out at the the time or operation intervals
specified.
Fault correction maintenance is related to the faults detected. The fault correction
maintenance described in this Manual involves the replacement of defective units. If
the user chooses to try and repair a defective unit instead, specialist knowledge is
often needed. This will not be found in the Manual.
The equipment must be overhauled in accordance with specified criteria, e.g. after a
certain number of operations. Overhaul of the equipment must be entrusted to
authorised service personnel.
1.1 Warning text

Careful attention must be given to text marked with:
DANGER
in death or serious personal injury.
WARNING
CAUTION
indicates a hazardous situation than can result in minor or moderate
injury.
1HYB800001-045 Rev.A 1
General Operating and Maintenance Instructions
1.2 Warning
WARNING
Circuit -breakers with pressurised porcelain insulators.
Mechanical damage to the porcelain can cause it to explode with the
subsequent risk of splintering. Work on the circuit-breaker that brings
about the risk of mechanical damage to the insulators should be carried
out at a reduced gas pressure, 0.125 MPa (abs).
2 1HYB800001-045 Rev.A
Operating and Maintenance Instructions Preventative maintenance
2. Preventative maintenance
2.1 Circuit-breaker
2.1.1 Circuit-breaker service life

Assuming that the recommended inspection intervals have been adhered to and the
appropriate measures have been implemented, the LTB E circuit-breaker will have a
service life exceeding 30 years or 10,000 mechanical operations.
The following points will ensure a long service life:
1. Burning-off of the arcing contacts is limited.
2. Each breaking unit is equipped with a absorption agent with the service life
equivalent to that of the circuit-breaker.
3. Bearings in the space filled with gas are maintenance-free.
4. The seals have double sealing rings.
Generally speaking, there are only two reasons to open the breaking unit:
– if the number of short-circuits x short-circuit current (kA) is approaching
the curve in Figure 2-1
or...
– if the number of operations for line, reactor or capacitor switching, as well as
switching of the load current1 has reached the level specified under the
heading “Inspection intervals” in the inspection chart.
Other reasons for opening the breaking unit are limited to mechanical
faults/incorrect adjustment of the drive system that may cause damage to
components inside the breaking unit.
N.B. Opening the breaking unit requires special instruction and may only be done
by trained and authorised personnel.
The curve that defines the permissible number of short-circuits can be expressed
approximately as:
for LTB 245E1: Σ n x I2 = 20000
for LTB 420E2: Σ n x I1.9 = 20000
where
n = number of short-circuits
I = short-circuit current, kA (RMS)
All short-circuit current levels can be included in the total of the number of short-
circuits x short-circuit current, for example for LTB 245E1, to the power of 2.
For example: LTB 245E1: 10x302+20x202+20x102=19,000.
1. All normal service switched-off and -on load currents are not to be included into this
formula- they are considered only in calculation of total number of mechanical CLOSE /
OPEN operations.
1HYB800001-045 Rev.A 3
Preventative maintenance Operating and Maintenance Instructions
2.1.2 Service life of arcing contacts with short-circuit interruption

The diagram below shows the number of interruptions versus short-circuit current
that the contacts in a LTB E circuit-breaker can manage before the metal losses due
to burning becomes so great that they must be replaced.
Number of interruptions
5000
2000
1000
500
200
LTB 420E2
100
LTB 245E1
50
20
kA
2 3 4 5 10 20 30 40 50 63
Short-circuit current
Figure 2-1. Number of operations with short-circuit current.
2.1.3 Tightness checking

The circuit-breakers are equipped with density monitors for checking the gas
density. Each density monitor is equipped with an alarm contact that gives an
electric signal in the event of abnormal leakage. Alarm level 1 gives an alarm signal
while alarm level 2 blocks.
N.B. A new or overhauled circuit-breaker should be checked for tightness by

reading the density monitors after about 1 month and then at 1-2 year
intervals in connection with the regular visual inspections.
4 1HYB800001-045 Rev.A
Operating and Maintenance Instructions Preventative maintenance
2.1.4 Cleaning the outside

The circuit-breaker insulators must be cleaned from salt and other contaminant
deposits at the same time as the cleaning of the other insulators in the substation.
The time interval for cleaning depends on local conditions, i.e. the amount of
atmospheric pollution.
N.B. All LTB E circuit-breakers are completely hose-proof, , i.e. circuit-breakers

in operation can be cleaned with high-pressure water without any risk of
water entering the circuit-breaker and causing damage to essential parts.
2.1.5 Lubricating the circuit-breaker

Use only the lubricants recommended in the document “Lubricants 1HYB800001-017”.
This is particularly important in cold climates with temperatures below -25˚C.
When supplied, the circuit-breaker bearings are lubricated with Grease “G”1 and
will not normally need lubricating except during major overhauls.
See the Overhaul instructions applicable for the circuit-breaker, for lubricating
sealing rings.
2.1.6 Rust protection

The opening springs are rust inhibited by painting with two-component paint.
2.2 Operating mechanism
2.2.1 Maintenance
Work on the operating mechanism with the circuit-breaker in the Closed position
and with tensioned closing springs always involves a certain risk. It is therefore
important that the guidelines in the document “Product information BLG 1002A”
or, “Product information BLK 222”, Safety regulations, are followed before the
work is started.
2.2.2 Cleaning
Clean the operating mechanism when necessary using a vacuum cleaner.
Check that the filters in the valves are clean. Replace them if they are dirty.
1. See the document “Lubricants" 1HYB800001-017 for the names of suppliers and brands for
grease and oils.
1HYB800001-045 Rev.A 5
Preventative maintenance Operating and Maintenance Instructions
2.2.3 Lubrication
The ball, roller and needle bearings in the operating mechanism are permanently
lubricated and require no maintenance. Lubrication is therefore limited to shafts in
the latch mechanism; these should be greased after 2000 operations. The worm gear
in the drive unit for BLG 1002A should be lubricated at the same interval. The
sliding surfaces of the spring fork and dashpot must be lubricated with Grease “G”1
and the chains with Oil “A”1, in connection with an overhaul.
When supplied the closing and opening dashpots are filled with Oil “S”1.
2.2.4 Rust protection

Certain steel parts in the operating mechanism have manganese phosphate surfaces
and then dipped in a rust inhibiting oil. This applies to latches, gear-wheels and
parts of the link system.
The closing springs are rust inhibited by painting with two-component paint (BLG
1002A) or by manganese phosphate surfaces and then dipped in a rust inhibiting oil
(BLK 222).
When supplied, the operating mechanism is equipped with desiccants for protection
against moisture during transport.
Despite the extensive rust inhibitor treatment, minor corrosion can occur after some
years especially if the circuit-breaker is located in a strongly corrosive environment.
Rust spots should be cleaned and new rust inhibitor applied with a brush or spray.
The recommended rust inhibitor is Grease “G”1or Tectyl 506
(ABB Art. No. 1241 0011-108).
N.B. Tectyl 506 forms a waxy protective skin when it dries and therefore it must
not be sprayed into bearings and latch mechanisms or on to gear-wheels and
chains.
2.3 Spare parts

Spare parts must be stored indoors in an approved storage space2 and in the original
packaging. This is particularly important for rubber components (seals etc.), which
must also be protected against sunlight to prevent them drying. Seals have a limited
shelf life so avoid storing them. Base frames can be stored outdoors.
1. See the document “Lubricants” 1HYB800001-017 for the names of suppliers and brands for
grease and oils.
2. Approved storage space:
roof, solid foundation, relative humidity less than 50%, temperature +20oC(±10°C)
6 1HYB800001-045 Rev.A
Operating and Maintenance Instructions Inspection intervals
3. Inspection intervals
Important checkpoints, acceptable tolerances, certain functional values for
adjustments, and recommended inspection intervals can be found in the following
inspection chart.
In corrosive or polluted air and in climates with a high relative humidity, it can be
necessary to halve the inspection intervals.
The specified inspection intervals should be considered as recommended guide
values, which can be increased or decreased depending on local conditions.
1HYB800001-045 Rev.A 7
Inspection intervals Operating and Maintenance Instructions
3.1 Maintenance summary
Condition of Com-
Explan- circuit- petence
Type of measure Inspection interval
ation breaker require-
during work ments
A Visual inspection 1-2 years a1 a2
B Preventive maintenance
Intermediate check
• Operation test including 3-6 years or 2,000 mech. 1) b1 b2
timing test CLOSE/OPEN operations.
• Thermovision check
• Greasing of Wormgear
C Preventive maintenance 15 years or 5,000 mech. 1), 3) b1 b2

• General check of circuit- CLOSE/OPEN operations.
breaker and operating
mechanism
D Overhaul
• Overhaul of breaking 2) c1 c2
chambers
• Line and transformer LTB 245E1:
circuit-breakers ΣnxI2=20,000
LTB 420E2:
• Capacitor-reactor and filter ΣnxI1.9=20,000
circuit-breakers
• Not synchronized 2,500 CLOSE/OPEN op.

with el. load.
• Synchronized 5,000 CLOSE/OPEN op.
with el. load.
• Major overhaul d1 c2
30 years or 10,000 mech. 1)
CLOSE/OPEN operations.
Explanations:
1. Mech. oper. = Mechanical Close-Open operations.
2. CLOSE/OPEN oper. with el load = Close-Open operations with electrical
loading.
3. Special requirements for resistance check of circuit-breakers operated
< 100 CLOSE/OPEN operations/year.
8 1HYB800001-045 Rev.A
Condition of circuit-breaker during work:

a1) Circuit-breaker in service.
b1) Closing springs unloaded, circuit-breaker open, disconnected and earthed. If
thermovision measurement is included, it shall be done at normal load before
the circuit-breaker is disconnected.
c1) Closing springs unloaded, circuit-breaker open, disconnected and earthed.
Poles/Breaking units dismounted and transported to workshop.
d1) Closing springs unloaded, circuit-breaker open, disconnected and earthed.
Complete circuit-breaker including operating mechanism transported to
workshop.
Competence requirements:
a2) Substation personnel with no special training.
b2) Personnel authorised by ABB to carry out assembly, commissioning and
maintenance work.
c2) Personnel authorised by ABB to carry out assembly, commissioning and
maintenance work. Support from ABB may be necessary in certain cases.
3.2 Maintenance category A
To be inspected Inspection interval Measures / Instructions / Tools
1.
Visual inspection 1-2 year Check external cleanliness, heater
element function, gas pressure, valves
and drainage holes.
No special tools needed.
See Chapter 2.1.3 and Chapter 2.1.4
and 1HSB515409-100 for BLG 1002A
or 1HYB800001-018 for BLK 222.
1HYB800001-045 Rev.A 9
3.3 Maintenance category B
1.
Visual inspection 3-6 years or 2,000 mech. CLOSE/ Check external cleanliness, heater
OPEN operations. element function, gas pressure, valves
and drainage holes.
or 1HYB800001-018 for BLK 222.
2.
Rating plates 3-6 years or 2,000 mech. CLOSE/ Make a note of the serial number.
OPEN operations.
3.
Operation counter 3-6 years or 2,000 mech. CLOSE/ Make a note of the number of
OPEN operations. operations.
4.
Visual inspection in 3-6 years or 2,000 mech. CLOSE/ Look for loose bolts and nuts, oil leaks
operating mechanism OPEN operations. from dashpots.
If leakage replace the complete
dashpot.
No tools necessary.
See Manual 1HSB515409-100 for BLG
1002A or 1HYB800001-018 for BLK
222.
5.
Corrosion inspection 3-6 years or 2,000 mech. CLOSE/ Visual inspection.
Rust protection OPEN operations. Rust stains polished off and treated
with rust protection.
See Chapter 2.2.4 .
6.
Greasing 3-6 years or 2,000 mech. CLOSE/ Circuit-breaker in open position, closing
OPEN operations. springs discharged. Greasing of the
worm gear ( only BLG 1002A) and
shafts in latches in the operating
mechanism with grease “M”.
See Chapter 2.1.5 ,Chapter 2.2.3 and
Manual 1HSB515409-100 for BLG
1002A or 1HYB800001-018 for BLK
222.
10 1HYB800001-045 Rev.A
7.
Thermovision 3-6 years or 2,500 mechanical To be carried out at full load before the
measurements Close-Open operations. circuit-breaker is taken out of service.
Checking the temperature rise of the
the external parts of the breaking unit.
The maximal allowed temperature
difference between phases is
5 degrees.
Thermovision camera.
The load current must be taken into
consideration during the measurements
as well as large variations in the load
current 3-4 hours before the
measurements.
See manual for the thermovision
camera.
8.
Operational test 3-6 years or 2,500 mechanical Operational test, if possible in
Close-Open operations. combination with measurement of
operating times, (incl. Close-Open
times).
1HYB800001-045 Rev.A 11
3.4 Maintenance category C
1.
Visual inspection 15 years or 5,000 mech. CLOSE/ Check external cleanliness, heater
OPEN operations. element function, gas pressure, valves
and drainage holes.
or 1HYB800001-018 for BLK 222.
2.
Rating plates 15 years or 5,000 mech. CLOSE/ Make a note of the serial number.
OPEN operations.
3.
Operation counter 15 years or 5,000 mech. CLOSE/ Make a note of the number of
OPEN operations. operations.
4.
SF6 gas 15 years or 5,000 mech. CLOSE/ Gas filling equipment.
OPEN operations.
• Filling of gas (if See Assembly instruction for applicable
necessary) circuit-breaker, ch 6.
• Dew point at normal Dew point maximum - 5 ˚C at rated
gas pressure in the filling pressure and + 20 ˚C
circuit-breaker. temperature.
5.
Insulators
• Visual inspection and 15 years or 5,000 mech. CLOSE/ Spray and rub the insulators clean.
cleaning. OPEN operations. Check cementing, bolts and nuts.
Spray equipment, clothes and
wrenches.
See Chapter 2.1.4
12 1HYB800001-045 Rev.A

6.
Main current circuit
• Resistance check. 15 years or 5,000 mech CLOSE/ Check resistance of circuit-breaker.
OPEN operations. Resistance bridge, test current min.
200 A DC.
Circuit-breakers only operating Resistance value as specified in
<100 CLOSE/OPEN applicable Assembly instructions for the
operations/year after 6-8 years or circuit-breaker in question.
2500 mech CLOSE/OPEN Higher values allowed for frequent
operations. operation with small currents (≤400Α).
Calculation of permissible resistance:
Rn In 1.65
R = ------- -----
2 I
R= Permissible increase in
resistance
Rn = Max. resistance as specified
in operating values
In = Rated current as specified on
rating plate
I= Current for which max.
resistance is calculated.
7a. ’
Contact system
• Opening position 15 years or 5,000 mech. CLOSE/ Inspection of reference holes in outer
OPEN operations. lever and mechanism housing.
See applicable Assembly instructions
for the circuit-breaker in question.
7b.
Operating
characteristics 15 years or 5,000 mech. CLOSE/ Measurement with electronic timer.
• Opening time OPEN operations. Nominal operating voltage.
• Closing time For times, see the applicable Assembly
• Close-Open time instructions for the circuit-breaker.
• Phase discrepancy Max phase discrepancy between
• Auxiliary switches phases:
• Contact travel at closing 4 ms; at opening 3 ms.
• Contact damping. max discrepancy between breaks in the
same phase:
at closing 3 ms; At opening 2 ms.
1002A or 1HYB800001-018 for BLK
222.
1HYB800001-045 Rev.A 13

8a.
Operational availability
• Pull rod system 15 years or 5,000 mechanical Check the tightening torque on bolts in
Close-Open operations. the pull-rod system.
Torque wrench.
Torque: See applicable Assembly
instructions for the circuit-breaker.
• Safety release of 15 years or 5,000 mechanical Measurement of minimum operating

operation Close-Open operations. voltage.
Closing coil: < 85% IEC ( < 72 % ANSI)
of nominal voltage.
Opening coil: < 70% IEC (< 56 % ANSI)
of nominal voltage.
’ Variable D.C. voltage source required.
• Anti-pumping relay 15 years or 5,000 mechanical Checking anti-pumping function:

Close-Open operations.
The circuit-breaker in open position, the
operating mechanism charged, CLOSE
and OPEN impulse given
simultaneously (the close button shall
be pressed).
The circuit-breaker will make a CLOSE-
OPEN operation and may not close
when the operating mechanism is
charged.
The pumping device must stay as long
as the close impulse remain. Lowest
operating voltage of the relay is
measured (85% of nominal).
8b.
Motor current 15 years or 5,000 mechanical Check the carbon brush on the motor.
Close-Open operations. If they are below 10 mm, change
carbon brush.
The motor current is to be measured at
the end of the charging operation. Max
allowed motor current is 110% of value
measured at routine test.
The charging time is allowed to change
up to 30% from value measured at
routine test.
The motor shall be able to charge the
springs at min. 85% of nominal voltage
(IEC).
See 1HSB515409-100 for BLG 1002A
or 1HYB800001-018 for BLK 222.
14 1HYB800001-045 Rev.A

8c.
Dashpot 15 years or 5,000 mechanical Checking of oil-level or recording of
Close-Open operations. damping during operation alternatively.
Recording of damping during operation
is made by means of a circuit breaker
analyzer with transducers connected to:
• main shaft of the circuit breaker
mechanism when checking the
opening dash-pot
• main shaft (cam shaft) of the
operating mechanism when
checking the closing dash-pot.
These measurements are to be carried
out only by specially trained personal.
1002A or 1HYB800001-018 for BLK
222.
8d.
Catch-gears 15 years or 5,000 mechanical Visual control of the adjustment.
Close-Open operations. Play of gaps in the catch-gears acc. to
1002A or 1HYB800001-018 for BLK
222.
Greasing of shafts and catch surfaces
with Grease “L” acc.to 1HYB800001-017
Change the signal from coil 1 to coil 2.
8e.
Coils 15 years or 5,000 mech CLOSE/ The resistances of coils and coil
OPEN operations. currents are allowed to differ +/- 10%
from value measured at routine test.
8f.
Mechanical interlocking 15 years or 5,000 mech. CLOSE/ In OPEN position the distance between
Only applicable for BLG OPEN operations. the interlocking arm and the
1002A interlocking disc shall be min. 2 mm.
In CLOSE position there must be full
contact between the arm and disc (No
gap is permitted).
See Manual 1HSB515409-100.
1HYB800001-045 Rev.A 15

8g.
Heaters
• Operating mechanism 15 years or 5,000 mech. CLOSE/ Checking of resistance:
OPEN operations. If applicable, check signal for loss of
power.
1002A or 1HYB800001-018 for BLK
222.
8h.
Central control cubicle 15 years or 5,000 mech. CLOSE/ Checking of resistance.
OPEN operations. Small cubicle:
48 W, 110 V R = 330 Ohms +/- 10%
48 W, 220 V R = 1000 Ohms +/- 10%.
Middle or large cubicle:
140 W, 110 V R = 86 Ohm +/-10%
140 W, 220 V R = 346 Ohm +/- 10%.
8i.
Thermostat 15 years or 5,000 mech. CLOSE/ If applicable, check that the thermostat
OPEN operations. is adjusted to requested value.
See Manual 1HYB800001-015.
8j.
Terminal blocks 15 years or 5,000 mech. CLOSE/ Tightening of screws or clamps.
OPEN operations. See Manual 1HSB515409-100 for BLG
1002A or 1HYB800001-018 for BLK
222.
8k.
Direct on line motor 15 years or 5,000 mech. CLOSE/ If applicable, check signal for loss of
starter OPEN operations. power.
1002A or 1HYB800001-018 for BLK
222.
16 1HYB800001-045 Rev.A
9.
Tightness of the SF6
gas 15 years or 5,000 mech. CLOSE/ Check the density switches and
• Density monitoring OPEN operations. signal/blocking circuits.
Accurancy test of the pressure gauge
must be done at standard reference
atmosphere i.e. +20 ˚C and 101.3 kPa
(1013 mbar).
Remove the density switch from the
circuit-breaker for checking of function.
N.B. Min permissible voltage for test

of the circuits in the density
switch (30 V).
See applicable Assembly Instruction for
the circuit-breaker.
10.
Blocking relays 15 years or 5,000 mech. CLOSE/ The relays shall close when a density
OPEN operations. switch is pulled out from a pole
pressurized to filling pressure.
11.
Corrosion 15 years or 5,000 mech. CLOSE/ Outside:
OPEN operations. Visual check, particularly check
protected components in non heated
compartments, pull-rod system, clevis
couplings, springs.
Treat with anti-rust oil if necessary.
See Chapter 2.2.4 and Manual
1HSB515409-100 for BLG 1002A or
1HYB800001-018 for BLK 222.
12a.
Lubrication 15 years or 5,000 mechanical Inspect and lubricate the latches.
Close-Open operations. See Chapter 2.1.5 , Chapter 2.2.3 and
1002A or 1HYB800001-018 for BLK
222.
1HYB800001-045 Rev.A 17
12b.
Worm gear 15 years or 5,000 mechanical • For BLG 1002A:
Close-Open operations. Greasing the operating
mechanism’s drive unit with Grease
“M”.
• For BLK 222:
Check the oil level in the worm gear
housing.
See Product information for the
13.
Tightening torque 15 years or 5,000 mech. CLOSE/ Check of tightening torque on screw
OPEN operations joints.
Tightening torques acc. to Assembly
Instruction and Overhaul Instruction.
Tightening torque for earthing 79 Nm.
16 1HYB800001-045 Rev.A
3.5 Maintenance category D
To be inspected Inspection intervals Measures / Instructions / Tools
1.
Overhaul of breaking
chambers Gas evacuated, poles/ breaking units
• Line and transformer LTB 245E1: dismounted and transported to a clean
circuit-breakers ΣnxI2=20,000 workshop.
LTB 420E2: Porcelain lift off, contacts and PTFE-
ΣnxI1.9=20,000 parts replaced with new ones.
• Capacitor bank circuit- Not synchronized:
breakers 2,500 CLOSE/OPEN operations See Manual Overhaul Instruction for
• Reactor circuit- with el. load. actual circuit-breaker.
breakers Synchronized: Standard tools, close fitting dust mask,
• Filter circuit-breakers long sleeved overall, protective plastic
5,000 CLOSE/OPEN operation with
or rubber gloves.
el. load.
See Manual Overhaul Instruction for
applicable circuit-breaker.
• All kinds of service. Alarming result at diagnostic test.
2.
Major overhaul of 30 years or 10,000 mech. Circuit-breaker.
complete circuit- CLOSE/OPEN operations. Disassembly of the poles and
breaker and operating mechanisms. New contacts and PTFE-
mechanism components are to be mounted.
Exchange of outer worn out parts.
If the circuit-breaker and operating
mechanism are overhauled for another
2,000 operations, selected worn out
parts are to be exchanged.
If the circuit-breaker and operating
mechanism are overhauled for another
10,000 operations, in principle all
moving parts are to be exchanged.
Protection against decomposed gas as
standard tools above.
Instructions:
For circuit-breaker, see Manual
Overhaul Instructions for actual circuit-
breaker.
Operating mechanism under
supervision from ABB.
3.
Capacitor 30 years or 10,000 mech. Check of values on:
CLOSE/OPEN operations. C = CN+5%,-0%
PD < 5 pC
Tan d < 0,2%.
1HYB800001-045 Rev.A 19
SF6 Circuit-Breaker Circuit-breakers HPL and LTB
Lubricants
1HYB800001-017 Rev.A
ABB Switchgear
ded as an undertaking from ABB H V Switchgear. ABB H V Switchgear takes no responsibility for errors
that can occur in the document.
HV Switchgear. It may not either be imparted to a third party or otherwise be used without authorisa-
Date: 2003-10-01
Lubricants
LIST OF CONTENTS
1. General ................................................................................ 1
1.1 Safety instructions.......................................................................... 1
2. Oil........................................................................................ 3
3. Grease ................................................................................. 5
1HYB800001-017 Rev.A i
Lubricants General
1. General
As a guide to the selection of oils and greases for circuit-breakers HPL and LTB
with operating mechanisms, a description is given below of the application areas as
well as trade names and suppliers.
1.1 Safety instructions

Protective gloves, long-sleeved overalls and eye protection must be worn when
handling greases and oils.
All spillage shall be covered with an absorption agent and taken care of as chemical
waste according to applicable local directives.
1HYB800001-017 Rev.A 1
General Lubricants
2 1HYB800001-017 Rev.A
Lubricants
2. Oil
Oil “A”
Thin, fully synthetic lubricating oil for precision components in the operating
mechanism and circuit-breaker. Also used for post lubrication of bearings that
cannot be lubricated with grease “G” without dismantling, e.g. links and link gears.
Viscosity at 40˚C: 62-65 cSt
Lowest pour temperature: -52˚C
Oil “D”
Breaker oil with a low viscosity ~ 6.0 cSt at 20˚C. Also used as oil in dashpots.
Dashpots with the letter “s” punched on the cover shall be filled with oil “S”.
Oil “S”
Silicone oil intended for dashpots in heavy-duty operating mechanisms, type BLG.
Only dashpots with the letter “s” punched on the cover shall be filled with this oil.
SUPPLIER Oil “A” Oil “D” Oil “S”
ABB art. No. 1171 2039-1 1171 3011-102 1173 7011-106
ABB spare part No. 1HSB875318-A 1HSB875318-B 1HSB875318-C
MOBIL MOBIL 1 (481127) Circuit-breaker oil -

5W-30 Univolt 42 (44)
CASTROL FORMULA RS - -
5W-50
SHELL TMO Synthetic NYSWITCHO 3 DC 200 Fluid 200
5W-30 NYSWITCHO 3X CS
OK Super-synthetic Circuit-breaker oil -

4W-40 A65
Kälte-Schalteroel X
1HYB800001-017 Rev.A 3
Lubricants
4 1HYB800001-017 Rev.A
Lubricants
3. Grease
Grease “G”
Low-temperature grease for all types of bearings, gearing and worm gears and
valves in air-blast circuit-breakers.
Also used for greasing sealing rings and crevice corrosion protection on breakers
type HPL
Grease “K”
Molykote grease for lubricating pins in link gears and in earthquake dampers.
Grease “N”
For lubricating moving contacts and puffer cylinders in SF6 circuit-breakers. The
grease shall be applied in a very thin layer on the contact’s sliding surfaces.
Grease “L”
Low-temperature grease especially suitable for lubricating precision components,
for example, latch mechanisms in operating mechanisms that shall work in severe
cold.
Grease “M”
Low-temperature grease for long-term and permanent lubrication of worm gears,
and spur gears and other machine elements. Counteracts wear and corrosion.
Grease “P”
Vaseline for coating contact surfaces on fixed joints on the inside of the breaking
unit.
Grease “S”
Fluoro-silicone grease for lubricating the EPDM-O-rings and as crevice corrosion
protection on circuit-breakers type ED as well as for lubricating rotating shaft seals
on circuit-breakers types LTB and HPL.
Grease “SV”
For lubricating moving contacts (opening contacts), silver-plated contacts and
brushed aluminium surfaces on fixed joints outdoors
1HYB800001-017 Rev.A 5
Lubricants
SUPPLIER Grease “G” Grease “K” Grease “N” Grease “L”
ABB art. No. 1171 4014-407 1263 0011-102 1171 4016-607 1171 4016-606
ABB spare part No. 5316 381-A 5316 381-M 5316 381-L 5316 381-H
ASEOL AG - - ASEOL SYLITEA

4-018
Dow Corning G-rapid plus
GULF 718EP Synthetic - -

grease
MOBIL Mobil grease 28 - -
Montefluos S.p.A. - Fomblin OT 20 -
SHELL Aero Shell - -

Grease 223
SUPPLIER Grease “M” Grease “P” Grease “S” Grease “SV”
ABB art. No. 1171 4016-612 1171 5011-102 1171 4014-406 1171 4016-610
ABB spare part No. 5316 381-J 5316 381-N 5316 381-G 5316 381-C
Klüber Isoflex Topas NB -

52
Dow Corning - - FS-3451 No. 2
Fluortech AB TP55
SHELL - Shell vaseline

8401
Statoil Electrical grease
1HYB800001-017 Rev.A 6
type BLK 222
Maintenance
1HYB800001-018 Rev.A
ABB Switchgear
Date: 2003-10-01
Maintenance Operating Mechanism
LIST OF CONTENTS
1. General ............................................................................... 1
2. Safety................................................................................... 3
2.1 Warning text ....................................................................................3
2.2 Safety directives..............................................................................4
3. Maintenance, general ......................................................... 7

3.1 Tools................................................................................................7
3.2 Cleaning equipment ........................................................................7
3.3 Spare parts.......................................................................................7
3.4 Test equipment ................................................................................7
4. Maintenance........................................................................ 9
4.1 General ............................................................................................9
4.2 Preparations for maintenance........................................................18
4.3 Cleaning ........................................................................................19
4.4 Corrosion.......................................................................................19
4.5 Lubrication ....................................................................................20
4.6 Heater element ..............................................................................20
4.7 Drive unit ......................................................................................21
4.8 Catch gear .....................................................................................23
4.9 Dashpot .........................................................................................25
4.10 Limit switch with auxiliary contact ..............................................26
4.11 Terminal blocks.............................................................................28
1HYB800001-018 Rev.A i
Maintenance Operating Mechanism
FIGURES
Figure 4-1. Operating mechanism BLK 222 ..................................................... 9

Figure 4-2. Electrical discharging of the closing springs. ............................... 10
Figure 4-3. Mechanical discharging of the closing spring. ..............................11
Figure 4-4. Mechanical charging .................................................................... 12
Figure 4-5. Switch Local/Remote, motor protection. ..................................... 13
Figure 4-6. Connecting the crank. ................................................................... 13
Figure 4-7. Slow manual Closing operation ................................................... 14
Figure 4-8. Closing catch gear’s roller ............................................................ 14
Figure 4-9. Switch Local/Remote, motor protection. ..................................... 15
Figure 4-10. Crank connection. ......................................................................... 15
Figure 4-11. Slow manual Open-operation. ...................................................... 16
Figure 4-12. Closing catch gear’s roller. ........................................................... 16
Figure 4-13. Operating panel. ........................................................................... 18
Figure 4-14. Heater element. ............................................................................. 20
Figure 4-15. Drive unit. ..................................................................................... 21
Figure 4-16. Replacing the motor ..................................................................... 22
Figure 4-17. Catch gear ..................................................................................... 23
Figure 4-18. Checking the play. ........................................................................ 23
Figure 4-19. Replacing the catch gear. .............................................................. 24
Figure 4-20. Dashpot ......................................................................................... 25
Figure 4-21. Limit switch with auxiliary contact. ............................................. 26
Figure 4-22. Time measurement, contact movement. ....................................... 27
Figure 4-23. Electrical equipment. .................................................................... 28
ii 1HYB800001-018 Rev.A
Maintenance Operating Mechanism General
1. General
This information applies for the spring operating mechanism BLK 222 intended for
operating circuit-breakers with integrated opening springs. Information is provided
in this instruction for maintenance and fault correction maintenance.
Preventive maintenance and overhaul of the mechanism BLK 222 should be carried
out at regular intervals.
• Visual inspection at 1-2 year’s intervals.
• Lubrication after 15 years or 2000 mechanical On-Off operations.
• Preventive maintenance after 15 years or 5000 mechanical On-Off operations.
• Overhaul after 30 years or 10 000 mechanical On-Off operations.
Overhaul and repair work may only be carried out by service personnel authorised
by ABB HV Switchgear.
1HYB800001-018 Rev.A 1
General Maintenance Operating Mechanism
2 1HYB800001-018 Rev.A
Maintenance Operating Mechanism Safety
2. Safety
2.1 Warning text

observed extra carefully. The warning texts are marked as set out below.
DANGER
WARNING
CAUTION
indicates a hazardous situation than can result in minor or moderate
injury.
N.B. used for hazards that may only result in damage to the installation.
1HYB800001-018 Rev.A 3
Safety Maintenance Operating Mechanism
2.2 Safety directives

On all types of work on high-voltage circuit-breakers, the risks listed below must be
taken into consideration and corresponding measures must be taken.
WARNING
Circuit-breakers with pressurised insulators.
Mechanical damage to the insulator can cause it to explode with the
Work on the circuit-breaker that brings about the risk of mechanical
0.125 MPa (abs).
WARNING
Do not operate the mechanism unloaded!
and trimmed with the associated circuit-breaker.
The standard operating cycle is O - 0.3 s - CO - 3 min. - CO. The time between
closing operations should not be less than 1 minute during the testing of circuit-
4 1HYB800001-018 Rev.A
Maintenance Operating Mechanism Safety
WARNING
Work requires training and product knowledge and may only be carried
out by authorised personnel.
Risk Measure
Working next to high voltage. Isolate and earth close to the work
place. If work must be carried out
close to live installation components,
the safety distance applying in the
country’s applicable safety
regulations must be observed.
Working on ladders and platforms. Work shall be carried out in

accordance with applicable safety
regulations in the country concerned.
Difficult weather conditions that
require short shifts with a great deal
of climbing on ladders and platforms,
should be avoided.
Working with low voltage. Switch off the control voltage and if
Both alternating (AC) and direct (DC) necessary the heating voltage.
current can be routed to the
Risk of crushing in the operating Operate the circuit-breaker to the
mechanism and link system. open position. Isolate and earth the
There is stored energy in the high-voltage side. Discharge the
opening and closing springs. The springs by switching off the motor
mechanism can be tripped by heavy current and perform a Close-Open
vibrations or by unintentional contact operation or move the operating
with mechanical latch components. mechanism’s drive shaft backwards
by hand (see the Product Information
for the operating mechanism). For
reasons of safety the closing springs
must be uncharged during
transportation as well as during
assembly and storage.
Working close to pressurised Work close to the circuit-breaker’s

insulators. insulators that may result in damage
The normal working pressure is up to to the insulator, must not be carried
0.8 MPa. Damage to the porcelain out until the gas has been emptied to
can result in splintering. max. 0.125 MPa (abs.) pressure.
1HYB800001-018 Rev.A 5
Safety Maintenance Operating Mechanism
6 1HYB800001-018 Rev.A
Maintenance Operating Mechanism Maintenance, general
3. Maintenance, general
All requisite equipment should be available before work is started so that
maintenance work can be carried out in the best way.
The following equipment is required.
3.1 Tools
• A normal set of tools including a torque wrench (10-100 Nm).
• Measuring scale.
• Vernier gauge.
• Lifting slings.
3.2 Cleaning equipment

• Vacuum cleaner.
• Drying cloths of a lint-free material.
3.3 Spare parts

• Lubricants and oils, see Lubricants, 1HYB800001-017 for suppliers and trade
names.
Grease “G”: ABB Art. No. 1171 4014-407
Grease “L”: ABB Art. No. 1171 4016-606
Grease “M” ABB Art. No. 1171 4016-612
Oil “A”: ABB Art. No. 1171 2039-1
• Anti-corrosion agent.
Valvoline Tectyl 506: ABB Art. No. 1241 0011-108
Grease “G”: ABB Art. No. 1171 4014-407.
• Locking fluid
Loctite 242, ABB Art. No. 1269 0014-410.
• Tool to crank the operating mechanism, ABB Art. No. 2172 733-186
3.4 Test equipment

• Equipment to record attenuation curves and operating values.
(e.g. Programma or ABB SA10)
1HYB800001-018 Rev.A 7
Maintenance, general Maintenance Operating Mechanism
8 1HYB800001-018 Rev.A
Maintenance Operating Mechanism Maintenance
4. Maintenance
4.1 General
The Operating and Maintenance Instructions for the circuit-breaker should be read and
followed before work on the circuit-breaker is started and while work is in progress.
WARNING
and trimmed with the associated pressurized circuit-breaker.
The component parts of the operating mechanism are integrated in a cabinet which
also contains a control panel with operating equipment. The top of the cabinet can
be removed and the operating panel opened to facilitate service and overhaul work.
2 1
5
3
B30200
Item
1 Drive unit
3 Operating panel
4 Closing spring
5 Heater element
Figure 4-1. Operating mechanism BLK 222
• Measure all operating values and record them. If the measured values
correspond with the specified values for the circuit-breaker, then only a visual
inspection, cleaning and lubrication are required.
1HYB800001-018 Rev.A 9
Maintenance Maintenance Operating Mechanism
4.1.1 Discharging the closing springs

It is important the closing springs are uncharged during maintenance when working
on the circuit-breaker or operating mechanism.
Electrical discharging of the closing springs.

1. Switch off the motor protection (1)
2. Turn the Local/Remote switch (2) on the operating panel to Local.
3. Perform an Open-Closed-Open operation.
4. Check that the spring is uncharged. The spring indicator (3) shows uncharged
spring.
5. The circuit-breaker is in the Open position.
1 4 2
Item
1 Motor protection
2 Switch Local/Remote
3 Spring indicator
4 Operating switch Closed/Open
B30201
Figure 4-2. Electrical discharging of the closing springs.
The motor protection should be reset when work has been completed.
10 1HYB800001-018 Rev.A
Mechanical discharging of the closing spring.

1. Unscrew the cover (1) so the motor circuit is cut.
2. Assemble the crank (3) and the crank attachment (4) as in Figure 4-3.
3. Crank anti-clockwise until the spring is fully uncharged.
4. Check that the spring is uncharged. The spring indicator (5) shows uncharged
spring.
Mechanism
Item
1 Cover
2 Screw M6 4 pcs.
3 Crank 4 2
4 Crank attachment
5 Spring indicator 3 1
B30202
Figure 4-3. Mechanical discharging of the closing spring.
1HYB800001-018 Rev.A 11
4.1.2 Mechanical charging of the closing spring

The closing spring can be manually charged, if there is no motor voltage available.
• Unscrew the cover (1) so that the crank can be inserted. Assemble the crank (2)
and the crank attachment (3) as set out in Figure 4-4.
• Crank clockwise until the spring indicator (4) shows a tensioned spring.
• Refit the cover.
Mechanism
Item
1 Cover
2 Crank
3 Crank attachment 3 1
4 Spring indicator
B30202
Figure 4-4. Mechanical charging
12 1HYB800001-018 Rev.A
4.1.3 Slow manual Closing and Opening operations

Some service work requires the circuit-breaker to operate slowly.
CAUTION
Slow manual closing and opening operations may only be carried out by
persons that are well conversant with the operation of the mechanism and
circuit-breaker as there is a risk of personal injury and mechanical
damage.
Slow manual closing operation of the operating mechanism

May only be carried out if:
• The circuit-breaker is in the
open position.
• The switch Local/Remote (1)
on the control panel is in the
Off position.
• The motor voltage is cut using
the motor protection (2).
Item
2 Motor protection
B30206
2 1
Figure 4-5. Switch Local/Remote, motor protection.
• Closing springs uncharged.

1. Assemble the crank (1) and crank attachment (2) as in Figure 4-6
Mechanism
Item
1 Crank 2
2 Crank attachment 1
B30052
Figure 4-6. Connecting the crank.
1HYB800001-018 Rev.A 13
2. Connect the crank and crank anti-clockwise so it is possible to attach the tool
(2) on the heel (3) and dog (1), see Figure 4-7.
3. Crank clockwise until the crank shaft stops against the closing catch gear (4).
Crank a further number of turns so that the roller (5) is under pressure.
4. Press using a screwdriver on the latch (6) for the closing catch gear.
5. Continue to crank clockwise until the link system (7) engages with the Open-
lock (8).
N.B. Check that the link system has engaged with the roller on the Open-lock.
6. Crank the crank 1-2 turns anticlockwise and remove the tool (2) from the dog.
8 2 3
Item 1
1 Dog
2 Tool Art. No. 2172 733-186 6
3 Heel

5 7
5 Roller
4
6 Latch
7 Link system
8 Open-lock
B30054
Figure 4-7. Slow manual Closing operation
7. Continue to crank anti-clockwise so

that the dog returns to its original
position. When the dog passes the
closing catch gear’s roller (5) this is
lifted up with a screwdriver, see B30056
Figure 4-8.
Figure 4-8. Closing catch gear’s roller
The circuit-breaker is now in the closed position and a normal opening operation
can be made.
14 1HYB800001-018 Rev.A
Slow manual opening operation

May only be carried out if:
• The circuit-breaker is in the
closed position.
• The switch Local/Remote (1)
on the control panel is in the
Off position.
• The motor voltage is cut using
the motor protection (2).
Item
2 Motor protection
3 Operating switch Closed/Open
2 3 1
B30206
Figure 4-9. Switch Local/Remote, motor protection.
• Closing spring tensioned.

1. Fit the crank (1) and crank attachment (2) as in Figure 4-11 and press in the
back lock with the crank attachment.
Mechanism
Item
2
1 Crank
2 Crank attachment B30052 1
Figure 4-10. Crank connection.
1HYB800001-018 Rev.A 15
2. Attach the tool (2) on the heel (3).

3. Crank the crank clockwise until it stops against the closing catch gear. Crank a
further number of turns so that the roller is put under pressure (5).
4. Press the latch (6) for the closing catch gear with a screwdriver.
5. Continue to crank clockwise until the tool (2) is clamped between the heel (3)
and the link system (8).
6. Press with a screwdriver on the latch (7) for the Open-lock.
2 3
Item
1
1 Dog
2 Tool Art. No. 2172 733-186 7
3 Heel 6
4 Closing arm
5 Roller
5
6 Latch, closing catch gear
7 Latch, Open-lock
B30057 8
4
8 Link system
Figure 4-11. Slow manual Open-operation.
7. Crank anti-clockwise until the tool (2)

is released. If not the link system (8)
follows the closing arm (4) repeat
point 6. When the dog passes the
closing catch gear’s roller (5) this is B30056
lifted up with a screwdriver, see
Figure 4-12.
Figure 4-12. Closing catch gear’s roller.
8. Remove the tool (2).

The circuit-breaker is now in the Open position. The spring must be tensioned
before a normal Closing operation can be performed.
16 1HYB800001-018 Rev.A
4.1.4 Interlocking system

The following electrical interlocks are integrated in the operating mechanism.
• Closing circuit
– Closing pulse to the Closing coil can only go through the auxiliary contact
if the circuit-breaker is in the open position.
– Closing pulse to the Closing coil can only go through the limit switch if
the closing springs are tensioned.
– Closing pulses are prevented when the density of the SF6-gas is lower than
the blocking level.
– Remaining Closing pulses are cut up by the anti pumping relay after a
completed Closing operation.
• Motor circuit
– The motor circuit is cut with the switch, with slow Open and Closing
operations.
– The motor circuit is cut with manual cranking of the spring.
1HYB800001-018 Rev.A 17
4.2 Preparations for maintenance

The following should be done before maintenance is started:
1. Switch the circuit-breaker to the open position.
2. Isolate and earth.
3. Switch of the motor current.
4. Perform an Close-Open operation so that the spring is discharged.
5. Cut the operating voltage and if necessary also the voltage to the heater.
1 2 3
Item
1 Operating panel
2 Operating switch
Close/Open
4 Spring indicator
B30203
Figure 4-13. Operating panel.
18 1HYB800001-018 Rev.A
4.2.1 Emptying the gas

Work that involves a risk of damaging the insulators must not be carried out until
the gas has been evacuated to a pressure of max. 0.125 MPa (abs).
WARNING
Unused SF6 gas is non-toxic, odourless and colourless. It is heavier than
air and can therefore easily collect in low-lying places, e.g. cable trenches,
tanks, etc., if released in large volumes
When large quantities of SF6 gas collect in such places, a risk of
asphyxiation may occur due to a lack of oxygen.
The SF6 gas is evacuated by using gas handling equipment, which cleans and
compresses the gas so that it can be reused or destructed.
N.B. Mixed gas, SF6 mixed with N2 or CF4, must not be reused unless the mixture
ratio is under control. (Can be checked with a meter that indicates the
percentage of SF6.)
4.3 Cleaning
• Clean the inside of the operating mechanism using a vacuum cleaner.
• Check that the filters in the valves are clean. If they are heavily soiled they
should be replaced.
4.4 Corrosion
Some of the steel mechanism parts have been surface treated with manganese
phosphate and then rust protected by dipping in oil. This applies to, among others,
latches and components in the link system.
Despite good rust protection small signs of rust attack can appear after a number of
years, especially on circuit-breakers erected in aggressive environments.
• Rust spots should be removed and new anti-corrosive agent should be applied
by brush or spray. Recommended anti-corrosive agents are Grease “G” or
Tectyl 506.
N.B. After drying Tectyl 506 forms a protective wax-like cover and must not be
sprayed on bearings as well as catch gears and gears.
1HYB800001-018 Rev.A 19
4.5 Lubrication
The ball, roller and needle bearings as well as worm gears in the operating
mechanism are permanently lubricated and require no maintenance. Therefore only
the shafts in the catch gears need to be lubricated.
Sliding surfaces for the dashpot should be lubricated during an overhaul with
Grease “G”.
4.6 Heater element

The operating mechanism is fitted with a heater element to prevent condensation
and should always be connected.
• Measure the resistance and check the voltage failure signal, if there is such,
after every 15 years or 2000 operations.
1
Item
1 Heater element
B30058
20 1HYB800001-018 Rev.A
4.7 Drive unit

• Measure the motor current at the end of the loading procedure. See the relevant
Assembly Instructions for the circuit-breaker, chapter Operating values.
The motor should be capable of charging the spring at 85% of its nominal
voltage (IEC).
Item
1 Drive unit
B30160
Figure 4-15. Drive unit.
1HYB800001-018 Rev.A 21
4.7.1 Replacing the motor

1. Fully discharge the closing spring. The spring indicator should be Green.
2. Crank anti-clockwise so that the closing arm (1) rests against the roller (2).
3. Remove the cover on the operating mechanism cabinet.
4. Loosen the screws (3) and the electrical connection.
5. Fit the new motor. Tighten the screws (3) with tightening torque 9 Nm.
TIGHTENING TORQUE
9 Nm
1
Item
1 Closing arm
2 Roller
3 Bolts M6x75 2 pcs

Washers 6.4x12x1.5 2 pcs

B30168
Figure 4-16. Replacing the motor
6. Lock the bolts using locking fluid, Loctite 242, ABB Art. No. 1269 0014-410.
7. Refit the cover.
4.7.2 Start switch

Check that the signal for voltage failure functions, if not replace the start switch.
22 1HYB800001-018 Rev.A
4.8 Catch gear

The operating mechanism is fitted as standard with a closing magnet and two
opening magnets, but can, on request, be equipped with double magnets on the
closing side.
1
Item
1 Open catch gear
2 Close catch gear
B30204
Figure 4-17. Catch gear
• Check and clean the shafts in the catch gear.

• Lubricate these with Grease “L” at an interval of 15 years or 2000 operations.
• Check that the voltage to the magnets does not fall below the minimum
voltage, see the delivery document for the operating mechanism.
• Check the play between the magnet arms and the auxiliary catch. The play can
be at least . 1 mm. If the play is outside the stated measurement the entire catch
gear should be replaced.
Item
1 Auxiliary catch
2 1 mm
2 Magnet arm
B20013
Figure 4-18. Checking the play.
1HYB800001-018 Rev.A 23
4.8.1 Replacing the Open or Close catch gear

1. Loosen the bolts (1).
2. Replace the complete Close or Open catch gear
3. Tighten the bolts (1) with a tightening torque 40 Nm and lock with Loctite 242,
ABB Art. No. 1269 0014-410.24
TIGHTENING TORQUE
40 Nm
Item
1 Bolts M8x70 3 pcs
B30062 1 1
Figure 4-19. Replacing the catch gear.
24 1HYB800001-018 Rev.A
4.9 Dashpot
The operating mechanism is fitted with a dashpot to dampen the final phase of the
opening movement.
Item
1 Dashpot
B30063
Figure 4-20. Dashpot
The oil level should be up to the mark. If necessary, fill up with oil “S”.
1HYB800001-018 Rev.A 25
4.10 Limit switch with auxiliary contact

The operating mechanism is fitted as standard with a 12 pole auxiliary contact
consisting of twelve opening and 12 closing contacts. Three closing contacts and
three opening contacts are used for the functioning of the operating mechanism.
The auxiliary contact shaft is in direct connection with the operating lever in the
operating mechanism and accordingly follows the movement of the circuit-breaker
contacts.
2 1
Item
1 Limit switch
2 Auxiliary contact
B30200
Figure 4-21. Limit switch with auxiliary contact.
After 15 years or 2000 operations,check the contact movement by measuring the

times and compare the results with those obtained during commissioning. The
comparison can then be used to check the condition of:
• Contact movement
• Contact damping.
26 1HYB800001-018 Rev.A
1. Connect a time-meter across the signal contacts 10, 19, 121 and 122 in
accordance with the circuit diagram.
2. Measure the times t1, t2 and t3
3. Turn the switch “Local/Remote” to the “LOCAL” position.
4. Connect the time-meter across terminals 10, 19, 121 and 122
5. Turn the switch “Close/Open” to “OPEN” and then to the “CLOSED” position.
6. Note down the times t1, t2 and t3.
7. Disconnect the time-meter.
8. Turn the switch “Local/Remote” to the “REMOTE” position.
Contact movement
Arcing contact
Closed
Auxiliary contact
Contact
movement
Open
t1 t3 Time
t2
t1 ms Proportional to the contact’s opening speed.

t2 ms Time that determines contact damping.
t3 ms Proportional to the contact’s closing speed.
B20018
Figure 4-22. Time measurement, contact movement.
1HYB800001-018 Rev.A 27
4.11 Terminal blocks

Check all screws and pins.
8
Item
1 Opening coil
1
2 Closing coil
3 Motor
2
5 Operating switch Close/Open
6 Electric counter
7 Limit contact
8 Auxiliary contact
9 Anti-condensation heater
10 Anti pumping relay
11 Interlock relay
12 Interlock relay 15 14 6 5 4
13 Motor contactor
14 Motor protection
3 7
15 Miniature switch, heater
12
11
10 9
13
B30205
Figure 4-23. Electrical equipment.
28 1HYB800001-018 Rev.A
mechanism BLK 222
1-pole operation
Overhaul Instructions
1HYB800001-046 Rev.A
ABB Switchgear
Date: 01-01-2005
LIST OF CONTENTS
1. General ............................................................................... 1
2. Safety................................................................................... 3
2.1 Warning text ................................................................................... 3
2.2 Safety directives ............................................................................. 4
3. Overhaul, general ............................................................... 7

3.1 Tools ............................................................................................... 7
3.2 Gas handling equipment................................................................. 7
3.3 Personal safety equipment.............................................................. 7
3.4 Cleaning equipment ....................................................................... 7
3.5 Spare parts...................................................................................... 8
3.6 Test equipment ............................................................................... 8
3.7 Premises ......................................................................................... 8
4. Dismantling the circuit-breaker......................................... 9

4.1 General ........................................................................................... 9
4.2 Gas................................................................................................ 10
4.3 Cleaning and waste handling ....................................................... 11
4.4 Dismantling the circuit-breaker pole for transport....................... 12
5. Dismantling the circuit-breaker pole .............................. 13

5.1 Dismantling the tripping mechanism’s pull-rod........................... 13
5.2 Removing the breaking unit ......................................................... 14
5.3 Removing the post insulator......................................................... 15
5.4 Dismantling the breaking unit...................................................... 16
6. Contact and Auto-Puffer replacement............................ 17

6.1 Inspection of the upper current path............................................. 17
6.2 Inspection of the Auto-Puffer....................................................... 18
6.3 Inspection of the lower current path............................................. 19
7. Overhaul of the mechanism ............................................ 21
8. Assembling the circuit-breaker pole .............................. 23

8.1 Treatment of contact surfaces ...................................................... 23
8.2 Treatment of sealing surfaces and seals ....................................... 24
8.3 Assembling the breaking unit....................................................... 25
8.4 Assembling the post insulator ...................................................... 26
8.5 Assembling the circuit-breaker pole ............................................ 27
1HYB800001-046 Rev.A i
8.6 Gas filling ..................................................................................... 28

8.7 Assembling the tripping mechanism’s pull-rod on the operating
lever .............................................................................................. 29
9. Dismantling the breaking unit for transport ...................31

9.1 Assembling the breaking unit after an overhaul........................... 32
10.Assembling the circuit-breaker and commissioning....35
ii 1HYB800001-046 Rev.A
FIGURES
Figure 4-1. Dismantling the circuit-breaker pole .............................................12

Figure 5-1. Dismantling the pull-rod ...............................................................13
Figure 5-2. Removing the breaking unit ..........................................................14
Figure 5-3. Removing the post insulator ..........................................................15
Figure 5-4. Dismantling the breaking unit .......................................................16
Figure 6-1. Upper current path .........................................................................17
Figure 6-2. Auto-Puffer.....................................................................................18
Figure 6-3. Lower current path ........................................................................19
Figure 7-1. Mechanism housing ......................................................................21
Figure 8-1. Assembling the breaking unit ........................................................25
Figure 8-2. Assembling the post insulator .......................................................26
Figure 8-3. Assembling the circuit-breaker pole .............................................27
Figure 8-4. Assembling the tripping mechanism’s pull-rod on the operating
lever. ..............................................................................................29
Figure 9-1. Dismantling the breaking unit .......................................................31
Figure 9-2. Fitting the breaking unit ................................................................33
Figure 9-3. Mechanism housing’s sign. ...........................................................34
1HYB800001-046 Rev.A iii

Overhaul Instructions General
1. General
This Overhaul Manual applies to the SF6 circuit-breaker type LTB 245E1, 1- pole
operation. This Manual contains information for overhaul and repair work.
Overhaul and repair work may only be carried out by technicians trained by
ABB HV Switchgear .
1HYB800001-046 Rev.A 1
Overhaul Instructions Safety
2. Safety
2.1 Warning text

observed extra carefully. The warning texts are marked as set out below:
DANGER
WARNING
CAUTION
indicates a hazardous situation that can result in minor or moderate
injury.
1HYB800001-046 Rev.A 3
Safety Overhaul Instructions
2.2 Safety directives
WARNING
Circuit-breaker with pressurised porcelain insulators.
Mechanical damage on the porcelain can cause it to explode with the
Work on the circuit-breaker that brings about the risk of mechanical
0.125 MPa (abs).
WARNING
and trimmed with the associated pressurised circuit-breaker.
The standard operating cycle is O - 0.3 s - CO - 3 min.-CO. The time between

closing operations should not be under 1 minute during the testing of circuit-
4 1HYB800001-046 Rev.A
Overhaul Instructions Safety
WARNING
Work requires training and product knowledge and may only be carried
out by authorised personnel.
Risk Measure
Working close to high voltage. Isolate and earth close to the work-
place. If work must take place close
to live installation components, the
safety distance applying in the
country’s applicable safety
regulations must be observed.
Working on ladders and platforms. Work shall take place in accordance

with applicable safety regulations in
the country concerned. Difficult
weather conditions that require short
shifts with a great deal of climbing on
ladders and platforms should be
avoided.
Working with low voltage. Switch of the control voltage and if

Both Alternating and Direct Current necessary the heating voltage.
can be routed to the operating
mechanism.
Risk of crushing in the operating Operate the breaker to the open

mechanism and link system. position. Isolate and earth the high-
There is stored energy in both the voltage side. Unload the springs by
closing and opening springs. The switching off the motor current and
mechanism can be tripped by heavy perform an Close-Open operation or
vibrations of by unintentional contact move the operating mechanism’s
with the mechanical latch drive shaft backwards by hand (see
components. the Product Information for the
operating mechanism). For reasons
of safety the closing springs must be
unloaded during transportation as
well as during assembly and storage.
Working close to pressurised Working close to the circuit-

insulators. breaker’s insulators that may result in
The normal working pressure is up to damage to the porcelain, must not be
0.8 MPa. Damage to the porcelain carried out until the gas has been
can result in splintering. emptied to max. 0.125 MPa (abs.)
pressure.
1HYB800001-046 Rev.A 5
Overhaul Instructions Overhaul, general
3. Overhaul, general
All requisite equipment and spare parts should be on hand, before work is started, to
ensure that the overhaul is carried out under the best possible conditions.
The following equipment is required.
3.1 Tools
• A standard tool kit with torque wrenches (10-100 Nm).
• Lifting devices and lifting slings. The weights of the circuit-breaker parts to be
lifted can be found on the applicable dimension drawing for the order.
3.2 Gas handling equipment

Gas handling equipment for evacuating, cleaning, compressing and storing the used
SF6 gas as well as instruments for monitoring the pressure and vacuum.
3.3 Personal safety equipment

• Full face mask with filter for fine particles and acidic gases.
• Long-sleeved overalls.
• Protective gloves of plastic or rubber.
3.4 Cleaning equipment

• Vacuum cleaner with micro-filter and plastic nozzle.
• Drying cloths of a lint-free material.
• Sealed storage containers for waste products and used absorption filter.
• Wire brush for contact surfaces of aluminium.
• Cleaning pad, e.g. Scotch Brite, for contact surfaces of copper.
• Industrial alcohol 95% (vol), C2H5OH, for cleaning inside surfaces.
• Heavy-duty plastic sheet and plastic bags to prevent the ingress of moisture and
to protect cleaned components before assembly.
1HYB800001-046 Rev.A 7
Overhaul, general Overhaul Instructions
3.5 Spare parts

• Contact set1
• Set of seals1
• Absorption agent1
• Lubricants, see Lubricants, 1HYB800001-017 for supplier and trade names
Grease “G”: ABB art. No. 1171 4014-407
Grease “N”: ABB art. No. 1171 4016-607
Grease “S”: ABB art. No. 1171 4014-406
Grease “P”: ABB art. No. 1171 5011-102.
• Anti-corrosion agent
Valvoline Tectyl 506, ABB art. No. 1241 0011-108.
• Locking fluid
Loctite 243, ABB art. No. 12690014-429.
• SF6 gas.
• Protective cover for the breaking unit, ABB art. No.1HSB445237-1.
• Protective cover for post insulator, ABB art. No. 5439 142-A.
3.6 Test equipment

• Equipment to record attenuation curves on the operating mechanism.
(e.g. Programma or ABB SA10)
• Operating time meter.
• Ohmmeter.
• Leak detector.
3.7 Premises
The circuit- breaker or breaking units must be opened indoors in a dry and clean
premises.
When the weather is good and settled and outdoor working conditions are similar to
indoor conditions, the breaking units can be removed outdoors and transported to
dry and clean premises for the overhaul.
N.B. Under no circumstances may the breaking unit be removed or dismantled

during rain or other unsettled weather conditions, nor when the relative
humidity is 80% or higher.
1. According to the spare parts lists for the circuit-breaker.
8 1HYB800001-046 Rev.A
Overhaul Instructions Dismantling the circuit-breaker
4. Dismantling the circuit-breaker
4.1 General
The instructions in the Operating and Maintenance Manual 1HYB800001-045
should be read and observed before the circuit-breaker is dismantled and during the
overhaul:
Check and note down the circuit-breaker’s operating values before dismantling.
Any deviations from the recommended values indicate that something must be
checked with special care during the overhaul.
The overhaul can take place in two different ways:
• First and foremost it is recommended that the entire circuit-breaker is
dismantled for transport to a service workshop, where it can be dismantled in
detail for an overhaul.
• Alternatively, and secondly, only the breaking unit is dismantled.
The latter method does not entail so much work, but may only be used when the
weather is settled and the outdoor working conditions are similar to indoor
conditions.
N.B. Removal and assembly of the breaking unit must not be done when the
weather is such that there is a risk of rain.
WARNING
The work requires trained staff with product knowledge and may only be
carried out by authorised personnel.
4.1.1 Preparations for the overhaul

The following must be done before starting the overhaul:
• Operate the circuit-breaker to Open position.
• Isolate and earth.
• Off-load the operating mechanism’s spring battery by switching off the motor
current and implementing a Close-Open operation.
• Switch off the control voltage and, if necessary, also the heater power.
1HYB800001-046 Rev.A 9
Dismantling the circuit-breaker Overhaul Instructions
4.2 Gas
Work on the circuit-breaker’s insulators or live components as well as transport and
dismantling of complete circuit-breaker poles from the frame, may not be done until
the gas has been evacuated to a pressure of max. 0.125 MPa (abs).
Gas shall be emptied fully to atmospheric pressure, when a normal pressurised
space, e.g. a breaking unit, shall be opened.
WARNING
If nitrogen, in those cases where nitrogen is used for cleaning the inside of
the circuit-breaker, is to be emptied into the free air, this shall be done
through a particle and absorption filter. Emptying shall take place
outdoors and at ground level.
WARNING
Unused SF6 gas is non-toxic, odourless and colourless. It is heavier than
air and can therefore easily collect in low-lying places, e.g. cable trenches,
tanks, etc., if released in larger volumes.
When large quantities of SF6 gas collect in such places, a risk of
asphyxiation may occur due to lack of oxygen.
4.2.1 Emptying the gas

The SF6 gas is evacuated and the circuit-breaker should be vacuum pumped using
the gas handling equipment, which cleans and compresses the gas so that it can be
reused or destructed.
After a vacuum has been pumped in the circuit-breaker, it is filled with dry nitrogen
at atmospheric pressure and then vacuum pumped again. In this way freely floating
dust is extracted from the circuit-breaker.
Finally, the circuit-breaker is filled again with dry nitrogen to atmospheric pressure.
The circuit-breaker is now ready for dismantling.
10 1HYB800001-046 Rev.A
Overhaul Instructions Dismantling the circuit-breaker
4.3 Cleaning and waste handling
CAUTION
Some decomposition products formed in the breaking unit can, when
coming in contact with moisture, become corrosive and can irritate the
skin, eyes and mucous membranes.
Protective gloves of plastic or rubber, long-sleeved overall and a full face mask with
a fine particle and acidic gas filter must be worn during the cleaning of the inside of
the circuit-breaker.
The dust (decomposition products) that forms in the circuit-breaker can be removed
using a vacuum cleaner fitted with a micro-filter and wiped off using a soft cloth
dampened with alcohol.
N.B. All dust, old absorption agent, used cloths, etc., should be collected in a
sealed vessel and treated as chemical waste according to applicable local
directives.
Protective gloves must be worn during all waste handling.
N.B. Protective gloves should be rinsed thoroughly in water after waste handling.
1HYB800001-046 Rev.A 11
Dismantling the circuit-breaker Overhaul Instructions
4.4 Dismantling the circuit-breaker pole for transport

Before the circuit-breaker pole is dismantled, the circuit-breaker must be taken out
of service, see Chapter 4.1.1, and the gas emptied, see Chapter 4.2.1. The density
monitor must be dismantled and the sealing cap (1) fitted to the non-return valve (2).
1. Dismantle the pull-rod between the operating mechanism and the circuit-
breaker
2. Place a lifting sling under the breaking unit’s upper flange as shown in
Figure 4-1 and prepare to lift with a crane. Now loosen the circuit-breaker pole
(5), removing the four bolts (3) on the frame and the four bolts (4) on the
protective pipe.
3. Lift up the circuit-breaker pole
and carefully lay it down on a
transport carriage. Block up the
circuit-breaker pole so it lies 1
horizontal. The bottom of the
transport crate can be used. The
blocks (6) under the breaking
unit’s insulator should be of an 2
elastic material, e.g. wood or
rubber.
3
N.B. If possible, keep the supports,
supplied on delivery, for this 5
purpose.
Transport to the workshop or a new
site should take place with care so as
not to damage the insulators.
Item
1 Sealing cap
2 Non-return valve 4

Nuts M20 4 pcs.

Nuts M12 4 pcs.
Washers 13x24x2.5 8 pcs.
5 Circuit-breaker pole
6 Blocks
B10055 6 6
Figure 4-1. Dismantling the circuit-breaker pole
12 1HYB800001-046 Rev.A
Overhaul Instructions Dismantling the circuit-breaker pole
5. Dismantling the circuit-breaker pole

Set uo the circuit-breaker pole is fitted vertically on a suitable frame, e.g. circuit-
breaker frame or a frame on the floor of the workshop.
5.1 Dismantling the tripping mechanism’s pull-rod

1. Dismantle the protective cover (8) and clean the cover’s four ventilation slots.
2. Measure and note down a reference, e.g. “Y”, so that the opening spring (5) can
be refitted to the same tension using nut (6) when reassembled.
Y=............. mm date...............
3. Refit the protective cover (8).
Item
1 Operating lever
2 Pin
3 Pull-rod
4 Spring housing
5 Opening spring
6 Nut
1
7 Lock nut 4
2
8 Protective cover 5
6
7 Y
9
B10056
8
Figure 5-1. Dismantling the pull-rod
1HYB800001-046 Rev.A 13
Dismantling the circuit-breaker pole Overhaul Instructions
5.2 Removing the breaking unit

1. Fit the lifting sling from the top of the breaking unit to the crane or overhead
crane. Tension the lifting sling moderately.
2. Remove the bolts (1) between the post insulator (2) and the breaking unit (3).
3. Lift the breaking unit
75-100 mm.
4. Remove the circlip (4), washer
(5) and pin (6).
Set up the breaking unit vertically on
a suitable surface so that it does not
fall over.
3
Item
1 Bolts M12x35 8 pcs. 6

Washers 8 pcs. 1
13x24x2.5
2 Post insulator
3 Breaking unit
4 Circlips 2 pcs.
2
5 Washers 2 pcs.
6 Pin
B10057
Figure 5-2. Removing the breaking unit
14 1HYB800001-046 Rev.A
Overhaul Instructions Dismantling the circuit-breaker pole
5.3 Removing the post insulator

Plan the work to remove the insulator so that it can be carried out quickly and
without long delays to prevent moisture in the air coming into lengthy contact with
the dust in the post and operating insulators.
N.B. Use personal safety equipment such as overalls, protective gloves and face
mask.
1. Position the lifting sling from the top of the post insulator to the crane or
overhead crane.
2. Remove the post insulator’s bolts (2) from the mechanism housing (3).
3. Lift the post insulator straight up until the operating insulator (7) is released.
Hold the operating insulator while lifting the post insulator.
N.B. Take care so as not to damage the operating insulator.

4. Remove the operating insulator (7) by removing the circlip (4), washer (5) and
pin (6).
5. Clean the operating insulator carefully and protect it using plastic sheet.
6. Clean the post insulator carefully, inside and outside, and protect it using
plastic sheet.
Item
1 Post insulator

1
3 Mechanism housing
4 Circlip
7 5 Washer
5
6 Pin
4 7 Operating insulator
6
B10058 3
Figure 5-3. Removing the post insulator
1HYB800001-046 Rev.A 15
Dismantling the circuit-breaker pole Overhaul Instructions
5.4 Dismantling the breaking unit

Plan the dismantling work so that it can be carried out quickly and without long
delays to prevent moisture in the air coming into lengthy contact with the dust in the
breaking unit and on the inside and outside of the breaking chamber insulator.
N.B. Use personal safety equipment such as overalls, protective gloves and face
mask.
Take care of the decomposition products, in the breaking unit, in the form of
powder, as the breaking unit is successively opened. First use a vacuum cleaner and
thereafter carefully wipe the dismantled components.
1. Remove the bolts (1) and cover (2) and lift out
1 3 2 4
the absorption agent container (3).
5
N.B. Place the bag with absorption agent in a
container for chemical waste.
2. Remove the bolts (4) and upper flange (5) with
the upper current path (6).
3. Remove the bolts (4) and breaking chamber
insulator (7) from the lower flange (8).
4. Rinse the inside of the breaking chamber 6
insulator with water.
Item

Washers 13x24x2,5 8 pcs.
2 Cover
3 Absorption agent container

7
5 Upper flange
6 Upper current path
7 Breaking chamber insulator

8
8 Lower flange 4
B10059
Figure 5-4. Dismantling the breaking unit
The main components of the breaking unit are now accessible for inspection,
cleaning and replacement of burnt or damaged parts.
16 1HYB800001-046 Rev.A
Overhaul Instructions Contact and Auto-Puffer replacement
6. Contact and Auto-PufferTM replacement

If the circuit-breaker is not going to be reassembled immediately after the cleaning
of the component parts, protect them against contamination and moisture by
packing them in plastic bags with a desiccant to absorb moisture.
The insulators are suitably protected by tying heavy-duty plastic sheet over the end
surfaces.
Check the upper and lower current paths and the Auto-PufferTM as described below.
If any component is burnt or worn and is replaced, replace also the other
components at the same time.
6.1 Inspection of the upper current path

Replace the entire current path if the upper current path’s fixed arcing contact,
Figure 6-1, has been burnt so that the distance to the reference surface is more than
6 mm or if the outside surface has been severely burnt. Replace also the upper
current path if the silver on the current path’s contacts is worn so that copper is
visible.
Tighten the bolts (2). Tightening torque 22.5 Nm.
1
Item.
1 Flange
2 Bolt M8x20
Retaining washer 2
Washer
3 Current path
4 Arcing contact 3
TIGHTENING TORQUE
22.5 Nm
max.6 mm
Reference surface
B10060
Figure 6-1. Upper current path
1HYB800001-046 Rev.A 17
Contact and Auto-Puffer replacement Overhaul Instructions
6.2 Inspection of the Auto-PufferTM

Move the contact spring upwards from position a to b. Lift off the Auto-PufferTM
and check that the sliding surfaces on the pull-rod are not worn.
Check that the nozzle is not punctured. Also check that the contact surfaces on the
Auto-PufferTM cylinder are not burnt or worn so that copper is visible.
Replace the entire Auto-PufferTM if it has burnt or worn surfaces or if the nozzle has
been punctured.
1
Item
1 Nozzle
2 Pull-rod Contact surface 4
3 Auto-PufferTM cylinder
4 Bolt M8x16 3
5 Contact springs
5 a
2
TIGHTENING TORQUE
22.5 Nm
Contact surface
B10061
Figure 6-2. Auto-PufferTM
18 1HYB800001-046 Rev.A
Overhaul Instructions Contact and Auto-Puffer replacement
6.3 Inspection of the lower current path

Check that the lower current path’s sealing ring (5), Teflon band (4) and
guide bush (6) are not worn. Also check that the valve washer (7) is flat and seals.
Check that the silver on the lower current path is not worn so that copper is visible.
If there are signs of wear, replace the lower current path.
Tighten the bolts (2). Tightening torque 22.5 Nm.
4
7
Item
1 Flange
2 Bolt M8x20
5
Retaining washer
Washer
3 Current path
4 Teflon band 3 6
5 Sealing ring
6 Guide bush
7 Valve washer 2
TIGHTENING TORQUE
1
22.5 Nm
B10062
Figure 6-3. Lower current path
1HYB800001-046 Rev.A 19
Overhaul Instructions Overhaul of the mechanism
7. Overhaul of the mechanism

Clean the mechanism housing using a vacuum cleaner and then wipe it. Inspect and
lubricate the bearings and sealing rings.
Protect untreated or manganese phosphated steel outside the gas chamber using
Valvoline Tectyl 506, ABB art. No. 1241 0011-108.
1. The operating shaft (2) is journalled on a large ball-bearing (4) on the outside
of the gas chamber. The bearing is visible for inspection and lubrication when
the operating lever (3) and circlip (5) are dismantled.
2. Pull the operating shaft (2) out of the mechanism housing and remove the ball-
bearing (4) from the shaft.
3. Lubricate the ball-bearing (4)
with grease “G”.
1
4. Remove the bushing (6) that
holds the sealing rings in
position by means of the two 2
bolts (M5), which are screwed
into the holes at the end of the
bushing. Replace the sealing Inner mechanism
rings (7, 8) in the bushing
behind the ball-bearing and
lubricate with grease “S”.
5. Check that the ball-bearing (9)
3
rotates easily.
Item
1 Mechanism housing
2 Operating shaft Outer mechanism

3 Operating lever 9 6 4
4 Ball-bearing 2
5 Circlip
6 Bushing
7 X-ring 69.2x5.7
8 O-ring 89.1x5.7
5
9 Ball-bearing
7 8
B10027
Bearings and O-rings
Figure 7-1. Mechanism housing
1HYB800001-046 Rev.A 21
Overhaul Instructions Assembling the circuit-breaker pole
8. Assembling the circuit-breaker pole

To re-assemble the breaking unit follow the dismantling instructions in the reverse
order, see Chapter 5.
N.B. When re-assembling the breaking unit, all sealing rings must be new. Careful
cleaning and treatment of the sealing surfaces is required.
8.1 Treatment of contact surfaces

Before re-assembling the breaking unit, treat the contact surfaces as follows:
8.1.1 Fixed contact surfaces

• Silver-plated:
If necessary, clean silver-plated contact surfaces, using a soft cloth and solvent
(alcohol).
N.B. Polishing using Scotch Brite or grinding must not take place.
• Copper surfaces
Copper surface must be clean and free from oxide. If necessary, clean with a
polishing cloth, e.g. Scotch Brite.
N.B. After cleaning with Scotch Brite always remove all loose particles from the
surfaces using alcohol.
• Aluminium surfaces
Brush clean contact surfaces of aluminium, using a wire brush. Immediately
thereafter carefully clean the surfaces to remove any loose particles with a dry,
clean cloth.. Then coat the surfaces with a thin layer of Vaseline, grease “P”
(ABB art. No. 1171 5011-102).
N.B. Grease should be applied within five minutes of cleaning and the joint should
be fitted within 15 minutes.
8.1.2 Moving contact surfaces

• Silver-plated:
If necessary, clean silver-plated movable contact surfaces, using a soft cloth
and solvent (alcohol).
• Lubrication:
Apply grease “N” (ABB art. No. 1171 4016-607) in a covering, but very thin
layer to the lower current path’s silver-plated section, the upper current path’s
contact surfaces and the Auto-PufferTM cylinder’s contact surfaces. Carefully
wipe off all excess grease.
1HYB800001-046 Rev.A 23
Assembling the circuit-breaker pole Overhaul Instructions
8.2 Treatment of sealing surfaces and seals

Clean, degrease and inspect all sealing surfaces in connection with the assembly.
N.B. Sealing grooves and other sealing surfaces must not have lateral scratches.
Any small scratches on sealing surfaces can be removed by polishing with a
fine abrasive, e.g. Scotch Brite. Polishing shall take place along the sealing
line and never across this.
When re-assembling the circuit-breaker, replace all seals with new seals.
Lubricate sealing surfaces and seals sparingly to facilitate the seal’s union against
the surface and as corrosion protection. Excess grease that can squeeze out on
flanges in the gas chamber must not occur.
Coat flange surfaces outside the seal with a thin, well-covering layer of anti-
corrosion agent matched to the flange material in question, usually Grease “G”
(ABB art.No. 1171 4014-407).
Degreasing and cleaning material:
• Alcohol.
Lubricating material for seals:
• Grease “G” for static seals
Grease “S” for moving seals, e.g. shaft seals.
24 1HYB800001-046 Rev.A
8.3 Assembling the breaking unit

1. Fit the Auto-PufferTM (1) on the lower current path (2). When the Auto-
PufferTM starts to go down over the Teflon band, carefully turn it so that the
Teflon band or the Auto-PufferTM cylinder’s fingers are not damaged.
2. Place the sealing ring on the lower flange (4) and lift on the breaking chamber
insulator (5). Centre it and tighten the bolts (6) to 60 Nm.
TIGHTENING TORQUE
60 Nm
3. Fit the upper current path (7) with the

sealing ring in the breaking chamber 8
insulator (5). Centre the current path in
relation to the Auto-PufferTM (1). Tighten
the bolts (6) to 60 Nm.
7
TIGHTENING TORQUE
60 Nm
First fi a new absorption agent container in 5

connection with the assembly of the breaking unit
on the post insulator, see Chapter 8.5.
Item
1 Auto-PufferTM 1
2 Lower current path

3 Bolt M8x20
Retaining washer 2
Washer
4 Lower flange
3
5 Breaking chamber insulator
6 Bolt M12x50
Washer 13x24x2.5
7 Upper current path B10063 4 6
8 Absorption agent container
Figure 8-1. Assembling the breaking unit
1HYB800001-046 Rev.A 25
8.4 Assembling the post insulator

1. Turn the operating lever (1) and link (2) over the edge of the mechanism
housing and fit the operating insulator (3) using pin (4), washer (5) and circlip
(6).
N.B. Fit the pin so that the circlip (6) faces towards the large bearing.
2. Place the sealing ring on the mechanism housing (9), lift on the post insulator
(7) and tighten the bolts (8) with the tightening torque 79 Nm.
TIGHTENING TORQUE
79 Nm
Item
1 Operating lever
7
2 Link
3 Operating insulator
4 Pin
5 Washer
6 Circlip 5
7 Post insulator 6
9 Mechanism
housing
3
4
8
1
9
2
B10064
Figure 8-2. Assembling the post insulator
26 1HYB800001-046 Rev.A
8.5 Assembling the circuit-breaker pole

1. Suspend the breaking unit in the lifting sling and pull out the Auto-PufferTM so
that the pull-rod (1) is accessible for assembly.
2. Carefully clean the sealing surface for the sealing ring on the post insulator (2).
Also clean the lower flange (3) and lubricate well using grease “G” so that the
sealing ring is held in place during the assembly. Place the sealing ring in its
slot.
3. Slowly lower the breaking unit so that it comes into position to fit the pin,
approx. 75-100 mm above the post insulator.
4. Connect the Auto-PufferTM’s
7
pull -rod (1) to the operating 9
8
insulator using pin (4), washer
10
(5) and circlip (6).
Item
1
1 Pull-rod
5
2 Post insulator
6
3 Lower flange
4 Pin
5 Washers 2 pcs.
6 Ciirclips 2 pcs.
7 Bolts M12x35 8 pcs. 3 4

7
8 Upper flange
9 Cover
10 Absorption agent container 2
B10065
Figure 8-3. Assembling the circuit-breaker pole
1HYB800001-046 Rev.A 27
5. When the pin is fitted, lower the breaking unit carefully onto the post insulator
and centre it. Tighten the breaking unit using the bolts (7) with the tightening
torque 60 Nm.
TIGHTENING TORQUE
60 Nm
6. Clean the sealing surface on the upper flange (8) and coat with grease “G”.
Place the sealing ring on top of the upper flange.
7. Open the new absorption agent package and place the agent in the absorption
agent container (10).
8. Fit the absorption agent container (10) and the cover (9) and tighten the bolts
(7) with the tightening torque 45 Nm.
N.B. Put on the cover immediately after the absorption agent container has been
fitted.
TIGHTENING TORQUE
45 Nm
8.6 Gas filling

• Vacuum-pump down to 100 Pa and let the vacuum pumping continue for at
least one hour after this pressure has been reached.
• Stop the vacuum pumping and fill the circuit-breaker with dry and pure
nitrogen to atmospheric pressure. Allow it to stand for a few hours or
overnight.
• Vacuum-pump again down to 100 Pa and fill with pure SF6 gas to
0.125 MPa (abs).
Store the filling hoses so that they are not exposed to moisture or contamination.
They must not be used other than for their intended purpose.
28 1HYB800001-046 Rev.A
8.7 Assembling the tripping mechanism’s pull-rod on the operating lever

1. Turn the operating lever (1) anticlockwise towards the open position and
connect it to the pull-rod (3) using the pin (2).
2. Remove the protective cover (8).
3. If the nut (6) has moved out of position adjust it to the dimension Y, see
Chapter 5.1.
4. Tighten the lock nut (7) to 200 Nm and lock it using locking fluid, ABB art.
No. 12690014-410 (Loctite 242).
5. Refit the protective cover.
Item
1 Operating lever
2 Pin
3 Pull-rod
4 Spring housing
5 Opening spring
1
6 Nut 4
2
7 Lock nut 5
8 Protective cover
9 Bolts M8x20 4 pcs. 3
6
Y
7
9
B10056 8
Figure 8-4. Assembling the tripping mechanism’s pull-rod on the operating lever.
The circuit-breaker is now ready for transportation.
1HYB800001-046 Rev.A 29
Overhaul Instructions Dismantling the breaking unit for transport
9. Dismantling the breaking unit for transport

Dismantling of just the breaking unit for overhaul may only be carried out in good
and settled weather conditions and if the relative humidity does not exceed 80%.
1. Take the circuit-breaker out of service.
2. Empty the gas, see Chapter 4.2.1. Fill with nitrogen to atmospheric pressure.
3. Operate the circuit-breaker slowly towards the closed position by cranking the
operating mechanism by hand. This is described in the Overhaul Instructions
for the operating mechanism. Stop cranking when the dimension 230-235 mm
as set out in Figure 9-1 is reached. The coupling link with pin (1) on the
operating insulator (4) is now in the correct position for dismantling.
4. Place a lifting sling around the top section of the breaking unit and prepare to
lift.
5. Remove the bolts (5) and carefully lift the breaking unit (6) a maximum
of 70 mm.
N.B. Do not lift the breaking

unit must not be lifted
more than 70 mm so as
6 7
not to damage the 2
circuit-breaker’s
interior. 3
If a large amount of moisture

should enter the post insulator,
fill it immediately with
nitrogen gas and transport it to
a workshop as soon as possible
for dismantling and careful
cleaning. 5 1
4
Item
8
1 Pin
230-235
2 Washer
3 Circlip
5 Bolt M12x35
Washer 13x24x2.5
6 Breaking unit
7 Auto-PufferTM
pull-rod
8 Post insulator B10066
Figure 9-1. Dismantling the breaking unit
1HYB800001-046 Rev.A 31
Dismantling the breaking unit for transport Overhaul Instructions
6. Disconnect the breaking unit (6) by removing the circlip (3), washer (2) and
pin (1).
N.B. Ensure that neither the circlips nor the washers fall into the post insulator
during the dismantling. Cover the opening, for example, by tying a cloth over
it.
7. Fit the protective cover, ABB art. No. 5439 142-A, with the sealing ring over
the post insulator (8). When the cover has been bolted in position, increase the
nitrogen pressure in the post insulator to 0.125 MPa abs.
8. Slide the Auto-PufferTM pull-rod (7) into the breaking unit (6) and fit the
protective cover, ABB art. No. 1HSB445237-1, with the sealing ring.
The breaking unit is now ready for transport.
If the post insulator or breaking unit is left in this condition for a long period
without the breaking unit being re-assembled , the post insulator or breaking unit
should be vacuum-pumped and filled with nitrogen, see Chapter 8.6.
9.1 Assembling the breaking unit after an overhaul

1. Suspend the breaking unit and remove the post insulator’s protective cover,
ABB art. No. 1HSB445237-1, and pull out the Auto-PufferTM so that the Auto-
PufferTM pull-rod (7) is accessible for assembly.
2. Reduce the nitrogen pressure in the post insulator (8) to atmospheric pressure
and remove the protective cover.
3. Carefully clean the sealing surface of the sealing ring on the post insulator (8)
and coat with grease “G”. Fit the sealing ring in its slot.
4. Slowly lower the breaking unit (6) so that it sits in position for fitting the pin,
approx. 60 - 70 mm above the post insulator.
5. Connect the Auto-PufferTM’s pull-rod (7) to the operating insulator (4) using
pin (1).
6. When the pin is fitted, lower the breaking unit (6) carefully down towards the
post insulator (8) and centre it. Bolt the breaking unit in position using the bolts
(5), with the tightening torque 60 Nm.
TIGHTENING TORQUE
60 Nm
7. Clean the upper flange (9) and coat with grease “G”. Place the sealing ring on
top of the upper flange.
8. Open the packaging of the new absorption agent and fill the agent in the
absorption agent container (12).
32 1HYB800001-046 Rev.A
Overhaul Instructions Dismantling the breaking unit for transport
9. Fit the absorption agent container (12) and the cover (10) and tighten the bolts
(11) with the tightening torque 45 Nm.
TIGHTENING TORQUE
45 Nm
11
Item
12 10 7
1 Pin 2
2 Washer 9 3
3 Circlip 6
5 Bolt M12x 35
Washer 13x24x2.5
6 Breaking unit
5 1
7 Auto-PufferTM pull-
4
rod
8 Post insulator 8
9 Upper flange
230-235
10 Cover
11 Bolt M12x35
Washer 13x24x2.5
12 Absorption agent
container
B10067
Figure 9-2. Fitting the breaking unit
10. Fill the circuit-breaker pole with gas.

a. Vacuum-pump down to 100 Pa and let the vacuum pumping continue for
at least one hour after this pressure has been reached.
b. Stop the vacuum-pumping and fill the circuit-breaker with dry and pure
nitrogen to atmospheric pressure. Allow it to stand for a few hours or
overnight.
c. Vacuum-pump again down to 100 Pa and fill with pure SF6 gas to
0.125 MPa (abs).
Store the filling hoses so that they are not exposed to moisture or contamination.
They must not be used other than for their intended purpose.
1HYB800001-046 Rev.A 33
Dismantling the breaking unit for transport Overhaul Instructions
11. Operate the circuit-breaker slowly towards the open position by cranking the
operating mechanism by hand and check that the alignment check hole,
D=6 mm, for the open position in the operating lever aligns with the hole in the
mechanism housing.
Adjustment of pull-rod in OPEN POSITION

Correct contact position when holes A and B coincide
Check with pin, diameter D=6
Inställning av manöverstång i FRÅN-LÄGE

Rätt kontaktläge när hål A och B sammanfaller
Kontrollera med en pinne diameter D=6
A A+B
B10032
Figure 9-3. Mechanism housing’s sign.
34 1HYB800001-046 Rev.A
Overhaul Instructions Assembling the circuit-breaker and commissioning
10. Assembling the circuit-breaker and commissioning

Assembling the circuit-breaker and commissioning are carried out in accordance
with applicable assembly instructions for the circuit-breaker in question.
After assembling the circuit-breaker, check and note down the operating values.
First overhaul.
Measured values
Check the following
Close-Open times(1) ms ms ms
Lowest control voltage to coil I V V V
Lowest control voltage to coil II V V V
Lowest control voltage from coil I V V V
Lowest control voltage from coil II V V V
Filling pressure (2) MPa (abs) MPa (abs) MPa (abs)
(1) The circuit-breaker must not be operated Open-Close without an intermediate delay of 300 ms.
(2) Filling pressure according to rating plate.
Check carried out on the:________________________________
1HYB800001-046 Rev.A 35
Assembling the circuit-breaker and commissioning Overhaul Instructions
Second overhaul.
Measured values
Check the following
Close-Open times(1) ms ms ms
Lowest control voltage to coil I V V V
Lowest control voltage to coil II V V V
Lowest control voltage from coil I V V V
Lowest control voltage from coil II V V V
Filling pressure (2) MPa (abs) MPa (abs) MPa (abs)
(1) The circuit-breaker must not be operated Open-Close without an intermediate delay of 300 ms.
(2) Filling pressure according to rating plate.
Check carried out on the:________________________________
36 1HYB800001-046 Rev.A
mechanism BLK 222
1-pole operation
Spare Parts
1HYB800001-047 Rev.A
ABB Switchgear
Article number:1HYB800001-047 Rev.A
Date: 01-01-2005
Spare Parts
LIST OF CONTENTS
1. General ................................................................................ 1
1.1 Circuit-breaker pole ....................................................................... 2
2. Breaking mechanism ......................................................... 3

2.1 Breaking mechanism...................................................................... 3
2.2 Contact set...................................................................................... 4
3. Post insulator...................................................................... 5
4. Mechanism .......................................................................... 7
4.1 Mechanism ..................................................................................... 7
4.2 Tripping mechanism....................................................................... 7
5. Accessories ........................................................................ 9
5.1 Absorption agent container ............................................................ 9
5.2 Density monitor.............................................................................. 9
5.3 Set of seals.................................................................................... 10
5.4 Assembly set ................................................................................ 10
5.5 Non-return valve .......................................................................... 10
6. Tools and lubricants......................................................... 11

6.1 Protective cover ............................................................................ 11
6.2 Lubricants..................................................................................... 11
1HYB800001-047 Rev.A i
Spare Parts
FIGURES
Figure 1-1. Circuit-breaker pole. ....................................................................... 1

Figure 1-2. Circuit-breaker pole. ....................................................................... 2
Figure 2-1. Breaking unit. ................................................................................. 3
Figure 2-2. Contact set. ..................................................................................... 4
Figure 3-1. Post insulator. ................................................................................. 5
Figure 4-1. Mechanism housing. ....................................................................... 7
Figure 4-2. Tripping mechanism. ...................................................................... 7
Figure 5-1. Absorption agent container. ............................................................ 9
Figure 5-2. Density monitor. ............................................................................. 9
Figure 5-3. Non-return valve. .......................................................................... 10
ii 1HYB800001-047 Rev.A
Spare Parts General
1. General
Spare parts for the SF6 circuit-breaker LTB 245E1 with operating mechanism
BLK 222 are supplied by:
ABB HV Switchgear
Box 124
Vadodara-390013
India
Spare parts recommended to be kept in stock are marked with an R. With more that
ten circuit-breakers in operation the spare parts marked with RR are also
recommended to be kept in stock. To be able to make quick replacements and avoid
long periods of downtime the parts marked by RRR can also be stocked.
Item Designation Note

1 Circuit-breaker pole RRR
2 Operating RRR
mechanism
3 Frame 1
B10034
Figure 1-1. Circuit-breaker pole.
Please state the type designation and serial number with all enquiries and orders of
spare parts or tools. Please also state the order number if possible.
1HYB800001-047 Rev.A 1
General Spare Parts
1.1 Circuit-breaker pole
Item Designation
1
1 Breaking unit
2 Post insulator
3 Mechanism
4 Tripping mechanism
B10122
Figure 1-2. Circuit-breaker pole.
Please state the type designation and serial number with all enquiries and orders of spare
parts or tools. Please also state the order number if possible.
2 1HYB800001-047 Rev.A
Spare Parts Breaking mechanism
2. Breaking mechanism
2.1 Breaking mechanism
1
Item Qty. Designation Note
1 1 Breaking chamber RR
insulator 2
2 1 Upper current path Included in
contact set
3 1 Lower current path Included in
contact set 4
4 1 Puffer Included in
contact set
B10123
Figure 2-1. Breaking unit.
1HYB800001-047 Rev.A 3
Breaking mechanism Spare Parts
2.2 Contact set
Qty. Designation Note

1 Contact set R
B10124
Figure 2-2. Contact set.
4 1HYB800001-047 Rev.A
Spare Parts Post insulator
3. Post insulator

1 1 Post insulator RR
2 1 Operating insulator RR
B10125
2
Figure 3-1. Post insulator.
1HYB800001-047 Rev.A 5
Spare Parts Mechanism
4. Mechanism
4.1 Mechanism

1 1 Mechanism RR
B10012
Figure 4-1. Mechanism housing.
4.2 Tripping mechanism

1 1 Tripping mechanism RR
B10126
Figure 4-2. Tripping mechanism.
1HYB800001-047 Rev.A 7
Spare Parts Accessories
5. Accessories
5.1 Absorption agent container

1
2
1 1 Absorption agent
container
2 1 Absorption agent R B10127
Figure 5-1. Absorption agent container.
5.2 Density monitor
Item Qty. Designation Note 2
1 1 Density monitor, R
temperature- 1
compensated - reference
volume
2 1 Density monitor, R
temperature-
compensated - bimetal B10052
Figure 5-2. Density monitor.
1HYB800001-047 Rev.A 9
Accessories Spare Parts
5.3 Set of seals

Set of seals for a complete circuit-breaker pole.
Qty. Designation Article number Note

1 Set of seals 5429 038-AX R
5.4 Assembly set

Set of bolts for a circuit-breaker pole.

1 Set of bolts R
Set of pins for a complete circuit-breaker pole.

1 Pins with circlips R
5.5 Non-return valve
1
1 1 Non-return valve RR
B10053
Figure 5-3. Non-return valve.
10 1HYB800001-047 Rev.A
Spare Parts Tools and lubricants
6. Tools and lubricants
6.1 Protective cover
Item Qty. Designation Article number Note

1 1 Protective cover for 5237 736-R R
breaking unit
2 1 Protective cover for 5439 142-A R
post insulator
6.2 Lubricants
6.2.1 Oil
Oil Article number Note

“A” 1HSB875318-A
“D” 1HSB875318-B
“S” 1HSB875318-C
6.2.2 Grease
Grease Article number Note

“G” 5316 381-A
“K” 5316 381-M
“N” 5316 381-L
“L” 5316 381-H
“M” 5316 381-J
“P” 5316 381-N
“S” 5316 381-G
“Sv” 5316 381-C
1HYB800001-047 Rev.A 11
type BLK 222
Spare Parts
1HYB800001-021 Rev.A
ABB Switchgear
Date: 2003-10-01
Spare Parts
LIST OF CONTENTS
1. General ................................................................................ 1
2. Motor ................................................................................... 3
3. Dashpot ............................................................................... 5
4. Catch gear ........................................................................... 7
5. Heater element.................................................................... 9
6. Electrical equipment ........................................................ 11
7. Lubricants ......................................................................... 13
7.1 Oil..................................................................................................13
7.2 Grease............................................................................................13
1HYB800001-021 Rev.A i
Spare Parts
FIGURES
Figure 1-1. Operating mechanism BLK 222. .................................................... 1

Figure 2-1. Motor. ............................................................................................. 3
Figure 3-1. Dashpot. .......................................................................................... 5
Figure 4-1. Catch gear. ...................................................................................... 7
Figure 5-1. Heater element. ............................................................................... 9
Figure 6-1. Electrical equipment, BLK 222. ....................................................11
ii 1HYB800001-021 Rev.A
Spare Parts General
1. General
Spare parts for the operating mechanism BLK 222 are supplied by:
ABB HV Switchgear
P.O. Box 124,
Vadodara - 390001,
India.
Replacement modules are supplied complete and fully tested.
Please state the type designation and the serial number with all enquiries and orders
of spare parts. Please also state the order number if possible.
2 1
5
3
B30200
Item
1 Drive unit
3 Operating panel
4 Closing spring
5 Heater element
Figure 1-1. Operating mechanism BLK 222.
1HYB800001-021 Rev.A 1
General Spare parts
2 1HYB800001-021 Rev.A
Spare Parts Motor
2. Motor
Type of motor Article number

1 Motor, 220 -250 V AC/DC 1HSB534460-2
1 Motor, 110 -127 V AC/DC 1HSB534460-1
B30068
Figure 2-1. Motor.
Please state the type designation and the serial number with all enquiries and orders of spare
parts. Please also state the order number if possible.
1HYB800001-021 Rev.A 3
Motor Spare parts
4 1HYB800001-021 Rev.A
Spare Parts Dashpot
3. Dashpot
Designation Article number

Dashpot 1HSB535256-C
30063
Figure 3-1. Dashpot.
1HYB800001-021 Rev.A 5
Dashpot Spare parts
6 1HYB800001-021 Rev.A
Spare Parts Catch gear
4. Catch gear
3
Item Designation Article number

1 Closing catch gear 110 V 1HSB535436B5
4
220 V 1HSB535436B7
2 Closing coil 1, Y3 60-72 V LA 516 771-AX
3 Opening catch gear 110 V 1HSB535436B3 5
220 V 1HSB535436B8
4 Opening coil 1, Y1 220-250 V LA 516 771-AY 1
5 Opening coil 2, Y2 110-125 V LA 516 771-AL

Y2-A, Y2-B 220-250 V LA 516 771-AZ
Double opening coil 110-125 V LA 516 771-AU
2
B30062
Figure 4-1. Catch gear.
1HYB800001-021 Rev.A 7
Catch gear Spare parts
8 1HYB800001-021 Rev.A
Spare Parts Heater element
5. Heater element
Designation Voltage range Article number

Heater element 110-127 V, 70 W 5291 805-1
220-254 V, 70 W 5291 805-2
110-127 V, 140 W 5291 805-3
220-254 V, 140 W 5291 805-4
B30058
1HYB800001-021 Rev.A 9
Heater element Spare parts
10 1HYB800001-021 Rev.A
Spare Parts Electrical equipment
6. Electrical equipment
Spare parts for electrical equipment BLK 222
Item Designation Voltage range Article number

1 Anti pumping 220-250 V DC 5619 758-1
relay 110-125 V DC 5619 758-2
2 Interlock relay 60-72 V DC 5619 758-3
3 Interlock relay 42-48 V DC 5619 758-4
4 Motor contactor 220-250 V DC 5351 749-1
110-125 V DC 5351 749-2
220-240 V AC 5351 749-3
5 Miniature switch 220-250 V DC 5344 027-40(1)
Motor (MCB) 110-125 V 5344 027-41(2)
6 Miniature switch 110-254 V 5344 027-18
Heater (MCB)
6 5 7
7 Counter 220-250 V DC 5692 965-1
110-125 V DC 5692 965-2
42-48 V DC 5692 965-3 3
2
(1) K4A 2-pole + auxiliary contact
(2) K8A 2-pole + auxiliary contact 1
4
B30209
Figure 6-1. Electrical equipment, BLK 222.
1HYB800001-021 Rev.A 11
Electrical equipment Spare parts
12 1HYB800001-021 Rev.A
Spare Parts Lubricants
7. Lubricants
7.1 Oil
Oil Article number

“A” 1HSB875318-A
“D” 1HSB875318-B
“S” 1HSB875318-C
7.2 Grease
Grease Article number

“G” 5316 381-A
“K” 5316 381-M
“N” 5316 381-L
“L” 5316 381-H
“M” 5316 381-J
“P” 5316 381-N
“S” 5316 381-G
“SV” 5316 381-C
1HYB800001-021 Rev.A 13

1HYB800001-042A-OM Manual (1-Pole) PDF

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1HYB800001-042A-OM Manual (1-Pole) PDF

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Product Manual

Article number: 1HYB800001-043 Rev.A

1.1 Design of the circuit-breaker

Item Part Weight, kg

Figure 1-1. Circuit-breaker type LTB 245E1

1.2 The circuit-breaker’s gas system

1.2.1 Opening and closing

Figure 1-2. Circuit-breaker pole in Close position

1.3 Operating mechanism

Article number: 1HYB800001-013 Rev.A

2. Assembly and connection ................................................. 5

Figure 1-1. Operating mechanism BLK 222. .................................................... 1

Figure 1-1. Operating mechanism BLK 222.

Figure 1-2. Lifting the operating mechanism.

2. Assembly and connection

2.1 Mechanical connection

On delivery the operating mechanism’s closing spring is uncharged.

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Figure 2-1. Operating mechanism.

2.2 Electrical connection

Figure 2-2. Earth clamp connection.

2.3 Loading the closing springs

2.3.1 Electrical loading

Figure 2-3. Electrical loading of the closing spring.

2.4 Normal operations, the circuit-breaker closed

Figure 2-4. Normal operating position.

2.5 Open, the circuit-breaker is open

Figure 2-5. Opening operation.

2.6 Closed, the circuit-breaker is closed

3 Tripping arm with interlock heel

Figure 2-6. Closing operation.

3.1 Remote/local operations

2 Operating switch, On/Off

Figure 3-1. Remote/local operations.

3.2 Close operation

2 Operating switch, On/Off

Figure 3-2. Close operation.

3.3 Open operation

2 Operating switch, On/Off

Figure 3-3. Open operation.

3.4 Rapid reconnection

4.1 Drive mechanism

Figure 4-1. Motor.

4.2 Catch gear

1 Opening catch gear

2 Closing catch gear

Figure 4-2. Catch gear.

Figure 4-3. Dashpot.

4.4 Limit switch with auxiliary contact

Figure 4-4. Limit switch with auxiliary contact.

4.5 Heater element

Figure 4-5. Heater element.

Article number:1HYB800001-044 Rev.A

5. Electrical connections ..................................................... 21

6. Pressurising the poles ..................................................... 23

8. Operating values .............................................................. 31

Figure 3-1. Component parts ............................................................................. 5

2.1 Warning text

2.2 Safety, general

The standard operating cycle is O - 0.3 s - CO - 3 min.-CO. The time between

Figure 3-1. Component parts

Figure 3-2. Lifting the operating mechanism

3.3 Storage before assembly

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