Abb HPL 72.5-300 B1

Product Manual
1HSB445416-2 en 4
HPL 72,5-300B1
BLG 1002A
3-pole operation
Product Manual
1
PRODUCT DESCRIPTION
- Circuit-Breaker
- Operating Mechanism
2
ASSEMBLY INSTRUCTIONS
- Circuit-Breaker
- Damping element
3
CHECKLIST
4
OPERATING AND MAINTENANCE
5
LUBRICANTS
6
OVERHAUL INSTRUCTIONS
7
OVERHAUL INSTRUCTIONS
- Circuit-Breaker
8
ENVIRONMENTAL INFORMATION
- SF6 gas
- Disposal and recycling
9
SPARE PARTS
- Circuit-Breaker
ABB Power Technologies AB

S-771 80 LUDVIKA 10
1HSB445416-260 en -
11
SF6 Circuit-Breaker HPL 72.5-300B1 with operating
mechanism BLG 1002A
1-, 2- and 3-pole operation
Product Description
1HSB445455-1 en 6

The information in this document is subject to alteration without prior notice and should not be regar-
ded as an undertaking from ABB Power Technologies AB. ABB Power Technologies AB takes no
responsibility for errors that can occur in the documentation.
ABB Power Technologies AB is not responsible for damage incurred due to the misuse of this docu-
ment.
The document, or parts thereof, may not be reproduced or copied without prior permission from ABB
Power Technologies AB. It may not either be imparted to third party or otherwise be used without aut-
horisation. Infringement hereof will be subject to action in accordance with applicable laws.
© ABB Power Technologies AB
Article number:
1HSB445455-1 en 6
Approval date:
2006-10-04
1HSB445455-1en6
Product Description
LIST OF CONTENTS
1. Description.......................................................................... 1
1.1 Design of the circuit-breaker...........................................................1
1.2 Weights of the circuit-breaker parts ................................................2
1.3 The breaking principle ....................................................................4
1.4 Function of the operating mechanism.............................................5
1.5 Standards.........................................................................................5
1HSB445455-1 en 6 i
Product Description
FIGURES
Figure 1-1. Circuit-breaker HPL 72.5-300B1, 1-pole operated .........................2

Figure 1-2. Circuit-breaker HPL 72.5-300B1, 2- and 3-pole operated ..............3
Figure 1-3. Circuit-breaker pole in Open position .............................................4
1HSB445455-1 en 6 iii
Product Description Description
1. Description
This Product Description applies to the SF6 circuit-breaker HPL 72.5-300B1 with
operating mechanism BLG 1002A.
HPL 72,5-300B1US is intended for synchronized energizing of capacitor banks
with non-solidly earthed neutral and HPL 72,5-300B1GS is intended for
synchronized energizing of capacitor banks with solidly earthed neutral.
1.1 Design of the circuit-breaker

The circuit-breaker consists usually of three separate poles. For special applications
e.g. railways application it consists of two poles.
Each pole has three main parts. At the lower end is a mechanism in an aluminium
alloy housing. Above the mechanism housing is a hollow post insulator in which the
insulating rod runs. At the top is the breaking unit.
Each breaking unit consists of a breaking chamber insulator, which, together with
an upper and a lower terminal flange, makes up the enclosure. The enclosure
contains the upper and the lower current paths and a puffer. The puffer runs on the
outside of the lower current path. The main contacts are integrated in the upper and
lower current paths.
If the circuit-breaker is 2- or 3-pole operated, the poles are interconnected by pull
rods enclosed in a protective tube.
The poles are mounted on separate hot-dipped galvanized frames. The frame
consists of two welded halves, which are interconnected with bolted cross stays.
1HSB445455-1 en 6 1
Description Product Description
1.2 Weights of the circuit-breaker parts
1.2.1 1-pole operated circuit-breaker
B10002
1-pole operated
Figure 1-1. Circuit-breaker HPL 72.5-300B1, 1-pole operated
Item Part Weight
1 Circuit-breaker pole See dimension drawing
2 Operating mechanism BLG 1002A 460 kg
3 Frame 86-200 kg
2 1HSB445455-1 en 6
1.2.2 2- and 3-pole operated circuit-breaker
1 1
4 2
2
4
3 3
B10301
2-pole operated 3-pole operated
Figure 1-2. Circuit-breaker HPL 72.5-300B1, 2- and 3-pole operated
Item Part Weight
1 Circuit-breaker pole See dimension drawing
2 Operating mechanism BLG 1002A 460 kg
3 Frame 86-200 kg
4 Protective tube and pull rod 1100-4000 mm, 16-64 kg
1HSB445455-1 en 6 3
1.3 The breaking principle

On opening, the puffer cylinder (1) is drawn downwards over the fixed piston and
the enclosed gas is compressed and forced at a high velocity out through the nozzle
(2) and the moving arcing contact (3).
When the arcing contacts (3 and 4) are

separated, an arc is produced which at
high currents obstructs the nozzle (2).
When the current approaches the current
zero passage, the gas starts to flow out
4
through the puffer cylinder (1). The
specially designed nozzle (2) ensures that 2
the gas flow is directed towards the arc. 3
The gas is allowed to pass both down
through the moving arcing contact (3) and
up past the fixed arcing contact (4). When 1
the arc has been cooled it is extinguished
and the current is interrupted.
There are separate main current contacts,
which open before and close after the
arcing contacts. They are not affected by
the arc on interruption.
On closing, the puffer cylinder (1) moves
upwards, the contacts engage and the
puffer cylinder is refilled with gas.
Figure 1-3. Circuit-breaker pole in Open position
4 1HSB445455-1 en 6
1.4 Function of the operating mechanism

The HPL circuit-breaker is operated by a motor-charged spring operating
mechanism BLG 1002A.
The operating mechanism is connected to the circuit-breaker pole through a pull rod
system.
The circuit-breaker is closed by closing springs, which are housed in the operating
mechanism. When the circuit-breaker is closed, the opening springs, which are
permanently connected to the circuit-breaker mechanism, get recharged.
The opening latch in the operating mechanism keeps the circuit-breaker in the
closed position. Opening the circuit-breaker only requires the release of the opening
latch, by activating the opening coil.
The normal operating sequence is:
O - 0.3 s- CO -3 min - CO (according to IEC) or CO -15 s- CO (according to
IEEE/ANSI).
1.5 Standards
The circuit-breakers comply with the requirements according to IEC and in most
cases also IEEE/ANSI and are restrike-free when breaking a capacitive load.
1HSB445455-1 en 6 5
ABB Power Technologies AB 1HSB445455-1 en 6
Circuit-Breaker Unit
SE-771 80 LUDVIKA 2006-10-04
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
SF6 Circuit-Breaker Operating Mechanism
BLG 1002A
Product Description
1HSB515432-100 en 6

ment.
Article number:
1HSB515432-100 en 6
Approval date:
2006-08-24
Product Description
LIST OF CONTENTS
1. Description.......................................................................... 1
1.1 Design of the operating mechanism................................................1
1.2 Normal operating mode ..................................................................2
1.3 Opening operation...........................................................................3
1.4 Closing operation ............................................................................4
2. Operations .......................................................................... 5
2.1 Remote/Local operation..................................................................5
2.2 Close operation ...............................................................................5
2.3 Open operation................................................................................6
2.4 Rapid reconnection .........................................................................6
3. Components........................................................................ 7
3.1 Drive unit ........................................................................................7
3.2 Mechanical interlocking..................................................................7
3.3 Catch gear .......................................................................................8
3.4 Damper............................................................................................8
3.5 Auxiliary contact.............................................................................9
3.6 Heating element ..............................................................................9
1HSB515432-100 en 6 i
Product Description
FIGURES
Figure 1-1. Operating mechanism .....................................................................1

Figure 1-2. Normal operating mode ..................................................................2
Figure 1-3. Opening operation ...........................................................................3
Figure 1-4. Closing operation ............................................................................4
Figure 2-1. Remote/Local operation ..................................................................5
Figure 2-2. Close operation ...............................................................................5
Figure 2-3. Open operation ................................................................................6
Figure 3-1. Drive unit ........................................................................................7
Figure 3-2. Interlocking mechanism ..................................................................7
Figure 3-3. Catch gear .......................................................................................8
Figure 3-4. Closing and Opening damper ..........................................................8
Figure 3-5. Auxiliary contact .............................................................................9
Figure 3-6. Heating element ..............................................................................9
1HSB515432-100 en 6 iii
1. Description
The spring operating mechanism BLG 1002A is intended for operating a circuit-
breaker with integrated opening springs.
N.B. Under no circumstances should the operating mechanism be operated without

first being attached and adjusted with the associated circuit-breaker.
1.1 Design of the operating mechanism

The operating mechanism consists of a spring battery with associated drive unit,
that automatically charges the spring battery after each closing operation.
A closing catch gear holds the charged closing spring prepared for the closing of the
circuit-breaker and the recharging of the opening springs. An opening catch gear
holds the closed circuit-breaker prepared for immediate opening.
The components of the operating mechanism are housed in a cubicle, which also
contains a control panel. The roof and doors of the cubicle can be removed to
facilitate service and overhaul procedures.
The standard operating sequence is O - 0.3 s - CO - 3 min - CO acc. to IEC or
CO - 15 s - CO acc. to IEEE/ANSI .
The time between closing operations should not be less than 1 minute during the
testing of circuit-breakers and relay systems involving more than 3 closing
operations.
Item 1
1 Drive unit
Ej Blockerad
2 Mechanism
3 Control panel
4 Spring battery 4
5
5 Heating element
(behind protection 3
plate)
Front Back, with the

cover removed
Figure 1-1. Operating mechanism
1HSB515432-100 en 6 1
1.2 Normal operating mode

During normal service the circuit-breaker is in the closed position. The opening
spring (1) on the circuit-breaker and the closing springs (2) in the operating
mechanism are charged. The circuit-breaker is kept in the closed position by the
opening catch gear (3) of the operating mechanism.
Item
1 Opening spring
2 Closing springs
1
3 Opening catch gear
B20028
Figure 1-2. Normal operating mode
2 1HSB515432-100 en 6
1.3 Opening operation

To open the circuit-breaker:
The latch in the opening catch gear (1) is released by actuating the opening coil. The
opening spring (2) pulls, via the pull rod (3), the operating lever (4) to the left. The
movement is damped at the end position by the opening damper (5). At the end
position the operating lever (4) rests against the cam disc (6).
The closing springs are still charged.
3 6
1
Item
1 Opening catch gear 5
2 Opening spring 4
3 Pull rod
2
4 Operating lever
5 Opening damper
6 Cam disc
7
7 Closing spring
B20029
Figure 1-3. Opening operation
1HSB515432-100 en 6 3
1.4 Closing operation

To close the circuit-breaker:
The latch in the closing catch gear (1) is released by actuating the closing coil. The
chain section (2) is released and transfers the energy from the closing spring (3) to
the cam disc (4). The cam disc (4) rotates 360° clockwise and pushes the operating
lever (5) to the right until the opening catch gear (6) engages. The movement is
damped in the end position by the closing damper (7). The opening spring (8) is
charged via the pull rod (9).
The chain section (10) travels up the same path as the chain section (2) travels
down.
9 1
6
Item
1 Closing catch gear

5
2 Chain section
3 Closing spring
4 Cam disc 8 2
5 Operating lever
6 Opening catch gear 4

3
7 Closing damper
10
8 Opening spring
7
9 Pull rod
10 Chain section
B20031
Figure 1-4. Closing operation
4 1HSB515432-100 en 6
Product Description Operations
2. Operations
2.1 Remote/Local operation

At normal operation mode the “Local/Remote/Disconnect” switch (1) is in the
“Remote” position for electrical remote operations. In the “Local” position,
operations can only be carried out using the “Open/Close” operation switch (2).
Item
1 Local/Remote/Disconnect switch
2 Open/Close operation switch
2 1
Figure 2-1. Remote/Local operation
2.2 Close operation

A Close operation using the “Open/Close” operation switch (2) or electrical remote
impulses can only take place if:
• The “Local/Remote/Disconnect” switch (1) is in the “Remote” or “Local”
position.
• The closing spring is charged.
• The circuit-breaker is in the open position.
• The gas pressure is greater than the blocking level.
Item
2 1
Figure 2-2. Close operation
1HSB515432-100 en 6 5
Operations Product Description
2.3 Open operation

An Open operation of a closed circuit-breaker can be made with the
“Local/Remote/Disconnect” switch (1) in the “Local” position and the
“Open/Close” operation switch (2) in the “Close” position.
Item
2 1
Figure 2-3. Open operation
2.4 Rapid reconnection

Automatic rapid reconnection, Open-0.3s-Closed-Open is possible if:
• The circuit-breaker is closed.
• The “Local/Remote/Disconnect” switch is in the “Remote” position.
• The mechanism’s closing spring is fully charged when the operating sequence
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, a Close
operation will always be completed before an Open operation is started, even if the
Close impulse has been given during a current Open operation.
6 1HSB515432-100 en 6
Product Description Components
3. Components
3.1 Drive unit

The drive unit is supplied with one or two motors with ratings of either
60 V DC, 110 V DC, 220 V DC, 60 V AC 50, 60 Hz, 110 V AC 50, 60 Hz or 220 V
AC 50, 60 Hz.
The motor or motors should be able charge the springs at 85% of the nominal
voltage (acc. to IEC).
Item
1 Drive unit
B20031
Figure 3-1. Drive unit
3.2 Mechanical interlocking

The interlocking mechanism prevents a closing operation from being carried out if
the circuit-breaker is already in the closed position. It also prevents closing if the
closing springs are uncharged or not fully charged. This can occur e.g. if the closing
catchgear is activated by hand or if a mechanical failure occurs in the catch gear.
Item 2
1 Limit switch 3
2 Interlocking lever 4
3 Interlocking disc
4 Cam disc
5 Operating rod
6 Operating lever shaft

B20007 5 6
Figure 3-2. Interlocking mechanism
1HSB515432-100 en 6 7
Components Product Description
3.3 Catch gear

The operating mechanism is as standard fitted with one closing coil and two
opening coils, but can on request be equipped with double coils on the closing side.
Standard voltage of the coils are 110, 220 V DC or AC, but other voltages may
occur.
The rated standard output of the coils is 200 W.
As an option, the coils can be rated to an output of 450 W when 2-cycle interruption
at 60 Hz is required.
Item
1 Catch gear
B20034 1
Figure 3-3. Catch gear
3.4 Damper
The operating mechanism is equipped with one Closing damper (1) to slow down
the rotating movement of the cam disc and one Opening damper (2) to dampen the
final phase of the opening movement.
Item
1 Closing damper
2 Opening damper
B20024
Figure 3-4. Closing and Opening damper
8 1HSB515432-100 en 6
Product Description Components
3.5 Auxiliary contact

The operating mechanism is as standard equipped with a 6-pole auxiliary contact (1)
consisting of six normally open and six normally closed contacts. Three normally
closed contacts and one normally open contact are used for the operating
mechanism’s own function.
As an option, it is possible to add six normally closed and six normally open
contacts or twelve normally closed and twelve normally open contacts.
The shaft (2) of the auxiliary contact is in direct connection with the operating lever
of the operating mechanism and follows the movement of the breaker contacts.
Item
1 Auxiliary contact
2 Shaft
2
1
B20035
Figure 3-5. Auxiliary contact
3.6 Heating element

The operating mechanism is equipped with a heating element to prevent
condensation and should always be connected.
Item
1 Heating element
6 5 4
3 2 1
B20036
1
Figure 3-6. Heating element
1HSB515432-100 en 6 9
SE-771 80 LUDVIKA 2006-08-24
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
SF6 Circuit-Breaker HPL 72,5-300B1 with operating
mechanism BLG 1002A
3-pole operation
Assembly Instructions
1HSB445410-2 en 7

ment.
Article number:
1HSB445410-2 en 7
Approval date:
2006-10-04
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 Preparations for assembling the operating mechanism.................14
4.6 Assembly of corona rings (if applicable)......................................15
4.7 Assembling the operating mechanism ..........................................16
4.8 Assembling the protective tube between poles .............................17
4.9 Final assembly of the circuit-breaker pole....................................17
4.10 Assembling the pull rods...............................................................18
4.11 Inspecting the bolted joints, etc.....................................................22
5. Electrical connections ..................................................... 23

5.1 Connection of the operating mechanism.......................................23
5.2 Assembly of busbars or overhead lines.........................................23
5.3 Charging the closing springs.........................................................24
6. Pressurizing the poles ..................................................... 25

6.1 Preparations...................................................................................25
6.2 Gas filling with SF6 gas................................................................26
6.3 Gas filling with mixed gas ............................................................29
6.4 Gas monitoring system..................................................................30
6.5 Leakage test...................................................................................31
6.6 Final inspection of the pull rod system .........................................31
6.7 Fitting the plate and cover.............................................................32
7. Commissioning................................................................. 33
1HSB445410-2 en 7 i
8. Operating values............................................................... 34
8.1 Times ............................................................................................ 34
8.2 Motor and control circuits ............................................................ 34
8.3 Resistance..................................................................................... 34
8.4 Contact stroke............................................................................... 34
ii 1HSB445410-2 en 7
FIGURES
Figure 3-1. Circuit-breaker 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 non-return valve on the circuit-breaker pole ..........................13
Figure 4-7. Fitting the circuit-breaker pole on the frame ................................14
Figure 4-8. Dismantling the plate and cover ....................................................14
Figure 4-9. Assembling the corona rings .........................................................15
Figure 4-10. Assembly of the operating mechanism .........................................16
Figure 4-11. Assembly of the protective tubes ..................................................17
Figure 4-12. Circuit-breaker poles on the frame ................................................17
Figure 4-13. Checking the closing lever’s locking lug ......................................18
Figure 4-14. Adjusting the operating mechanism ..............................................18
Figure 4-15. Assembling the pull rod between the operating mechanism and
pole A1 ..........................................................................................19
Figure 4-16. Assembling the pull rods ...............................................................21
Figure 5-1. Operating mechanism ...................................................................23
Figure 5-2. Charging the closing springs .........................................................24
Figure 6-1. Gas filling ......................................................................................26
Figure 6-2. Density monitor and union nut ......................................................28
Figure 6-3. Gas monitoring ..............................................................................30
Figure 6-4. Final inspection of the pull rod system .........................................31
Figure 6-5. Fitting the plate and cover .............................................................32
1HSB445410-2 en 7 iii
Assembly Instructions General
1. General
This Assembly instruction applies to the SF6 circuit-breaker HPL 72.5-300B1 with
operating mechanism BLG 1002A for 3-pole operation and contains all essential
information for assembly and commissioning.
Read through the entire Assembly instruction before starting the assembly work.
1HSB445410-2 en 7 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 indicated 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.
1HSB445410-2 en 7 3
Safety Assembly Instructions
2.2 Safety, general
WARNING
Circuit-breaker with pressurized porcelain insulators.
Mechanical damage on the porcelain can cause it to explode with the
following risk of splintering.
Work on the circuit-breaker that entails risk of mechanical damage to the
insulators should be carried out at reduced gas pressure, 0.125 MPa (abs).
WARNING
Circuit-breaker with pressurized composite insulators.
WARNING
Do not operate the operating mechanism unloaded!
Operations should take place only after the mechanism has been
connected and adjusted to the associated pressurized circuit-breaker.
The standard operating sequence 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-
breakers and relay systems involving more than 3 closing operations.
4 1HSB445410-2 en 7
Assembly Instructions Delivery
3. Delivery
Check on arrival that the delivery is in accordance 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 Power Technologies AB, Circuit Breaker Unit.
3.1 Weights
The weights of the circuit-breaker parts are as follows:
B10070
Figure 3-1. Circuit-breaker parts
Item Part Weight
1 Circuit-breaker pole Stated on the applicable dimension drawing for the order
2 Operating mechanism 465 kg
3 Frame 86-200 kg
4 Pull rod and protective tube 1100-4000 mm, 16-64 kg
1HSB445410-2 en 7 5
Delivery Assembly Instructions
3.2 Unpacking
The operating mechanism with blocking beams is packed in a wooden crate or on a
pallet. The crate is marked with the 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 cubicle,
see Figure 3-2. Slings must not be placed around the cubicle when lifting.
One sling should be attached to the lifting eye and another sling attached around the
bracket on the bottom when the operating mechanism is supplied in a crate, see
Figure 3-2.
The blocking beams should be stored for future maintenance and overhauling.
The circuit-breakers should be kept in the transport packaging until just before
assembly.
All packing material can be recycled.
Supplied in a crate Supplied on a pallet

B20023
Figure 3-2. Lifting the operating mechanism
6 1HSB445410-2 en 7
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).
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. According to Swedish standard the presence of white
rust is no reason to reject goods.
Upon arrival each unit should be checked regarding the following:
• The delivery corresponds with the order and shipping documents
• Damage due to transport and missing parts
If damage is discovered or suspected the case should be opened and photos 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 should 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)
1HSB445410-2 en 7 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 should not stand in water. The circuit-breakers
can be stored outdoors. When stored outdoors 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 should be kept indoors in an approved store and in their original
packing. This is especially important for rubber components (seals etc.), which
should also be protected from sunlight to avoid drying. Gaskets have a limited
storage life, so avoid storing them. Frames can be stored outdoors.
8 1HSB445410-2 en 7
Assembly Instructions Assembly
4. Assembly
4.1 Preparations
Before starting the assembly, make certain that all required tools and documents are
at hand.
• Standard tools with torque wrenches (9 - 550 Nm).
• Lifting devices and lifting slings.
• Lubricants, see Lubricant instruction for the names of suppliers and brands.
Grease “G”: ABB article number 1171 4014-407
Grease “SV”: ABB article number 1171 4016-610.
• Contact paste.
• Applicable dimension drawings and wiring diagrams for the order.
4.1.1 Assembly markings

The circuit-breakers are delivered dismantled in transport units. The parts are
marked to facilitate assembly. The circuit-breaker poles and operating mechanisms
have been routine 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.
4 3 2
Item
1 Operating mechanism
2 Circuit-breaker pole A1
3 Circuit-breaker pole B1
4 Circuit-breaker pole C1
B10070
1
Figure 4-1. Assembly markings
1HSB445410-2 en 7 9
Assembly Assembly Instructions
4.1.2 Foundation
The circuit-breaker foundation must be flat and level. Figure 4-2 shows the
permitted deviations in mm. for the position of the foundation bolts and for the
phase spacing.
Adjust any deviations using spacer washers, see Chapter 4.3, Assembling the frame
on the foundation. The nominal dimensions are stated on the applicable dimension
drawing.
max. 4 mm
±1 mm
±1 mm
max. 4 mm
Bolt length ≥ 110 mm

B10071
Figure 4-2. Foundation
10 1HSB445410-2 en 7
4.2 Frame assembly

The frame is supplied as welded halves (1) with six cross stays (2) and nuts, bolts
and washers (3).
Bolt the halves (1) together as shown in Figure 4-3. Fit the cross stays (2)
according to the numbering 1-4, using the supplied nuts, bolts and washers (3).
N. B. Make sure the stays are fitted as indicated in Figure 4-3 and to the
intended operating mechanism.
Tighten the bolted joints with a tightening 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 2
1
B10005
Figure 4-3. Frame assembly
1HSB445410-2 en 7 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). The dimension of the foundation bolts (1), washers (3) and nuts (2)
are stated on the applicable dimension drawing for the order.
Fill the gap between the lower nut and foundation with spacer washers (4).
The gap should be as small as possible.
Tighten the lower nut against the spacer washers (4). For the final tightening of the
frame, use the upper nut, which is tightened with a tighening torque of 300-350 Nm
for M24 and 500-550 Nm for M30 nut.
N.B. Final tightening of the bolted joint is done after the operating mechanism and
the protective tubes between the poles have been fitted.
Foundation bolts (1), nuts (2) and spacer washers (4) are not supplied.
1 2 3
Item
1 Foundation bolts L ≥ 110 mm

(not supplied)
2 Nuts (not supplied) 24 pcs.
3 Washers 24 pcs.
10
6
4 Spacer washers (not supplied)
≥ 110 mm
5 Foundation
6 Frame foot 4 20
10
TIGHTENING TORQUE
300-350 Nm (M24) 2
B10006
or
500-550 Nm (M30)
Figure 4-4. Frame assembly on the foundation
12 1HSB445410-2 en 7
4.4 Assembling the circuit-breaker pole on the frame

Place a lifting sling around the top of the breaking unit as shown in Figure 4-5 and,
using this method, lift the circuit-breaker pole from its horizontal position in the
transport packaging.
Note the position of the lifting sling! For composite insulators: Place the lifting
sling as close to the terminal flange as possible and not on the rubber surface.
Check that the bolts (1) are tightened with a tightening torque of 45 Nm before
lifting the pole to vertical position.
B10007
Figure 4-5. Lifting the circuit-breaker pole
Check that the circuit-breaker

pole does not leak before
assembly on the frame.
1. Loosen the sealing cap (1).
2. Press the valve cone of the
non-return valve (2) inwards
using a rod with a diameter 1
of about 5 mm. A clear
hissing noise should be heard
from the pole. If no hissing
noise is heard, the pole
leaks. This must be
rectified before assembly. 2
B10008
3. Fit the sealing cap (1).
Figure 4-6. The non-return valve on the circuit-breaker pole
1HSB445410-2 en 7 13
Fit a circuit-breaker pole to each frame according to Figure 4-7. Fit the bolts,
washers and nuts (1) and tighten by hand.
N. B. Final tightening is carried out when the operating mechanism has been
fitted.
Item

Nuts M20 4 pcs.
B10009
Figure 4-7. Fitting the circuit-breaker pole on the frame
4.5 Preparations for assembling the operating mechanism

Remove all the pole covers (1)
and the plates(2) with the Close-
Open signs, to gain the best
possible access to the pole
mechanisms.
Item
1 Cover
2 Plate
B10012
1 2
Figure 4-8. Dismantling the plate and cover
14 1HSB445410-2 en 7
4.6 Assembly of corona rings (if applicable)

Circuit-breakers with composite insulators may be supplied with corona rings.
Assemble the corona rings as in Figure 4-9.
Tighten the bolts (3) and the bolts (5) with a tightening torque of 60 Nm.
Item
1 Corona ring 2 pcs.
2 Bracket 4 pcs.

Washer 10,5x20x2 4 pcs.
4 Bolts M10x25 4 pcs. 1

Washer 10,5x20x2 8 pcs.
Nuts M10 4 pcs.
TIGHTENING TORQUE 2
60 Nm
4
3
B10300
Figure 4-9. Assembling the corona rings
1HSB445410-2 en 7 15
4.7 Assembling the operating mechanism

The operating mechanism is delivered with the closing springs correctly adjusted to
the corresponding circuit-breaker pole.
Fit the operating mechanism as indicated in Figure 4-10.
Fit all bolts, washers and nuts (1) and tighten them by hand. Then tighten the bolted
joints (1) with a tightening torque of 79 Nm.
2 1
Item

Nuts M12 10 pcs.
Washers 13x24x2.5 20 pcs.
2 Spring washer 13x29x3 4 pcs.
1
1
TIGHTENING TORQUE
79 Nm
B10072 1 1
Figure 4-10. Assembly of the operating mechanism
16 1HSB445410-2 en 7
4.8 Assembling the protective tube between poles

Fit the protective tubes with a pull rod inserted in each tube, see Figure 4-11.
Tighten all bolted joints (1) on the protective tube with a tightening torque of
79 Nm.
Item

Nuts M12 16 pcs.
TIGHTENING TORQUE
79 Nm
B10073
Figure 4-11. Assembly of the protective tubes
4.9 Final assembly of the circuit-breaker pole

Tighten the frame to the foundations using the upper nut with a tightening torque of
300 Nm.
Tighten the poles to the frame with a tightening torque of 300 Nm.
TIGHTENING TORQUE
300 Nm
B10074
Figure 4-12. Circuit-breaker poles on the frame
1HSB445410-2 en 7 17
4.10 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 rod 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.
• Assembling the pull rods between the poles.
4.10.1 Preparations for assembling the pull rods

• Check that the closing lever’s (1) locking lug rests against the closing catch
gear’s roller (2).
Item
1 Closing lever
2 Roller, closing catch gear
B10013 1
Figure 4-13. Checking the closing lever’s locking lug
• Adjust the operating mechanism as indicated in Figure 4-14. Press down the
locking lug (1) on the operating lever by inserting a tool, for example a large
screwdriver, in the hole (2). Insert the screwdriver in the hole (3) and press the
operating lever to the right.
2 1 3 2
Item
1 Locking lug
2 Hole in mechanism 3
3 Hole in mechanism
B10035
Figure 4-14. Adjusting the operating mechanism
18 1HSB445410-2 en 7
4.10.2 Assembling the pull rods between the operating mechanism and pole A1
Each pole is supplied set to a basic setting and its Closed and Open positions are
determined. Adjustment is made as indicated below (see Figure 4-15).
• Move the operating lever (3) and the pull rod (2) from the operating
mechanism towards its Closed position by hand sufficiently far so that the pull
rod (5) can be placed between the coupling link (4) and the pull rod (2) from
the operating mechanism.
• Simultaneously screw the pull rod (5) into the pull rod (2) from the operating
mechanism (right-hand thread) and the pole’s coupling link (4) (left-hand thread).
N. B. Remember the two spring washers (6) under each locking nut (8).
• Turn the pull rod (5) so its length decreases at the same time as the operating
lever (3) moves towards its Open position. The pull rod (5) has 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 alignment of the holes using a pin with
6 mm diameter. Check that the pull rod (5) is screwed past the alignment check
holes (9 and (10). The tightening torque for the locking nuts (8) is 300 Nm.
.
TIGHTENING TORQUE 2 3
300 Nm 1
Item
1 Mechanism housing
2 Pull rod from operating mechanism
3 Operating lever
4 Coupling link
5 Pull rod (turnbuckle screw)
6 Spring washers 25x44x1,8 8

9
4
7 Alignment check hole in operating 10
lever
8 Locking nuts
9 Alignment check hole in pull rod

6
10 Alignment check hole in coupling link
7
Figure 4-15. Assembling the pull rod between the operating mechanism and pole A1
1HSB445410-2 en 7 19
4.10.3 Assembling the pull rod between poles A1 and B1

• Thread the locking nuts (2 and 3) see Figure 4-16, to the end of the threads on
the pull rods (4). This is particularly important for the locking nuts (3).
N. B. Observe the double nuts (3).

• Fit two spring washers (9) on the right-hand end of the pull rod (4) and thread
on the coupling link (1) two turns on the pull rod (4).
• Dismantle the locking screw with the square washer (7), cylindrical pin (8) and
the coupling link (5) from the operating lever (6) on pole B1 and screw the
coupling link two turns onto the pull rod (4). Insert the coupling link (5)
between the forks of the operating lever (6). Turn the pull rod (4) using the nut
(3) so that the rod is screwed into the coupling links on both poles B1 and A1,
whereby the distance between the coupling links decreases.
• When the distance has decreased so that the alignment check holes, D=25 mm,
in the lever (6) and coupling link (5) align with each other, fit the cylindrical
pin (8) and locking screw with square washer (7). Tighten the locking screw (7)
with a tightening torque of 22.5 Nm. Secure with Loctite 270.
TIGHTENING TORQUE
22.5 Nm
• After the cylindrical pin (8) has been assembled and secured with the locking
screw and washer (7), continue to turn the pull rods in the same direction. The
torque will increase as the operating lever (6) is pulled towards the Closed
position (to the right) and the opening spring on the B1 pole contracts.
• Lock the pull rod (4) using the locking nuts (2,3) when the alignment check
hole (10) aligns with the corresponding alignment check hole in the mechanism
housing. Tighten the locking nuts (2,3) with a tightening torque of 300 Nm.
TIGHTENING TORQUE
300 Nm
• Repeat the procedure to assemble the pull rods between pole B1 and pole C1.
20 1HSB445410-2 en 7
Pole C1 Pole B1 Pole A1

4
4
5 1 5 2,9 1
3,9 2,9 3,9
7,8
7,8 10
10 6 6
10 6
Figure 4-16. Assembling the pull rods
Item
1 Coupling links (right-hand thread) 2 pcs.
2 Locking nuts (right-hand thread) 2 pcs.
3 Locking nuts (left-hand thread) 4 pcs.
4 Pull rods, pole A1-B1 and pole B1-C1 2 pcs.
5 Coupling links (left-hand thread) 2 pcs.
6 Operating levers 3 pcs.
7 Locking screws and square washer 3 pcs.
8 Cylindrical pins 3 pcs.
9 Spring washers 21x36x1,6 8 pcs.
10 Alignment check hole in operating lever
1HSB445410-2 en 7 21
4.11 Inspecting the bolted joints, etc.

• Use a 6 mm diameter pin to check that the operating lever’s alignment check
hole is aligned with the predrilled hole in the mechanism housing.
• Check that all bolted joints are tightened to the correct tightening torque in
accordance with the table below.
Bolted joint Tightening torque (Nm)
Frame 430
Foundation 300-350 (M24) or 500-550 (M30)
Corona ring for post insulator 60

(if applicable)
Operating mechanism 79
Protective tube 79
Circuit-breaker pole 300
Pull rod 300
Density monitor 10
End cover 22,5
Plate 22,5
Cover 9
22 1HSB445410-2 en 7
Assembly Instructions Electrical connections
5. Electrical connections
5.1 Connection of the operating mechanism

Insert the operation and signal cables through the gland plate in the bottom of the
cubicle. Fit the gland plate with a gland suitable for the cable. 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
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 cubicle.
B10015
1
5.2 Assembly of busbars or overhead lines
WARNING
Work must not be carried out on a pressurized 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 flanges 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.
1HSB445410-2 en 7 23
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 paste 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.
5.3 Charging the closing springs

Close the circuit-breaker and start the motor to charge the closing springs (1). The
drive sprocket (2) rotates anticlockwise and pulls up the chain section (3) so that the
spring yoke (4) is lifted and charges the closing springs. The chain section (5) runs
down, while the chain sections (6) and (7) do not move.
Item
1 Closing springs
2 Drive sprocket
3 Chain section
2
4 Spring yoke
6
3
5 Chain section 7
5
6 Chain section
1
7 Chain section
B20027
Figure 5-2. Charging the closing springs
24 1HSB445410-2 en 7
Assembly Instructions Pressurizing the poles
6. Pressurizing the poles
WARNING
All extra equipment, e.g. integrated earthing switches for disconnecting
circuit-breakers, must be mounted on the circuit-breaker before
pressurizing 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
During commissioning, the SF6 gas or the gas mixture needs to be refilled
to the pressure stated on the rating plate. Different gas pressures can occur,
depending on different requirements with regard to the lowest ambient
temperature.
Pressurization takes place directly from a gas cylinder using the gas filling
equipment, ABB article number 1HSB 445439-A for SF6 gas and 1HSB 445439-B
for gas mixture.
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 “Local/Remote/Disconnect” switch in the
“Remote” position.
• Switch on the motor starter so the closing springs are charged.
• Open the terminal blocks to which the density monitor cables are connected
and interrupt the circuit to the interlocking relays.
1HSB445410-2 en 7 25
Pressurizing the poles Assembly Instructions
6.2 Gas filling with SF6 gas
Item
1 Gas cylinder
2 Regulator 3
3
3 Density monitor (old or new
design) 6
9
4 Coupling 5 4 8 7
5 Valve
6 Gas valve on the circuit-breaker
7 Hose
8 Adaptor
9 Nipple with union nut
10 Equal union cross
11 Valve
2
B10016 10 11
Figure 6-1. Gas filling
1. Place the gas cylinder (1) in a protected area.

2. Check the filling pressure and any possible gas mixture stated on the circuit-
breaker rating plate.
3. Fit the regulator (2) on the gas cylinder (1). Set the right filling pressure,
compensated for the temperature as indicated in table 6-1 or table 6-2, on the
regulator.
4. Pull the O-rings off the density monitor (3) with your fingers.
N. B. Do not use a sharp tool.

5. Lubricate the O-rings thoroughly with grease “G” and refit them on the density
monitor.
26 1HSB445410-2 en 7
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 (3) is connected to coupling (4), then valve (11) must be closed.
However, if the density monitor (3) is connected to the equal union cross (10),
then valve (5) should be closed.
7. Connect coupling (4) to the circiut-breaker’s gas valve (6).
8. Connect the gas-filled hose (7) to the coupling (4).
9. Connect the hose (7) to the gas cylinder (1).
10. Go from the circuit-breaker to the protected area and let the gas flow until the
regulator (2) switches off.
11. Wait until the gas temperature has reached the circuit-breaker temperature level
before reading the gas pressure on the density monitor (3). Adjust the pressure
if necessary.
12. Dismantle the hose (7) from the coupling (4) on the circuit-breaker.
13. Close the valve to the density monitor (3).
14. Dismantle the coupling (4) from the circuit-breaker.
15. Release the pressure on the density monitor (3) by opening valve (5) or
valve (11).
16. Dismantle the density monitor (3) from the coupling (4) 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 indicated in table 6-1.
Table 6-1. Filling pressure

Filling pressure in MPa (abs) stated on the rating plate
0,5 0,7 0,5 0,7
Filling pressure read on the gauge
Temp. when MPa bar MPa bar MPa bar MPa bar
filling °C (abs) (abs) (abs) (abs) (overp.) (overp.) (overp.) (overp.)
+40 0.54 5.4 0.75 7.5 0.44 4.4 0.65 6.5
+30 0.52 5.2 0.72 7.2 0.42 4.2 0.62 6.2
+20 0.50 5.0 0.70 7.0 0.40 4.0 0.60 6.0
+10 0.48 4.8 0.66 6.6 0.38 3.8 0.56 5.6
±0 0.46 4.6 0.63 6.3 0.36 3.6 0.53 5.3
-10 0.44 4.4 0.61 6.1 0.34 3.4 0.51 5.1
-20 0.42 4.2 0.58 5.8 0.32 3.2 0.48 4.8
-30 0.40 4.0 0.30 3.0
1HSB445410-2 en 7 27
18. Close the valve on the gas cylinder (1) when all poles have been filled.
19. Disconnect the hose (7) from the gas cylinder (1) and release the pressure in the
regulator (2) by pressing in the non-return valve.
20. Release the regulator’s adjustment pressure by turning the adjuster valve so
that the next C.B. to be assembled is not filled with the wrong pressure.
N. B. When the density monitor (1) is finally fitted, tighten the union nut (2)
with a tightening torque of 10 Nm as indicated in Figure 6-2.
Item
1 Density monitor
2 Union nut
TIGHTENING TORQUE
10 Nm
B10017 1 2
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.
28 1HSB445410-2 en 7
6.3 Gas filling with mixed gas

A mixture of SF6 and either N2 or CF4 gas is used at low temperatures, to prevent
condensation of the SF6 gas. Check the rating plate if this is applicable.
N. B. When filling with mixed gas, always fill the SF6 gas first.
The proportions of gas for pressurization should be according to the rating plate.
Example.
For a circuit-breaker with a filling pressure of 0.70 MPa abs (+20 °C), first fill
0.52 x 0.7 = 0.36 MPa abs (+20 °C) SF6 gas and then N2 or CF4 gas to
0.70 MPa abs (+20 °C).
N. B. When reading from the precision gauge, correct the filling pressure be
depending on the temperature as indicated in table 6-2.
Gas filling otherwise takes place as indicated in chapter 6.2.
Table 6-2. Filling with mixed gas

Refilling pressure in MPa (abs) stated on the rating plate.
SF6 Total filling SF6 Total filling
pressure pressure
Refilling pressure read on the gauge
Temp. when
MPa bar MPa bar MPa bar MPa bar
gas filling
(abs) (abs) (abs) (abs) (overp.) (overp.) (overp.) (overp.)
°C
+40 0.39 3.9 0.75 7.5 0.29 2.9 0.65 6.5
+30 0.37 3.7 0.72 7.2 0.27 2.7 0.62 6.2
+20 0.36 3.6 0.70 7.0 0.26 2.6 0.60 6.0
+10 0.34 3.4 0.66 6.6 0.24 2.4 0.56 5.6
±0 0.33 3.3 0.63 6.3 0.23 2.3 0.53 5.3
-10 0.32 3.2 0.61 6.1 0.22 2.2 0.51 5.1
-20 0.30 3.0 0.58 5.8 0.20 2.0 0.48 4.8
-30 0.29 2.9 0.57 5.7 0.19 1.9 0.47 4.7
1HSB445410-2 en 7 29
6.4 Gas monitoring system

• Secure the protective tube (1) to the frame using the pipe clips (2) and bolts,
nuts and washers (3).
• Fit a bushing (4) on each cable to be pulled through the protective tube and pull
through the cable.
• Also fit a bushing to the other end of the protective tube.
• Connect the cable to the density monitor’s terminal blocks.
• Drill three 23 mm diameter holes in the gland plate (5) on the bottom of
the operating mechanism and fit cable glands (6) with sealing washers (7)
and nuts (8) in the holes.
• Insert the cables through the cable glands in the operating mechanism and
connect them to the terminal blocks as stated on the applicable operating
mechanism’s circuit diagram.
• Tighten the cable glands (6) to secure the cables.
• Secure the cables to the frame’s leg using pipe clips (9) and nuts, bolts and
washers (10).
N. B. The cable ends for the density monitor should be sufficiently long so that
the density monitor can be disconnected from the non-return valve
without having to disconnect the cable.
Item
1 Protective tube
2 Pipe clip

Nuts M6 5 pcs.
Washers 6.4x15x1.5 10 pcs.
Retaining washers 5 pcs. 10 9
4 Bushing
5 Gland plate
6 Cable gland
7 Sealing washer
8 Nut
9 Pipe clips 4 pcs.

Nuts M5 4 pcs. 4
7 5
Washers 5.3x10x1 8 pcs. 6 1 2
B10078 3
Figure 6-3. Gas monitoring
30 1HSB445410-2 en 7
6.5 Leakage test

Perform a leakage test using a leak detector around the density monitor’s connections.
6.6 Final inspection of the pull rod system

Before performing a final inspection of the pull rod system, the circuit-breaker
should be filled with gas to the nominal pressure.
1. Switch the circuit-breaker to Closed position from a well protected area.
2. Tighten the nuts (1) moderately.
3. Switch the circuit-breaker to Open position from a well protected area.
Item Pole A3 Pole A2 Pole A1

Closed
1 Locking nuts position
(right-hand thread)
2 Alignment check hole

in operating lever
3 Locking nuts
(left-hand thread)
Open
3 1 position
3 1
2
2
Figure 6-4. Final inspection of the pull rod system
4. Use a 6 mm diameter pin to check that the alignment check hole (2) aligns with
the predrilled hole in the mechanism housing. Any requisite adjustment is done
by loosening the locking nuts and turning the pull rod. Tighten the locking nuts
(3) on all poles with a tightening torque of 300 Nm.
TIGHTENING TORQUE
300 Nm
5. Check that the pull rods are threaded past the alignment check holes in the
coupling links.
1HSB445410-2 en 7 31
6. Switch the circuit-breaker to Closed position from a well protected area.

7. Tighten the locking nuts (1) on the poles A1 and B1 with a tightening torque of
300 Nm.
TIGHTENING TORQUE
300 Nm
8. Switch the circuit-breaker Open, Close and Open again from a protected area.
9. Complete by setting the operating switch in the operating mechanism in Open
position.
6.7 Fitting the plate and cover

• Fit the end cover (1) using the bolts, nuts and washers (2) on the mechanism
housing for the C1-pole. Tighten the bolts with a tightening torque of 22,5 Nm.
• Fit all plates (3) with Close and Open signs using bolts and washers (5).
Tighten with a tightening torque of 22,5 Nm.
• Then fit all covers (4) using
bolts and washers (5). Tighten
with a tightening torque of
9 Nm.
Item
1 End cover

Washers 13x24x2.5 8 pcs. 2
Nuts M12 4 pcs.
1
3 Plate
4 Cover

Washers 8.4x16x1.6 9 pcs.
TIGHTENING TORQUE
9 and 22,5 Nm
4 5 3
B10137
Figure 6-5. Fitting the plate and cover
32 1HSB445410-2 en 7
Assembly Instructions Commissioning
7. Commissioning
Before commissioning the circuit-breaker, carry out all the checks as indicated in
“Checklist for assembling and commissioning 1HSB445410-100” and fill in the
operating values for the installation.
1HSB445410-2 en 7 33
Operating values Assembly Instructions
8. Operating values
The operating values in this instruction apply to SF6 circuit-breaker
HPL 72.5-300 B1 with operating mechanism BLG 1002A.
8.1 Times
Closing time < 65 ms
Opening time coil I 20 ± 3 ms
Opening time coil II 20 ± 3 ms
Close-Open time(1) max 55 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. 20 s
Operating voltage opening coil I V (according to the rating plate)
Operating voltage opening coil II V (according to the rating plate)
Operating voltage closing coil I V (according to the rating plate)
Operating voltage closing coil II V (according to the rating plate)
8.3 Resistance
Main circuit resistance per breaking chamber max 38μΩ.
8.4 Contact stroke

Main contact stroke is 210 ±4 mm.
34 1HSB445410-2 en 7
Circuit-breaker Unit
SE-771 80 LUDVIKA 2006-10-04
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
SF6 Circuit-Breaker Circuit-Breakers HPL and LTB
Assembly of damping element

1HSB445409-4 en -

ment.
Article number:
1HSB445409-4 en -
Approval date:
2004-09-14
Assembly of damping element
LIST OF CONTENTS
1. General ................................................................................ 1
1.1 Design of damping element ............................................................1
2. Assembly of the damping elements to the foundation... 2
1HSB445409-4 en - i
Assembly of damping element General
1. General
This Assembly instruction applies to damping elements used for circuit-breaker and
bypass switchgear.
The damping elements are used in areas where there is a risk of earthquakes. The
dampers are used to prevent damages on the installed switchgear.
The dampers are fixed to the foundation bolts and mounted on an adapter plate
which have a hole pattern that suits a standard circuit-breaker frame.
1.1 Design of damping element

The spring washers (1) in the damping element
are delivered adjusted and measured.
The damping housing is delivered with the
1
internal surfaces well greased with grease “K”,
ABB art no. 1263 0011-102.
The damping elements do not need any further
overhaul during its lifetime.
2
Item
1 Damping housing
2 Spring washers 55 pcs.

3
3 Adjustment washers 10 pcs.

4
4 Friction ring 1 pcs.
5
5 Cone 1 pcs.
6 Retaining ring 1 pcs.
7 Guide cone 1 pcs.

7 6
8 Guide 1 pcs.
Figure 1-1. Design of the damping element
1HSB445409-4 en - 1
Assembly of the damping elements to the Assembly of damping element
2. Assembly of the damping elements to the foundation

1. Adjust the nuts (1) to the same level using the spacer washers (2). Tighten the
nuts (1) with a tightening torque of 350 Nm.
TIGHTENING TORQUE
350 Nm
2. Place the adapter plate (3) on the the nuts (2).

3. Assemble the guide cones (4) and the guides (5) on the foundation bolts. Check
that the guides (5) are in the right position. Grease the sliding surface between
the guide cones (4) and the guides (5) with grease “K”, ABB art no.
1263 0011-102.
4. Tighten the guide cones (4) with a tightening torque of 350 Nm. The
foundation bolts must not be higher than the guide cones (4).
TIGHTENING TORQUE
350 Nm
Item
8
1 Nut M24 (not supplied) 4 pcs.
2 Spacer washers (not supplied)
3 Adapter plate 1 pcs.

6
4 Guide cone 4 pcs.
5 Guide 4 pcs.
6 Damping element 4 pcs.

Washers 13x24x2,5 24 pcs.
10
8 Frame
5
Washers 31x56x4 8 pcs. 3
Nuts M30 4 pcs.
7
10 Washers 4 pcs.
4
9 2 1
Figure 2-1. Assembling the damper on the adapter plate
2 1HSB445409-4 en -
Assembly of damping element Assembly of the damping elements to the
5. Lift up the adapter plate (3) against the guide cones/guides. Use a piece of
wood for help.
6. Assemble the damping elements (6) to the adapter plate (3) using the bolts and
washers (7). Check that the guides (5) are in the right position in the lower part
of the damping elements (6). Tighten the bolts crosswise and by hand to avoid
bending. Tighten the bolts with a tightening torque of 79 Nm.
7. Assemble the frame (8) on the adapter plate (3) using the bolts and washers (9).
Tighten the bolts with a tightening torque of 350 Nm.
8. The correct pre-tension of the spring washers inside the damping elements (6)
is reached automatically when the bolts (7) are tightened.
1HSB445409-4 en - 3
ABB Power Technologies AB 1HSB445409-4 en -
Circuit-Breaker Division
SE-771 80 LUDVIKA 2004-09-14
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
SF6 Circuit-Breaker Circuit-breakers HPL and LTB
Check list, assembly

1HSB445410-100 en 4

ment.
Article number:
1HSB445410-100 en 4
Approval date:
2004-08-20
Check list, assembly Check list for assembly and commissioning
1. Check list for assembly and commissioning

The following points should be checked and the check list completed before the
circuit-breaker is commissioned and taken into service. The check list should 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 check hole in the
operating lever should align with the predrilled hole in the mechanism housing.
The pull rods should be screwed past the alignment check holes in the coupling
links.
Operating mechanism
4. Make an visual inspection to check that oil from the oil dampers 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 operation from a protected area
in connection with gas filling and test operations. Set the
“Local/Remote/Disconnect” switch to “Remote”.
7. Connect the gas filling equipment for gas filling.
8. Fill each pole with gas one after the other from a protected area and perform an
operational test three times as indicated in in the assembly instructions.
9. Check the heating elements.
10. Make sure that the thermostat, if provided, is set to 10°C 1.
1. Other thermostat settings may occur, according to customers request.
1HSB445410-100 en 4 1
Check list for assembly and commissioning Check list, assembly
Operating values
11. Compare the operating values of the circuit-breaker with the applicable
operating values for the circuit-breaker in the Assembly Instructions and note
the measured values in the table below.
CAUTION
Open-Close operations should not be performed without a time 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 indicated above have been completed, the circuit-breaker can
be commissioned and taken into service.
2 1HSB445410-100 en 4
SE-771 80 LUDVIKA 2004-08-20
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
SF6 Circuit-Breaker Circuit-breakers HPL
Operating and Maintenance

1HSB445409-100 en 8

ment.
Article number:
1HSB445409-100 en 8
Approval date:
2005-08-19
LIST OF CONTENTS
1. General ................................................................................ 1
1.1 Warning text ....................................................................................1
1.2 Warning ...........................................................................................2
2. Preventive 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................................................................17
1HSB445409-100 en 8 i
FIGURES
Figure 2-1. Number of operations versus short-circuit current .........................4
1HSB445409-100 en 8 iii
Operating and Maintenance General
1. General
This Operating and Maintenance Instruction applies to SF6 circuit-breaker
HPL with operating mechanism BLG 1002A.
The instruction contains recommendations for the care and guidelines for the
maintenance of high-voltage circuit-breakers HPL. The instructions are divided into
three parts:
• Inspection intervals
• Instructions for preventive maintenance of circuit-breakers
• Instructions for preventive maintenance of operating mechanisms
Periodic maintenance must be carried out at the time or operation intervals
specified.
The equipment must be overhauled in accordance with specified criteria, e.g. after a
certain number of operations. Overhaul of the equipment must be carried out by
authorised service personnel.
1.1 Warning text

DANGER
in death or serious personal injury.
WARNING
in death or serious personal injury.
CAUTION
injury.
N.B. is used for hazards that may only result in damage to the installation.
1HSB445409-100 en 8 1
General Operating and Maintenance
1.2 Warning
WARNING
Circuit-breaker with pressurized porcelain insulators.
Mechanical damage on the porcelain can cause it to explode with the
WARNING
WARNING
The standard operating sequence is O - 0.3 s - CO - 3 min.- CO. The time between
2 1HSB445409-100 en 8
Operating and Maintenance Preventive maintenance
2. Preventive maintenance
2.1 Circuit-breaker
2.1.1 Circuit-breaker service life

Assuming that the recommended inspection intervals have been carried out and the
appropriate measures have been implemented, the HPL circuit-breaker will have a
service life exceeding 30 years or 10,000 operations.
The following points will ensure a long service life:
1. Contact erosion of the arcing contacts is limited
2. Each breaking unit is equipped with an absorption agent with a 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 O-rings.
Generally speaking, there are only two reasons to open the breaking unit:
– if the number of interruptions x short-circuit current (kA) is approaching
the curve on Figure 2-1.
or...
– if the number of operations for line-, reactor-, or capacitor switching, as
well as switching the load current 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 instructions 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:
Σ n x I1.8 = 20,000
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 to the power of 1.8. For example:
20x301.8+30x201.8+40x101.8=18,230.
1HSB445409-100 en 8 3
Preventive maintenance Operating and Maintenance
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 of a HPL circuit-breaker can manage before the metal losses due to
burning becomes so great that they must be replaced.
Number of interruptions
5,000
2,000
1,000
500
200
100
50
20
kA
2 3 4 5 10 20 30 40 50 63
Short-circuit current
Figure 2-1. Number of operations versus 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 a set of contacts that can be wired to
give an alarm in the event of abnormal leakage. Level 1 gives an alarm signal, while
Level 2 is used for blocking purpose.
N.B. A new or overhauled circuit-breaker should be checked for tightness by

reading the density monitors after approx. 1 month and then at 1-2 year
intervals in connection with the regular visual inspection.
4 1HSB445409-100 en 8
Operating and Maintenance Preventive maintenance
2.1.4 Cleaning the outside

Porcelain insulators must be cleaned from salt and other contamining deposits at the
same time as the cleaning of the other insulators in the substation. The time interval
for cleaning depends on the local conditions, i.e. the amount of atmospheric
pollution.
N.B. All HPL circuit-breakers with porcelain insulators 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.
Composite insulators do not normally require any cleaning. Solvents or water-
hosing with high pressure may damage the silicone surface of the insulator.
2.1.5 Lubrication of the circuit-breaker

Use only the lubricants recommended in the Lubricants instructions. This is
particularly important in cold climates with temperatures below -25°C.
The circuit-breaker bearings are permanently lubricated with Grease “G”1 and do
normally not need lubrication except during major overhauls.
See the Overhaul Instructions applicable for the circuit-breaker for lubrication of
O-rings.
The worm gear in the drive unit is lubricated with Grease “M”1.
2.1.6 Rust protection

The closing and opening springs are rust protected 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 charged closing springs always involves a certain risk. It is therefore
important that the safety directives and instructions in the Overhaul instructions for
the operating mechanism 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 ventilation valves are clean. Replace them if they are
dirty.
1. See the document “Lubricants” 1HSB445409-1 for the names of suppliers and brands for
grease and oils.
1HSB445409-100 en 8 5
Preventive maintenance Operating and Maintenance
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 mechanisms and the worm gear in the drive unit. These should be
lubricated after 5,000 operations. The sliding surfaces of the spring fork and damper
must be lubricated with Grease “G”1 and the chains with Oil “A”1 in connection
with an overhaul.
The bearings in the operating mechanism are lubricated with Grease “G”1 and will
normally not need to be lubricated except during major overhauls.
The closing and opening dampers are filled with Oil “S”1.
2.2.4 Rust protection

Certain steel parts in the operating mechanism have manganese phosphated surface
treatment and are then dipped in a rust protection oil. This applies to latches, gear
wheels, parts of the link system, etc.
The closing and opening springs are rust protected by painting with two-component
paint.
The operating mechanism is equipped with anti-corrosion vapour phase inhibitors.
These inhibitors are only for protection during transport.
Despite the extensive rust protection treatment, minor corrosion can occur after
some years especially if the circuit-breaker is located in a strongly corrosive
environment. Rust stains should be cleaned and new rust protection applied with a
brush or spray.
The recommended rust inhibitor is Grease “G”1or Valvoline Tectyl 506
(ABB Article No. 1241 0011-108).
N.B. Valvoline Tectyl 506 forms a waxy protective skin when it dries and should
therefore 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
also must be protected from sunlight to prevent them drying. Seals have a limited
shelf life. Support frames can be stored outdoors.
1. See the document “Lubricants” 1HSB445409-1 for the names of suppliers and brands for
greases and oils.
2. Approved storage space:
roof, solid foundation, relative humidity less than 50%, temperature + 20° C (± 10° C)
6 1HSB445409-100 en 8
Operating and Maintenance Inspection intervals
3. Inspection intervals
Inspection of HPL circuit-breakers with operating mechanism BLG 1002A:
Important checkpoints, acceptable tolerances, certain functional values for
adjustments, and recommended inspection intervals can be found in the following
inspection chart.
The specified inspection intervals should be considered as recommended guide
values, and may be increased or decreased depending on the local conditions.
In corrosive or polluted air and in climates with a high relative humidity, it can be
necessary to halve the inspection intervals.
1HSB445409-100 en 8 7
Inspection intervals Operating and Maintenance
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 15 years or 5,000 mech. 1) b1 b2

CLOSE/OPEN
operations.
• General check of circuit-
breaker and operating
mechanism
• Thermovision check
C Overhaul
• Breaking chambers c1 c2
• Line and transformer ΣnxI1.8 =20,000 2)

circuit-breakers
• Capacitor, reactor and filter

circuit-breakers
- Not synchronized 2,500 CLOSE/OPEN op. 2)
with el. load.
- Synchronized 5,000 CLOSE/OPEN op. 2)
with el. load.
• Major overhaul 30 years or 10,000 mech. 1) d1 c2

CLOSE/OPEN
operations.
Explanations:
1. Mech. CLOSE/OPEN operations. = Mechanical Close-Open operations.
2. CLOSE/OPEN op. with el load = Close-Open operations with electrical
loading.
8 1HSB445409-100 en 8
Status of circuit-breaker during work:

a1) Circuit-breaker in service.
b1) Closing springs uncharged, circuit-breaker open, disconnected and earthed. If
thermovision measurement is included, it should be done at normal load
before the circuit-breaker is disconnected.
c1) Closing springs uncharged, circuit-breaker open, disconnected and earthed.
Poles/breaking units dismounted and transported to workshop.
d1) Closing springs uncharged, 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 / Tools/ Instructions
1.
Circuit-breaker 1-2 years. Visual inspection.
Check external cleanliness, heating
element function, gas pressure,
ventilation valves and drainage holes.
No special tools needed.
See chapter 2.1.3 and chapter 2.1.4
and Overhaul instructions for the
Operating mechanism.
1HSB445409-100 en 8 9
3.3 Maintenance category B
1.
Circuit-breaker 15 years or 5,000 mech. CLOSE/ Visual inspection.
OPEN operations. Check external cleanliness, heating
element function, gas pressure,
ventilation valves and drainage holes.
No special tools needed.
See chapter 2.1.3 and chapter 2.1.4
and Overhaul instructions for the
2.
Operating mechanism 15 years or 5,000 mech. CLOSE/ Visual inspection.
OPEN operations. Look for loose bolts and nuts, oil leaks
from dampers.
If leakage has occurred, replace the
complete damper.
No tools necessary.
See Overhaul instructions for the
3.
Rating plates 15 years or 5,000 mech. CLOSE/ Make a note of the serial number.
OPEN operations.
4.
Operation counter 15 years or 5,000 mech. CLOSE/ Make a note of the number of
OPEN operations. operations.
5.
SF6-gas
• Filling of gas (if 15 years or 5,000 mech. CLOSE/ Gas filling equipment.
necessary) OPEN operations. See Assembly instructions for the
circuit-breaker.
• Dew point at normal Dew point maximum - 5° C at rated
pressure in circuit- filling pressure and + 20° C
breaker. temperature.
6a.
Porcelain insulators 15 years or 5,000 mech. CLOSE/ Visual inspection.
OPEN operations. Spray and rub the insulators clean.
Check cementing, bolts and nuts.
Spray equipment, clothes and
wrenches.
See chapter 2.1.4.
10 1HSB445409-100 en 8
6b.
Composite insulators 15 years or 5,000 mech. CLOSE/ Visual inspection.
OPEN operations. Check for damages to the insulators.
See chapter 2.1.4.
7.
Main current circuit 15 years or 5,000 mech. CLOSE/ Check resistance of circuit-breaker.
OPEN operations. Resistance bridge, test current min.
200 A DC.
Resistance value as specified in
applicable Assembly instructions for the
circuit-breaker.
Higher values allowed for frequent
operation with small currents (≤400 A).
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.
8.
Temperature rise 15 years or 5,000 mech. CLOSE/ Thermovision measurement.
OPEN operations. To be carried out at full load before the
circuit-breaker is taken out of service.
Check 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.
1HSB445409-100 en 8 11
9a.
Contact system
• Opening position 15 years or 5,000 mech. CLOSE/ Inspection of alignment check holes in
OPEN operations. operating lever and mechanism
housing.
See Assembly instructions for the
circuit-breaker.
9b.
Operating
characteristics
• Opening time 15 years or 5,000 mech. CLOSE/ Measurement with electronic timer.
• Closing time OPEN operations. Nominal operating voltage.
• Close-Open time For times, see Assembly instructions
• Phase discrepancy for the circuit-breaker.
• Auxiliary switches Max. phase discrepancy between
phases: at closing 4 ms; at opening 3 ms.
• Contact travel
Max. discrepancy between breaks in
• Contact damping
the same phase: at closing 3 ms; at
opening 2 ms.
See Overhaul Instructions for the
12 1HSB445409-100 en 8
10a.
Operation availability
• Pull rod system 15 years or 5,000 mech. CLOSE/ Check the tightening torque of nuts in
OPEN operations. the pull rod system.
Wrench size: 36 mm.
Torque: 300 Nm.
circuit-breaker.
• Safety of operation 15 years or 5,000 mech. CLOSE/ Measurement of minimum operating

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 device 15 years or 5,000 mech. CLOSE/ Check the anti-pumping function.
OPEN operations. The circuit-breaker in open position, the
operating mechanism charged, “Close”
and “Open” impulse given
simultaneously (keep the close button
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 remains. Lowest
operating voltage of the relay is
measured (85% of nominal).
10b.
Motor current 15 years or 5,000 mech. CLOSE/ Check the carbon on the motor/motors.
OPEN operations. If it is below 10 mm, change carbon.
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 vary up
to 30% from the value measured at
routine test.
The motor should be able to charge the
springs at min. 85% of nominal voltage
(acc. to IEC).
1HSB445409-100 en 8 13
10c.
Damper 15 years or 5,000 mech. CLOSE/ Check the oil-level or record the
OPEN operations. damping during operation alternatively.
Record the damping during operation
by using a circuit-breaker analyzer with
transducers connected to:
• main shaft of the circuit-breaker
mechanism when checking the
opening damper
• main shaft (cam shaft) of the
operating mechanism when
checking the closing damper.
These measurements should only be
carried out by specially trained
personnel.
10d.
Catch gears 15 years or 5,000 mech. CLOSE/ Visual control of the adjustment.
OPEN operations. Play of gaps in the catch gears acc. to
Overhaul instructions for the operating
mechanism.
Greasing of shafts and catch surfaces
with Grease “L” acc. to Lubricant
instructions.
Change the signal from coil 1 to coil 2.
10e.
Coils 15 years or 5,000 mech. CLOSE/ The resistances of coils and coil
OPEN operations. currents are allowed to differ +/- 10%
from the value measured at routine test.
10f.
Mechanical interlocking 15 years or 5,000 mech. CLOSE/ In “Open” position, the distance
OPEN operations. between the interlocking arm and the
interlocking disc should be min. 2 mm.
In “Close” position, there must be full
contact between the arm and disc (no
gap is permitted).
10g.
Heating elements 15 years or 5,000 mech. CLOSE/ Check the resistance.
OPEN operations. If applicable, check signal for loss of
power.
14 1HSB445409-100 en 8
10h.
Central control cubicle 15 years or 5,000 mech. CLOSE/ Check the resistance.
(if applicable) OPEN operations. Small cubicle:
48 W, 110 V R = 330 Ohms +/- 10%
48 W, 220 V R = 1000 Ohms +/- 10%.
Medium or large cubicle:
140 W, 110 V R = 86 Ohm +/-10%
140 W, 220 V R = 346 Ohm +/- 10%.
10i.
Thermostat 15 years or 5,000 mech. CLOSE/ If applicable, check that the thermostat
OPEN operations. is adjusted to requested value.
See Checklist, assembly HPL and LTB.
10j.
Terminal blocks 15 years or 5,000 mech. CLOSE/ Check tightening of screws or clamps.
OPEN operations. See Overhaul instructions for the
10k.
Direct on line motor 15 years or 5,000 mech. CLOSE/ If applicable, check signal for loss of
starter OPEN operations. power.
11.
Tightness of SF6-gas
• Density monitoring 15 years or 5,000 mech. CLOSE/ Check the density switches and
OPEN operations. signal/blocking circuits.
Accuracy 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).
circuit-breaker.
12.
Blocking relays 15 years or 5,000 mech. CLOSE/ The relays should close when a density
OPEN operations. switch is pulled out from a pole
pressurized to filling pressure.
1HSB445409-100 en 8 15
13.
Corrosion, 15 years or 5,000 mech. CLOSE/ Visual inspection.
rust protection OPEN operations. Particularly check protected
components in unheated
compartments, pull rod system, clevis
couplings, springs.
Rust stains polished off and treated
with rust protection.
See chapter 2.2.4 and Overhaul
instructions for the Operating
mechanism.
14.
Greasing 15 years or 5,000 mech. CLOSE/ Grease the the worm gear and shafts in
OPEN operations. latches in the operating mechanism
with grease “M”.
Lubricate sliding surfaces of the springs
bridge in the operating mechanism with
Grease “M” and chains with Oil “A”.
See chapter 2.1.5, chapter 2.2.3 and
Overhaul instructions for the Operating
mechanism.
15.
Interlocking devices
(Only applicable for 15 years or 5,000 mech. CLOSE/ Visual inspection.
disconnecting circuit- OPEN operations. With the disconnecting circuit-breaker
breakers) in “Open” position, carry out a check
according to Check list, Interlocking.
See also Operating instructions,
Disconnecting function.
Lubricate the joint between the blocking
disc and the rod piston on the operating
mechanism AD100 with grease “G”.
16.
Tightening torque 15 years or 5,000 mech. CLOSE/ Check the tightening torque on screw
OPEN operations joints.
Tightening torques acc. to Assembly
instructions and Overhaul Instructions.
Tightening torque for earthing 79 Nm.
17.
Operation 15 years or 5,000 mech. CLOSE/ Operating test, if possible in
OPEN operations. combination with measurement of
operating times (incl. Close-Open
times).
circuit-breaker.
16 1HSB445409-100 en 8
3.4 Maintenance category C
To be inspected Inspection intervals Measures / Instructions / Tools
1.
Overhaul of breaking
chambers
• Line and transformer ΣnxI1.8 =20,000 Gas evacuated, poles/breaking units
circuit-breakers dismounted and transported to a clean
workshop.
• Capacitor, reactor and Porcelain lift off, contacts and PTFE-
filter circuit-breakers parts replaced with new ones.
- Not synchronized 2,500 CLOSE/OPEN operations See Overhaul instructions for the
with el. load. circuit-breaker.
- Synchronized 5,000 CLOSE/OPEN operation with Standard tools, close fitting dust mask,
el. load. long sleeved overall, protective plastic
or rubber gloves.
• All kinds of service Alarming result at diagnostic test. See Overhaul instructions for the
circuit-breaker.
2.
Major overhaul of 30 years or 10,000 mech. Disassembly of the poles and
complete circuit- CLOSE/OPEN operations. mechanisms. New contacts and PTFE-
breaker and operating components are to be mounted.
mechanism 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-breakers, see Overhaul
instructions for the circuit-breaker.
Overhaul of the operating mechanism
only 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%.
1HSB445409-100 en 8 17
SE-771 80 LUDVIKA 2005-08-19
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
Lubricants
1HSB445409-1 en 6

ment.
Article number:
1HSB445409-1 en 6
Approval date:
2006-08-24
Lubricants
LIST OF CONTENTS
1. General ................................................................................ 1
1.1 Safety instructions...........................................................................1
2. Lubricants ........................................................................... 3
2.1 Oil....................................................................................................3
2.2 Grease..............................................................................................4
1HSB445409-1 en 6 i
Lubricants General
1. General
This instruction is a guide to the selection of oils and lubricants for circuit-breakers
HPL and LTB with operating mechanism. It also covers earthing switches and
disconnectors.
A description is given below of the application areas as well as trade names and
suppliers.
1.1 Safety instructions

Protective gloves, long-sleeved overall and eye protection must be worn when
handling lubricants and oils.
All spillage should be covered with an absorption agent and taken care of as
chemical waste according to applicable local directives.
1HSB445409-1 en 6 1
Lubricants Lubricants
2. Lubricants
2.1 Oil
Oil “A”
Thin, fully synthetic lubricating oil for precision components in the operating
mechanism and circuit-breaker. Also used for lubrication of bearings that can not 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”
Circuit-breaker oil with a low viscosity ~ 6.0 cSt at 20°C. Also used as oil in
dampers. Damper with the letter “s” punched on the cover should be filled with oil
“S”.
Oil “S”
Silicone oil intended for dampers in heavy-duty operating mechanisms, type BLG.
Only dampers with the letter “s” punched on the cover should 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
1HSB445409-1 en 6 3
2.2 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 O-rings and crevice corrosion protection on breakers type
HPL and for moving contacts (opening contacts) for disconnectors.
Grease “K”
Molykote grease for lubricating pins in link gears and earthquake dampers.
Grease “N”
For lubricating moving contacts and puffer cylinders in SF6 circuit-breakers. The
grease should be applied in a very thin layer on the sliding surfaces of the contacts.
Grease “L”
Low-temperature grease particularly suitable for lubricating precision components,
for example latch mechanisms in operating mechanisms that should work in severe
cold climates.
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.
Also reduces electrical resistance in the lubrication point, and therefore suitable for
electrical joints and for lubricating contacts on earthing switches and disconnectors.
Grease “P”
Vaseline for coating contact surfaces on fixed joints on the inside of the breaking
unit.
Grease “S”
Fluorosilicone 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) for disconnectors, silver-plated
contacts and brushed aluminium surfaces on fixed joints outdoors.
4 1HSB445409-1 en 6
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-X 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
1HSB445409-1 en 6 5
SE-771 80 LUDVIKA 2006-08-24
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
SF6 Circuit-Breaker Operating mechanism
BLG 1002A
Overhaul Instructions
1HSB515409-100 en 8

ment.
Article number:
1HSB515409-100 en 8
Approval date:
2005-08-12
1HSB515409-100en8
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........................................................................ 8
4.1 General ............................................................................................8
4.2 Preparations for maintenance........................................................11
4.3 Cleaning ........................................................................................12
4.4 Corrosion.......................................................................................12
4.5 Lubrication ....................................................................................13
4.6 Heating element ............................................................................14
4.7 Drive unit ......................................................................................15
4.8 Catch gear .....................................................................................16
4.9 Damper..........................................................................................17
4.10 Link system and spring battery .....................................................19
4.11 Auxiliary contact...........................................................................19
4.12 Terminal blocks.............................................................................21
4.13 Manual closing and opening operations........................................22
1HSB515409-100 en 8 i
FIGURES

Figure 4-2. Interlocking mechanism ..................................................................9
Figure 4-3. Releasing the interlocking .............................................................10
Figure 4-4. Control panel ................................................................................. 11
Figure 4-5. Heating element ............................................................................14
Figure 4-6. Drive unit ......................................................................................15
Figure 4-7. Catch gear .....................................................................................16
Figure 4-8. Checking the clearance .................................................................16
Figure 4-9. Closing and Opening damper ........................................................17
Figure 4-10. Damping curve, Closing damper ..................................................18
Figure 4-11. Damping curves, Opening damper ................................................18
Figure 4-13. Auxiliary contact ...........................................................................19
Figure 4-14. Time measurement, contact travel ................................................20
Figure 4-15. Example of electrical equipment ...................................................21
Figure 4-16. Manual closing of the operating mechanism ................................22
Figure 4-18. Fitting the blocking beams ............................................................23
Figure 4-19. Interlocking, circuit-breaker open, closing springs uncharged .....24
Figure 4-20. Operating mechanism, manual closing operation .........................25
Figure 4-21. Manual opening operation ............................................................26
Figure 4-23. Fitting the blocking beams ............................................................27
Figure 4-24. Interlocking, circuit-breaker closed, closing springs uncharged ...28
Figure 4-25. Operating mechanism, slow manual operation .............................29
Figure 4-26. Check dimension, closing springs .................................................30
1HSB515409-100 en 8 iii
Overhaul Instructions General
1. General
This Overhaul Instruction applies to the spring operating mechanism BLG 1002A
intended to operate circuit-breakers with integrated opening springs. Information
regarding overhaul is provided in this instruction.
Preventive maintenance and overhaul work on the operating mechanism
BLG 1002A should be carried out at regular intervals.
• Visual inspection at intervals of 1-2 years.
• Lubrication after 15 years or 5,000 mechanical Close-Open operations.
• Preventive maintenance after 15 years or 5,000 mechanical Close-Open
operations.
• Overhaul after 30 years or 10,000 mechanical Close-Open operations.
Overhauling and repair work may only be carried out by service personnel
authorised by ABB Power Technologies AB.
1HSB515409-100 en 8 1
Overhaul Instructions Safety
2. Safety
2.1 Warning text

DANGER
WARNING
CAUTION
injury.
N.B. used for hazards that may only result in damage to the installation.
1HSB515409-100 en 8 3
Safety Overhaul Instructions
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 pressurized porcelain insulators.
Mechanical damage to the porcelain can cause it to explode with the
WARNING
WARNING
Do not operate the mechanism unloaded!
Operations should take place only when the mechanism has been
closing operations should not be less than 1 minute when circuit-breakers and relay
systems are tested with more than 3 closing operations.
4 1HSB515409-100 en 8
WARNING
The 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 next to the work
place. If work should take place next
to live equipment, the safety distance
in the applicable safety regulations
must be observed.
Working on ladders and platforms. Work should take place in

accordance with applicable safety
regulations. Work during difficult
weather conditions that requires
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 heater voltage.
current can be routed to the
operating mechanism.
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 both the high voltage side. Uncharge the
opening and the 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 drive shaft on
with the catch components. the operating mechanism backwards
by hand (see chapter 4.13, Manual
closing and opening operations). For
reasons of safety the closing springs
must be uncharged during
transportation as well as during
assembly and storage.
Working next to pressurized Work next to the insulators of the

insulators. circuit-breaker that may result in
The normal working pressure is up to damage to the porcelain must not
0.8 MPa (abs). Damage to the take place until the gas has been
porcelain can result in splintering. reduced to max. 0.125 MPa (abs.)
pressure.
1HSB515409-100 en 8 5
Overhaul Instructions Maintenance, general
3. Maintenance, general
All required equipment should be available before work is started so that
maintenance work can be carried out in the most effective way.
The following equipment is required.
3.1 Tools
• A normal set of tools including torque wrenches (9-550 Nm).
3.2 Cleaning equipment

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

• Lubricants and oils, see the Lubricants Instruction 1HSB445409-1 for suppliers
and trade names.
Grease “G”: ABB Art. No. 1171 4014-407.
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.
3.4 Test equipment

• Equipment to record damping curves and operating times.
(e.g. Programma or ABB SA10).
1HSB515409-100 en 8 7
Maintenance Overhaul Instructions
4. Maintenance
4.1 General
The Operating and Maintenance Instructions for the circuit-breaker should be read
before work on the circuit-breaker is started and followed while work is in progress.
WARNING
connected and adjusted with the associated pressurized circuit-breaker.
The components of the operating mechanism are housed in a cubicle, which also
contains a control panel. The roof and doors of the cubicle can be removed to
facilitate service and overhaul procedures.
Item 1
1 Drive unit Ej Blockerad
2 Operating mechanism
3 Control panel
4 Spring battery 4
5
5 Heater element
(behind protection 3
plate)

cover removed
• Measure all operating times and note them down. If the measured values
correspond to the specified values for the circuit-breaker, then only a visual
inspection, cleaning and lubrication are required.
8 1HSB515409-100 en 8
Overhaul Instructions Maintenance
4.1.1 Mechanical interlocking

The interlocking mechanism prevents a closing operation from being carried out if
the circuit-breaker is already in the closed position. It also prevents closing if the
closing springs are uncharged or not fully charged. This can occur e.g. if the closing
catch gear is activated by hand or if a mechanical failure occurs in the catch gear.
• Check that the gap between the interlocking arm (2) and the circumference of
the interlocking disc (3) is 2 mm as indicated in Figure 4-2.
• Check that the closing circuit is closed when the arm rests on the circumference
of the interlocking disc (3) (i.e gap = 0 mm).
Item
2 mm 2
1 Limit switch
2 Interlocking arm
3 Interlocking disc
4 Cam disc
5 Operating rod
5
B20019
Figure 4-2. Interlocking mechanism
1HSB515409-100 en 8 9
Releasing the mechanical interlocking

If the movement of the cam disc has been stopped by the interlocking arm, it is not
possible to carry out a closing operation until the cam disc has been returned to its
normal position.
1. Manual uncharging of the closing springs.
a. Turn the “Local/Remote/Disconnect” switch on the control panel to the
“Disconnect” position.
b. Switch off the motor voltage with the direct-on-line starter.
c. Turn the “Hand/Motor” switch on the drive unit to the “Hand” position so
that the shaft for manual cranking is visible. Put the crank on the shaft.
2. Press the reverse catch button hard using a screwdriver and crank clockwise,
see Figure 4-3a, until the locking lug on the operating lever (1) is well past the
closing roller (2).
3. Rectify the cause of the fault.
4. Crank anticlockwise, see Figure 4-3b, until the locking lug on the operating
lever (1) rests against the roller (2) in the closing catch gear.
1 2
Item
1 Operating lever
2 Roller in closing catch

gear
B20020
a b
Figure 4-3. Releasing the interlocking
10 1HSB515409-100 en 8
4.2 Preparations for maintenance

The following should be done before maintenance is started:
1. Switch the circuit-breaker to the open position.
2. Isolate and earth.
3. Switch off the motor current.
4. Perform a Close-Open operation so that the closing and opening springs are
uncharged.
5. Switch off the control voltage and, if necessary, also the heating voltage.
4
Item
1 Control panel
2 Close/Open switch
3 Local/Remote/Disconnect
switch
4 Electric counter
5 Spring indicator
B20009
1 2 5 3
Figure 4-4. Control panel
1HSB515409-100 en 8 11
4.2.1 Emptying the gas

Work that entails risk of damaging the insulators should not take place until the gas
pressure has been reduced to 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.
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 either N2 or CF4, should not be reused unless the
mixture ratio is kept 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 ventilation valves are clean. If they are dirty, 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, for instance, to
catches, gears and components in the link system.
Despite good rust protection, small signs of corrosion can appear after a number of
years, especially on circuit-breakers installed in very 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
Valvoline Tectyl 506.
N.B. After drying, Valvoline Tectyl 506 forms a protective wax-like film. Make
sure that Tectyl is not sprayed on bearings, catch gears, gears or chains.
12 1HSB515409-100 en 8
4.5 Lubrication
The ball, roller and needle bearings in the operating mechanism are permanently
lubricated and require no maintenance. Therefore only the shafts in catch gears and
the worm gear in the drive unit need to be lubricated.
• Check whether the chains in the operating mechanism are dry and corroded
and, if necessary, lubricate with Grease “G” or oil “A”.
Sliding surfaces for the spring yoke and dampers should be lubricated during
overhaul with Grease “G” .
1HSB515409-100 en 8 13
4.6 Heating element

The operating mechanism is fitted with a heating element to prevent condensation
and should always be connected.
• Measure the resistance and check the voltage failure signal, if applicable, after
every 15 years or 5,000 operations.
Item
1 Heating element
6 5 4
3 2 1
1
B20010
Data
The values of the heating elements are according to below:
For ambient temperatures > -25°C and 220 V: R=691 Ohms ±±10%, 70 W
For ambient temperatures > -25°C and 110 V: R=173 Ohms ±10%, 70W
For ambient temperatures > -40°C and 220 V: R=691 Ohms ±10%, 70 W +
R=346 Ohms ±10% 140 W
For ambient temperatures > -40°C and 110 V: R=173 Ohms ±10% 70W +
R=86 Ohms ±10%, 140 W
For ambient temperatures > -55°C and 220 V: R=691 Ohms ±10%, 70 W +
2 x R=346 Ohms ±10%, 140 W
For ambient temperatures > -55°C and 110 V: R=173 Ohms ±10% 70W +
2 x R=86 Ohms ±10%, 140 W
70 W heating elements are permanently connected , while heating elements with

140 W or 2x140 W for temperatures below -25°C are thermostat controlled.
14 1HSB515409-100 en 8
4.7 Drive unit

• Check and clean the shafts in the catch gear and the worm gears in the drive
unit.
• Lubricate these with Grease “M” at intervals of 15 years or 2,000 operations.
• Measure the motor current at the end of the spring charging procedure at
intervals of 15 years or 5,000 operations. See the relevant Assembly
Instructions for the circuit-breaker, chapter Operating values.
The motor is capable of charging the springs at 85% of its nominal voltage (IEC).
Item
1 Drive unit
B20011
4.7.1 Hand-Motor switch

Check that the signal for voltage failure functions. If not, replace the “Hand/Motor”
switch.
1HSB515409-100 en 8 15
4.8 Catch gear

The operating mechanism is as standard fitted with one closing coil and two
opening coils, but can on request be equipped with double coils on the closing side.
Closing catch gear

Item
1 Catch gear
Opening catch gear
B20012

• Check that the voltage to the coils does not fall below the minimum voltage,
see the delivery document for the operating mechanism.
• Check the play between the magnet arm (2) and the auxiliary catch (1), see
Figure 4-8. The play must be at least 1 mm. If the play is outside the specified
dimension, replace the entire catch gear.
Item
1 Catch
2 1 mm
2 Magnet arm
B20013
Figure 4-8. Checking the clearance
16 1HSB515409-100 en 8
4.9 Damper
The operating mechanism is fitted with a Closing damper (1) to slow down the
rotation of the cam disc, and an Opening damper (2) to dampen the final phase of
the opening movement.
Item
1 Closing damper
2 Opening damper
2
B20014
Figure 4-9. Closing and Opening damper
1HSB515409-100 en 8 17
4.9.1 Closing damper

Check the oil level in the damper by recording the damping effect during operation.
• Connect a travel transducer to the cam shaft in the operating mechanism and
record a damping curve. Check the damping distance and the damping time as
indicated in Figure 4-10. If the measured values for “a” and “b” are outside the
specified values, replace the complete damper.
“b”
“a”
“a” = damping distance 15-25 mm

“b” = damping time 80-300 ms
B20015
Figure 4-10. Damping curve, Closing damper
4.9.2 Opening damper

Check the oil level in the damper by recording the damping effect during operation.
• Connect a travel transducer to the breaker’s shaft and record a damping curve.
Check the damping distance and the damping time as indicated in Figure 4-11.
If the recorded curve differs from the correct curve, replace the complete
damper.
B20016
Wrong Right Wrong
Figure 4-11. Damping curves, Opening damper
18 1HSB515409-100 en 8
4.10 Link system and spring battery

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

The operating mechanism is as standard fitted with a 6-pole auxiliary contact (1)
consisting of six normally open and six normally closed contacts. Three normally
closed and one normal open contact are used for the operating mechanism’s own
function.
The shaft (2) of the auxiliary contact (1) is in direct connection with the operating
lever in the operating mechanism and accordingly follows the movement of the
circuit-breaker contacts.
Item
1 Auxiliary contact
2 Shaft
2 1
B20017
After 15 years or 5,000 operations, check the contact travel by measuring the
opening and closing times and compare the results with those obtained during
commissioning. The comparison can then be used to check the condition of:
• Contact travel.
• Contact damping.
1HSB515409-100 en 8 19
1. Connect a time-meter across the signal contacts 20, 29, 291 and 292 in
accordance with the circuit diagram.
2. Measure the times t1, t2 and t3.
3. Turn the “Local/Remote/Disconnect” switch to the “Local” position.
4. Connect the time-meter across terminals X1:190 and X1:192.
5. Turn the “Close/Open” switch to the “Open ” position and then to the “Closed”
position.
6. Note down the times t1, t2 and t3.
7. Disconnect the time-meter.
8. Turn the “Local/Remote/Disconnect” switch to the “Remote” position.
Contact travel
Arcing contact
Closed
Auxiliary contact
Contact travel
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 4-14. Time measurement, contact travel
20 1HSB515409-100 en 8
4.12 Terminal blocks

Check all screws and pins.
11
1
Item
13
1 Auxiliary contact
2 Motors
2
3 Hand/Motor switch
4 Relays
12
5 Contactors, for motor
circuit
3
6 Direct-on-line starters
7 Miniature circuit-breakers
8 Plug socket
4
9 Thermostat
10 Fuses
11 Opening coil 14
5
12 Terminal block
12
7
13 Closing coil
4
14 Cover
8
9
4
10 7
B20022
Figure 4-15. Example of electrical equipment
1HSB515409-100 en 8 21
4.13 Manual closing and opening operations

Some service work require the circuit-breaker to be operated manually, for example
preparing for overhaul of the breaking unit on a two chamber breaker.
CAUTION
Manual closing and opening operations may only be carried out by
personnel that are very familiar with the operation of the mechanism and
circuit-breaker, as there is a risk of personal injury and mechanical damage.
Manual closing of the operating mechanism

Manual closing should only be carried out if:
1. The circuit-breaker is in the open position.
2. The “Local/Remote/Disconnect”
switch (1) on the control panel is
in the “Disconnect” position.
3. The motor voltage is switched
off with the direct-on-line
starters (2), (3).
4. The “Hand/Motor” switch (4) is 1
in the “Hand” position so that the
shaft for manual cranking is
released.
Item
2 Direct-on-line starter
3 Direct-on-line starter
2
4 Hand/Motor switch 3
B20002
Figure 4-16. Manual closing of the operating mechanism
22 1HSB515409-100 en 8
5. The closing springs are uncharged.

a. Place the crank (1) on the shaft.
b. Press the reverse catch button (2) hard using a screwdriver to release the
reverse catch and uncharge the springs. Crank clockwise until the spring
yoke has reached the bottom position and rests against the foot of the
frame.
Item
1 Crank
2 Reverse catch button Direction

of rotation
3 Hand/Motor switch
Direction Direction
of force of force
1
B20003 3 2
6. Blocking beams are fitted.

Fit the blocking beams
(1) around the guide rod
so that the fixing hole is
facing out towards the
cubicle. Fit the bolts (2)
in the blocking beams.
Item
1 Blocking beams 2 pcs.
2 Bolts M8x60 2 pcs. 1 1

2 2
B20004
Figure 4-18. Fitting the blocking beams
1HSB515409-100 en 8 23
7. The interlocking mechanism is disengaged.

a. Press the operating rod (1) or the interlocking arm (2) upwards.
b. Insert the blocking pin (3) in the hole (4).
2
4
Item
1
1 Operating rod
2 Interlocking arm Open

3 position
3 Blocking pin
Closed
4 Hole for blocking pin position
B20005
Figure 4-19. Interlocking, circuit-breaker open, closing springs uncharged
8. The blocking beams have moved against the mechanical end stop.
Crank anticlockwise, normally 6-8 turns, max. 10 turns.
9. The closing catch gear is released.
Press down the armature on the closing coil (1) see Figure 4-20.
The manual closing operation can be interrupted at any time before the locking lug
engages the roller. Press in the reverse catch button, so that the circuit-breaker runs
slowly towards its open position and stops in the required position when the button
is released.
1. Crank anticlockwise 310 turns. The cam disc (2) then rotates approx. 3/4 of a
turn and actuates the stop roller (3) so that the operating lever (4) slowly moves
the circuit-breaker towards the closed position. Towards the end of the
movement a click is heard when the locking lug (5) on the operating arm
engages behind the roller (6) in the tripping mechanism.
2. Crank a few more turns anticlockwise, so that the tip of the cam disc (2) leaves
the stop roller (3). The operating lever is pulled quickly towards the open
position by the power of the opening spring until the locking lug (5) hits the
roller (6).
3. Crank anticlockwise until the locking lug (7) is just resting against the roller
(8), thereby returning the cam disc to its normal position and releasing the
pressure on the blocking beams.
4. Remove the blocking beams.
5. Check that the locking lug (7) rests against the roller (8). Otherwise the cam
disc will be in the wrong position and the operating mechanism could be
damaged during an opening operation.
24 1HSB515409-100 en 8
6. Pull the blocking pin (3) out of the hole (4) , see Figure 4-19.
7. Turn the “Hand/Motor” switch to the “Motor” position.
8. Switch on the motor voltage with the direct-on-line starters.
9. Set the “Local/Remote/Disconnect” in the “Remote” position.
The circuit-breaker is now in the closed position and a normal opening operation
can be carried out.
N. B. Check that the blocking beams are removed before carrying out an opening
operation.
Item
1 Closing coil 2
2 Cam disc
3 Stop roller
4 Operating lever
6
5 Locking lug 8
5
6 Roller, opening catch gear
7 Locking lug
B20006
Figure 4-20. Operating mechanism, manual closing operation
1HSB515409-100 en 8 25
Manual opening operation

Manual opening operation should only be carried out if:
1. The circuit-breaker is in the closed position.
2. The “Local/Remote/Disconnect”
switch (1) on the control panel is
in the “Disconnect” position.
3. The motor voltage is switched
off with the direct-on-line
starters (2), (3).
1
4. The “Hand/Motor” switch (4) is
in the “Hand” position so that the
hand crank shaft can be released.
Item
2 Direct-on-line starter 2
3 Direct-on-line starter 3
4 Hand/Motor switch
B20002
Figure 4-21. Manual opening operation
26 1HSB515409-100 en 8
5. The closing springs are uncharged.

a. Place the crank (1) on the shaft.
b. Press the reverse catch button (2) hard using a screwdriver to release the
reverse catch and discharge the springs. Crank clockwise until the spring
yoke has reached the bottom position and rests against the foot of the
frame.
Item
1 Crank
2 Reverse catch button

Direction
3 Hand/Motor switch of
of rotation
Direction of Direction of
force force
1
B20003
3 2
6. Blocking beams are fitted.

Fit the blocking beams
(1) around the guide rod
so that the fixing hole is
facing out towards the
cubicle. Fit the bolts (2)
in the blocking beams.
Item
1 Blocking beams 2 pcs.

1 1
2 2
B20004
Figure 4-23. Fitting the blocking beams
1HSB515409-100 en 8 27
7. The interlocking arm (1) is locked by the pin (5) and stops in the horizontal
position against the locking disc (4).
a. Press the interlocking arm (1) upwards.
b. Insert the blocking pin (2) in the hole (3).
1
3
Item
1 Interlocking arm
2 Blocking pin
Open
3 Hole for blocking pin 2 position
Closed
4 Locking disc position
4
5 Pin 5
B20007
Figure 4-24. Interlocking, circuit-breaker closed, closing springs uncharged
The manual opening operation requires “fetching” the operating lever (7) with the
cam disc (4), see Figure 4-25. The trip catch gear can then be released and the
operating mechanism is ready for a manual opening operation.
1. Crank anticlockwise until the blocking beams move against the mechanical end
stop. A light resistance on the crank can be felt. The cranking normally takes
6-8 turns, max. 10 turns.
2. Release the closing catch gear by pressing the armature on the closing coil (1),
Figure 4-25, so that the locking lug (2) is disengaged from the roller (3).
3. Turn the crank approx. 300 turns anticlockwise. If the crank is turned too many
turns, a “bang” is heard when the cam disc (4) moves past the stop roller (5)
and returns once again to the position shown in Figure 4-25, top figure. Make a
new attempt. Follow the instructions from point 1 and crank a few turns less.
4. Press in the reverse catch button in the drive unit.
5. Release the crank and let it rotate until it stops.
6. Release the opening catch gear by tapping the armature (6) lightly with e.g. a
screwdriver. The opening springs pull the operating lever (7) towards the open
position. The movement is stopped when the stop roller (5) falls onto the cam
disc (4).
7. Keep the reverse catch button pressed in until the circuit-breaker has been
drawn into the open position by the opening springs. If the spring force is not
sufficient to move the locking lug (2) far enough to engage in the locked
position against the roller (3), press in the button and turn the crank clockwise.
8. Remove the blocking beams.
28 1HSB515409-100 en 8
9. Check that the locking lug (2) rests against the roller (3) in the closing catch
gear. Otherwise crank anti-clockwise until the locking lug rests against the
roller (3).
10. Pull the blocking pin (2) out of the hole (3), see Figure 4-24.
11. Turn the “Hand/Motor” switch to the “Motor” position.
12. Switch on the motor voltage with the direct-on-line starters.
13. Turn the “Local/Remote/Disconnect” switch to the “Remote” position.
The circuit-breaker is now in the open position and a normal closing operation can
be carried out.
N.B. Check that the blocking beams have been removed before carrying out an
opening operation.
3
2 1
Item
1 Closing coil
2 Locking lug

6
4 Cam disc
5 Stop roller
6 Armature
7 Operating lever
B20008
Figure 4-25. Operating mechanism, slow manual operation
1HSB515409-100 en 8 29
4.13.1 Manual charging of the closing springs

1. Crank anticlockwise until the closing springs are fully charged. Check by
measuring between the bridge and the frame foot.
2. Turn the “Hand/Motor” switch on the drive
unit to the “Motor” position.
294 +2
3. Reset the direct-on-line starters.
4. Turn the “Local/Remote/Disconnect”
switch on the control panel to the
“Remote” position.
5. Make a test operation.
B20021
Figure 4-26. Check dimension, closing springs
30 1HSB515409-100 en 8
SE-771 80 LUDVIKA 2005-08-12
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
mechanism BLG 1002A
3-pole operation
1HSB445409-201 en 5

ment.
Article number:
1HSB445409-201 en 5
Approval date:
2006-10-04
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 disposal .........................................................11
4.4 Dismantling the circuit-breaker pole for transport........................12
5. Dismantling the circuit-breaker pole .............................. 13

5.1 Unloading the tripping mechanism pull rod .................................13
5.2 Removing the breaking unit..........................................................15
5.3 Removing the post insulator .........................................................16
5.4 Dismantling the breaking unit.......................................................17
6. Contact and puffer replacement ..................................... 18

6.1 Replacing the upper current path ..................................................18
6.2 Replacing the puffer......................................................................19
6.3 Replacing the lower current path ..................................................20
7. Overhaul of the mechanism housing ............................. 21
8. Assembling the circuit-breaker pole .............................. 22

8.1 Treatment of contact surfaces .......................................................22
8.2 Treatment of sealing surfaces and seals ........................................23
8.3 Assembling the breaking unit .......................................................24
8.4 Assembling the post insulator .......................................................25
8.5 Assembling the circuit-breaker pole .............................................26
1HSB445409-201 en 5 i
8.6 Gas filling ..................................................................................... 27

8.7 Assembling the tripping mechanism pull rod on the operating lever
28
9. Dismantling the breaking unit for transport ................... 30

9.1 Assembling the breaking unit after an overhaul........................... 31
10.Assembling and commissioning .................................... 34
ii 1HSB445409-201 en 5
FIGURES
Figure 4-1. Dismantling the circuit-breaker pole .............................................12

Figure 5-1. Unloading the pull rod ..................................................................13
Figure 5-2. Removing the operating interlocking, disconnecting circuit-
breakers .........................................................................................14
Figure 5-3. Unloading the pull rod, disconnecting circuit-breakers ................14
Figure 5-4. Removing the breaking unit ..........................................................15
Figure 5-5. Removing the post insulator .........................................................16
Figure 5-6. Dismantling the breaking unit .......................................................17
Figure 6-1. Upper current path ........................................................................18
Figure 6-2. Puffer .............................................................................................19
Figure 6-3. Lower current path ........................................................................20
Figure 7-1. Mechanism housing ......................................................................21
Figure 8-1. Assembling of the breaking unit ...................................................24
Figure 8-2. Assembling the post insulator .......................................................25
Figure 8-3. Assembling the circuit-breaker pole .............................................26
Figure 8-4. Assembling the tripping mechanism pull rod on the operating
lever ...............................................................................................28
Figure 8-5. Assembling the tripping mechanism pull rod on the operating lever,
disconnecting circuit-breakers ......................................................29
Figure 9-1. Dismantling the breaking unit .......................................................30
Figure 9-2. Assembling the breaking unit .......................................................32
Figure 9-3. Sign on the mechanism housing ....................................................33
1HSB445409-201 en 5 iii
Overhaul Instructions General
1. General
This Overhaul instructions applies to the SF6 circuit-breaker HPL 72.5-300B1,
3-pole operation. This instruction contains information for overhaul and repair
work.
Overhaul and repair work may only be carried out by technicians trained by ABB
Power Technologies AB, Circuit-Breaker Unit.
1HSB445409-201 en 5 1
2. Safety
2.1 Warning text

observed extra carefully. The warning texts are marked as indicated below.
DANGER
WARNING
CAUTION
indicates a hazardous situation than can result in minor or moderate
injury.
N. B. is used for hazards that may only result in damage to the installation.
1HSB445409-201 en 5 3
Safety Overhaul Instructions
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 pressurized porcelain insulators.
Mechanical damage to the porcelain can cause it to explode with the
WARNING
WARNING
Do not operate the mechanism unloaded!
Operation should take place only after the mechanism has been connected
and adjusted with the associated pressurized circuit-breaker.
4 1HSB445409-201 en 5
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 should take place close
to live equipment, the safety distance
in the applicable safety regulations
must be observed.
Working on ladders and platforms. Work should take place in

accordance with applicable safety
regulations. Work during difficult
weather conditions that requires
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
operating mechanism.
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 both the high voltage side. Uncharge the
opening and the 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 the mechanical latch mechanism drive shaft backwards by
components. hand (see the Overhaul instructions
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 pressurized Work close to the insulators of the

insulators. circuit-breaker that may result in
The normal working pressure is up to damage to the porcelain must not
0.8 MPa (abs.). Damage to the take place until the gas pressure has
porcelain can result in splintering. ben reduced to max. 0.125 MPa
(abs.).
1HSB445409-201 en 5 5
Overhaul Instructions Overhaul, general
3. Overhaul, general
Before the overhaul work is started, all the necessary equipment and replacement
parts should be available so that the overhaul work can be carried out in the most
effective way.
The following equipment is needed.
3.1 Tools
• A normal set of tools and torque wrenches (9-550 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 particle and acidic gases.
• Long-sleeved overall.
• Protective gloves of plastic or rubber.
3.4 Cleaning equipment

• Vacuum cleaner with micro-filter and plastic nozzle.
• Drying cloths of a lint-free material.
• Sealed storage containers for waste products and used absorption filters.
• Wire brush for contact surfaces of aluminium.
• Cleaning pad, e.g. Scotch Brite, for contact surfaces of copper.
• Industrial alcohol 95% (vol), C2H5OH, for cleaning inside surfaces.
• Heavy-duty plastic sheet and plastic bags to prevent the ingress of moisture and
to protect cleaned components before assembly.
1HSB445409-201 en 5 7
Overhaul, general Overhaul Instructions
3.5 Spare parts

• Set of contacts1
• Set of seals1
• Absorbtion agent1
• Lubricants, see Lubricants instruction for the names of suppliers and brands
Grease “G”: ABB Art. No. 1171 4014-407
Grease “K”: ABB Art. No. 1263 0011-102
Grease “N”: ABB Art. No. 1171 4016-607
Grease “S”: ABB Art. No. 1171 4014-406
Grease “SV”:ABB Art. No. 1171 4016-610
Grease “P”: ABB Art. No. 1171 5011-102.
• Anti-corrosion agent
Valvoline Tectyl 506, ABB Art. No. 1241 0011-108.
• Locking fluid.
Loctite 270, ABB Art. No. 1269 0014-408.
• SF6 gas.
• Nitrogen gas.
• Protective cover for the breaking unit, ABB Art. No.1HSB445237-1.
• Protective cover for post insulator, ABB Art. No. 5439 142-A.
• Tensioning tool for tripping mechanism, ABB Art. No. 1HSB446381-A.
• Tensioning tool for tripping mechanism on disconnecting circuit-breakers,
ABB Art. No. 1HSB446381-D.
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 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 unstable weather conditions, nor when the
relative humidity is 80% or higher.
1. According to the spare parts lists for the circuit-breaker in question.
8 1HSB445409-201 en 5
Overhaul Instructions Dismantling the circuit-breaker
4. Dismantling the circuit-breaker
4.1 General
Before the circuit-breaker is dismantled and during the course of the dismantling
work, the directives in the Operating and Maintenance Instruction must be read and
followed.
Check and note down the operating values of the circuit-breaker before dismantling.
Any deviation from the recommended values indicates that something must be
carefully checked 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 it may only be used when the
weather is good and settled and the 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. Removal and assembly of breaking units must not be done when the
weather is such that there is a risk of rain.
WARNING
This work requires training and 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 the “Open” position.
• Isolate and earth.
• Uncharge the spring battery by switching off the motor current and perform a
Close-Open operation.
• Switch off the control voltage and, if necessary, also the heating power.
1HSB445409-201 en 5 9
Dismantling the circuit-breaker Overhaul Instructions
4.2 Gas
Work on the insulator of the circuit-breaker 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 reduced to a pressure of max 0.125 MPa (abs).
Gas should be emptied fully to atmospheric pressure before opening a
normally pressurised space, e.g. a breaking unit.
WARNING
When nitrogen gas is used for cleaning inside the circuit-breaker, the gas
may be discharged into the atmosphere, but only via a dust and absorption
filter. The emptying operation must be done 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 Removing the gas

Remove the SF6 gas and vacuum pump the circuit-breaker using the gas handling
equipment. This cleans and compresses the gas so that it can be reused or be
disposed of.
N.B. Mixed gas, SF6 mixed with either 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.)
After vacuum pumping, the circuit-breaker is filled with dry nitrogen gas until
atmospheric pressure is reached and is then vacuum pumped again. In this way any
floating dust inside the circuit-breaker will be extracted.
Finally the circuit-breaker is filled again with dry nitrogen until atmospheric
pressure is reached. The breaker is now ready to be dismantled.
10 1HSB445409-201 en 5
Overhaul Instructions Dismantling the circuit-breaker
4.3 Cleaning and waste disposal
CAUTION
Some decomposition products formed in the breaking unit become
corrosive when coming in contact with moisture 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. Drying cloths, protective gloves and vacuum cleaner bags should be

rinsed thoroughly in water after waste handling.
1HSB445409-201 en 5 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 removed, see Chapter 4.2.1. The density monitor
must be dismantled and the sealing cap (1) fitted on the non-return valve (2).
1. Remove the pull rod between the operating mechanism and the circuit-breaker pole.
Loosen the pull rods between the circuit-breaker poles.
2. Place a lifting sling under the upper terminal flange of the breaking unit as shown in
Figure 4-1 and prepare to lift with a crane.
N.B. For composite insulators: Place the lifting sling as close to the terminal flange as
possible and not on the rubber surface.
3. Now loosen the circuit-breaker pole (5), removing the four bolts (3) on the frame
and the four bolts (4) on the protective tube to the operating mechanism and the four
bolts to (4) to the next circuit-breaker pole..
4. Lift up the circuit-breaker pole and
carefully lay it down on a transport
carriage. Block up the circuit-breaker
pole so it lies horizontally.The
1
bottom of the transport crate can be
used The blocks (6) under the
breaking unit insulator should be of
an elastic material, e.g. wood or
rubber. 3 2
N. B.If possible, keep the supports
supplied on delivery for this
purpose.
5
Transport to the workshop or 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 8 pcs.
Washers 13x24x2.5 16pcs.
Spring washers 13x24x2,5 16 pcs.
5 Circuit-breaker pole
6 Blocks
B10019
6 6
Figure 4-1. Dismantling the circuit-breaker pole
12 1HSB445409-201 en 5
Overhaul Instructions Dismantling the circuit-breaker pole
5. Dismantling the circuit-breaker pole

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 Unloading the tripping mechanism pull rod

For disconnecting circuit-breakers, see Chapter 5.1.1.
1. Remove the bottom cover of the tripping mechanism (1).
2. Measure and note down a reference dimension, e.g. “Y”, so that the opening
spring (7) can be refitted to the same tension using the nut (8).
Y=............. mm date................
3. Fit the tool 1HSB446381-A and tension the adjuster screw (10) so that the
tripping mechanism pull rod (5) is unloaded from the operating lever (3) in the
mechanism housing.
4. Remove the pin (4).
Item
1 Bottom cover
3 Operating lever
4 Pin
5 Pull rod 3
5 4
6 Spring housing
7 Opening spring
6
8 Locking nut
9 Tool 1HSB446381-A 7 8
B10020
9 1
Figure 5-1. Unloading the pull rod
1HSB445409-201 en 5 13
Dismantling the circuit-breaker pole Overhaul Instructions
5.1.1 Unloading the pull rod, disconnecting circuit-breakers

1. Disconnect the operating interlocking (1) from the operating rod by removing
the bolt (4).
2. Dismantle the operating interlocking with the glass cover (3) and spacer (5)
and the protective plates (6) from the tripping mechanism by loosening the
bolts (2).
Item 5 4
1 Operating interlocking 6

Washers 10.5x20x2 8 pcs.
1
3 Glass cover
2
4 Bolt 3
5 Spacer
6 Protective plates 2 pcs.
Figure 5-2. Removing the operating interlocking, disconnecting circuit-breakers

3. Measure and note down a reference dimension, e.g. “Y”, so that the opening
spring (6) can be refitted to the same tension using the nut (7).
Y=............. mm date................
4. Fit the tensioning tool (2) 1HSB446381-D with the bottom cover (1).
5. Tension the adjuster screw (3) to uncharge the tripping mechanism pull rod (4)
from the operating lever (5) in the mechanism housing.
6. Remove the pin (8).
8
Item
1 Bottom cover
6 5
2 Tool 1HSB446381-D
3 Adjuster screw 7
4 Pull rod
Y
5 Operating lever
4
6 Opening spring
7 Locking nut
8 Pin 1 2
3
Figure 5-3. Unloading the pull rod, disconnecting circuit-breakers
14 1HSB445409-201 en 5
5.2 Removing the breaking unit

1. Fit the lifting sling from the top of the breaking unit to the crane or the
overhead crane. Tension the lifting sling moderately.
N.B. For composite insulators: Place the lifting sling as close to the terminal flange
as possible and not on the rubber surface.
2. Remove the bolts (1) between the post insulator (2) and the breaking unit (3).
3. Lift the breaking unit
100-150 mm.
4. Remove the circlip (4), washer
(5) and pin (6).
N. B. Ensure that neither the 3

circlip (4) nor the washer 4
6
(5) fall into the post
insulator (2) during
dismantling. Cover the
opening, for example by
tying a cloth over it.
Set up the breaking unit verticallly
on a suitable surface so that it does
not fall over.
1
Item
5
2 Post insulator
3 Breaking unit
2
4 Circlip
5 Washer
6 Pin
B10021
Figure 5-4. Removing the breaking unit
1HSB445409-201 en 5 15
Dismantling the circuit-breaker pole Overhaul Instructions
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 insulator and on the insulating rod.
N. B. Use personal safety equipment such as overall, protective gloves and face
mask.
1. Position the lifting sling from the top of the post insulator (1) to the crane or
overhead crane.
N.B. For composite insulators: Place the lifting sling as close to the terminal flange
as possible and not on the rubber surface.
2. Remove the bolts (2) between the post insulator and the mechanism
housing (3).
3. Lift the post insulator (1) straight up until the insulating rod (7) is released.
Hold the insulating rod (7)while lifting the post insulator (1).
N. B. Take care so as not to damage the insulating rod (7).

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

6 4
3 Mechanism housing
1
4 Circlip
5 Washer 7
6 Parallel pin
7 Insulating rod
2
5
3 B10026
Figure 5-5. Removing the post insulator
16 1HSB445409-201 en 5
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 lenghty 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 overall, protective gloves and face
mask.
Collect the decomposition products in the breaking unit in the form of powder when
the breaking unit is opened. First use a vacuum cleaner and thereafter carefully wipe
the removed components.
1. Remove the bolted joints (1) and the cover (2) 1 3 2 4
and lift out the absorption agent container (3).
N. B. Place the bag with absorption agent in a

container for chemical waste. 5
2. Remove the bolts (4) and upper terminal flange
(5) with the upper current path (6).
3. Remove the bolts (4) and the breaking chamber
insulator (7) from the lower terminal flange (8).
4. Rinse the inside of the breaking chamber 6
insulator (7) with water.
Item

2 Cover
3 Absorption agent container 7

5 Upper terminal flange
6 Upper current path
7 Breaking chamber insulator 8

B10022
4
8 Lower terminal flange
Figure 5-6. Dismantling the breaking unit
The main components of the breaking unit are now accessible for inspection,
cleaning and replacement of burnt or damaged components.
1HSB445409-201 en 5 17
Contact and puffer replacement Overhaul Instructions
6. Contact and puffer replacement

If the circuit-breaker is not going to be reassembled immediately after cleaning the
components, 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 sheets over the end
surfaces.
Inspect the upper and lower current paths and the puffer as described below. If any
component is burnt or worn and is replaced, replace also the other components at
the same time.
6.1 Replacing the upper current path

Replace the entire upper current path (3) if the fixed arcing contact (4) , Figure 6-1,
has been burnt so that the distance to the reference surface is more than 9 mm or if
the outside surface has been severely burnt. Replace also the upper current path (3)
if the silver surface on the upper current path (3) is worn so that the copper is
visible.
Tighten the bolted joints (2) with a tightening torque of 22.5 Nm.
Item
1 Upper terminal flange 1

Washers 8,4x20x2 8 pcs.
Spring washers 8,4x18x2 8 pcs.
3 Upper current path 2
4 Arcing contact
3
TIGHTENING TORQUE
max. 9 mm
22.5 Nm
Reference surface
B10023
Figure 6-1. Upper current path
18 1HSB445409-201 en 5
Overhaul Instructions Contact and puffer replacement
6.2 Replacing the puffer

Lift off the puffer and check that there is no wear on the sliding surfaces of the pull
rod.
Check that the nozzle (1) is not punctured. Also check that the contact surfaces on
the puffer cylinder (3) are not burnt or worn so that copper is visible.
N.B. If the upper current path has been replaced because the fixed arcing contact is
burnt, the puffer must also be replaced.
Replace the entire puffer if it has burnt or worn surfaces.
1
Item
1 Nozzle
2 Pull rod
4
3 Puffer cylinder

Washers 8,4x16x1,6 8 pcs. 3
Contact
surfaces
TIGHTENING TORQUE
22.5 Nm
B10025
Figure 6-2. Puffer
1HSB445409-201 en 5 19
Contact and puffer replacement Overhaul Instructions
6.3 Replacing the lower current path

Remove the lower current path (3) from the lower terminal flange (1).
Check that the silver on the lower current path (3) contacts is not worn so that
copper is visible.
If there are signs of wear, replace the whole lower current path (3).
Tighten the bolted joints (2) with a tightening torque of 22.5 Nm.
Item
3

2
3 Lower current path
4 Puffer
5 Puffer guide
6 Teflon band 1
TIGHTENING TORQUE 5
22.5 Nm
B10024
Figure 6-3. Lower current path
20 1HSB445409-201 en 5
Overhaul Instructions Overhaul of the mechanism housing
7. Overhaul of the mechanism housing

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

3 Operating lever
9 6 4
4 Bearing 2
5 Circlip
6 Bushing
7 X-ring 69.2x5.7
8 O-ring 89.1x5.7
9 Bearing 5
7 8
B10027
Bearing and O-rings
Figure 7-1. Mechanism housing
1HSB445409-201 en 5 21
Assembling the circuit-breaker pole Overhaul Instructions
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 O-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 surfaces
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 surfaces must be clean and free from oxide. If necessary clean with a
cloth, and solvent (alcohol), or with 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 Scotch Brite. 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
must be fitted within 15 minutes.
8.1.2 Movable contact surfaces

• Silver-plated surfaces
If necessary, clean silver-plated movable contact surfaces, using a soft cloth
and solvent (alcohol).
• Non-silver-plated surfaces
Clean moving contact surfaces that are not silver-plated in a similar way to
silver-plated surfaces. However, they may also be cleaned with Scotch Brite.
After cleaning with Scotch Brite always remove all loose particles.
• Greasing
Apply Grease “N” (ABB art. No. 1171 4016-607) is applied in a covering, but
very thin layer to the male contacts and the puffer cylinder surfaces.
Carefully wipe off all excess grease.
22 1HSB445409-201 en 5
Overhaul Instructions Assembling the circuit-breaker pole
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 should take place along the
sealing line but never across it.
When re-assembling the circuit-breaker, replace all seals with new ones.
Grease sealing surfaces and seals sparingly to facilitate the sealing against the
surface and as corrosion protection. Excess grease that could seep out on flanges in
the gas chamber must not occur.
Coat flange surfaces outside the outer 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.
1HSB445409-201 en 5 23
8.3 Assembling the breaking unit

1. Fit the puffer (1) on the puffer guide. When the puffer (1) starts to go down
over the Teflon band, carefully turn it so that the Teflon band is not damaged.
N. B. Take care so that the Teflon band on the piston is not damaged when the
puffer is moved down.
2. Fit the lower current path (2) over the puffer (1) and puffer guide. Tighten the
bolts (3) with a tightening torque of 22.5 Nm.
TIGHTENING TORQUE
22.5 Nm
3. Place the O-ring on the lower terminal flange (4) and lift the breaking chamber
insulator (5). Centre it and tighten the bolts (6) with a tightening torque of
60 Nm.
4. Fit the upper current path (7) with the O- 6
ring on the breaking chamber insulator (5).
Centre the current path in relation to the
puffer (1). Tighten the bolts (6) with a
tightening torque of 60 Nm. 7
TIGHTENING TORQUE
5
60 Nm
N.B. Fit the new absorption agent container

first in connection with re-assembly of the 1
breaking unit on the post insulator see
Chapter 8.5
.
Item
2
1 Puffer
2 Lower current path
3
4 Lower terminal flange 4
5 Breaking chamber insulator
6
B10028
6 Bolt M12x50 16 pcs.
Washer 13x24x2.5 16 pcs.
7 Upper current path
Figure 8-1. Assembling of the breaking unit
24 1HSB445409-201 en 5
8.4 Assembling the post insulator

1. Turn the support lever (1) and link (2) over the edge of the mechanism housing
and fit the insulating rod (3) using the parallel pin (4), washer (5) and
circlip (6).
N. B. Fit the parallel pin (4) so that the circlip (6) faces towards the large
bearing.
2. Place the O-ring on the mechanism housing (9), lift the post insulator (7) and
tighten the bolts (8) with a tightening torque of 79 Nm.
3
TIGHTENING TORQUE
79 Nm
7
Item
1 Support lever
2 Link
3 Insulating rod 4 6
4 Parallel pin
5 Washer
6 Circlip
7 Post insulator
8 Bolts M16x50 8 pcs

Washers 17x30x3 8 pcs
9 Mechanism housing
8
5
9
1
B10029
Figure 8-2. Assembling the post insulator
1HSB445409-201 en 5 25
8.5 Assembling the circuit-breaker pole

1. Suspend the breaking unit in the lifting sling and pull out the puffer so that the
pull rod (1) is accessible for assembly.
2. Carefully clean the sealing surface for the O-ring on the post insulator (2). Also
clean the lower terminal flange (3) and lubricate well using grease “G” so that
the O-ring is held in place during the assembly. Place the O-ring in its groove.
3. Slowly lower the breaking unit so that it comes into position to fit the parallel
pin (4), approx. 100-150 mm above the post insulator (2).
4. Connect the puffer pull rod (1) to
7
the insulating rod using parallel 9
8
pin (4), washer (5) and circlip (6)
10
N. B. .Ensure that neither the

circlip (6) nor the washer
(5) fall into the post 1
insulator (2) during
dismantling. Cover the 4 6
opening, for example by
tying a cloth over it.
Item
3
1 Pull rod
2 Post insulator
4 Parallel pin 7 5
5 Washer
6 Circlip 2
8 Upper terminal flange
9 Cover
10 Absorption agent container

B10030
Figure 8-3. Assembling the circuit-breaker pole
26 1HSB445409-201 en 5
5. When the parallel pin (4) is fitted, carefully lower the breaking unit on to the
post insulator (2) and centre it. Tighten the breaking unit using the bolts (7)
with a tightening torque of 60 Nm.
TIGHTENING TORQUE
60 Nm
6. Clean the sealing surface on the upper terminal flange (8) and coat with grease
“G”. Place the O-ring on top of the upper terminal flange (8).
7. Open the new absorption agent package and place the agent into the absorption
agent container (10).
8. Fit the absorption agent container (10) and the cover (9) and tighten the bolts
(7) to a torque of 60Nm.
TIGHTENING TORQUE
60 Nm
N. B. Fit the cover immediately after the absorption agent container has been
fitted.
8.6 Gas filling

• Vacuum pump down to 100 Pa and let the 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 to stand for a few hours or overnight.
• Vacuum pump again down to 100 Pa and fill with pure SF6 gas to a pressure of
0.125 MPa (abs).
Store the filling hoses so that they are not exposed to moisture or contamination.
They must not be used for other purposes than intended.
1HSB445409-201 en 5 27
8.7 Assembling the tripping mechanism pull rod on the operating lever
For disconnecting circuit-breakers, see Chapter 8.7.1.
1. Turn the operating lever (3) anti-clockwise towards the open position and
connect it to the pull rod (5) using the pin (4). Coat the pin (4) with grease “M”
before assembly. Secure the pin (4) with the locking washer and screw.
Tighten with a tightening torque of 22,5 Nm and secure with locking fluid,
ABB art No. 1269 0014-408 (Loctite 270).
2. If the nut (8) has been moved out of position, adjust it to dimension Y,
see Chapter 5.1.
3. Unload the spring force using the bolt before removing the tool
1HSB446381-A.
4. Clean the drainage groove in the bottom cover (1) and refit the bottom cover on
the tripping mechanism.
Item
1 Bottom cover
2 Bolts M10x50 4 pcs
3 Operating lever
4 Pin
5 Pull rod 3
6 Spring housing 5 4
7 Opening spring
6
8 Locking nut
9 Tool 1HSB446381-A 7 8
B10020
9 1
Figure 8-4. Assembling the tripping mechanism pull rod on the operating lever
The circuit-breaker is now ready for transport.
28 1HSB445409-201 en 5
8.7.1 Assembling the tripping mechanism pull rod, disconnecting circuit-breakers

1. Turn the operating lever (5) anti-clockwise towards the Open position and
connect it to the pull rod (4). Coat the pin (8) with grease “M” before assembly.
Secure the pin (8) with the locking washer and screw. Tighten with a tightening
torque of 22,5 Nm and secure with locking fluid, ABB art No. 1269 0014-408
(Loctite 270).
2. If the nut (7) has been moved out of position, adjust it to dimension Y,
see Chapter 5.1.1.
3. Unload the spring force using the adjuster screw (3) before removing the tool
1HSB446381-D with the bottom cover.
Item
1 Bottom cover
2 Tool 1HSB446381-D
3 Adjuster screw
4 Pull rod
5 Operating lever 6 5
6 Opening spring 8
7
7 Locking nut
8 Pin Y
1 2
3
Figure 8-5. Assembling the tripping mechanism pull rod on the operating lever,
disconnecting circuit-breakers
The disconnecting circuit-breaker is now ready for transport.
1HSB445409-201 en 5 29
Dismantling the breaking unit for transport Overhaul Instructions
9. Dismantling the breaking unit for transport

Dismantling of only the breaking unit for an 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 gas 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 instruction for
the operating mechanism. Stop cranking when the dimension 250 mm is
reached as indicated in Figure 9-1. The coupling link with parallel pin (1) on
the insulating rod (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 it.
5. Remove the bolts (5) and very carefully lift the breaking unit (6) a maximum of
70 mm.
N. B. Do not lift the breaking unit more than 70 mm so as not to damage the
circuit-breaker’s internal components.
6 7 3
1
Item
1 Parallel pin
2 Washer
3 Circlip
4 Insulating rod
5 Bolt M12x35 8 pcs. 2
Washer 13x24x2.5 8 pcs. 4
6 Breaking unit 5
7 Puffer pull rod
8
8 Post insulator
250
B10082
Figure 9-1. Dismantling the breaking unit
30 1HSB445409-201 en 5
Overhaul Instructions Dismantling the breaking unit for transport
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.
6. Disconnect the breaking unit (6) by removing the circlip (3), washer (2) and
parallel pin (1).
N. B. Ensure that neither the circlips (3) nor the washers (2) fall into the post
insulator (8) during dismantling. Cover the opening by, for example tying
a cloth over them.
7. Fit the protective cover, ABB art. No. 5439 142-A, with the O-ring over the
post insulator (8). When the cover has been bolted in position, increase the the
nitrogen pressure in the post insulator to 0.125 MPa (abs).
8. Slide the puffer pull rod (7) into the breaking unit (6) and fit the protective
cover, ABB art. No. 1HSB445237-1, with the O-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, vacuum pump the post insulator or
breaking unit and fill with nitrogen gas, 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 puffer so that its 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 O-ring on the post insulator (8) and
coat with grease “G”. Fit the O-ring in its groove.
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 puffer pull rod (7) to the insulating rod (4) using the parallel
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) and tighten with a tightening torque of 60 Nm.
TIGHTENING TORQUE
60 Nm
7. Clean the upper terminal flange (9) and coate with grease “G”. Place the O-ring
on top of the upper terminal flange (9).
8. Open the packaging of the new absorption agent and fill the agent in the
absorption agent container (12).
1HSB445409-201 en 5 31
Dismantling the breaking unit for transport Overhaul Instructions
9. Fit the absorption agent container (12) and the cover (10) and tighten the bolted
joints (11) with a tightening torque of 60 Nm.
TIGHTENING TORQUE
60 Nm
11 10
12
6
Item 9
1 Parallel pin 1 7
3
2 Washer
3 Circlip
4 Insulating rod
5 Bolt M12x 35 8 pcs.
Washer 13x24x2.5 8 pcs. 2
6 Breaking unit 4
5
7 Puffer pull rod
8 Post insulator 8
9 Upper terminal flange 250

10 Cover
12 Absorption agent container
B10083
Figure 9-2. Assembling the breaking unit
10. Filling the circuit-breaker pole with gas.

a. Vacuum pump down to 100 Pa and let the 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 gas 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 a
pressure of 0.125 MPa (abs).
Store the filling hoses so that they are not exposed to moisture or contamination.
They shall not be used other purpose than intended.
32 1HSB445409-201 en 5
Overhaul Instructions Dismantling the breaking unit for transport
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 on 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. Sign on the mechanism housing
12. Disconnecting circuit-breakers: Re-assemble the pull rod interlocking

according to the relevant assembly instructions manual.
1HSB445409-201 en 5 33
Assembling and commissioning Overhaul Instructions
10. Assembling and commissioning

Assemble and commission the circuit-breaker in accordance with the applicable
assembly instructions.
After the circuit-breaker is assembled, check and make a note of the operating
values.
First overhaul.
Measured values
Check the following
Close-Open times(1) ms ms ms
Main circuit resistance μΩ μΩ μΩ
Filling pressure(2) MPa (abs) MPa abs) MPa (abs)
(1) The circuit-breaker should not be operated Open-Close without a time delay of 300 ms.
(2) Filling pressure according to rating plate.
Check carried out on the:________________________________
34 1HSB445409-201 en 5
Overhaul Instructions Assembling and commissioning
Second overhaul.
Measured values
Check the following
Close-Open times(1) ms ms ms
Main circuit resistance μΩ μΩ μΩ
Filling pressure(2) MPa (abs) MPa (abs) MPa (abs)
(1) The circuit-breaker must not be operated Open-Close without a timedelay of 300 ms.
(2) Filling pressure according to rating plate.
Check carried out on the :________________________________
1HSB445409-201 en 5 35
Circuit-breaker Unit
SE-771 80 LUDVIKA 2006-10-04
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
SF6-gas
1HSB445409-2 en 3

ment.
Article number:
1HSB445409-2 en 3
Approval date:
2004-08-20
SF6-gas
LIST OF CONTENTS
1. SF6 gas................................................................................ 1
1HSB445409-2 en 3 i
SF6-gas
FIGURES
Figure 1-1. Impulse voltage withstand, kV, 10 mm gap ....................................1

Figure 1-2. Contribution to the greenhouse effect in per cent ...........................2
1HSB445409-2 en 3 iii
SF6-gas SF6 gas
1. SF6 gas
Sulphur hexafluoride, SF6, is a synthetic gas that is colourless, odourless and non-
combustible. The gas is formed through a chemical reaction between molten
sulphur and fluorine gas. The six fluorine atoms are symmetrically positioned
around the sulphur atom, which makes it chemically very stable. At room
temperature the gas does not react with any other substance.
The stability of the gas is the reason behind its use in electrical equipment as it gives
extremely high electrical insulation and can effectively extinguish arcs. These
characteristics found in SF6 make it possible to design apparatus and equipment
with a small footprint, that require less material, are safe and have a long service
life. In electrical equipment, the SF6 gas is only used in enclosed and sealed
systems, such as insulation gas in switchgear and as insulation and extinguishing
medium in circuit-breakers for high and medium voltages.
The dielectric strength of SF6 is
kV
approx. 2.5 times better than air.
The SF6 gas is usually used at a 250
pressure of 0.3-0.5 MPa and then
insulates approximately 10 times 200
better than atmospheric air. These
characteristics are utilised to
150
construct small, compact units that
give an all around low
environmental impact. 100
The gas is strongly electronegative, 50

i.e. the gas molecules capture free
electrons, and form heavy negative
ions with low mobility. This is
0.1 MPa
0.5 MPa
Vacuum
SF6
SF6
Air
Oil
effective against the occurrence of

electron avalanches, which can
result in flashovers.
Figure 1-1. Impulse voltage withstand, kV, 10 mm gap
In connection with discharges, the SF6 gas partly decomposes. This takes place in
the temperature interval where the arc is extinguished, 1500-5000 K, and provides
efficient cooling. Gaseous and solid decomposition products are then formed. All
decomposition products are reactive, which means that they are quickly degraded
and disappear.
During normal operation, the concentration of gaseous decomposition products is
kept low by integrated absorbers. The solid decomposition products are primarily
metal fluorides in the form of a powder. The powder can easily be taken care of as a
separate waste product and does not constitute a long-term environmental hazard.
For service and maintenance, special routines apply as decomposition products in
large quantities are corrosive and toxic.
1HSB445409-2 en 3 1
SF6 gas SF6-gas
Pure SF6 gas is non-toxic and is not dangerous to inhale if the oxygen content is at
least 20%. SF6 is approx. 5 times heavier than air. This means that the gas can
collect for example in cable trenches or at the bottom of tanks.
WARNING
The risk of asphyxiation can occur due to a lack of oxygen in such
areas where large quantities of SF6 gas can collect.
The SF6 molecule contributes to %

the greenhouse effect, but contains
no chlorine and thereby does not 70
affect the ozone layer. Ever since
SF6 gas started to be used 50 years 60
ago, small amounts of the gas have
leaked out into the atmosphere. 50
There is now approx. an 3 x10-12
volume part of SF6 in the
40
atmosphere. Due to the low
concentration, its contribution
30
towards the total greenhouse effect
is less than one thousand.
20
10
0
CO2 CH4 Others SF6
Figure 1-2. Contribution to the greenhouse effect in per cent
Electrical equipment with SF6 has been used for a long time with good results.
When the equipment or switchgear has to be opened, the SF6 gas is collected and
reused.
The policy of ABB is that no SF6 gas should be released during installation, service
or decommissioning of equipment.
2 1HSB445409-2 en 3
2004-08-20
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
SF6 Circuit-Breaker Circuit-breakers HPL and LTB
Disposal and recycling

1HSB445409-3 en 3

ment.
Article number:
1HSB445409-3 en 3
Approval date:
2004-08-20
Disposal and recycling
LIST OF CONTENTS
1. Disposal and recycling ...................................................... 1

1.1 General ............................................................................................1
1.2 Taking care of spent equipment ......................................................1
1.3 The circuit-breaker’s component parts ...........................................1
1.4 SF6-gas............................................................................................1
1.5 Porcelain..........................................................................................2
1.6 Electronics.......................................................................................2
1.7 Metals..............................................................................................2
1.8 Plastics ............................................................................................2
1.9 Oils and greases ..............................................................................3
1.10 Rubber.............................................................................................3
1.11 Other materials................................................................................3
1HSB445409-3 en 3 i
Disposal and recycling Disposal and recycling
1. Disposal and recycling
1.1 General
ABB Power Technologies attempts to minimize environmental impact during the
entire service life of the product. Environmental aspects are in focus during
technical and product development. An eco-cycle approach is attained and the
impact on the environment and possibilities of recycling are observed.
Manufacturing processes are selected that are as gentle as possible on the
environment.
1.2 Taking care of used equipment

Worn-out products should be taken out of service in an environmentally correct
manner according to the following instructions.
After discarding used equipment, a great deal of materials, or the energy content of
materials, can be recycled after sorting and cleaning. The degree of recycling varies
depending on the technical resources and experience available in respective
countries.
Non-recyclable components should be taken to an approved recycling centre for
destruction or disposal.
1.3 Circuit-breaker components

The greatest weight share in a circuit-breaker, almost 70%, is porcelain. The
remaining 30% is mainly metal, primarily iron, steel and aluminium. Rubber and
different plastics make up approximately 0.5% each and chemicals and gas less than
0.5%.
1.4 SF6-gas
Before disposal of a circuit-breaker, the SF6-gas must be emptied. All handling of
SF6-gas must be done carefully and in accordance with applicable regulations to
prevent gas leakage. The gas can be taken care of in different ways depending on the
circumstances:
• Regenerated on site, and reused in other equipment
• Sent to a gas supplier for regeneration
• Sent for destruction at a special waste disposal centre
When the circuit-breaker is filled with mixed gas, the SF6 -gas is separated from the
mixture for continued handling as set out above. Alternatively, the gas mixture can
be sent for destruction without being separated.
ABB Power Technologies will make an offer for handling the gas when the circuit-
breaker is to be discarded.
1HSB445409-3 en 3 1
1.5 Porcelain
Porcelain can after cleaning be left for disposal or used for other purposes, for
example as filling material.
1.6 Electronics
Leave electronic equipment at an approved recycling company or sort in its
component parts and take care of accordingly.
1.7 Metals
Sort metals according to type and surface treatment and leave to an approved
recycling company. After removal of any paint or other surface treatment the metal
can generally be melted down and used in new products. Many iron, steel and
aluminium parts are large and easy to identify, for example, the frame and
mechanism housing.
The aim of ABB Power Technologies is to reduce the use of precious metals and the
emission of environmentally hazardous metals. Recycling these is extremely
important.
Precious metals such as copper and silver are expensive and occur only in small
quantities in the earth’s crust. Copper is primarily used in the current paths, puffer,
contacts and cables. Silver plating of contacts can occur. Some metals can cause
damage if discharged. This appliesnamong others to copper, but also to zinc and
nickel which are used sparingly as surface treatment.
1.8 Plastics
Separate different types of plastic and leave at an approved recycling centre or
recycling company. The energy content in thermoplastics and thermoset plastics can
frequently be recovered through combustion in purpose built installations.
Generally, thermoplastics can be melted down and used again without degrading
quality too much. Composites can be fractionised and used as filling agent in other
materials or be left for disposal.
The composites found in small quantities in insulators, pipes and cable glands are
thermoset plastics. Thermoplastics can be found in components such as guide rings,
belts, bushings and support rings. The thermoplastics in sleeves, nozzles, pipe and
collars contain fluorine and are not suitable for recycling- They can, however, be
disposed of without risk of leaking hazardous substances.
2 1HSB445409-3 en 3
1.9 Oils and greases

Empty oils, greases etc. before disposal and leave at an approved recycling centre or
to a recycling company. Oil waste can be separated into oil, water and different
contaminants through the use of gravimetric forces. In many cases the oil can be
reused. Alternatively, the energy content can be recovered through combustion in
purpose built installations.
Oil can be found in dampers and grease is used as a lubricant.
1.10 Rubber
Rubber can be left at an approved recycling centre either for disposal or reuse.
Rubber can be found in seals.
1.11 Other materials

Sort and leave other materials at an approved recycling centre.
1HSB445409-3 en 3 3
2004-08-20
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
mechanism BLG 1002A
1-, 2- and 3-pole operation
Spare Parts
1HSB445409-300 en 6

ment.
Article number:
1HSB445409-300 en 6
Approval date:
2006-10-04
1HSB445409-300en6
Spare Parts
LIST OF CONTENTS
1. General ................................................................................ 1
2. Circuit-breaker .................................................................... 3
2.1 Circuit-breaker pole ........................................................................3
2.2 Breaking unit...................................................................................4
2.3 Set of contacts .................................................................................5
2.4 Post insulator...................................................................................6
2.5 Mechanism ......................................................................................7
3. Accessories ........................................................................ 8
3.1 Absorption agent container .............................................................8
3.2 Density monitor...............................................................................8
3.3 Sets of seals.....................................................................................9
3.4 Assembly sets..................................................................................9
3.5 Non-return valve .............................................................................9
4. Tools and lubricants......................................................... 10

4.1 Protective cover.............................................................................10
4.2 Tools for unloading the tripping mechanism ................................10
4.3 Lubricants......................................................................................11
1HSB445409-300 en 6 i
Spare Parts
FIGURES
Figure 1-1. Circuit-breaker HPL 72.5-300B1, 1- pole operated ........................1

Figure 1-2. Circuit-breaker HPL 72.5-300B1, 2- and 3-pole operated ..............2
Figure 2-1. Circuit-breaker pole ........................................................................3
Figure 2-2. Breaking unit ...................................................................................4
Figure 2-3. Set of contacts .................................................................................5
Figure 2-4. Post insulator ...................................................................................6
Figure 2-5. Mechanism housing ........................................................................7
Figure 2-6. Tripping mechanism ........................................................................7
Figure 3-1. Absorption agent container .............................................................8
Figure 3-2. Density monitor ...............................................................................8
Figure 3-3. Non-return valve .............................................................................9
Figure 4-1. Tensioning tools ............................................................................10
1HSB445409-300 en 6 iii
Spare Parts General
1. General
Spare parts for the SF6 circuit-breaker HPL 72.5-300B1 with operating mechanism
BLG 1002A are supplied by:
SE-771 80 Ludvika
Sweden
Tel: +46 (0) 240-78 20 00
HPL 72,5-300B1US is intended for synchronized energizing of capacitor banks
with non-solidly earthed neutral and HPL 72,5-300B1GS is intended for
synchronized energizing of capacitor banks with solidly earthed neutral.
Spare parts recommended to be kept in stock are marked with an R. With more than
ten circiuit-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.
B10002
1-pole operated
Figure 1-1. Circuit-breaker HPL 72.5-300B1, 1- pole operated

Item Designation Note
1 Circuit-breaker pole RRR
2 Operating mechanism RRR
3 Frame
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.
1HSB445409-300 en 6 1
General Spare Parts
1 1
4 2
2
4
3 3
B10301
2-pole operated 3-pole operated
Figure 1-2. Circuit-breaker HPL 72.5-300B1, 2- and 3-pole operated

1 Circuit-breaker pole RRR
2 Operating mechanism RRR
3 Frame
4 Protective tube with pull rod
Please state the type designation and seial number with all enquiries and orders of
spare parts or tools. Please also state the order number if possible.
2 1HSB445409-300 en 6
Spare Parts Circuit-breaker
2. Circuit-breaker
2.1 Circuit-breaker pole
N.B. For HPL72,5-300B1US or HPL 72,5 -300B1GS

Pole A, Pole B and Pole C have different
mechanisms.
Please specify which pole that should be replaced
when ordering spare parts. 2
B10047
Figure 2-1. Circuit-breaker pole

1 Breaking unit
2 Post insulator
3 Mechanism
4 Tripping mechanism
1HSB445409-300 en 6 3
Circuit-breaker Spare Parts
2.2 Breaking unit
B10028
Figure 2-2. Breaking unit
Item Qty Designation Note

1 1 Breaking chamber insulator RR
2 1 Upper current path Included in set of contacts
3 1 Lower current path Included in set of contacts
4 1 Puffer Included in set of contacts
4 1HSB445409-300 en 6
2.3 Set of contacts
Upper current path Puffer Lower current path

B10048
Figure 2-3. Set of contacts
Qty Designation Note

1 Set of contacts R
1HSB445409-300 en 6 5
Circuit-breaker Spare Parts
2.4 Post insulator
B10049
2
Figure 2-4. Post insulator

1 1 Post insulator RR
2 1 Insulating rod RR
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.
6 1HSB445409-300 en 6
2.5 Mechanism
2.5.1 Mechanism
1
N.B. For HPL72,5-300B1US or HPL72,5-300B1GS
Pole A, Pole B and Pole C have different
mechanisms.
Please specify which mechanism that should be
replaced when ordering spare parts.

1 1 Mechanism RR
B10012
Figure 2-5. Mechanism housing
2.5.2 Tripping mechanism

1 1 Tripping mechanism RR
B10050
Figure 2-6. Tripping mechanism
1HSB445409-300 en 6 7
Accessories Spare Parts
3. Accessories
3.1 Absorption agent container 1

2

1 1 Absorption agent container
2 1 Absorption agent R
B10117
Figure 3-1. Absorption agent container
3.2 Density monitor
2
1 1 Density monitor, R 1
temperature compensated
- reference volume
2 1 Density monitor, R
- bimetal
3
(Old design)
3 1 Density monitor, R
- bimetal
(New design)
B10052
Figure 3-2. Density monitor
8 1HSB445409-300 en 6
Spare Parts Accessories
3.3 Sets of seals

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

1 Set of seals 1HSB446309-A R
3.4 Assembly sets

Set of bolts for a circuit-breaker pole

1 Set of bolts 1HSB446309-B R
Set of pins for a complete circuit-breaker pole

1 Pins with locking rings 1HSB446309-C R
3.5 Non-return valve 1
B10053
Figure 3-3. Non-return valve

1 Non-return valve 1HSB442541-C RR
1HSB445409-300 en 6 9
Tools and lubricants Spare Parts
4. Tools and lubricants
4.1 Protective cover
Item Qty Designation Article number Note

1 1 Protective cover for breaking unit 1HSB445237-1 R
2 1 Protective cover for post insulator 5439 142-A R
4.2 Tools for unloading the tripping mechanism
Item Qty Designation Article number Note

1 1 Tensioning tool, circuit-breaker 1HSB446381-A R
2 1 Tensioning tool, disconnecting 1HSB446381-D R
circuit-breaker
2
1
B10054
Figure 4-1. Tensioning tools
10 1HSB445409-300 en 6
Spare Parts Tools and lubricants
4.3 Lubricants
For individual grease and oil, see lubricant instruction 1HSB445409-1.
1HSB445409-300 en 6 11
SE-771 80 LUDVIKA 2006-10-04
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
SF6 Circuit-Breaker Operating mechanism
BLG 1002A
Spare Parts
1HSB515409-200 en 7

ment.
Article number:
1HSB515409-200 en 7
Approval date:
2006-09-22
Spare Parts
LIST OF CONTENTS
1. General ................................................................................ 1
2. Components........................................................................ 3
2.1 Drive unit ........................................................................................3
2.2 Damper............................................................................................4
2.3 Catch gear .......................................................................................6
2.4 Auxiliary contact.............................................................................7
2.5 Heating element ..............................................................................8
2.6 Electrical equipment .......................................................................9
3. Lubricants ......................................................................... 10
1HSB515409-200 en 7 i
Spare Parts
FIGURES

Figure 2-1. Drive unit ........................................................................................3
Figure 2-2. Closing damper ...............................................................................4
Figure 2-3. Opening damper ..............................................................................5
Figure 2-4. Catch gear .......................................................................................6
Figure 2-5. Auxiliary contact .............................................................................7
Figure 2-6. Heating element ..............................................................................8
Figure 2-7. Electrical equipment .......................................................................9
1HSB515409-200 en 7 iii
Spare Parts General
1. General
Spare parts for operating mechanism BLG 1002A are supplied by:
SE-771 80 Ludvika
Sweden
Tel: +46 (0) 240-78 20 00
Replacement modules are supplied complete and fully tested.
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.
4
5
3

cover removed
Item
1 Drive unit
2 Mechanism
3 Control panel
4 Spring battery
5 Heating element (behind protection plate)
1HSB515409-200 en 7 1
Spare Parts Components
2. Components
2.1 Drive unit
B20031
Type of drive unit(1) Article number

1 Motor, 220 V 0-60Hz 2361 113-AU
2 Motors, 220 V 0-60 Hz 2361 113-AV
1 Motor, 110 V 0-60Hz 2361 113-AS
2 Motors, 110 V 0-60 Hz 2361 113-AT
(1) See wiring diagram
or tools. Please also state the order number, if possible.
1HSB515409-200 en 7 3
Components Spare Parts
2.2 Damper
2.2.1 Closing damper
B20032
Figure 2-2. Closing damper
Designation Article number

Closing damper 5256 707-BN
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.
4 1HSB515409-200 en 7
2.2.2 Opening damper
B20033
Figure 2-3. Opening damper

Opening damper HPLxxxA1, 3-pole 5256 707-BP
HPLxxxB1, 3-pole
HPLxxxA4
HPLxxxB4
HPLxxxB2 5256 707-BH
HPLxxxA1,1-pole 5256 707-BR
HPLxxxB1, 1-pole
HPLxxxA2
HPL B1, 1-pole 5256 707-BS
HPL B1, 3-pole 5256 707-BV
HPL B3
HPL B1, 1-pole, HI-speed 5256 707-BY
HPL B2, B4 “50 kA” 5256 707-BT
HPL B2, B4 “63 kA” 5256 707-BZ
HPL B2, Hi-speed 5256 707-CD
LTB E1, 3-pole 5256 707-BX
LTB E2 5256 707-BU
LTB E, US/GS 5256 707-CC
or tools. Please also state the order number, if possible.
1HSB515409-200 en 7 5
2.3 Catch gear
B20034

Closing catch gear Standard 1-coil 5436 009-V
1-coil, with interlock 5436 009-AB
device
2-coils 5436 009-X
2-coils, with 5436 009-AC
interlocking device
Opening catch gear Standard 5436 009-Z
With manual 5436 009-AD
opening device
With manual 5436 009-AF
opening and 69
device
6 1HSB515409-200 en 7
B20035

Auxiliary contact 6- or 12-pole 5751 805-F
18-pole 5751 805-H
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.
1HSB515409-200 en 7 7
2.5 Heating element
6 5 4
3 2 1
B20036
Designation Voltage range Article number

Heating element 110-127 V AC, 70 W 5291 800-R
220-254 V AC, 70 W 5291 800-S
110-127 V AC, 70+140 W 5291 800-U
220-254 V AC, 70+140 W 5291 800-V
110-127 V AC, 5291 800-X
70+140+140 W
220-254 V AC, 5291 800-Y
70+140+140 W
8 1HSB515409-200 en 7
2.6 Electrical equipment

Spare parts for electrical equipment BLG 1002A.
Item Designation Voltage range Article number

1 Contactors 110-125 V DC 5351 749-2
110-130V, 50/60 Hz 5351 749-4
220-250 V DC 5351 749-1
220-250 V, 50/60 Hz 5351 749-3
2 Direct-on-line motor 110-125 V, 4-6 A 5576 0760-2
starters
220-250 V, 2.4-4A 5576 0760-1
3
3 Relay, 3-pole 42-48 V DC 5619 758-4
110 V DC 5619 758-2
125 V DC 5619 758-8
220 V DC 5619 758-1
2
250 V DC 5619 758-7
Relay, 4-pole 42-48 V DC 5619 750-4
110 V DC 5619 750-2
1
125 V DC 5619 750-8
220 V DC 5619 750-1
250 V DC 5619 750-10
4 Counter 42-48 V DC 5692 965-13
110-125 V DC 5692 965-12
220-250 V DC 5692 965-11
B20002
Figure 2-7. Electrical equipment
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.
1HSB515409-200 en 7 9
Lubricants Spare Parts
3. Lubricants
For individual grease and oil, see lubricant instruction 1HSB445409-1.
10 1HSB515409-200 en 7
SE-771 80 LUDVIKA 2006-09-22
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20

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Product Manual

ABB Power Technologies AB

ABB Power Technologies AB

© ABB Power Technologies AB

Figure 1-1. Circuit-breaker HPL 72.5-300B1, 1-pole operated .........................2

1.1 Design of the circuit-breaker

1.2 Weights of the circuit-breaker parts

1.2.1 1-pole operated circuit-breaker

Figure 1-1. Circuit-breaker HPL 72.5-300B1, 1-pole operated

Item Part Weight

1 Circuit-breaker pole See dimension drawing

2 Operating mechanism BLG 1002A 460 kg

1.2.2 2- and 3-pole operated circuit-breaker

2-pole operated 3-pole operated

Figure 1-2. Circuit-breaker HPL 72.5-300B1, 2- and 3-pole operated

Item Part Weight

1 Circuit-breaker pole See dimension drawing

2 Operating mechanism BLG 1002A 460 kg

4 Protective tube and pull rod 1100-4000 mm, 16-64 kg

1.3 The breaking principle

When the arcing contacts (3 and 4) are

Figure 1-3. Circuit-breaker pole in Open position

1.4 Function of the operating mechanism

ABB Power Technologies AB

© ABB Power Technologies AB

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

N.B. Under no circumstances should the operating mechanism be operated without

1.1 Design of the operating mechanism

Front Back, with the

Figure 1-1. Operating mechanism

1.2 Normal operating mode

Figure 1-2. Normal operating mode

1.3 Opening operation

1 Opening catch gear 5

Figure 1-3. Opening operation

1.4 Closing operation

1 Closing catch gear

6 Opening catch gear 4

Figure 1-4. Closing operation

2.1 Remote/Local operation

2 Open/Close operation switch

Figure 2-1. Remote/Local operation

2.2 Close operation

2 Open/Close operation switch

Figure 2-2. Close operation

2.3 Open operation

2 Open/Close operation switch

Figure 2-3. Open operation

2.4 Rapid reconnection

3.1 Drive unit

Figure 3-1. Drive unit

3.2 Mechanical interlocking

6 Operating lever shaft

Figure 3-2. Interlocking mechanism

3.3 Catch gear

Figure 3-3. Catch gear

Figure 3-4. Closing and Opening damper

3.5 Auxiliary contact

Figure 3-5. Auxiliary contact

3.6 Heating element

Figure 3-6. Heating element

ABB Power Technologies AB