5409 704E-5 rev 3 B 88-10-31 ABB HV Switchgear DIRECTIONS FOR ERECTION AND MAINTENANCE OF OrL-1 DESIGNATIONS AND REFERENCES When ordering spare parts, and in ell correspondence regarding this circuit-breaker, state the number of this instruction and the particular part should then be designated as follows: "Are-control device 5409 TO4E-5:AC-23". State the manufacturing serial number of the circuit-breaker in accordance with the rating plate. LIST OF CONTENTS GENERAL DESCRIPTION Page 3 MODE OP OPERATION 4 Circuit-breaker 4 Operating device 8 ERECTION 8 Delivery units 8 Checking of packing specification 9 Storage 9 Lifting 9 Assembly 10 Framework "1 Bracket for measuring transforners 1 Erection of operating device 12 Assembly of circuit-breaker 12 Mounting of current transformers 4 Checking and adjusting of the ON-position 15 Erection of circuit-breaker 16 Connections 16 Terminating measures 16 ‘Trial operation 1 MAINTENANCE 1 Contacts, general 7 Checking the burning of the plug contact 1 Dismantling of the plug contact with pull-rod 1 DH Sunny 8 4h GP BD eee - ‘aD aD5409 704E-5 rev 1 Page 2 LAK 7B-08-28 Replacement of the plug contact tip Reassembly of the plug contact with pull rod Inspection of the arc-control device and the fixed contact Filling up with oil and checking of the level Shaft sealing in the base plate The operating device Cleaning of the circuit-breaker Lubrication of the circuit-breaker TESTING Measurements Connection of speed recorder Operating coils TOOLS SPARE PARTS Page 20 20 20 21 22 24 24 24 2b 24 26 26 27ABB HV Switchgear 041 level indicator “7 Gas discharge valve “8 Cover -9 |Position indicator 4 =1 4 Post insulator 2 3 -4 [Upper terminal }0 | Protective tube 5 1 6 Base frame EEEEE Breaking unit Operating device Lower terminal As-12 |Framework of circuit-breaker The circuit-breaker is a three-pole oil-minimum cirouit- breaker for outdoor connection, intended to be mounted either on a high framework with operating device BLH 54 or on a low framework with operating device BLH 52. The circuit-breaker poles are mounted on a base frame AA-8 containing, among other things, operating shaft, opening springs and position in- dicator AA-9. An arc-control device of cross-blast type is built into the breaking unit AA-5. The fixed contact is provided with an arcing ring and tipped with contact metal. The circuit-breaker poles have gas discharge valves At-2 for the gases formed during interruption, and in pole A there is ap oil level indicator AA-1. On special order the circuit-breaker framework AA~12 can be fitted with eupporting beams for measuring transformers or surge divertere on either long side or on both long sides when two sets are assembled. Connection boxes for the measuring transformers are then placed on special brackets on one end of the framework. A oD aeoee eas Page 4 LAK 78-01-05 MODE OF OPERATI Circuit-breaker of 9 Breaker on high framework 10 6 RS — Figure aB 4B-7 [Post insulator AB-6 [Base frame AB-9 |Position indicator AB-10 | Protective tube AB-13 | Starting spring for opening operation Breaker on low framework Operating shaft with protective tube Bearing with sealing device Pull-rod from operating device Operating link Mechanism housing Operating ara Pull-rod for piug contact ABA14 AB+15 AB~16 AB+17 ABA~16 AB-19 AB-20 The figure shows the circuit-breaker mechanism in the base frame A&-8 when the circuit-breaker is in the closed position. The operating moveuent is transmitted from the operating device via the pull-rod 43-16 and the oper- ating link AB-17 to the conmon operating shaft AB~14 and the three mechanisa housings AB-18. The starting spring AB-13 helps the circuit-breaker mechanism to attain the correct speed rapidly during the opening operation. The oi] dashpot in the operating device reduces the speed towards the end of the opening operat but does not influence the closing speed. The position indicator AB-9 consists of a moving flag AB-911 with the text ON which, in the ON position, covers the fixed flag with the text CFP. The position indicator is visible through a protective plexigiess window. Fer cirouit-breakers cn low framework the position indicators ere p: the operating device.ABB HV Switchgear AC-7 | Post insulator AC~14 | Operating shart AC~16 | Mechanism housing AC~20 | Pull-red for plug contact AC~22 | Flange \C-23 | Arc-control device AC-2¢ | Plug contact AC-25 |Contact housing (guide for plug contact) AC~26 | Fixing flange AC-27 |Holder for arc-control device The operating shaft AC-14 is supported in the mechanism housing AC-18, the supports being o: tight. Its inner part is provided with an which transmits the operating moverent to the moving plug contact AC-24 ty an opereting rod 40-20 made of insulating naterial passing hollow post insulator aC. 7. ‘The breaking unit AC-5 shell be filled wit! The level can be observed from out: in the oil level indicator AA-1. de the pole The gas discharge valve AA-2 is noreally open and thus ventilates the space above the oi] surface. To prevent oil losses in conjunction with interruptions, the valve is closed by the overpressure arising, and the gases formed during interruption are discharged through a small hole. When filling up with oil, the cover AA-3 shall te unscrewed. If an oil pump is available, filling up with oil can be carried out through the cock CB-19. The upper terminal AC-4 is connected to the fixed contact in the arc-control device AC-2} through the holder 40-27. ABB‘Breaking unit Plug tip Lower terpinal Contact guides Post insulator Roller contact Insulating pull-rod Spring washer Flange Lock nut lug contact Link screw Guide for plug contact Screw Figure AD shows the contact housing with the plug contact AD=24, the three contact guides AD-29 and the three roller contacts AD-30. The lower terminal AD-6 is connected to the plug contact AD-24 via the contact guides AD-29 and the roller contacts AD-30. The plug contact is connected to he operating shaft the mec! housing sE-18 by means of the glass fibre rod AE-20 and the operating arm AE-19.ABB HV Switchgear 5409 104E-Srev 2 Page 7 4B Post insulator AE-36 Base plate 45-37 Protective tube E38 Spring 35-39 Operating shaft 28-40 Pull-rod AEG Operating aro AE=42 Mechaniso housing 4E=43 Operating ara AEA dd lass fibre rod 4-45 Fixing flange 45-45 Stop screw Cylindrical pin Connector Spring washer Lock nut Mechanism housing Drain cock Lock nut Spring washer Stud bolt Dise Information plate for measure "a"5409 7045-5 Page & LAK 78-07-05 Operating device ERECTION Delivery units The operating device AA-11, which is of a spring type, effectuates the closing operation, keeps the circuit-breaker in the closed position and frees it for the opening operation. The operating Bovenents are transmitted by an operating rod within the protective tube AA-10. The closing springs are charged automatically by a built-in motor immediately after every closing operation. The opening springs are charged during the closing operation and effec- tuate the opening operation after an impulse to the trip-free de- vice in the operating device. The opening operation always has Precedence and can be carried ovt even during a closing operation. The operating device is provided with coils for electrical remote and local operation and with a pushbutton for local mechanical tripping of the circuit-breaker. The closing springs can also be charged manually by means of a crank. The operating device in- cludes auxiliary contacts, which indicate the position of the circuit-breaker, and terminal blocks for operating and signal leads. The circuit-breaker type HLC 36-52 has an operating device of type BLE 54 or BLE 52. The description of the operating device and directions for use and maintenance are given in a separate instruction. Erection shall be carried out in accordance with the relevant @imension print. 1. The three circuit-breaker poles fitted on the base plate with link systen The breaking unit and post in- t sulators are filled with oil = and always mounted on the base plate. The arc-control devices are mounted in the breaking units. This delivery unit is ready for use and requires only a check of the adjustment of the plug contact, see page 15. For delivery, the gas dischazge valve is replaced by a sealing plug. The poles are stayed against each other with a common bar. ttt 2. The operating device ‘The operating device is within 2 its protective cover and com- pletely equipped and ready for use. breaker framework 3a. The cil All the legs, supporting beams and stays of the framework are bundled together with straps and can be 3e lifted as 2 unit with a pair of lifting slings. Each part is marked with letters A, B, C etc.y see under the heading "Assesbly of the Framework".ABB HV Switchgear 3b. The operating rod wit! ive tube (cee figure AD) ——e- the link between the & 3e 2. a washers are packed ine ate box. oO Connection boxes 3a Cables for the ceconéary Checking of packing specification Check with the aid of the separstely sent packing specification thet ell the parts have been received. Check alsc thst the Parts of the circuit-breaker have not been desaged during trans- port, and during this inspection pey special attention te aii insulators. Storage Before assembly the poles, filled up with oi! to the correct level, and the base plate may be stored outdoors under 2 ter- fatlin, The circuit-btreaker framework or parts of the frat work may also be stored outdoors covered by e tarpaulin. The same applies to the operating device, which in addition must have the electrical heating switched on. Measuring transformers cen also be stored outdoors covered by a tarpaulin. For a longer period of storage, and aise under severe 2tuos- Pheric conditions, the base plate AA-8 should te placed cn suitable support so that the lower parts are not damage: During lifting of a circuit-breaker without the framework the centre of gravity lies above the base frame, and there- fore suitable measures must be taken to prevent the circuit breaker from overbalancing. AbDPage 10 TO4E-5 LAL 77-01-05 Assembly ‘The circuit-breaker frame k shall be ascenbled accoréing to the figure, and consists of the parts given in the tables below. Each part has been checked in a jig regarding dimensions and @rilling, and is marked in accordance with the table, with capital letters, F A B 6 I [Figure Ba [Figure Bas | Number |Part Designa- | Without | with Length Part Designa- | Number] Length Marking | tion bracket | bracket | mm Marking | tion = la tee 2 2 ayo [a ws [2 [eno B Leg 2 2 2140 B 2140 c Foot 4 4 60 c 60 > Girder - 1 1555 |r | z Girger - 1 1555 | Te0 F Fastening je | 1670 | iron 2 2 780 | | 830 G Stay 2 2 1670 I | 952 |B Girder 2 | - 830 x 2090 |Z Stay 4 6 952 P 1655 J Girder - 2 | 1870 RL 1655ABB HV Switchgear oll be asse the parts given in the table below. in a jig regarding disensions and @: varked in accordance with the table with capital le: Figure BAB Fort carking | Designation Nuwoer j Foot Leg Leg Stay Stay Girder I e BA - dashes - and figure w the brackets for the if transformers. For double brackets on framework according to figur the girders D and E have the leng*h 2500 um. In this case the brackets are fitted to each side of the framework (see figure BD-5), If there is a connection box for measuring transformers, two fastening irons narked N, length = T46 are fixed cn cne end of the framework a special clamp 1) they can be p: two sets of measuring transforners, both connection boxes can be mounted on the same fastening iron. See figure BD-€. 4 articies packed in box Jc, page 9. 4h BD ED PDEting device The operating device shall be placed in the framework in ec- cordance with the relevant dimension pri The device, which shall be in the OFF position with dischergeé closing springs, shall be properly secured. The pul]-rod AE-16 shall be secured to the connector on the operating arm of the device, and the protective tube AE-10 shall be placed above the pull-rea. pez ASE] titers Tansee 7 a ® “ 2 Pigure EB BB-1 | Rating plate on the base plate of the | | circuit-breaker |BB.2_| Rating plate on the operating device Ensure that the manufacturing serial number of the opereting device in accordance with the square "I" on the label BB-2 is the same as the one in the corresponding square on the label BB-1. The serial number of the circuit-breaker is in square B, Assently of circuit-breaker The base frame of the circuit-breaker vith the three circuit- breaker poles shall be placed on the fravework in accordance with the dimension print. The frame shall be fixed firmly against the framework. The pull-rod AE-16, with the spring washer end lock nut AE-36 and 9 and discs AE-47 and AE-45 shall be preliminarily screwed in with 11 turns onto the connector of the circuit-breaker. The two stud bolts AE-44 shall be fastened in the circuit-bresker. The protective tube AE-10 will then be clamped with the two stud bolts AB-44. Loosen the connector in the operating device and screw it wit approximately 11 turns onto the pull-rod.ABB HV Switchgear The transport plugs BC-4 on the circuit-treaker poles shal) be moved and replaced by the seperately packaged gas discharge va. BC-6, with their outlet openings downwards. ¥ ; The top cap BC-7 with the oil level indicator BC-5 shall be turned so that the oil level indicator can be seen from the | side of the operating device. (See the relevant dimension print). After assembly, check that the circuit-breaker poles are filled with oil. See the instructions under the heading "Filling up with cil and checking of the cil level", Check also the oil level in the oi] dashpot in the operating device in accordance with the instructions. ABDBase plate End of frerework End of framew: Supporting bes Girders Connection bex | cabies Fount the connection boxes BL-6 and the current transformers. The seal- ing device and nece: clamps (5 m. steel strip 10x0.3, BD-2/3 lock washers 5: 5 for the cable: ere seper. ately packed and sent in the connection toxes. The high voltage leads vetween the circuit- breaker and the current transforners ere not shown on the above figure. Figure 3E Cable clenps ED-6:1 an ty zpei4 u EE-1 | Cables BE-2 | Stee) strip BE-3 | Lock washer BE-4 | Supporting bean, 4 (BD-4215 2) The cables BE-1 shell ve laié beside each other and kept to- 3 gether by means of the steel + strip BE-2, which shall be cut off to'a suitable length y pulled tight and locked by a washer BE-3, The cables shall then be placed so that the lock washer is turned to- wards the supporting bean BE-4 and locked with another lock washer outside the bean.ABB HV Switchgear eee eet Page 15 BIB 88-10-32 Figure EF Cable clam: 8: BF-1 | cables BF-2 | Steel strip BF-3. | Lock washers BF-4 | Leg of fremewori: (D-3) Also on the legs of the work the cables should b placed beside each other 2 kept together by the stee! strip BF-2 and the lock washer 3F-3, The lock washe> should be turned outwards when fixing onto the les. Checking and adjusting of the ON-position On each circuit-breaker there is an instruction plate in accordance with figure BG, which gives a test measurement of 146 mp. from the upper edge of the arc-control device AC-23 to the plug tip. During adjustwent of the three poles in the workshop this measurement is persitted to deviate a maximum of plus 2 mm. The measure "a" in figure AE shall be adjusted according to informa- tion plate AE-46 in the mechanism housing aE-40. This "a" measure gives the ON-position of the circuit-breaker. Operate the circuit-breaker slowly by hand towards the closed position in accordance with the instructions for the use of the operating device. Adjust the ceasure "a" by turning the pull-rod AE-16 (left-hand thread in one end and right-hand thread in the other) in suitsble direction. One turn on the pull-rod increases or decreases the measure "a" 3.5 um and the measure "x" (figure BG) 10 am. When the "a" measure has been obtained the plug contact will be in its correct ON-position in the arc-control device, that is to say the measure "x"=146 mm according to figure BC. © Adjusting end checking contacts e Figure BG 36-1 _| Instruction plate Replace contacts when distance is 152 a0 Arc-control device 5414 082-F | Nove: 1) Before operating the circuit-breaker - even for a slow manus] operation - the nut AE-39 shall be tightened. It may only be loosened during adjustment of the length of the pull-rod AB-16. 2) Bo not operate the circuit-breaker at full speed until it hes been ascertained that the circuit-breaker poles and also the dashpot are filled with oil of the correct quality to the c Check that greasing has been done with grease & betwee AE-45 and washer AE~47,Connections hen the "o" measure is correctly adjusted (and therexith the x" measure according to figure BG) the circuit-bresker is operated at full speed, after which the measure "a" is checked again. ection of circuit-treaker The circuit-breaker shall be set up in accordance with the relevant dimension.print. The foundation must be level and sufficiently firm. No rocking or twisting can be allowed. Deviations of any nature should be corrected by means of sh: plates screwed onto the foundation. A final check shell be wade, to ensure that ail the bolts and nuts in the framework are sufficiently tightened. #11 leads shall have an area sufficient to ensure that heat is never led to the circuit-breaker. Tre high voltage leads shall be connected to the terminals sC-4 and AC-6. The leads shall be placed so that the circuit-breaker poles cannot be subjected to damaging nechanicel stresses. Clean all contact surfaces carefully before assembly. It is advantageous to coat all current- carrying surfaces with a thin layer of grease E. The operating and signal leads shall be connected to the ‘ersinal blocks in the operating device in accordance with the relevant connection diagram. The earthing lead shal) be connected to the earthing device, wnich is located on one of the legs of the framework. ‘Terminating weasures Clean and lubricate the circuit-breaker before taking into service, in accordance with the instructions on page 22. Lubrication is especially necessary if the circuit-breaker has been stored for a long period before erection.ABB HV Switchgear opera MAINTENANCE Contacts, general Operate the circuit-breaker a few times in toth directions, doth by means of the local push-buttons on the operat: device and of electrical rerote centro}. If a measuring drum is evailable, record the woveuent diseraa, which should be compared with the standard diagram enclosed, and also filed for comperison with diagrams recorded later, order to oktsin some a breaker, See heading “Testing”. If nothing abnorual occurs during the trial operation, the circuit-breaker is ready to be taken into service. The circuit-breaker in service ehali be maintained regulerly - the first time after one year's service and thereafter ev third year unless service experience motivates other inte: las During overhaul the circuit-breaker shall te in the CFF-positicn and the closing springs of the operating device shall ve discharged. NOTE: Deformed locking elements (e.g. spring washers, cir- clips) and deforned or damaged gaskets must be replaced. Circuit-oreakers which have been in the closed position for an extended period get 2 coating on the current-transpitting surfaces of the contacts, which increases the resistance i the wain current circuits, This coating can be easily re- moved by operating the circuit-breaker a few tines in the unloaded condition. This operation also fevourably affects the component wechanisas and contributes to « high degree of Preparedness, while at the same time constituting a check on the operating and signal devices. All breaking contacts are tipped with contact material and dimensioned for a large number cf interruptions of moderate currents, As a guide for determining the programme of over haul, it can be stated that the contacts should be checked after 400 interruptions of the rated current or after three interruptions of the short-circuit current. For inspection of the fixed contact see the Information for the arc-control device of the circuit-breaker. Checking the burning of the plug contact In order that the estimate of the degree of burning shall ve fairly reliable, the measurements must be made accurately. ABB ASEA BROWN ROVERCover Fixed contect Ruler | Are-controi device | Terminal holder g contac: UW 3 Operate + at full speed into the closed position and dis- mantle the cover CA-1 and the fixed contact CA-2. Place the rulers Ck-3 as shown in the figure and read the measure "n". Nominally this should be 287 uz. If the measure “n" approaches 292 wi plug contact shall be di; mantled for exai When reassembling the fixed contact CAk-2, check carefully that the O-ring CAA-7 is without defects. It shall be correctly placed in the slot and must not be damaged. If the difference between the measure "n" of the poles accord- ing to figure CA, on a newly checked circuit-breaker is greater than 2 mz, an adjustment with CB-12 mst ce made. The oil shall then be drained off and the cover CB-i8 on the mechanist housing CB-20 shell be removed in accordance with the instruc- tions under the heading “Dismantling of the plug contact with pull-rod". For adjusting the plug contact, the nut for the link screw CB-12 shall be loosened, whereupon the insulated pull-rod shall be turned until the required measurement is obtcined. 5 on. : Figure CAA |caa-2 [Fixed contact Caa-4 | Arc-control device caa-7_| O-ring Figure CAABB HV Switchgear of the plug con tact with pull During dismantling, the circuit-treaker position. The closing spring in the opera: discharged, All the oil shal) te drained from the ‘the cock CB-19. The cover CB-18 and the gasket C2. removed by taking away the bolts, nuts and spring washers C2-1 The circlips CB-13 shall be removed and thereafter the pin as : a The plug contact Cb-8 and the insulating pull-rod 03-11 ca: now be pulled out of the circuit-breaker through the hole at the bottom of the mechanism housing CB-20. In the poles without s drain cock there are six litres of oil left. ‘This 0i1 shall be drained off ty wiscrewing the bottom plug. Figure CE Breaking Guide for plug contact Plug contact Ro2ler contacts Post insulator Pull-red for plug contact Lirk screw Circlips cB-14 | P CB-15 | Operating arn 16 Bolts, nuts and sp: cB-26 | ABB(7 24 If it has been deternined by measuring in accordance with figure CA that the burning on the plug contact tip CC-21 4 cr approaches 6 om, the plug contact tip must be replaced by a new one. 23 he plug contact with pull-rod The plug contact ard pull-rod stall be mounted in the correct pole end the plug contact shall then be pushed in so far that ‘the link screw CB-12 can be fastened by the pin CB-14 and the ‘The cover CB-18 with the gasket CB-17 shall be mounted in their proper place on the mechanism housing CB-2C. The bolts shall be well tightened so that the gasket makes an oil-tight seal. Fill with cil in accordance with the instructions on page 27. A closing operation shal! be made with the operating device and thereafter the dimension "n" in figure CA shall be measured. This measurement should be in agreement with the values given in the figure AB. Inspection of the arc-control device ané the fixed contect ‘The fixed contact and the appertaining arcing ring in the arc- contro! device ere estimated to have such a long life length that the degree of burning need be checked only in conjunctio: with overhaul of the plug contact. See the applicat’ structicn for the arc-control device. The weight of the ere- control device is epprexinately 10 kg (22 1b) end it con there- fore be lifted by hand.ABB HV Switchgear During service, the oil level ray only be p level s rly checked. all be approximately in the ¢ ator CE-25. 24 t an oil ter cf the el The cireuit-breaker has room for proximately 90 kg. of oil. The w and the lower oi] speces in each circuit-treaker pole, CE-6 and CE-10, are connected with each other ty the check valve CB-26, Refilling with therefore, requires @ certain tine. Oi1 is filled fron the top when the cover of the top cap CE-1 has been re- zoved. ‘The oil can be drained drain cock CE-19. Figure CE Top cap Breaking unit Contact device 0i1-filled post insule Drain cock new has been = ie 26 CE-24 |Gas discharge valve CE-25 | 011 level indicator CE-26 | Check valve : The upper oi) space beccnes polluted in 3 E 40 due course by the conbustion products = po formed during breaking, withcut its Ue i extinguishing or insulating properties ik ! being appreciably impaired. The I i breaking unit should be cleaned on | | inside during maintenance of the con- 4 | tacts and, at the same tine, the | I should be filtered or rep! F oil. If it is suspected that the in- Pe sulating capability of the oil ‘| reduced by ncisture, this should ve a_/*) checked by 2 crackle test. (The oil in the lower of] space is very little affected by breaking.) For refilling, first class non-free zing cireuit-treaker oil, ASE: oi! 7 1301-102, shell be used. This hee s fregzing point vhich ie lover thon ~50°C and a yiscosity which is na 19 40c8t at -20°%C.CF-3 and CF plate age occurs round the sha 0 shall be replaced 9, the O-rings |Fawe cr-1 | Base plate oe ares | or-3 O-ring $60/54.5x3 Ball beering O-ring $70/64.5x3 Spacer Washer 930.25x50x1 Mechanism housing Shaft For-10 hopes jjer-12 icF-13 ler-14 forts CP-16, her-17 Jcr-1e ing #40/ Sleeve Cover Pin Indicating flag Operating ero Screw Pull-rod Screw 34 5x3ABB HV Switchgear 5a09 fea Lax 76-08-28 Before dismantling, a check shall be made that the circuit-tres is in the open position end that the closing springs of the ing device are discharged. The circuit-breaker poles shal) be erptied of oil. ountes . e 1, The cover CP-12 of the mechanien housing shal) te ¢: On the pull-rod CF-17 the pin CF-13 and the correepond. in the lower end of the pull-rod in the operating device be dismounted. 2, The screw CF-16 shall be loosened and the operating arm cF-'5, the washer CF-7 and the spacer CF-6 shall be pulled off. 3. On circuit-breakers of recent design the sleeve CF-1! has teen fitted with two threaded holes M4 according to figure CF. The screvs shell be threaded into these holes and the sieeve shall \ then be pulled out. Thereafter the ball bearing CF-¢ shail ce coaxed out. Two screws M4 shall be threaded into the two holes in the sleeve CF-2 and the sleeve shall be pulled out. If the sleeve CF-11 has no holes it should be fitted with holes \ on site. 4, The shaft CF-9 and the sealing box of the mechanism housing shall be cleaned with a soft cloth so that no scratches occur on the sealing surfaces. 5. The O-rings on the sleeve CF-2 shall be dismounted and cleaned. The O-ring slots, the shaft CF-9 and the sealing box shall ve lubricated with teflon grease F. New O-rings shall be ccunted and the sleeve shal) be carefully guided into place. 6. The remeining parts shall be mounted in the opposite order of sequence to the one described above.The operating device For maintenance of the operating device, see the directions in the relevant instruction. Cleaning of the circuit-treaker ne circuit-breaker shall be cleaned regularly in accordance with local service experience and at least twice e year. Specie] attention shall be paid to all parts made of insule- ting material. Clean cloths of non-fluffy materiel pust be used. Cotton waste is unsuitable and should be avoided. on of the circuit-breaker ‘The circuit-breaker shall be lubricated regularly. ‘The bear- ings end sliding surfaces shall be sparingly lubricated with oil B and the operating coils with oil A. All untreated steel surfaces exposed to the air shall be coated with a thin coat of grease E, Grease E and oi] B are vodern universa) lubricating media which, with advantage, may be used to replace all types ear- lier recommended for lubricating circuit-breakers and opera- ting devices, with the exception of oil A, which should still be used for lubricating precision apparatus such as operating coils and valves. The trade names of approved lubricants with the above designa- tions are givenon information sheet 5409 S068. For checking the mechanical and electrical operation of the circuit-breaker certain tests are of great value. With the aid of the data obtained during tests the type and extent of mea- sures to bé taken during subsequent overheuls can be determi- ned. TESTING Asa basis for testing use the "Functional Values" according to the list of information. Measurements The tests which are primarily recommended are as follows: a) Measurement of the resistance of the current path >) Measurement of the closing and opening time c) Measurement of the closing end opening speeds of the plug contact by recerding the movenent diagran a) Measurement of the lovest operating voltage for the operating coils e) Measurement of the resistance in the operating coils and heaters The resistance of the current path in a) ie measured at the terminals of the circuit-breaker. Measurements can be made either by the volt-ampere method or by means of a Thomson bridge. ‘The closing and opening times of the circuit-breaker in b) can be measured by means of a cynchronous clock or by means of 4SEA's recording drum 1776 900-A according to inforsation No. 5691 $0¢Ba. A wovenent diagram for c) can be recorded on the operating link AB-17. 4 recorder with a rotating drum with known speed shall be connected as shown in figure DA. The method of determining the speeds and the permissible liit velues can be seen from the "Functional Values". On request, information will be given by ASEA regarding the recording apperatus with rotating drum in accordance with our information ,. 5691 9O1E. See the heading "Connection of speed recorder" on page 25.ABB HV Switchgear Figure DA DA-1 | Operating shaft DA-2 | Indicating arm 1657 731-A Ta-3 | Hole DA-4 | Indicating rod DA-5 |Speed recorder 1777 593-C DA-6 | Connector When measuring the speed of the plug contact with the speed recorder DA-5, the indicating arm DA-2 shall be mounted onto the operating shaft DA-1 ‘The arp shall be fastened to the shaft with the bolts and nuts which are already there. The indicating rod DA-4 should be fastened with its connector DA hole Da-3. 6 in the5409 TOLE-5, Fage 26 LAK 76-01-05 Operating coils As a supplement to points d) and e) under the heading "Measurements" on page 24, the following data which applies to the coils for the most usual voltage is given below: Direct voltage | Resistance | Designation | volt ono for ordering 220 260 71-6 110 70 -aR 55 20 -s 4a 5 2 24 3.5 2 TOOLS The following tools facilitate the maintenance of the circuit-breaker. Tool Number Intended for Speed recorder | 1777 595-C | Checking of the speed of the plug contact Recording drum | 1778 900-A | Measurement of the operating times of the circuit-treaker Indicating arn | 1657 731-8 | Speed recorder 1777 593-CABB HV Switchgear SPARE PARTS ‘igure BA Name of item Qty/complete breaker O-ring O-ring O-ring Gasket Oil gauge glass Gasket Fixed contact Are-control device Contact tube Contact piece Insert Gasket Gasket Contact tip Plug contact Gasket 6x6 1-645 Spiral 1-660 Insulator Pull-zod Gasket Cock Gasket Gasket O-ring URN Be UO OU OU SU OU 5409 TOaE-5 Page 27 LAK 78-01-05ABB HV Switchgear pence anel Lek 85-05-23 SPARE PARTS OIL-MINIMUM CIRCUIT-BREAKER TYPE HLC 36-52/1250 B RESERVDELAR OLJEMINIMUMBRYTARE TYP HLC 36-52/1250 B aeeen ae oon } Of Oe AMYAAAAAY Recommended spare parts are marked R Rekonmenderade reservdelar ar markta For more than 10 breakers in service we also recommend spare parts marked RR For mer dn 10 brytare i drift rekon menderar vi dven reservdelar mirkta RR5409 725-2 Page 2 Sida 2 Lek 85-05-23 Following information must be given with the order for spare parts 1 Complete type designation and manufacture number of the breaker. For example: "HLC 36/1250 B No. 2185 119" 2 Name and article No. of the parts. For example: "Gasket 2152 939-3" 3 The List contains the number of parts required for one complete breaking element. At ordering of complete sets of spare parts for one or several breakers this number must be multiplied by the number of breaking elements the breaker/breakers consist of. For example: One HLC 36/1250 B consists of 3 breaking elements. Thus one complete breaker requires 3x5 = 15 contact pieces 2658 994-3. Vid bestallning av reservdelar m&ste féljande uppgifter Lannas 1 Fullstindig typbeteckning och tillverkningsnummer fér brytare, Ex: HLC 36/1250 8 nr 2185 119" 2 delaras benamning och artiketnr Ex: "Packning 2152 939-3" 3 I Listan anges det antal delar som ing&r i ett komplett brytelement.. Vid bestdllning av kompletta satser reservdelar tilt en eller flera brytare m&ste man allts& multiplicera med det antal brytelement dessa inneh@ller. Ex: HLC 36/1250 B innehAller 3 st brytelement. Fér en hel brytare Btg@r allts@ 3x5 = 15 kontaktstycken 2658 994-3,ABB HV Swi sheet blad See sheet Se blad See sheet Se blad O00 5409 725-2 Page 3 Sida 3 LBk 85-05-23 QE See sheet 4 Se blad See sheet Se blad See sheet Se blad‘age 4 Sica Lek 85-05-23ABB HV Switchgear elele OO } \ | } i i osdooe ABB5409 725-2 Page 6 Sida 6 LBK 85-05-23ABB HV Switchgear 5409 725-2 Page 7 Side 7 LBK 85-05-235409 TO4E-T rev 2 ABB HV Switchgear "Lx 84-01-09 MAINTENANCE INSTRUCTIONS OJL-MINIMUM CIRCUIT-BREAKER TYPE HLC 72.5/2000 (U) DESIGNATIONS AND REFERENCES When ordering epere parts and in inquiries and other correspondence, ‘the type designation and manufacturing number of the circui breaker according to ite rating plate, the number of these In structions and the designation of the parts concerned shall be given as in the following example: Contact piece 5409 704z-7-C-10. LIST OF CONTENTS ‘Type designations Page 2 General information on the maintensnce of the circuit-treaker Protective measures Reducing of pressure in the bresking unit Emptying of oi] Breaker pole Dismounting of top cap Cleaning of oi1 level indicator Fixed contact Arc-control device Roving centact 2 Moving contact with pull-rod 3 Adjustment of moving contact with pull-rod Contact device Exhaust gas filter Overpressure valve Mechanism housing 19 Insulator types 20 External mechanism 2 Dashpot for opening operation 22 Sterting buffer 24 i Filling up with oi] 26 : Pressurizing 21 Testing 29Type designations There sre 2 mein variants of the circuit-breaker, with the following type designation: © 12.5/2000 Rated voltege 72.5 Normal current 2000 A ‘The breaking units are pressurized, which makes the circuit-breaker restrike-free. Normal working pressure 0.3-0.7 MPa can be read on manometers placed on the mechaniem housinga. © 12.5/2000 U Rated voltage 12.5 Normal current 2000 A The breaking units are not pressurized and the circuit- breaker is not restrike-free. It has no manometers on ‘the mechanism housings. Generel information on the meintenance of the circuit-breaker Circuit-breakers which have not been operated for a consid~ erable time acquire a coating on the current-carrying sur- faces of the contacts, which increases the resistance in the main current paths. This coating shall be removed by means of operating the circuit-breaker a few times st no- load. Operating constitutes, in addition, an appropriate exercise and a check of the functioning of the operating equiprent. A routine overhaul to check the oil level and pressure of the breaking units should be made as often as an opportunity presents itself. In areas where there is air pollution, ell sulators should also be cleaned at the same time, with clean cloths of non-fluffy material.ABB HV Switchgear The circuit-breaker shall, during overhaul, ve dead and earthed. In addition, care shall be taken that the circuit- breaker is in the open position and that the closing springs of the operating device are discharged (except in the case of certain specified action and checking of measurements) NOTE: If both the terminals on the breaking unit are earth the operating times of the ci stance, cannot be measured. Draining off of oil, reducing of pressure in the breaking uni and opening of the top caps should be carried out in accoré- ance with the directions given in these Instructions. During all handling of circuit-breaker oil, evacuation of gas and opening of top caps, the use of open fire and tobacco smoking are forbidden.5409 TG4E-7 Page 4 LEK 62-04-20 Figure 4 Evacuation of gae and oi} cock Hose for evacuation of gas Circuit-bresker framework Hose for gas filling and evacuation Cock R 1/2" Cock R 1/2" Hose for evacuation of gas 032 drum Nitrogen gas cylinder 8 cock shall always remain openABB HV Switchgear 5409 704E: Page 5 LKK 04-20 Reducing of pressure in the breaking unit In order to be able to carry out a check of the condit: the contacts and arc-control devices, the top caps of the breaking units mst be opened. Before this can be done, che pressure must be reduced. 1 For a pressurized circuit-breaker, evacuation of gas and open- ing of the *reaking unit shall be ca: with the following directions: ta For evacuation, the gas filling equipment recommended by ASE (catalogue No. LA 937 0014) or something similar shall te used (see Figure A). The cock A-1 shall be closed. The drain hose A-2 shall be fastened to an appropriate place, e.g. in the circuit-breaker framework A-3, and the hose shall be directed away froz working site at the gas cylinder and from flammable obje The filling hose A-4 shall be connected to the upper cock A-5 of the circuit~breaker and the cock shall be opened. +b Care shall be taken that there is no-one near the cutlet of the drain hose. The safety lisit is a winimn of 2 wy The drain valve A-1 shall be opened. te When the gas has been emptied out of the top cap the circuit- breaker shall be operated 3 times and a large part of the gas which is dissolved in the oil will then be released and es- cape. 1a The drain valve A-i shall be closed and nitrogen ges from th gas cylinder 4-9 shall be filled into the breaking unit until the overpressure valve opens. The drain valve 4-1 sha be evacuated. 1 be opened and the gas shall again ve Gas filling and evacuation shall be repeated according to item 14. Non-pressurized circuit-breskers can contain some overpressure and for this reason the cock A-5 shall be opened before the breaking unit is opened. The procedure described in item i is not required. At major overhauls or replacement of oil, the oil shall ve emptied out through the drain valve A-6 and the hose A-7 into the oil drum 4-8. Ewptying of oil will take less tine if the unit has been pressurized to 0.1-0.2 MPa with nitrogen gas. ABB5409 7048~ Page 6 LKK 64-01-09 Breaker pole Figure B Breaker pole See also ‘Top cap Inner cap (pressurized design only) Exhaust gas filter +P Terminal flange Overpressure valve +0 Arc-control device E Fixed contact Moving contact b+ KHL Rolling contact 3-10] Insulator B-11] Lower terminal flange B-12| Insulating pull-rod +L 3-13] Mechaniew housing - bottom frame +T 3-14] Manometer (pressuri design only) B-15| Cocks 3-16] Terminal B-17| 0i1 level indication B-18] Gasket 1) B-19| Gasket 2) B+20| O-ring 9330/319.3/5.7 1) 2) For pressurized design 6196/150 t= Not pressurized design $205/150 In the case of circuit-breakers with oil gauge glass (B-17( the gasket B-19 has the dimensions 960/50.5 t=3. In the case of circuit-breakers with level indicator (B-17) the gasket B-19 has the dimensions 960/54.5/3 (O-ring). x Tightening torque max 40 Nm if the insulators B-10 are spiral fastened according to figure SA.ABB HV Swit 5409 TOSE-7 Page 7 LEK 82 04-20 cap When the breaking unit has been emptied of gas the top cap 3-1 can be dismounted. In pressurized circuit-breskers there is also an inner cap 3-2, which must be lifted out for the contacts to become accessible for dismounting and insp+ Draining off of oil is not required for a simple inspec: of the contacts. At replacement of the t: the nov: plug contact or at inspection and cleaning of the oil level indicator B-17 and the overpressure valve B-5 the oil level must, however, be lowered. Clea ng of oil level indicator The circuit-breakers can be fitted with either an oil ga! glass or @ mechanical level indicator B-17 for the oil. Cleaning of the mechanical indicator must be carefully carried out by means of washing with, for instance, petroleum spirits. After cleaning, a check shall be made that the movable parts move easily without tending to get caught. ADDThe screws which hold the fixed contact B-7 shall be loosened and the contact shall be lifted out. If the contact is undamaged, it cen be sssumed that the moving contact B-8 and the arc-control device B-6 are free from defects. If the contact is burnt, the tip of the moving contact 3-8 and the arc-control device B-6 should be inspected and, if necessary, repaired. If the burns on the fixed contact are minor, it is sufficient to rub avay any blisters with a fine file. If the burns are so large that the dimension "x", Figure C some- where around the circumference begins to approach 0 mm, the con- tact must be repaired. Figure C Fixed contact js, Contact bracket Retaining ring Check valve Countersunk head screw M5x12 Washer Screw M5x12 Connection Screw M5x8 Spring Contact piece Contact holder Ted arcing ring Plug contact The arcing ring C-13 and the tab (-12 are made of arc resistant mate- rial. The arcing ring is pressed fast to the contact holder C-11, which means that if the arcing ring is so burnt that it can no longer be used, both it and the contact holder must be replaced. i 1. The screws C-4 shall be dis- a mounted and the contact holder wl C=11 shall be carefully dravn ' ' t ! [1 off so that the springs C-9 end the tabs C-12 do not get lost. 2. The contact pieces C-10 hall be changed. Before the screws C. are tightened @ check shall be made that the new contact pieces are lying parallel with the centre line of the contact bracket.ABB HV Switchgear 5409 7048-7 Page 9 LEK 62-04-20 Figure D Mounting of fixed contact 5 a1 | Rubber bana D-2 ct piece D-3 | Guide plug $23 a D-4 | Tab p-5 | Springs 3. 2 springs D-5 shall be mounted : 1 the slot on each contact piece D-2. It is appropriate to fasten the springs with a rubber band D-1. 4. In order to facilitate mounting the tabs D-d a guide plug D-3 th the diameter 23 mm shall be inserted into the contact opening. The tabs shell be mounted from atove in the e slot on each contact piece as the 6 0 upper arrow shows. Qe 5. The contact holder C-11 shali be carefully moved down over the tabs and springs. The contact holder shall be directed so that the screw holes will centre with the corresponding screw hole in the contact bracket C-1. The rubber tand shell be removed and the contact holder shall be pushed down. 6. The guide plug shall be removed and a check shell be made that the steering on all the tabs C-12 is in the slot on the arcing ring 0-13. 7. Finally, a check shall be made that the contact pieces with their tabs are freely movable in relation to each other end that they, after being pressed in, return to their positions of rest. The screws C-4 shall be tightened. 8. Mounting Before the fixed contact is mounted on the arc-control device the contact surface of the top bracket E-2, which is of alumin- ium, shell be coated with a thin layer of grease E in order prevent oxidation. The surface shall then be polished with an emery cloth, with the grease remaining on. The corresponding contact surface on the fixed contact does not need to be treated as it is silver-plated. The fixed contact shall be put into place and carefully pressed down through the O-ring E-18. The screws E-20 shall be tight- ened. Any superfluous grease shall be wiped away. ABB2403 TO4E-T Fage 1C LKK 62-04-20 Section A-A | Oa ts ss os wor anaud th es ‘ E-10 E-11 E-12 E-13, E14 E-15 E16 E18 E-19 E-20 Figure E Arc-contrel device Fixed contect (Figure C) Flange lange Insulating tube External tube Distance tube Top disc Gap disc (five) Guide bolt Spacer Roll pin 5x12 Roll pin 8x20 Pin Onring $60/54.5/3 Screw ScrewABB HV Switchgear The screws holding the arc-contro} device B-6 fast shal LEK 62-04-20 and the arc-control device shall be lifted out. Figure F Figure The arc-control de be replaced with @ new one or repaired if the hole in the top gap 4 elliptically from d=25 mm to ¥=28 mo according to Figure F. In the case of minor turns or if the arc-control device is only contaminated by sooty oil, it is sufficient to rinse it in pure circuit-breaker oil. ‘The arc-control device shail ve dismounted by means of loosen- ing the screws E-19 crosswise and then removing the flanges E-2 and E-3, the externa] be taken out and cleaned. Severely burnt parts shal) be replaced by new ones. At remounting of the are-contro! device the disc package in the device shall be compressed with a force of approximately 70 kN. In order to obtain this force the dimension "a" shall, at mounting, be 2,5-3,5 mm, See Figure G. This is achieved ty placing a number of spacers E-13 on top of the bottom dise E-11, Care shall be taken that the washer package ie well pressed down into the external tube E-5. : The flange E-2 shall be put on and the screws E-19 shall be carefully tightened crosswise until the flange E-2 is pressed against the flange E-3. During mounting the fixed con- tact E-1 shall be mounted on the flange E-2 end a guide bolt with f24am shall be put into the disc package E-7-6-9-10 and “it. The guide bolt can be ordered from sSBi - article number 6896 730-1. P r to mounting, @ check shall be ade that the contact ourface between the flanges E-? and E-3 is well cleaned from oxide. A > AD »so 3 ‘The moving plug contact rod H-5 is fitted with a threaded-on contact tip H-3 of arc-resistant copper-tungeten alloy. In order for the contact tip to become accessible for inspection and replace- ment, approximately 10 litres of oi] should be drained out of the breaking unit. With the help of the tool H-i the con- tact tip can be threaded off. The tool shall be pressed against the tip and pulled round with @ T-spanner with square 12.5 mn (1/2") socket. Minor burn blisters can be rubbed away with e fine file. If the dimension "2" is burnt down to 12 um or if the tip is severely burnt obliquely, it should be replaced with a new one ("2"=16 mm). The ring H-4 shall also be replaced if it is burnt. At mounting care shall be taken to turn the cup spring H-6 as shown in the figure below. Figure H Moving contact Tool - catalogue No. LA 937 0070 Clamp Contact tip Ring Contact rod Cup spring $18.5/10.2 t=0.9AB B HV Switchgear oving contect with pull-rod these parts are to be inspected paired, all the oil must ve emptied out of the breaker pole and the pole must be loosened and lifted from the bottom frene of the circuit-breaker, after which the If the contact rod K-1 or the pull-rod k-é are replaced with new ones, the dimension "L," must be measured and reset before holes for the roll pin K-2 can be bored. Measuring shall be carried out in accord- ance with Figure L and its text. Figure K Moving contact with pull-rod Contact rod Roll pin 3 1-20 Cup spring D=23/12 c=1.5 Nut mi2 Bye-bolt Miz Lock ring $11 Pin $12 135 Pull-rod x K K Ke K. K. K+2 146 *5 moving contact with pull-rod according to Figure K ‘The dimensions "L," and "L," shal measured. "L," shall be 2621 um when the ex- tefnal reference dimension "a" is 700.5 mm in the fully closed posi- tion. See Figures T and ¥. Ly aby thy = 37 L, = the distance between the centre of the hole $12 in the operating arn I-4 and the upside of the mechanism housing. Figure L Contact + pull-rod length Are-control device Contact rod + pull-rod (Figure K) Mechanism housing Operating aroABB HV Switchgear Contact device = j 8-9 Disc 7; | : Rolling contact Tae” Contact guides (three) e", aaa Pull-rod + plug contect ( ¢ 3 Hollow insulator for the break: ae unit : j ¥-6 |ferminal flange 7 I M Gasket 1) Y ¥-8 [Screw M6x25 4 ¥-9 |Cup spring $16/6.4 te2 7 5 M-10 | Cup spring 929/13 te3 / Z Mo1t [ut M12 ,” ! In order for the contact device ’ — Figure M to becone accessible fo: , - r overhaul, the insul: ’ ing unit M-5 shall be dismounted. i The contact guides M-3 are threaded i nto the terminsl flange N-6 and are, |i ou moreover, locked with the nute and i 6 cup springs M=10-11 ' | At mounting it must ve noted that the A guides N-5 shall be screwed fest | “ against the faced surface of the - pre terminal flange N-6. 4 ja 1) For pressurized design 196/150 Not pressurized design 6205/1507 8. 1 12 3 4 5 Figure N Exhaust @% overpressure valve Nei | Exhaust gos filter (see Fig. n-2 | overpressure valve (see Fig. 0) N-3 | cock R 1/2" N-4 | Gasket for cock N-3 926/16 ta5 N-5 | Top cap n-6 | Inner cap (for pressurized cirouit-breakers) Figure 0 Overpressure valve 1 |Vaive seat 2 |Valve body 3 |Valve disc 4 | Spring 5 |Guide -6 |Spray protection 7 |Onring 50/24 .2/3 8 ]O-ring 45/39.2/3 0-9 [o-ring $25/19.2/3 0-10 | o-ring $35/29.2/3 0-11 | cup spring $14/6.4 ta1.5 0-12 | Nut M6 0-13 | Screw Méx40 Pressurized circuit- breaker Méx16 Non-pressurized circuit-breaker 0-14 | Screw M6x25+ . 5409 7048-7 ABB HV Switchgear Page 17 LKK 62-04-20 Figure P Exhaust gas filter 1 |serew mext2 2 |Rubber washer $20/10 te? 3 [Sleeve 4 |Filter 5 |Wesher 6 |Circlip 7 |Valve pipe upper 8 [Jointing sleeve -9 |Clemp 40 [Valve pipe lower Exhaust _gas filter The filter shall prevent solid po: lutants from following the exh gases and causing s leak in tne overpressure valve N-2. Cleaning is required only if the circuit-breaker oil has become very full of soot. The filter shall be unscrewed and cleaned, e.g. in petroleum spirits. Overpressure valve It is important that the overpressure velve, Figure 0, be tight. In order for it to be able to tighten it must be clean inside. At major overhauls or if leakage occurs, the 4 mounting screws: 0-14 shall be loosened. Then the valve body 0-2 shall be removed and its component parts can be easily cleaned, e.g. in petroleum spirits. A check shall be made that the seal- ing surface for O-rings 0-9 and 0-10 on the valve disc 0-3 is free from defects and that the elots for 0- rings 0-7, 0-8, 0-9 and 0-10 are clean and free from defects. When replacing O-rings it is important thet O-rings 0-9 and 0-10 ve of proper design (ground) and proper quality of rubber. When the valve is being wounted on the circuit-bresker the exhaue? ges holes "a" shell be turned downwards and be covered with the spray protection 0-6. For pressurized circuit-breakers the valve shall be adjusted in conjunction with filling up with gas, so that it closes above 0.4 MPa and opens below 0.6 MPa. Adjustment shall be made with the help of the screw 0-13, In non-pressurized circuit-breakers the screw 0-13 is so short that the Pring O-4 cannot be charged. The overpregsure in such breakers Will, therefore, be low (and ie not adjustable). ney PADD H5409 Page 18 LEK 83-03-31 14 15 16 |? 18 19 20 21 22 Reza 23 24 Figure 8 Mechanism housing Nechaniso housing - bottom frame Protective plate Aro Ring nut M60. 170 Nm Bearing housing Ball bearing Dise $50/1¢ ted Screw M12x25 Shaft Lock ring Sleeve O-ring $90.6/79.2/5.7 R-13] Gasket 9105/82 tad R-14| O-ring $60.5/54.5/3 R-15] O-ring $40.2/34.2/3 R-16] Bell bearing R-17| arm R-18| Manoneter R-19] Nipple R-20| Gasket $15/6.5 tag * R-21| O-ring f14.1/9.3/2.4* R-22| Cock R-23| Gaaket 926/16 tap R-24| Menometer holder x On pressurized cireuit- breakers onlyABB HV Switchgear m housing Dismounting of bearing The external arm R-3 on the shaft R-9 shall be removed and the lock ring R-10 shall be loosened. The bearing R-6 can now be dismounted. In the sleeve R-11 there are 2 M4 tapped holes. 2 screws shall be put into these holes end with the help of the screws the sleeve shall be pulled out. If the be: very firmly fastened, it can be necessary to dismount ¢ breaker pole and the arm R-17 and to use a puller for dismount- ing of the bearing. If replacement of the O-ring R-12 end the gasket R-13 is neces- sary, the bearing housing must also be dismounted. The ring nut R-4 shall be screwed off with a special wrench - article number 6896 729-B. The bearing housing shall be pre- vented from rotating with the help of another special wrench - article number 6896 729-c. It must be noted that the ring nut is very hard-drawn. Mounting of bearing After careful cleaning, the bearing parts shall be remounted in reverse order. 411 gaskets and damaged parts shall be replaced with new ones. The thread on the ring nut R-4 and the bearing housing R-5 well as the O-ring R-12 shell be lubricated with grease The tightening torque of the ring nut shall be 770 No. The special tool mentioned in item 1 above shall be used. The O-rings R-14-15 and the tightening surfaces for these in the sleeve R-11 and the bearing housing R-5 and the shaft R-9 shall be lubricated with grease F. The bearing R-6 shall be lubricated with grease E. The bearing R-16 shall be mounted entirely unlubricated. It shall be lubricated with the oil which ie later filled into the breaker poles. When, finally, the lock ring R-10 is put into place, a careful check shall be made that the ring goes into ite slot in the bearing housing R-5. Manometer Pressurized circuit-breakers are in each pole fitted with a manometer R-16 with appurtenant holder R-24 and nipple K-19. Non-pressurized circuit-breakers do not have these parts and the cock R-22 is screwed directly against the flange on the mechanism housing.N Not pressurized design _ Pressurized design Figure S$ Insulator types The wain types of insulators. A Insulent for spiral fastening Gasket 6x6 1-640 Flange Spiral $9.3 1a630 Insulator with cement jointed flange circuit-breaker can be fitted with 2 Insulator with loose mounting flanges. The insulent S-1 shall be fastened with a tightly wound spiral spring s-¢ which shall be pushed into a turned slot in the mounting flange S-3 lower flange on every insulator sha}] be sealed after mounting, with a rub- ber gasket S-2. The length shall be adjusted at mounting and the joint shall be sealed with rubber glue when the gasket has been pressed down into place. Insulator with mounting flanges jointed with cement.ABB HV Switchge LEK 62-04-20 See alse Figure 1 Externe] wechaniem| P00 8? -1 | Starting buffer v 2 | Opening spring ¥ 5 | Adjusting screw '-4 | Position indicator 5 6 Dashpot u Pull-rod to oper- ating device 7 | Operating arm Pole C -6 | Pull-rod 9 | Coupling piece 10] Operating arn Pole B 11] Operating arm Pole A nen the circuit-breaker is in the fully closed position the reference dimension "a" shall be = 7070.5 mm. The dimension 14626 mm accordii Figure L shall then be msinteined all 3 poles. When delivered, all the pins in the arms ?-7, T-10 end T-17 lubricated with grease E. In conjunction with tinor overhauls th: pins shall be lubricated with oil B If the link system must for some rea- son be dismounted, it shail be lubri- cated with grease E prior to remount- ing. The opening spring 7. rust- protected by means of dipping in the anti-rust agent Tectyl. The opening spring T-2 can at over- hauls, as need arises, be rust- protected by means of spraying with anti-rust agent from an atomizer. The spring T-2 can even be rust- protected by means of applying grease E with a brush.40 JO4E-1 opening operation Figure U Dashpot for opening operation Dashpot (housing) Bottom valve Piston cylinder Gasket $16/10.7 Plug O-ring $60.6/49.2/5.7 O-ring $20.1/15.3/2.4 Lock nut Piston rod tet.5 v-11 u-12 U-13, U-14 U-15, u-16 U-17 Stop sorew Shaft aro (4-pole) Pull-roa Pull-rod to operating device Nut Protective tube between cizcuit-breaker and operat~ ing deviceABB HV Switchge: a 5409 TO4E-7 Page 23 LKK 82-04-21 In the external mechanism pole & there is a dashpot for the o ing operation U-1, which is connected to the operating erm U-i3 ‘The dashpot, which shall slow down the contact movement before the contacts reach the open position, is when delivered filled D (circuit-treaker oil). Subsequent fi1 of oil shali be carried out through the hi for the plug Pilla be carrie: is in its upper position, i.e. when the circuit-breaker is in the closed position, Oil shall be filled in up to the edge of the hcle. If leakage is suspected, and at major overhauls, the dashpot sha?) be dismounted for cleaning and replacement of the gaskets U-7 and U-€. Prior to dismounting, the dimensions "a" and "b" shall be Measured so thet the dashpot can be adjusted to exactly the sane dimension at remounting. The damping will become stronger if the cylinder U-4 is screved down further into the housing U-1 (the dimension "b" will ve Gecreased) and weaker if the cylinder is acrewed up. Alteration of the setting should, however, be avoid if for some reason the setting must be altered it is important to check that the piston U-3 with the piston rod U-10 do not hit the bottom of the cylinder at opening operation and do not go up and touch bottom in the other end of the cylinder at closing ope: ‘ion. In both the positions there should be a play of epproxi- nately 5 mm. This can be adjusted by means of screwing the piston rod U-10 out of or into the shaft U-12, After overha the lock 8 check shall be made that the stop screw U-11 and nut U-9 have been tightened. ABB5409 T04E-7 rev 1 Page 24 LKK 83-03-31 Starting buffer Figure V Starting buffer Starting buffer (housing) Cup spring Guide bolt Dise arn Roller Opening spring Screw M12x40 mut M12 Spring washer Washer At pole C in the externs] mechanism there is a starting buffer ver The sterting buffer contains a cup spring package consisting of a number of cup springs V-2 which at closing operation of the circuit-breaker are compressed by the arm V-5 with the roller V-6 which is pressed against the guide bolt V-3. The compression takes place towards the end of the contact movement and slows it down so that a soft damping is obtained.ABB HV Switchgear At opening operation the energy which at closing operation hee been stored up in the buffer contributes to obteining swift acceleration and high opening speed for the contacts. ‘The opening apring V-7 maintains the opening speed and ensures thet the contacts reach the fully open position At major overhauls the buffer should be dismounted, cate eaned end The circuit-breaker shall be placed in the open position. 1) mounting screws of the buffer shall be loosened end the buffer shall be lifted out from the bottom frame. Prior to dismounting of the buffer, the dimen: The buffer shall be disnounted by means of renoving the screw, nut, washer and spring washer V-8-9-10-11. After cleaning, the whole guide bolt V-3 and the entire surfece of all the cup springs V-2 shall be lubricated with grease G and then the buffer shall ve remounted. The dimension "b" measured prior to dismounting shall be adjusted so that it is maintained after the nut V-9 has been tightened. The reference dimension "a" = 707 0.5 shall ve maintained when the contacts are in the closed position - see Figures L and 7. The opening speed can be increased by means of placing an extre cup spring Y-2 or an appropriate spacer washer in the cup epring package. The opening speed can be decreased by means of taking a cup spring V-2 or a spacer washer, if there are any, out of th cup spring package. [SEA BROWN DOVERLEK 62-04-20 Filling up with The circuit-breaker is, when delivered, filled with resistant insulsting oll (oi1 D). After en overhaul or at re~ placenent of oil, en equivalent oil should be filled in. ‘The oi! consumption is approxinately 40 1/pole. It is appropriate to carry out filling with the help of @ pump which shall be connected via a hose to the drain cock A-6 on the mechanism housing. The cock A-5 on the top cap shall be opened and the oil shall be pumped in until it runs out through that cock. Superflucus oil shell be collected in a suitable vessel which shall be hung up below the cock. As soon as oil begins to run through the cock A-5, the cock A-6 shall be closed and when the superfluous oi! has run out, the cock A-5 shall be closed. After filling up with oil the oil level shall be checked. For circuit-breakers with oil gauge glass the glass shall be red and for circuit-breakers with oil level indicator the pointer shall point to the centre of the green field. Prior to filling up with oil, a simple pump with the necessery hosea cen be ordered from ASHA. The pump, which has catalogue number LA 937 0015, shall be driven ty a small electric hand- @rilling machine.ABB HV Switchgear 5409 7068 Fressuriaing 7 Page 27 LKK 82-04-20 Restrike-free pressurized circuit-breakers shell, prior to bei: taken into service, be pressurized - see Pigure A. Pressurizing shell be carried out with nitrogen gas from the gas cylinder 4-9 (not normally supplied by ASEA). The reducing valve with the necessary hoses according to Figure A, catalogue number LA 937 0014, cen be ordered from ASEA. ‘The reducing valve shall be set at approximately 0.6 MPa. The cock A-1 shell be closed and the cock A-5 shall be opened. Gas filling shall be begun. When the pressure has reached 0.5-0.6 MPs the overpressure valve shall open. Filling shall then be closed off. ‘The overpressure valve shall close before the pressure has dropped below 0.4 MPa. If the overpressure valve Figure 0 opens at higher pressure thon 0.6 MPa or closes at lower pressure than 0.4 MPa, the pressure level shall be adjusted with the screw 0-13. The pressure will be raised if the screw 0-13 ie screwed in and lowered if it is screwed out. After necessary adjustwent, gas shell be filled in to approxi wately 0.05 MPa above the closing pressure of the overpressure valve, in order to compensate for @ minor quantity of the gas which after some time will be dissolved in the ofl. The cock A-5 shall be closed and the pressurizing equipment shal) be removed. ‘The breaker pole shall be wiped clean on the outside and a check shell be made that there is no leakage of oil anywhere. f | After a day cr two a check shall be made on the mwanometers thet no gas is leaking out. ABB RSEABAOWN BOVERFigure X Speed measurement XL x-2 X-3 ob Recording drum Pull-rod Indicating arm TableABB HV Switchgear Testing 5409 704E-7 rev 1 Page 29 LKK 83-03-31 Prior to taking a new or an overhauled circuit-breaker into service the functional values of the circuit-breaker should be checked. Even prior to overhaul of an old circuit-breaker it can be of interest to measure the functional values, because these can give an idea as to the condition of the circuit-breaker and as to whether special action should be taken at the overhaul. Opening and closing time shall be measured with an appropriate digitel clock, e cronotron or an oscillograph. The resistence in the main current path between the terminals ‘igure X-a-b) shall be measured with an appropriate measuring bridge (e.g. Thomaon bridge). The measuring current should be as a pinimim 100 A. Too high resistance can depend upon poorly cleaned current passages, e.g. between the arc-control device B-6 and the flange Be4, or poorly tightened scree C-6-8. The contact speed shall be measured with a recording drum X-1 which shall be placed on a table X-§. The drum is connected to an indicating arm X-3 with the pull-rod X-2. ‘The indicating arm shall be screwed fast to the external operat- ing arm of the circuit-breaker, in the Bepole. The length is adapted so that the contact travel for the moving contact = 2 x in- dicated contact travel and the contact speed = 2 x indicated speed. The measuring equipment can be ordered from ASEA. The recording drum has article number: 1777 593-D. The indicating arm with pull-rod has article number: 6896 729-A.ABB HV Switchge 5409 725-1 FromiDate — LBK 85-02-27 SPARE PARTS OIL-MINIMUM CIRCUIT-BREAKER TYPE HLC 72.5/2000 (U) RESERVDELAR OLJEMINIMUMBRYTARE TYP HLC 72,5/2000 (U) Recommended spare parts are marked Rekommenderade reservdelar ar mirkta = For more than 10 breakers in service we also recommend spare parts marked RR For mer Sn 10 brytare i drift rekon menderar vi Sven reservdelar mirkta RR9409 725-1 Page 2 Sida 2 LBK 85-02-27 The oil minimum circuit-breaker HLC 72.5/2000 is available in 2 main types. 1 Restrike-free with pressurized breaking units HLC 72.5/2000 2 Not restrike-free and not pressurized breaking units HLC 72.5/2000 U Oljeminimumbrytare typ HLC 72,5/2000 férekommer i 2 huvud- utféranden, 1 Rtertandningsfri med trycksatta brytelement HLC 72,5/2000 . 2 Icke Stertandningsfri och icke trycksatta brytelement HLc 72,5/2000 U. Following information must be given with the order for spare parts. 1 Complete type designation and manufacture number of the breaker. For example: “HLC 72.5/2000 No. 2185 119" 2 Name and article No. of the parts. For example: "Gasket 2152 930-330" 3 The List contains the number of parts required for one complete breaking element. At ordering of complete sets of spare parts for one or several breakers this number must be multiplied by the number of breaking elements the breaker/breakers consist of. For example: One HLC 72.5/2000 consists of 3 breaking elements. Thus one complete breaker requires 8x3=24 contact pieces 2658 996-3. Vid bestdllning av reservdelar mBste fdljande uppgifter Lamas 1 Fullstandig typbeteckning samt tillverkningsnumner fdr brytare. Ex: "HLC 72,5/2000 nr 2185 119" 2 Delarnas ben’mning och artiketnr. Ex: "Packning 2152 930-330" 3 I Uistan anges det antal delar som ingfr i ett komplett brytelement. Vid bestallning av kompletta satser reservdelar till en eller flera brytare m&ste man allts8 multiplicera med det antal brytelement dessa inneh@ller. ex: En HLC 72,5/2000 inneh€ller 3 st brytelement. Far en hel brytare StaGr allts&: 8x3=24 st kontaktstycken 2658 994-3.ABB HY Sw 5409 Page Lak n—2 25 34 36 43 50 oe) 7 ‘Se blad See sheet 4 Se blad 4 725-1 3 Sida 3 85-02-27 See oheet 7 Se blad 7 See sheet 4 Se blaa & 6 6 sheet 5 Se blad See sheet 7 Se a) lad 7 A!8 aTABB H\ 9409 725-1 Page 5 Sida 5 LBK 85-02-27 a5409 725-1 Page 7 Sida 7 LK 85-02-27 p PADDED5409 725-1 Page 8 Sida 8 Lek 85-02-27 ptm No.]Name of item Bendmning Article No. Jaty Note os nr Artikelnr Ant Ann f Jelenent | 1 o-ring o-ring 2152 930-330 | 1 Ir 2 i 2152 929-90 1 R 3 | 2152 930-60 3 rr | 4 2152 929-40 2 Rk 5 Gasket Packning 2152 939-31 1 ik 6 O-ring o-ring 2152 2011-313 | 1 R ? ~ 2152 2011-505 | 1 R 8 2152 929-35 1 R 9 2152 929-25 1 R 10 | 2152 929-45, 1 R | "1 } 2152 929-30 1 R | 1 | 2152 2012-435 | 2 R 13 | Washer Bricka 2152 970-7 1 R 1% | Gasket Packning 2152 853-2 1 Re 15 o-ring o-ring 2152 929-14 1 Re 16 | Gasket Packning 2152 745-58 3 R 17 | Gasket Packning 2152 939-33 4 Re Gasket Packning 2152 939-6 4 R 18 [Ring Ring 2151 771-1 1 R 19 | Disc spring Tallrikstjader 2195 706-1 1 R 20 | washer Bricka 2152 2022-94 | 1 R 21 |Washer Bricka 2152 2022-36 | 2 R 22 —‘Joit Level glass Oljest&ndsglas 2543 704-c 1 RR 23 [Tube filter Rorfilter 2590 710-1 1 2% | Sleeve Hylsa 2158 773-1 1 25 valve pipe Ventitror 5429 068-K 1 R 26 |Contact point Pluggspets 2658 991-5 1 2 — | Contact rod Kontaktst ang 2658 987-25 1 28 | Plug contact Pluggkontakt 2658 985-AN 1 RR 29 | Connect ion Férbindning 2632 824-3 8 R 30 |Contact piece Kontaktstycke 2658 994-3 8 R 31 | Spring Fjader 2191 706-1 16 32 | Insert Insats 2658 982-8 8 R 33 | contact tube Kontaktrér 2658 4039-E 1 R 34 | contact Kontakt 5412 037-N 1 35 | valve disc Venti lkagla 6523 131-1 1 36 [over pressure velve | wvertrycksventit | 6523 016-P 1 * Over pressure valve | Bvertrycksventit | 6523 016-V 1 “ 37 | Disc Bricka 5419 169-39 1 Rr | 38 ae 5419 166-31 5 39 5419 169-41 1 40 5419 169-42 2 | 4“ . 5419 169-43 1 42 [Extinguishing chamber | slackningskammare | 5414 082-U 1 RR 43 [Rolling contact Rullkontakt 5413 035-c 1 44 |Manometer Grad. MPa | Manometer Grad.MPa | 5298 878-6 1 aR + or “pst fetter =" psr_| 5298 870-1 1 RR | 45 | vatve Vent it 2541 701-1 2 46 [Operating insulator | Mandverisolator 2184 4372-4 1 RR Only for pressurized C.B. HLC 72.5/2000 Endast for trycksatt brytare * Only for non-pressurized ¢.8. HLC 72.5/2000 U Endast fér icke trycksatt brytareABB HV Switchgear 5409 725-1 Page 9 Sida 9 Bk 85-02-27 Item no. 50 Insulators for HLC 72.5/2000 RR (pressurized design) Pos nr 50 Isolatorer fér LC 72,5/2000 RR Ctrycksatt utfdrande) Insulator art. No. | Colour | Length mm | Creepage distance mm Isolator art. nr Langd mm | Krypavst@nd mm 2732 2040-4 Brown | 806 2000 2732 2040-p fran 806 2310 2732 2040-€ Grey 806 2000 Gra Item No. 50 Insulators for HLC 72.5/2000 U RR (Non pressurized design) Pos nr 50 Isolatorer fér HLC 72,5/2000 U RR (Icke trycksatt utférande) insulator art. No. |Cotour | Length m | Creepage distance mm tsolator art. mr | Farg Langd mn | Krypavst nd am le73z 2084-1 Brown | 800 2000 Brun le732 2084-5 800 2310 le732 2084-6 Grey 800 2000 Gra Art.No. Set of contacts for 3 phases 5409 717-¥ R Kontaktsats for 3 poler Set of gaskets for 3 phases pressurized 5409 717-AA R Packningssats for 3 poler —trycksatt Non pressurized sag. 717-x a Icke trycksatt