Abb HPL 245-550B2 & HPL 2450550TB2 BLG 1002a

SFo Circuit-Breaker HPL 245-550Ei2 and
HPL 245-55OTB2 with operating

mechanism BLG 1002A
1-pole operation
Product Description
1HS8445455-3 en 6
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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. lt may not either be imparted to third party or otherwise be used without aut-
horisation. lnfringement hereof will be subject to action in accordance with applicable laws.
O ABB Power Technologies AB
Article number:
1 HS8445455-3 en 6
Approval date:
2006-09-21
Product Description
LIST OF CONTENTS
1 . Description......... 1
l.l Design of the circuit-breaker....... I

1.2 Weights fbr the circuit-breaker parts 2
1.3 The breaking principle 3
1.4 Function of the operating mechanisnr 4
1.5 Standards 4
1HS8445455-3 en 6
Product Description
il 1HS8445455-3 en 6
Product Description
FIGURES
Figure l -1. Circuit-breaker, HPL 245-55082 and 245--550T82 ........... .............2
Figure I -2. Circuit-breaker pole, Opening - Closing .......
1 H58445455-3 en 6 iii
Product Description
IV 1 HS8445455-3 en 6
Product Description Description
1 Description
This Product Description applies to the SF6 circuit-breaker HPL 245-55082 or
245-55OTBZ with operating mechanism BLG 1002A.
1.1 Design of the circuit-breaker

The circuit-breaker consists of three separate poles, and each pole has three main
parts. At the lower end is a mechanism in an aluminium alloy housing. Above the
mechanism housing are hollow post insulators (or a hollow insulator if the circuit-
breaker is equipped with composite insulators) in which the insulating rod runs.
At the top is the breaking unit.
Each breaking unit consists of two breaking chamber insulators, which, together
with the two upper terminal flanges and a T-mechanism housing, make up the
enclosure. The enclosure contains the upper and lower current paths and the puffers.
The puffers run on the outside of the lower current paths. The main contacts are
integrated in the upper and lower current paths.
When each pole contains several breaking units in series, the breaking units can be
connected in parallel with grading capacitors and/ or pre-insertion resistors.
The poles are mounted on separate hot-dipped galvanized frames. The frame
consists of two welded halves, which are interconnected with bolted cross stays.
1 HSB445455-3 en 6 1
Description Product Description
1.2 Weights for the circuit-breaker parts
2 1
3
3
4
4
5
5
B1 0068
810207
HPL 550T82 with capacitor and HPL 4208.2 without capacitor and
pre-insertion resistor pre-insertion resistor
Figure I -1. Circuit-breaker HPL 245-55082 and 245-550T82
Item Part Weight

1 Breaking unit without capacitor See dimension drawing
and pre-insertion resistor
2 Breaking unit with capacitor and See dimension drawing
pre-insertion resistor
3 Post insulator See dimension drawing
4 Operating mechanism 460 kg
5 Frame 100-200 kg
2 1 HS8445455-3 en 6
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 tbe nozzle
(2) and the arcing contact (3).
4 2 31
Figure I -2. Circuit-breaker pole, Opening - Closing
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 a current zero passage, the gas starts to flow out
through the puffer cylinder (l). The specially designed nozzle (2) ensures that the
gas flow is directed towards the arc. The gas is allowed to pass both both down
through the moving arcing contact (3) and up past the fixed arcing contact (4).
When the arc has been cooled, it is extinguished and the current is intemrpted.
There are separate main current contacts, which open before and close after the
arcing contacts. They are not affected by the arc on intermrption.
On closing, the puffer cylinder (1) moves upwards, the contacts engage and the
puffer cylinder (I ) is refilled with gas.
1 HS8445455-3 en 6 3
1.4 Function of the operating mechanism

The HPL circuit-breaker is operated by a motor-charged spring operating
mechanism BLGl002A.
The operating mechanism is connected to the circuit-breaker pole through a pull rod
system.
The circuit-breaker is closed by the 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-breakers mechanism, get recharged.
The opening latch in the operating mechanism keeps the breaker in the closed
position. Opening of 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) orCO - 15 s - CO (according to

rEEE/ANSr).
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.
4 1HSB445455-3 en 6
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ABB Power Technologies AB 1 HS8445455-3 en 6
Circuit-Breaker Division
2006-09-21
SE-77180 LUDVIKA
SWEDEN
Telephone: +a6 (0) 240782000
Telefax: +a6 (0) 240 78 23 20
SFo Circuit-Breaker Operating Mechanism
BLG 1OO2A
Product Description
1HSB51 5432-100 en 6
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The document, or parts thereof, may not be reproduced or copied without prior permission from ABB
Article number:
1HS8515432-100 en 6
Approvaldate:
2006-08-24
Product Description
LIST OF CONTENTS
1 Description.............. 1
l.l Design of the operating mechanism.............. I
1.2 Normal operating mode 2

1.3 Opening operation.......... ^,
1.4 Closing operation ..................4
2. Operations........ 5
2.1 Remote/Localoperation 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 Auxiliarycontact.. 9
3.6 Heatingelement......... 9
1HSB51 5432-100 en 6
Product Description
il 1HS85'l 5432-100 en 6
Product Description
FIGURES
Figure I -1. Operating mechanism I
Figure l-2. Normal operating mode 2
Figure 1-3. Opening operation 3
Figure 1-4. Closing operation ... 4
Figure 2-1. Remote/Local operation 5
Figve2-2. 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
1HS8515432-100 en 6 iii
Product Description
IV 1HSB515432-100 en 6
1. Description
The spring operating mechanism BLG 1002,4, 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 - l5 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
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1 Drive unit
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2 Mechanism
3 Control panel ilt

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5 Heating element
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Front Back, with the
cover removed
Figure I -l . Operating mechanism
1HSB51 5432-100 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.
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1 Opening spring
2 Closing springs
1
3 Opening catch gear
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Figure I -2. Normal operating mode
2 1HS8515432-100 en 6
1.3 Opening operation

To open the circuit-breaker:
The latch in the opening catch gear (l ) 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.
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1 Opening catch gear
2 Opening spring 4
3 Pull rod
2
4 Operating lever
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6 Cam disc
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7 Closing spring
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820029
Figure l-3. Opening oPeration
3
1HSB51 5432-100 en 6
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.
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Item f
1 Closing catch gear
5
2 Chain section
3 Closing spring
4 Cam disc I 2
5 Operating lever 6(
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6 Opening catch gear a
4
3
7 Closing damper
10
8 Opening spring
7
I Pull rod
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10 Chain section :il:
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820031
Figure I -4. Closing operation
4 1HSB515432-100 en 6
Product Description Operations
2, Operations
2.1 Remote/Local operation
At normaloperation mode the "Local/Remote/Disconnect" switch (l) 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
Local/Remote/D iscon nect switch

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2 Open/Close operation switch tr21 M

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Figure 2- l. 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
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2
1 Local/RemoteiDiscon nect switch
OpeniClose operation switch

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Figure 2-2. Close operation
1HSB51 5432-100 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 (l) in the "Local" position and the
"Open/Close" operation switch (2) in the "Close" position.
Item
Br=a B W M rera
1
2
Local/Remote/Discon nect switch
Open/Close operation switch

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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 1HS8515432-100 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, 220Y DC,60 V AC 50, 60H2,110 V AC 50,60 Hzor22OY
AC 50, 60 Hz.
The motor or motors should be able charge the springs at 85Vo of the nominal
voltage (acc. to IEC).
Item
'1
Drive unit
o
820031
Figure 3-1. Drive unit
3.2 Mechanical interlocking

The interlocking mechanism prevents a closing operation from being carried out if
the circuirbreaker 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 o 2
3
1 Limit switch
2 lnterlocking lever 4
3 lnterlocking disc
4 Cam disc
5 Operating rod s
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6 Operating lever shaft
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B20007 5 6
Figure 3-2. Interlocking mechanism
1HSB51 5432-100 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 Y 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 intemrption
at 60Hz is required.
Item
1 Catch gear
E20034 1
Figure 3-3. Catch gear
3.4 Damper
The operating mechanism is equipped with one Closing damper (l ) 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
820024
Figure 3-4. Closing and Opening damper
I 1HS8515432-100 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
820035
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.
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Item
L I
1 Heating element T -'1
----------------
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654
321
1
820036
Figure 3-6. Heating element
1HSB51 5432-100 en 6 I
Components Product Description
10 1 HSB51 5432-100 en 6
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ABB Power Technologies AB 1HSB515432-100 en 6

Circuit-Breaker Unit
2006-08-24
SE-771 80 LUDVIKA
SWEDEN
Telephone: +a6 (0) 240 78 20 00
Telefax: +a6 (0) 240 78 23 20
SFo Circuit-Breaker HPL 245-55082 and
HPL 245-550T82 with operating
mechanism BLG 1002A
1-pole operation
Assembly lnstructions
1 HSB445410-3 en 12
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Article number:
1HSB445410-3 en 12
Approvaldate:
2006-12-11
LIST OF CONTENTS
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 I
4.t Preparations ,..9
4.2 Frame assembly..... .ll
4.3 Assembling the frame on the foundation...... .t2
4.4 Assembling the post insulator on the frame.. .13
4.5 Preparations for assernbl ing the operating mechanism...... .14
4.6 Assembly of corona ring on the post insulator .... .15
4.7 Assembling the operating mechanism .16
4.8 Final assembly of the post insulator..... .18
4.9 Assembling the breaking unit ............ .19
4.10 Assembling the pull rods............ .25
4.tt Dismantling the tensioning tool . .27
4.t2 Inspecting the bolted joints, etc.. .29
5. Electrical connections 30
5.I Connection of the operating mechanism.... ...30
5.2 Assembly of busbars or overhead lines...... ...30
5.3 Charging the closing springs........ ...3 I
6. Pressurizing the poles 32

6.1 Preparations ,.32
6.2 Gas filling with SF6 gas.............. JJ
6.3 Gas filling with mixed gas.............. 36
6.4 Gas monitoring system... .......37
6.5 Leakagetest........... .......38
6.6 Fitting the plate and cover.... .......38
1 HS8445410-3 en 12
1H58445410-3 en 12
FIGURES
Figure 3-1. Circuit-breaker, HPL 245-55082 and 24-5-550TBZ ........................5
Figure 3-2. Lifting the operating mechanism ..6

Figure 4- l. Assembly markings ...........9
Figure 4-2. Foundation ........10

Figure 4-3. Fmme assembly ..... I I
Figure 4-4. Frame assembly on the foundation ........12

Figure 4--5. Lifting the post insulator l3
Figure 4-6. The post insulator non-return valve ....... l3
Figure 4-7. Fitting the post insulator on the frame ... t4
Figure 4-8. Dismantling the plate and cover 14
F'igure 4-9. Assembly of the corona ring 15
Figure 4-10. Assembling the operating mechanism l6

Figure 4-l l. Unloading the pull rod, disconnecting circuit-breakers ...... l7
Figure 4-12. Post insulator on the frame ......... l8
Figure 4-13. Dismantling the transport cover ......... t9
Figure 4- 14. Assembling the breaking unit 20
Figure 4-l -5. Joining together the brer*ing unit and insulating rod ............. ......21
Figure 4-16. Dismantling the locking washer .............22
Figure 4- 17. Assembling the capacitor
Figure 4- 18. Assembling the corona rings .....24
Figure 4-19. Checking the closing lever's locking lug ......................................25

Figure 4-20. Adjusting the operatingmechanism ........25
Figure 4-21. Assembling the pull rod ......26
Figure 4-22.Dismantling the tensioning tool ............ .....................27
Figure 4-23.Dismantling the tensioning tool, disconnecting circuit-breakers ..28

Figure 5-1. Operating mechanism ..... ..30
Figure 5-2. Charging the closing springs ........3 I
Figure 6-1. Gas filling ........33
Figure 6-2. Density monitor and union nut ............. ......................35
Figure 6-3. Gas monitoring ....... ....3 I
Figure 6-4. Fitting the plate and cover ....38
1H58445410-3 en 12 iii
iv 1HS8445410-3 en 12
Assembly lnstructions General
1. General
This Assembly instruction applies to the SF6 circuit-breaker HPL 245-55082 and
245-550T82 with operating mechanism BLG 1002A for 1-pole operation and
contains all essential information for assembly and commissioning.
Read through the entire Assembly instruction before stafting the assembly work.
1HS8445410-3 en 12 1
General Assembly lnstructions
2 1HS84454'10-3 en 12
Assembly lnstructions 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. used for hazards that may only result in damage to the installation'
3
1HS8445410-3 en 12
Safety Assembly lnstructions
2.2 Safety, general
WARNING
Circuit-breaker with pressurized porcelain insulators.
Mechanical damage to 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 sequnece is o - 0.3 s - co - 3 min. - Co. The time between
closing operations should not be less than I minute during the testing of circuit-
breakers and relay systems involving more than 3 closing operations.
4 1HS8445410-3 en 12
J
Assembly lnstructions 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, CircuirBreaker Unit.
3.1 Weights
The weights of the circuit-breaker parts are as follows:
3
3
4 4
810207 B1 0068
HPL 550TB2 with capacitor and HPL 42082 without capacitor and
Figure 3-1. Circuit-breaker, HPL 245-55082 and 245-550T82
Item Part Weight

1 Breaker pole without capacitor and Stated on the applicable dimension drawing for
pre-insertion resistor the order.
2 Breaker pole with capacitor and pre- Stated on the applicable dimension drawing for
insertion resistor the order.
3 Operating mechanism 465 kg
4 Frame 86-200 kg
1HS8445410-3 en 12 5
(/
Delivery Assembly lnstructions
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 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.
o
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N
Supplied in a crate Supplied on a pallet
820023
Figure 3-2. Lifting the operating mechanism
6 1HS8445410-3 en 12
Deliveqr
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
Ifdamage 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 storel, 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.
l. An approved store is defined as consisting of

roof
firm base
humidity below 50Vo
temperature 20"C (+1 0'C)
1H58445410-3 en'12 7
Delivery Assembly lnstructions
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 parls 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.
1HS8445410-3 en 12
8
Assembly lnstructions Assembly
4. Assembly
4.1 Preparations
Before starting the assembly, make certain that all required tools and documents are
at hand.
a Standard tools with torque wrenches (9 - 550 Nm).
a Lifting device and lifting slings.
a Lubricants, see the Lubricants Instruction for suppliers and brand names
Grease "G": ABB Art. No. I l7l 4014-407
Grease "SV": ABB Art. No. l17l 4016-610.
a Contact paste.
a Applicable dimension drawings and wiring diagrams for the order.
4.1.1 Assembly markings

The circuit-breakers are delivered dismantled in two gas-tight transport units. The
parts are marked to facilitate assembly. The circuit-breaker poles and operating
mechanisms have been routine tested together. Breaking units and post insulators
having the same marking, e.g. A l, are assembled together. Breaking units and post
insulators only need to be assembled together mechanically and after that filled with
gas.
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.
illtlillIililill
Item
1 Operating
7
mechanism A1
2 Operating 8 4
mechanism B1
9 5
1
3 Operating
mechanism C1 6 2
4 Post insulator A1
3
5 Post insulator B1
6 Post insulator C'1
7 Breaking unit A1
8 Breaking unit 81
9 Breaking unit C1 B1 0069
Figure 4-1. Assembly markings
1HS8445410-3 en 12 I
,f
Assembly Assembly lnstructions
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.
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 for the order.
+1 mm
+1 mm
+ +
Bolt length > 110 mm
B'10004
Figure 4-2. Foundation
10 1HSB445410-3 en 12
Assembly lnstructlons Assembly
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 bolts (3) only with finger force.
N.B. Final tightening should be made after assembly at the foundation.
!tem
1 Frame halves 2 pcs. 1
2 Stays 6 pcs.
3 Bolts M20x60 8 pcs.
Nuts M20 B pcs.
Washers 21x37x3 16 pcs.
3
2
fr tr
3
ii
I
.ll
4
ii
tl
IL _-]l
E-
-
Bl 0005
Figure 4-3. Frame assembLy
1HSB445410-3 en 12 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 (l), washers (3) and nuts (2)
are stated on the applicable dimension drawing for the order.
Foundation bolts (1), nuts (2) and spacer washers (4) are not supplied.
Fill the gap between the lower nut and the 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 against the foundation, use the upper nut, which is tightened with a tightening
torque of 300-350 Nm for M24, or 500-550 Nm for M30 nut.
TIGHTENING TORQUE
300-350 Nm (M24)
or
500-550 Nm (M30)
\
Tighten the bolts (3) in Figure 4-3 with a tightening torque of 430 Nm.
123
TICHTENING TORQUE
430 Nm
Item o
6
1 Foundation bolts, L > 110 mm E
(not supplied) :', / E
o
2 Nuts (not supplied) 24 pcs. 4 f//
a")
R
3 Washers 24 pcs.
o
4 Spacer washers (not supplied)
5
5 Foundation
6 Frame foot
B1 0006 2
Figure 4-4. Frame assembly on the foundation
12 1H58445410-3 en 12
/
4.4 Assembling the post insulator on the frame

Place a lifting sling around the top of the post insulator as shown in Figure 4--5 and,
using this method, lift the post insulator from its horizontal position in the transport
crate.
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.
\\
H,)
%.ot..''
\
S ....\
"'.
\\-
*s'\
\\.*
'i..)
%'.\ \
B1 0086
Figure 4-5. Lifting the post insulator
Check that the post insulator 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
of about 5 mm. A clear
hissing noise should be
heard from the pole. If no
1
hissing noise is heard, the

post insulator leaks. This
must be rectified before
assembly.
3. Fit the sealing cap (1). 2

B1 0008
Figure 4-6. The post insulator non-return valve
1HSB445410-3 en 12 13
J
Fit a post insulator on each frame according to Figure 4-7.Fit the bolts, washers and
nuts (l) and tighten by hand.
N.B. Final tightening is carried out when the operating mechanism has been fitted.
1
Item
Nuts M20 4 pcs.
B 1 0087
Figure 4-7. Fitting the post insulator on the frame
4.5 Preparations for assembling the operating mechanism

Remove all the pole covers (l)
and the plates (2) with the Close-
Open signs, to gain the best
possible access to the pole #
mechanisms. --
Item e>a
1 Cover
2 Plate
810012
12
Figure 4-8. Dismantling the plate and cover
14 1HSB445410-3 en 12
4.6 Assembly of corona ring on the post insulator

If the circuit-breaker has composite insulators, assemble the supplied corona ring as
in Figure 4-9.
Tighten the bolted joints (3) and the bolted joints (4) with a tightening torque of
60 Nm.
Item
1 Corona ring 1 pcs.

2
2 Bracket 4 pcs
3 Bolts M10x30 4 pcs 1
Washers 10,5x25x4 8 PCS

Nuts M10 4 pcs
4 Bolts M10x25 4 pcs

Washers 10,5x25x4 4 pcs
3
-__l
TICHTENING TORQUE 4
60 Nm
Figure 4-9. Assembly of the corona ring
1 H58445410-3 en 12 15
J
4.7 Assembling the operating mechanism

For disconnecting circuit-breakers, see chapter 4.7. l.
The operating mechanism is delivered with the closing springs correctly adjusted to
the corresponding circuit-breaker pole.
The operating mechanism is fitted as indicated in Figure 4-10.
Fit all bolts, washers and nuts (l) and tighten them by hand. Then tighten the bolted
joints (1) with a tightening torque of 79 Nm.
2
Item
1
1 Bolts M12x50 1O pcs.
Nuts M12 10 pcs. {
Washers 13x24x2.5 20 pcs.
2 Spring washer 13x29x3 4 pcs.

/
1 1
TIGHTENING TORQUE
79 Nm
810088
Figure 4-10. Assembling the operating mechanism
16 1HS8445410-3 en 12
,/
4.7.1 Assembling the operating mechanism, disconnecting circuit-breakers

l. Remove the transport cover (1). Fit the guiding block (3) and the bottom
cover (2).
2. Tension the adjuster screw (4) to unload the tripping mechanism pull rod (5)
from the operating lever (6) in the mechanism housing.
3. Unload the spring pressure by releasing the nut (7) before dismantling the
transport unloading unit (8).
Item
8
1 Transport cover
2 Bottom cover with spacing rod *
3 Guiding block"
7
4 Adjuster screw"
6
5 Pull rod
6 Operating lever
5
J
7 Nut I
J
8 Transport unloading unit I
. lncluded in tensioning tool 1HS8446381-D 1

2 3
4
Figure 4- l l . Unloading the pull rod, disconnecting circuit-breakers
The operating mechanism is delivered with the closing springs correctly adjusted to
the corresponding circuit-breaker pole.
The operating mechanism is fitted as indicated in Figure 4-10.
Fit all bolts and tighten them by hand. Then tighten the bolted joints (1) with a
tightening torque of 79 Nm.
TIGHTENING TORQUE
79 Nm
1H58445410-3 en 12 17
J Assembly Assembly lnstructions
4.8 Final assembly of the post insulator

Tighten the post insulator to the frame with a tightening torque of 300 Nm.
TIGHTENING TORQUE
300 Nm
B1 0089
Figure 4-12. Post insulator on the frame
18 1H58445410-3 en 12
4.9 Assembling the breaking unit

Place a lifting sling around the breaking unit as shown in F'igure 4-13 and lift the
breaking unit horizontally from the transport packaging.
N.B. The breaking unit should be balanced and lifted horizontally.
1. Dismantle the transport cover ( I ) and the cover (3) from the breaking unit (-5)
and the transport cover (6) on the post insulator (7). Save all the transport
covers for future overhaul work.
N.B. The locking washer (8) under the cover (3) should remain in place so that it
holds the breaking unit's contact system in the sealed position.
Item
1 Transport cover with O-ring

4
Washers 13x28x3 16 pcs. 3
Nuts M12 8 pcs.
1 2
J Cover with two O-rings
@ @
4 Bolts M10x25 4 PCS 6
Washers 10.5x22x2 4 PCS
5 Breaking unit
o
6 Transport cover with O-ring 8

N.B. On the back
7 Post insulator of the T-mechanism
7
8 Locking washer
B1 0090
Figure 4-13. Dismantling the transport cover
1HS8445410-3 en 12 19
I Assembly lnstructions
Assembly
2. Check that the O-ring ) is well-cleaned and apply a layer of grease "G". Also
(I
apply a thin layer of grease "G" on the sealing face for the O-ring on the post
insulator's top terminal flange and a generous layer of grease on the surface
outside the sealing groove. Place the O-ring ( I ) in its groove.
3. Lower the breaking unit (2) onto the post insulator (3). Centre the breaking unit
on the insulating rod (4). Check that the O-ring (1) is in position.
N.B. The breaking unit (2) should be lowered straight over the insulating rod (4).
Item
1 O-ring
2 Breaking unit
4
3 Post insulator
4 lnsulating rod
1
81 0091
Figure 4-14. Assembling the breaki,ng unit
20 1HSB445410-3 en 12
/
4. Join together the breaking unit (l) and the post insulator (2) using the nuts,
bolts and washers (3). Tighten only by hand.
5. Fit the pin (4) and circlip (5) on the back of the T:mechanism housing. Check
that the circlip (5) sits correctly in its groove. The insulating rod can be
adjusted vertically, if necessary, using the adjuster bolt (6) once the nut (7) has
been loosened.
Item
1 Breaking unit
2 Post insulator 4
3 Bolts M 12x80 4 pcs

Washers 13x24 x2.5 B pcs
Nuts M12 4 pcs
-' 5
4 Pin, D= 22 mm
5 Circlip 2
6 Adjuster bolt 1 pcs N.B. the back

of the T-mechanism
7 Locking nut '1 pcs
3
7
6
B1 0092
Figure 4-15. Joining together the breaking unit and insulating rod
1HS8445410-3 en 12 21
J
6. Thread in a bolt (2), M8, in the threaded hole in the locking washer (1) and pull
out the locking washer (l), see Figure 4-16.
7 . Check that the O-rings and sealing faces are clean. Apply a layer of grease "G"
to the O-rings and sealing faces.
8. Refit the sealing cover (3) without damaging the sealing face. Tighten the bolts
(4) with a tightening torque of 45 Nm.
TIGHTENING TORQUE
45 Nm
9. If the circuit-breaker is equipped with capacitors see chapter 4.9.1.
10. If the circuit-breaker is equipped with corona rings see chapter 4.9.2.
11. Tighten the breaking unit (5) against the post insulator (6) using the bolts (7),
tightening torque 79 Nm.
TIGHTENING TORQUE
79 Nm
5
Item
1 Locking washer
1
2 Bolt M8
3 Sealing cover
2
4 Bolts M1Ox25 4 pcs. e @
Washers 10.5x22x2 4 pcs.
5 Breaking unit > o @ 4
6 Post insulator 'l -z

3
N.B. On back
7 Bolts M12x80 4 pcs. of the T-mechanism
Washers 13x24x2.5 B pcs.
Nuts M'12 4 pcs.
7 6
N.B. On the back

of the T-mechanism
81 0093
Figure 4-16. Dismantling the locking washer
22 1HS8445410-3 en 12
/
4.9.1 Assembling the capacitors (if applicable)

If the circuit-breaker is equipped with capacitors, assemble as follows:
I. Fit the capacitor brackets (I ) on the capacitors. Tighten the bolts (2) by hand.
2. Attach a lifting device on the capacitor and lift it into position.
3. Fit the bracket against the flange, separated by the spacer washer (5), and
tighten the bolts (4) by hand.
4. Fit the bracket on the T:mechanism housing (3) using the bolts (4).
5. Tighten the bolts (2) with a tightening torque of 79 Nm.
TIGHTENING TORQUE
79 Nm
TIGHTENING ToRQUE
60 Nm
Repeat points 2-6 to fit the other capacitor.
5
!tem
1 Capacitor brackets 2 pcs.
2 Bolts M'12x35 4 pcs.
Spring washer 4 pcs.
3 T-mechanism housing
3
Spring washer 4 pcs. 4
5 Spacer washer 4
1 2
81 01 20
Figure 4-17. Assembling the capacitor
1HS8445410-3 en 12 23
4.9.2 Assembling the corona rings (if applicable)

If the circuit-breaker is equipped with corona-rings, assemble as follows:
1. Remove the bolts (1 or 4) that hold the terminal flange against the breaking
chamber insulator.
2. Lift the corona ring (2) into position and refit the bolted joints (1 or 4). Tighten
the bolts by hand.
3. Fit the bolt (3) with washers and nut.

4. Tighten all bolts (l and 3) with atightening torque of 60Nm.
TIGHTENING TORQUE
60 Nm
Repeat points I -4 to fit the other corona rings.
3
2
ooQoo
c
/b',o\
t-
i-':'J
1
1
3
3
4 3
HPL 245-550T82 Bto2't2
HPL 245-55082 B1 01 21
Figure 4- I B. Assembling the corona rings
Item
Washers 13x28x3 2 pcs
2 Corona ring
3 Bolt M10x35 1 or 3 pcs.
Washers 10.5x25x4 2 or 6 pcs.
Nut M10 1 or 3 pcs.

24 1HS8445410-3 en 12
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.
4.10.1 Preparations for assembling the pull rods

. Check that the closing lever's (I ) locking lug rests against the closing catch
gear's (2) roller.
Item
1 Closing lever
2 Roller, closing catch gear
81 001 3 1
Figure 4-19. Checking the closing lever's locking lug
a Adjust the operating mechanism as indicated in Figure 4-20. Press down the
locking lug (l) on the operating lever by inserting a tool, for example a large
screwdriver, in the hole (2). Insen a screwdriver in hole (3) and press the
operating lever to the right.
21 32
Item
1 Locking lug
\
2 Hole in mechanism 3
) o d
3 Hole in mechanism C
B1 0035
Figure 4-20. Adjusting the operating mechanism
1HS8445410-3 en 12 25
4.10.2 Assembling the pull rod between the operating mechanism A1 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 4-21).
. 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 6 mm.
diameter rod. Check that the pull rod (5) is screwed past the alignment check
holes (9 and l0). The tightening torque for the locking nuts (8) is 300 Nm.
5 2 3
Item
1 Mechanism housing
sp
2 Pull rod from the operating
1
mechanism
3 Operating lever
b o ) 4 Coupling link
5 Pull rod (turnbuckle screw)
b Spring washers
10 4 6
7 Alignment check hole in
operating lever
,=-J 8 Locking nuts

]I
I Alignment check hole in pull rod
10 Alignment check hole in

coupling link
I
8
7
TIGHTENING TORQUE
B1 001 4 300 Nm
Figure 4-21. Assembling the pull rod

Repeat the procedure to assemble the pull rods between the operating mechanism
Bl and pole Bl and between operating mechanism Cl and pole Cl.
26 1HSB445410-3 en 12
4.11 Dismantling the tensioning tool

N.B. For disconnecting circuit-breakers, see chapter 4.1I .l .
. Unload the spring pressure using the adjuster screw (4) before dismantling the
bottom cover (1) and the tool (3). Save the tensioning tool for future overhaul
work.
a Refit the bottom cover (I ) and tighten the bolts (2) with a tightening torque of
45 Nm.
TICHTENING TORQUE
45 Nm
a Fit the bolt (5) and washers in the bottom cover (l) and tighten the bolt with a
TIGHTENING TORQUE
79 Nm
Item
1 Bottom cover
3 Tool 1HSB446381-A
4 Adjuster screw
5 Bolt M16x30 1 pcs
Washer 17x30x3 2 pcs
34 15 2
810095
Figure 4-22. Dismantling the tensioning tool
1HSB445410-3 en.12 27
Assembly Assembly !nstructions
4.1 1 .1 Dismantling the tensioning tool, disconnecting circuit-breakers

. Unload the spring pressure using the adjuster screw (3) before dismantling the
bottom cover (1) and the guiding block (2). Save the tensioning tool for future
overhaul work.
_1
Item
1 Bottom cover with spacing rod .
2 Guiding block. 5
3 Adjuster screw* 6-
4 Pull rod
KI s 4
5 Operating lever
* lncluded in tensioning tool 1 HS8446381-D

1 2
3
Figure 4-23. Dismantling the tensioning tool, disconnecting circuit-breakers
28 1HS8445410-3 en 12
4.12 lnspecting the bolted joints, etc.

a Use a 6 mm diameter rod to check that the operating lever's alignment check
hole is aligned with the predrilled hole in the mechanism housing.
a 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 s00-550 (M30)
Corona ring for post insulator 60

(if composite insulators)
Operating mechanism 79
Post insulator 300
Sealing cover 45
Breaking unit 79
Capacitor (if applicable) 79 and 60
Corona ring for breaking 60

chamber (if applicable)
Bottom cover 45
Pull rod 300
Bottom cover center bolt 79
Density monitor 10
Plate 22,5
Cover I
1HS8445410-3 en 12 29
E lectri cal con nectio n s Assembly lnstructions
5. Electrical connections
5.1 Connection of the operating mechanism
Insert the operation and signal cables through the gland plate at 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 as
disconnectable blocks with termination of a stranded conductor with a cross-section
of max. 6 mm2 intended for motor circuits, AC circuits and supply circuits.
Connect the earth wire to the earth terminal (l) on the side of the cubicle.
810015 1
Figure 5-1. Operating mechanism
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.
30 1H38445410-3 en 12
Assembly lnstructions El ectrical con n ection s
Using contact paste or grease

l. 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 Art. No. L1714016-610, on copper surfaces.
4. Assemble 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 their aluminium sides face the
aluminium surfaces and the copper sides face 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 units.
5.3 Charging the closing springs

Close the circuit-breaker and start the motor to charge the closing springs (l). 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.
r--------.l
Item
1 Closing springs
2 Drive sprocket
3 Chain section
I 2
4 Spring yoke il,, J( 6
3
5 Chain section 7
I 5
b Chain section I
1
t:
7 Chain section
t 4
I
__l
820027
Figure 5-2. Charging the closing springs
1HSB445410-3 en 12 31
Pressurizing the poles Assembly lnstructions
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 po1es.
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, article number lHSB 445439-4 for SF6 gas and lHSB 445439-8 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 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 intemrpt the circuit to the interlocking relays.
32 1HS8445410-3 en 12
Assembly lnstructions Pressurizing the poles
6.2 Gas filling with SF6 gas
3
3
Item
6 1 Gas cylinder
9
5 4 8 7 2 Regulator
3 Density monitor (old or new

design)
4 Coupling
5 Valve
6 The breaker's gas valve

7 Hose
8 Adaptor
I Nipple with union nut
10 Equal union cross
1 11 Valve
| _____ |
B1 001 6 10 11
Figure 6-1. Gas filling
l. 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. Set the right filling pressure,
compensated for the temperature as indicated in table 6-l 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 sharp tools.
5. Lubricate the O-rings thoroughly with grease "G" and refit them on the density
monitor.
1HS8445410-3 en 12 33
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 (l l) should 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 circuit-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 breaker to the protected area and let the gas flow until the
regulator (2) switches off.
I l. 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 at the density monitor (3) by opening valve (5) or
valve (l 1).
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 Bl and Cl.
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
r0 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
34 1HS8445410-3 en 12
I 8. Close the valve on the gas cylinder ( 1) when all poles have been filled.
19. Disconnect the hose (7) from the gas cylinder (l ) and release the pressure in the
regulator (2) by pressing in the non-return valve.
20. Release the set pressure in the regulator by turning the adjuster valve so that the
next circuit-breaker 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 l0 Nm as indicated in Figure 6-2.
Item
1 Density monitor
2 Union nut
TIGHTENING TORQUE
l0 Nm B1 001 7
l2
Figure 6-2. Density monitor and union nut
21. operate the 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.
1HSB445410-3 en 12
35
6.3 Gas filling with mixed gas

A mixture of SF6 and either N2 or CFa 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 sF6
gas to 0.52 x 0.7 = 0.36 MPa abs (+20 "C) 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
depending on the temperature as indicated in table 6-2.
Gas filling takes place otherwise as indicated in chapter 6.2.
Table 6-2. Filling with mixed gas

Filling pressure in MPa (abs) stated on the rating plate
sFo Totalfilling sFo Totalfilling pressure
pressure
Filling pressure read on the gauge
Temp.when
MPa bar MPa bar MPa bar MPa bar
gas filling
oc (abs) (abs) (abs) (abs) (overp) (overp) (overp) (overp)
+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 o.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
t0 0.33 3.3 0.63 6.3 0.23 2.3 0.53 5.3

-10 0.32 3.2 0.6'l 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
36 1HSB445410-3 en 12
6.4 Gas monitoring system

a Drill a 23 mm diameter hole in the gland plate (l) on the bottom of the
operating mechanism and fit a cable gland (2) with a sealing washer (3) and
nut (4) in the hole.
a Insert the cable through the cable gland in the operating mechanism and
connect it to the terminal blocks as stated on the applicable operating
mechanism's circuit diagram.
a Tighten the cable gland (2) to secure the cable.
a Secure the cable to the frame's leg using pipe clips (5) and nuts, bolts and
washers (6).
a Connect the cable to the density monitor's terminal blocks.
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 Gland plate
2 Cable gland
3 Sealing washer
4 Nut
5 Pipe clips 4 pcs
6 Bolts M5x20 4 pcs

Nuts M5 4 pcs
6
Washers 5.3x10x1 8 pcs
4 1
2
3 B'10018
Figure 6-3. Gas monitoring
1HS84454'10-3 en 12 37
6.5 Leakage test

Perform a leakage test using a leak detector around the density monitor's
connections.
6.6 Fitting the plate and cover

Fit the end cover (1) using bolts, nuts, washers (2) on the mechanism housing
for the Cl-pole. Tighten the bolts with a tightening torque of 22.5 Nm.
a Fit all plates (3) with the Close and Open signs using bolts and washers (5).
Tighten with a tightening torque of 22.5 Nm.
TIGHTENING TORQUE
22,5 Nm
a Fit all the covers (4) using

bolts and washers (5).
Tighten with a tightening
torque of 9 Nm.
TIGHTENING TORQUE
9Nm
2
Item
1
1 End cover

Nuts M12 4 pcs.
3 Plate oFe
4 Cover
5 Bolts M8x16 I pcs

Washers 8.4x16x1 .6 9 pcs
B1 0080
4 5 3
Figure 6-4. Fitting the plate and cover
38 1HS8445410-3 en 12
Assembly lnstructions Commissioning
7. Gommissioning
Before commissioning the circuit-breaker, carry out all the checks as indicated in
"Check list for assembling and commissioning 1HSB445410-100" and fill in the
operating values for the installation.
i,
1HSB445410-3 en 12 39
Operating values Assembly lnstructions
8. Operating values
The operating values in this instruction apply to SF6 circuit-breakers
HPL245-55082 and HPL245-550T82 with operating mechanism BLG 1002A.
8.1 Times
Closing time <65ms

Opening time coil I 19+3ms
Opening time coil ll 19+3ms
Close-Open time(1) <47 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 ll V (according to the rating plate)
Operating voltage closing coil I V (according to the rating plate)

Operating voltage closing coil ll V (according to the rating plate)
8.3 Resistance
Main circuit resistance per breaking unit < 40 pA.
8.4 Contact stroke

Main contact stroke is 208 +4 mm.
40 1H58445410-3 en 12
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ABB Power Technologies AB 1HS8445410-3 en 12
2006-1 2-1 1
SE-77180 LUDVIKA
SWEDEN
Telephone: +a6 (0) 24O7820OO
Telefax: +a6 (0) 240 78 23 20
SFo Circuit-Breaker Gircuit-Breakers HPL and LTB
Assembly of damPing element

1HS8445409-4 en -
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Article number:
1 HS8445409-4 en -
Approvaldate:
2004-09-14
Assembly of damping element
LIST OF CONTENTS
I.l Design of damping element ....
2. Assembly of the damping elements to the foundation... 2
1 HS8445409-4 en -
Assembly of damping element
1 H58445409-4 en -
Assembly of damping element General
1. General
This Assembly instruction applies to damping elements used for circuirbreaker 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 ( l) 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 001l-102.
The damping elements do not need any further
overhaul during its lifetime.
2
!tem
1 Damping housing
3
2 Spring washers 55 pcs.
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
8 Guide 1 pcs tl
ttll
lll 8
Itll
Figure I - I . Design of the damping element
'1
1 HS8445409-4 en -
Assembly of the damping elements to the Assembly of damping element
2. Assembly of the damping elements to the foundation

I . 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 001 t-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 tl
tl
8
1 Nut M24 (not supplied) 4 pcs il
2 Spacer washers (not supplied)

il
3 Adapter plate 1 pcs il
il 6
4 Guide cone 4 pcs -J il
ll
5 Guide 4 pcs lt
lt
6 Damping element 4 pcs
il
7 Bolts M12x60 24 pcs. il
il
Washers 13x24x2,5 24 pcs.
10 lt
Frame tl
8

3
Nuts M30 4 pcs.
7
10 Washers 4 pcs.
4
I 2 1
Figure 2-1. Assembling the damper on the adapter plate
2 1 HS8445409-4 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.
1 HSB445409-4 en - 3
Assembly of the damping elements to the Assembly of damping element
4 1 HS8445409-4 en -
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ABB Power Technologies AB 1 HS8445409-4 en -
SE-771 80 LUDVIKA 2004-09-14
SWEDEN
Telephone: +a6 (0) 240782000
Telefax: +a6 (0) 24078 23 20
SFo Circuit-Breaker Circuit-breakers HPL and LTB
Check list, assembly

1HS8445410-100 en 4
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The document, or pafis thereof, may not be reproduced or copied without prior permission from ABB
Article number:
1 HS8445410-100 en 4
Approvaldate:
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
I nsf ellqtinn.
Serial
Circuit-breaker pole
l. 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 l.
l. 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 ll ms MS MS
Opening time coil I MS MS MS
Opening time coil ll MS MS MS
Close-Open time ms MS MS
Lowest control voltage closing coil I V V V
Lowest control voltage closing coil ll V V V
Lowest control voltage opening coil I V V V
Lowest control voltage opening coil ll V V V
Main circuit resistance po pA pA

Filling pressure(1) MPa (abs) MPa (abs) MPa (abs)
(1) Filling pressure in accordance with the rating plate
12. Check carried out by:

1 3. If points I - 1 I as indicated
above have been completed, the circuit-breaker can
be commissioned and taken into service.
2 1 HS8445410-100 en 4
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ABB Power Technologies AB 1HSB445410-100 en 4
SE.771 80 LUDVIKA 2004-o8-20
SWEDEN
Telephone: +46 (0) 2407820O0
Telefax: + O (0) 240 78 23 20
SFo Circuit-Breaker Circuit-breakers HPL
Operating and Maintenance

1 HS8445409-100 en 8
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Article number:
1HS8445409-100 en 8
Approvaldate:
200s-08-'t9
LIST OF CONTENTS
1.2 Warning 2
2. Preventive maintenance 3
2.1 Circuit-breaker.................. 3
2.2 Operatingmechanism. 5
2.3 Spare parts. 6
3. lnspection intervals......... 7
3.1 Maintenancesummary 8
3.2 Maintenance category A . 9

3.3 Maintenance category B.. t0
3.4 Maintenance category C................ t7
1 HS8445409-100 en I
ii 1 HS8445409-1 00 en 8
FIGURES
Figure 2-1. Number of operations versus short-circuit cun'ent ...4
1 HS8445409-100 en 8 iii
IV 1 HS8445409-1 00 en B
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

Waming text occurs where required and indicates that the text in question should be
A DANGBR
indicates an immediate hazardous situation that, if not avoided,
in death or serious personal injury.
will result
A WARNING
CAUTION
injury.
N.B. is used for hazards that may only result in damage to the installation.
1 HS8445409-100 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
insulators should be carried out at reduced gas pressure, 0.125 MPa (abs)
WARNING
insulators should be carried out at reduced gas pressure, 0.125 MPa (abs)
WARNING
The standard operating sequence is O - 0.3 s - CO - 3 min.- CO. The time between
2 1 HSB445409-100 en 8
Operating and Maintenance P reve ntive mai ntenance
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:
l. 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- I .
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 "[nspection 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:
InxIl'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+40x I0
l'8=l 8,230.
1 HS8445409-1 00 en 8 3
P reventive m ai ntenance Operating and Maintenance
2.1.2 Service life of arcing contacts with short-circuit interruption

The diagram below shows the number of intemrptions 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
1
Short-circuit current
Figure 2- I . 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 I gives an alarm signal, while
Level2 is used for blocking purpose.
N.B. A new or overhauled circuirbreaker should be checked for tightness by

reading the density monitors after approx. 1 month and then at 7-2 year
intervals in connection with the regular visual inspection.
4 1 HS8445409-1 00 en 8
Operating and Maintenance P reventive mai ntenance
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"l 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"
l.
2.1.6 Rust protectaon

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
diny.
1. See the document "Lubricants" IHSB445409-I for the names of suppliers and brands for
grease and oils.
1 HS8445409-100 en I 5
P reventive m ai nte n ance 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 worrn 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"l and the chains with Oil'A"l in connection
with an overhaul.
The bearings in the operating mechanism are lubricated with Grease "G"l 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. l24l 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 rpu""2 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.
l. 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 5OTo,temperature + 20" C (+ l0'C)
6 1 HSB445409-1 00 en 8
Operating and Maintenance lnspection intervals
3. lnspection intervals
Inspection of HPL circuitbreakers with operating mechanism BLG 10024:
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.
1 HS8445409-100 en 8 7
lnspection intervals Operating and Maintenance
3.1 Maintenance summary

Gondition of Com-
Explan- circuit- petence
Type of measure lnspection 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.
a General check of circuit-
breaker and operating
mechanism
a Thermovision check
C Overhaul
. Breaking chambers c1 c2
a Line and transformer Lnxll'8 =20,000 2)

circuit-breakers
a 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.
o Major overhaul 30 years or 10,000 mech 1) d1 c2

CLOSE/OPEN
operations.
Explanations:
l. Mech. CLOSE/OPEN operations. = Mechanical Close-Open operations.
2. CLOSE/OPEN op. with el load = Close-Open operations with electrical

loading.
8 1 HS8445409-1 00 en 8
Status of circuit-breaker during work:

al) Circuirbreaker in service.
bI) Closing springs uncharged, circuit-breaker open, disconnected and earthed. If
thermovision measurement is included, it should be done at normal load
before the circuirbreaker is disconnected.
cl ) Closing springs uncharged, circuit-breaker open, disconnected and earthed.

Poles/breaking units dismounted and transported to workshop.
dl ) Closing springs uncharged, circuit-breaker open, disconnected and earthed.

Complete circuit-breaker inc luding operating mechanism transported to
workshop.
Com petence req u irements :
aZ) Substation personnel with no special training.
bZ) 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 lnspection interval Measures / Tools/ lnstructions
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.
1 HS8445409-1 00 en I 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.
lf 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.
SF5-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.
a 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 1 HS8445409-1 O0 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, lest current min.
2OO 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:
o _
- Rn7lnlt65
^ 2li)
f= Permissible increase in
resistance
Rn = Max. resistance as specified
in operating values
In = Rated current as specified on
rating plate
| - Current for which max.
resistance is calculated.
8.
Temperature rise 15 years or 5,000 mech. CLOSE/ Thermovision measu rement.
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.
1 HSB445409-1 00 en 8 11

9a.
Contact system
. Opening position 15 years or 5,000 mech. CLOSE/ lnspection 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 for
. Phase discrepancy the circuit-breaker.
. Auxiliary switches Max. phase discrepancy between
. Contact travel
phases: at closing 4 ms; at opening 3 ms.
. Contact damping
Max. discrepancy between breaks in
the same phase: at closing 3 ms; at
opening 2 ms.
See Overhaul lnstructions for the
12 1HS8445409-100 en 8
To be inspected !nspection interval Measures / Tools/ lnstructaons

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 srze: 36 mm.
Torque:300 Nm.
circuit-breaker.
a Safety of operation 15 years or 5,000 mech. CLOSE/ Measurement of minimum operating

OPEN operations. voltage.
Closing coil: 85% IEC (72 % ANSI)
of nominalvoltage.
Opening coil:7O/" IEC (56 % ANSI)
of nominalvoltage.
Variable D.C. voltage source required.
a 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. lf 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"/" ol nominal voltage
(acc. to IEC).
1 HSB445409-1 oo 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 "[-'acc. to Lubricant
instructions.
Change the signal from coil 1 to coil 2.
10,e.
Coils 15 years or 5,000 mech. CLOSE/ The resistances of coils and coil
OPEN operations. currents are allowed to differ +l- 1Oo/o
from the value measured at routine test.
1 0f.
Mechanical interlocking 15 years or 5,000 mech. CLOSE/ ln "Open" position, the distance
OPEN operations. between the interlocking arm and the
interlocking disc should be min. 2 mm.
ln "Close" position, there must be full
contact between the arm and disc (no
gap is permitted).
1 og.
Heating elements 15 years or 5,000 mech. CLOSE/ Check the resistance.
OPEN operations. lf applicable, check signal for loss of
power.
14 1 HSB445409-100 en 8

10h.
Central control cubicle 15 years or 5,000 mech. CLOSE/ Check the resistance.
(if applicable) OPEN operations. Smallcubicle:
48 W, 1 10 V Fl = 330 Ohms +l- 1Oo/"
48 W, 22O V R = 1000 Ohms +l- 1O"/o
Medium or large cubicle:
140 W 1 10 V R = 86 Ohm +l-1A"/"
140 W 22OV R = 346 Ohm +/- 10%.
10i.
Thermostat 15 years or 5,000 mech. CLOSE/ lf applicable, check that the thermostat
OPEN operations. is adjusted to requested value.
See Checklist, assembly HPL and LTB.
10i.
Terminalblocks 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/ lf applicable, check signal for loss of
starter OPEN operations. power.
11.
Tightness of SF5-gas
. Density monitoring 15 years or 5,000 mech. CLOSE/ Check the density switches and
OPEN operations. signaliblocking 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.
1 HS8445409-1 00 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.
disconnectin g circuit- OPEN operations. With the disconnecting circuit-breaker
breakers) in "Open" position, carry out a check
according to Check list, lnterlocking.
See also Operating instructions,
Disconnectin g f unction.
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 lnstructions.
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 lnspection intervals Measures / lnstructions / Tools

1.
Overhaul of breaking
chambers
. Line and transformer Inxl1.8 =20,000 Gas evacuated, poles/breaking units
circuit-breakers dismounted and transported to a clean
workshop.
a Capacitor, reactor and Porcelain lift off, contacts and PTFE-
ilter ci rcuit-breakers
f 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.
o 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.
lf the circuit-breaker and operating
mechanism are overhauled for another
2,000 operations, selected worn out
parts are to be exchanged.
lf 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.
lnstructions:
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 = Cru+5%,-0%
PD<5pC
Tan d < O,2o/o.
1 HS8445409-1 00 en 8 17
18 1 HS8445409-1 00 en B
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2005-08-1 9
SE-771 80 LUDVIKA
SWEDEN
Telephone: +a6 (0) 24078 20 OO
Telefax: +46 (0) 240 78 23 20
SFo Circuit-Breaker Circuit-Breakers HPL and LTB
Lubricants
1HS8445409-1 en 6
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Article number:
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Approval date:
2006-08-24
Lubricants
LIST OF CONTENTS
2. Lubricants 3
2.1 oi1....... 3
2.2 Grease...
1HS8445409-1 en 6
Lubricants
1HSB445409-1 en 6
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
General Lubricants
2 1HS8445409-1 en 6
Lubricants Lubricants
2. Lubricants
2.1 oir
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 40oC: 62-65 cSt

Lowest pour temperature: -52oC
oil "D"
- 6.0 cSt at 20oC. Also used as oil in
Circuit-breaker oil with a low viscosity
dampers. Damper with the letter "s" punched on the cover should be filled with oil
.6S".
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 11737011-106
ABB spare part No. 1HS8875318-A 1 HSB87s31 8-B 1 HS8875318-C
MOBIL MOB|L 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
Kdlte-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 ofthe 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 rrSV"
For lubricating moving contacts (opening contacts) for disconnectors, silver-plated
contacts and brushed aluminium surfaces on fixed joints outdoors.
4 1 HSB445409-1 en 6
SUPPLIER Grease "G" Grease "K" Grgase "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 s316 381-L 5316 381-H
ASEOL AG ASEOL SYLITEA

4-018
Dow Corning G-rapid plus
GULF 7'l8EP 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 38'l-X 5316 381-N 5316 381-G 5316 381-C
Kluber lsoflex Topas NB

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

8401
Statoil Electrical grease
1HS8445409-1 en 6 5
6 1HSB445409-'I en 6
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1HSB445409-'I en 6
SE-77180 LUDVIKA 2006-08-24

SWEDEN
Telephone: +a6 (0) 24O7820OO
Telefax: +46 (0) 240 78 23 20
SFo Circuit-Breaker Operating mechanism
BLG 1OO2A
Overhaul lnstructions
1 HSB515409-100 en 8
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Article number:
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Approvaldate:
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1 HS851 5409-1 00en8

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 Too1s.......... 7
3.2 Cleaningequipment. 7
3.3 Spare parts. 7
3.4 Testequipment......... 7
4.1 General .....8

4.2 Preparations for maintenance....................... ... ll
4.3 Cleaning 12
4.4 Corrosion... 12
4.5 Lubrication 13
4.6 Heatingelement...... t4
4.7 Drive unit t5
4.8 Catch gear 16
1.9 Damper...... 17
4.10 Link systern and spring battery t9

4.11 Auxiliary contact....... t9
4.12 Terrninal b|ocks......... 2l
4.13 Manual closing and opening operations... 22
1HS8515409-100 en 8
'l HS8515409-100 en 8
FIGURES
Figure 4-1. Operating mechanism .. ...8

Figure 4-2. lnterlocking mechanism ...9
Figure 4-3. Releasing the interlocking ......... l0
Figure 4-4. Control panel ......... ............ I I
Figure 4-5. Heatingelement ..................14
Figure 4-6. Drive unit ......l5
Figure 4-8. Checking the clearance ...
Figure 4-9. Closing and Opening damper ...17
Figure 4-10. Damping curve, Closing damper ... l8
Figure 4-11. Damping curves, Opening damper ........ l8
Figure 4-13. Auxiliary contact .... ... l9
Figure 4-14. Time measurement, contact travel 20
Figure 4-15. Example of electrical equipment ................. ..............21

Figure 4-16. Manualclosing of the operating mechanism ..............................*22
Figure 4-17. Drive unit .....23
Figure 4-18. Fitting the blocking beams
Figure 4-19. lnterlocking, circuit-breaker open, closing springs uncharged .....24
Figure 4-20.Operating mechanism, manualclosing operation .........................25
Figure 4-21. Manual opening operation ....26
Figure 4-22.Driveunit
Figure 4-23. Fitting the blocking beams ....27

Fi gure 4-24. Interlockin g, circuit-breaker closed, closin g springs unchzrged ... 28
Figure 4-25.Operating mechanism, slow manual operation .........29

Figure 4-26.Check dimension, closing springs .........30
1HSB515409-100 en 8 iii
iv 'l HSB515409-100 en 8
Overhaul lnstructions 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 l-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.
1 HSB51 5409-1 00 en 8 1
General Overhaul lnstructions
2 1HS8515409-100 en 8
Overhaul lnstructions 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 lnstructions
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.
WARNING
WARNING
Do not operate the mechanism unloaded!
Operations should take place only when the mechanism has been
The standard operating sequence is O - 0.3 s - CO - 3 min. - CO. The time between
closing operations should not be less than I minute when circuit-breakers and relay
systems are tested with more than 3 closing operations.
4 1HSB515409-100 en 8
Safety
WARNING
The work requires training and product knowledge and may only be
carried out by authorised personnel
Risk Measure
Working next to high voltage lsolate and earth next to the work
place. lf 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
Risk of crushing in the operating Operate the circuit-breaker to the

mechanism and link system. open position. lsolate 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 untilthe gas has been
porcelain can result in splintering. reduced to max.0.125 MPa (abs.)
pressure.
1HSB51s409-100 en 8 5
1HSB515409-100 en 8
6
Overhaul lnstructions 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 A normal set of tools including torque wrenches (9-550 Nm).
3.2 Cleaning equipment

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

a Lubricants and oils, see the Lubricants Instruction 1HSB445409-1 for suppliers
and trade names.
Grease "G": ABB Art. No. ll11 4Ol4-4O7.

Grease "M": ABB Art. No. 1171 4016-612.
Oil "A": ABB Art. No. 1171 2039-1.
a Anti-corrosion agent.
Valvoline Tectyl506: ABB Art. No. l24l 0011-108

Grease "G": ABB Art. No. ll71 4014-407.
3.4 Test equipment

a Equipment to record damping curves and operating times
(e.g. Programma or ABB SA10).
1HS8515409-100 en 8 7
Maintenance Overhaul lnstructions
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
tr + I'
-I
l,
1 Drive unit
It
2 Operating mechanism
3 Control panel Ir
.ll
\
4 Spring battery 4 i,
ilt
5
5 Heater element Ir
(behind protection 3 = l'
plate) tl
-___-__jj
t;
L| _'ll
cover removed
Figure 4-1. Operating mechanism
a 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 1HS8515409-100 en 8
Overhaul lnstructions 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 ifthe
closing springs are uncharged or not fully charged. This can occur e.g. if the closing
catch gear is activated by hand or ifa 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 Bap = 0 mm).
!tem
2
E
1 Limit switch E
(\l
2 lnterlocking arm
3 lnterlocking disc
4 Cam disc
5 Operating rod
4
fl
u
fl
5
82001 9
Figure 4-2. Interlocking mechanism
1HS8515409-100 en I I
Releasing the mechanica! 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 "HandlMotor" 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 (l) 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.
Item
1 Operating lever
2 Roller in closing catch

gear
820020
a b
Figure 4-3. Releasing the interlocking
10 1HS8515409-100 en 8
4.2 Preparations for maintenance

The following should be done before maintenance is started:
l 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
w
cM m
m
e Eo
m
3 Local/Remote/D iscon nect
switch
O
M e oo
4 Electric counter
oro€ t-a
@
5 Spring indicator
B20009
1 2 53
Figure 4-4. Control panel
11
1 HSB51 5409-1 00 en 8
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
a Clean the inside of the operating mechanism using a vacuum cleaner.
a 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" .
1HSBs15409-100 en B 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 l5 years or 5,000 operations.
Item
1 Heating element
-----------f
654
321
oroH E'
@
1
82001 0
Data
The values of the heating elements are according to below:
For ambient temperatures > -25oC and220 V: R=691 Ohms #107o,70 W
For ambient temperatures > -25oC and 110 V: R=173 Ohms *107o, 70W
For ambient temperatures > -40oC and220 V: R=691 Ohms *107o, 70 W +

R=346 Ohms +107o 140 W
For ambient temperatures > -40oC and 110 V: R=173 Ohms +10% 70W +
R=86 Ohms +1O7o,140 W
For ambient temperatures > -55oC and220 V: R=691 Ohms +107o,70 W +

2 x R=346 Ohms *107o, 140 W
For ambient temperatures > -55oC and 110 V: R=173 Ohms *107o 70W +
2 x R=86 Ohms +107o, 140 W
70 W heating elements are perrnanently connected , while heating elements with

140 W or 2xl4O W for temperatures below -25oC are thermostat controlled.
14 1HS8515409-100 en 8
4.7 Drive unit

a 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 l5 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 857o of its nominal voltage (IEC).
Item
1 Drive unit
@
Hi:= u:
o
820011
4.7.1 Hand-Motor switch

Check that the signal for voltage failure functions. If not, replace the "Hand/Motor"
switch.
1HS8515409-100 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
L
1
Opening catch gear
820012

a Check that the voltage to the coils does not fall below the minimum voltage,
see the delivery document for the operating mechanism.
a Check the play between the magnet arm (2) and the auxiliary catch (1), see
Figure 4-8. The play must be at least I mm. If the play is outside the specified
dimension, replace the entire catch gear.
Item
1 Catch
1mm
2 Magnet arm
820013
Figure 4-8. Checking the clearance
16 1 HS8515409-'100 en 8
4.9 Damper
The operating mechanism is fitted with a Closing damper (l) 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
-l
E |_
2
82001 4
Figure 4-9. Closing and Opening damper
17
1HSB515409-100 en 8
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.
..brt
"a" = damping distance 15-25 mm

"b" = damping time 8G300 ms
82001 5
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- l I .
If the recorded curve differs from the correct curve, replace the comprete
damper.
82001 6 Wrong Right Wrong

Figure 4-11 . Damping curves, Opening damper
18 1HS8515409-100 en 8
4.10 Link system and spring battery

Perform a visual check ofthe 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 (l )
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 ( I ) 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
_t
82001 7
Figure 4-l3. Auxiliary contact
After l5 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.
1HS8515409-100 en 8 19
I . 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 "LocaURemote/Disconnect" switch to the "Local" position.
4. Connect the time-meter across terminals Xl :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
Arci contact
Closed
Auxiliary
"ont""\
Contact trave! I
\
a
Open /
t1 t3 Time
t2
tl ms Proportionalto the contact's opening speed.

t2 ms Time that determines contact damping.
t3 ms Proportional to the contact's closing speed.
82001 8
Figure 4-14. Time measurement, contact travel
20 1HSB515409-100 en 8
4.12 Termina! blocks

Check all screws and pins
11
1
!tem
13
1 Auxiliary contact
2 Motors
2
3 Hand/Motor switch
4 Relays
BI
]E 12
5 Contactors, for motor
circuit
3
6 Direct-on-line starters
7 M in iature ci rcu it-breakers
8 Plug socket
4
I Thermostat e
10 Fuses
11 Opening coil 14
5
12 Terminal block
12
7 e
13 Closing coil
4
14 Cover
8
I
4 o
s20022
10 7
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:
L The circuit-breaker is in the open position.

2. The "Local-/Remote/Disconnect"
switch (1) on the control panel is lEi m E sE
in the "Disconnect" position. #5 eM ao o
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 ffi
1 Local/Remote/D iscon nect switch
2 Direct-on-line starter
3 Direct-on-l ine starter

2
4 Hand/Motor switch 3 WhJ
_-ffiB
820002
Figure 4-16. Manual closing of the operating mechanism
22 1HS8515409-100 en 8
5. The closing springs are uncharged.
a. Place the crank (l) 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 ofthe
frame.
F
H
rffir
Item Jri#hlr-Jl
Tffifl
1 Crank
2 Reverse catch button Direction

of
3 Hand/Motor switch
Direction Direction
of force of force
820003 3 2
6. Blocking beams are fitted.

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

1
2 Bolts MBx60 2 pcs 1
2
820004
2 I
Figure 4-l8. Fitting the blocking, beams
23
1HS8515409-100 en 8
7. The interlocking mechanism is disengaged.
a. Press the operating rod (l) orthe interlocking arm (2) upwards
b. Insert the blocking pin (3) in the hole (4).
2
4
Item
1
1 Operating rod
2 lnterlocking arm x Open

3 position
3 Blocking pin U
Closed
4 Hole for blocking pin position
820005
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 (I ) see Figure 4-20.
The manual closing operation can be intemrpted 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.
I . Crank anticlockwise 310 turns. The cam disc (2) then rotates approx. 314 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 (g). otherwise the cam
disc will be in the wrong position and the operating mechanism could be
damaged during an opening operation.
24
1HS8515409-100 en 8
6. Pull the blocking pin (3) out of the hole (4) , see Figure 4- I9.
7. Turn the "HandlMotor" 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 Cam disc
3 Stop roller
4 Operating lever
6
6 Locking lug I
5
6 Roller, opening catch gear
7 Locking lug
I Roller, closing catch gear
820006 I t t
Figure 4-20. Operating mechanism, manual cLosing operation
1HS8515409-100 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.
m
a
Fiisl
-g :HtsP
raE
@
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
1 Local/Remote/D iscon nect switch
2 Direct-on-line starter
2
3 Direct-on-line stafter 3
4 Hand/Motor switch
B20002
Figure 4-2 L 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 ofthe
frame.
F
U
Item
1 Crank
ffiP cw
2 Reverse catch button
3 Hand/Motor switch
V
Direction of 1 Direction of
force
@ l1 force
A rR-
820003 2
3
6. Blocking beams are fitted.

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

1
1
2
2 _l
820004
Figure 4-23. Fitting the blocking beams
1HS8515409-100 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).
3
Item
1 lnterlocking arm
2 Blocking pin
Open
3 Hole for blocking pin 2 position
Closed
4 Locking disc position
4 E
5 Pin il 5
B20007
l
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.
l. 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. l0 turns.
2. Release the closing catch gear by pressing the armature on the closing coil (1),
Figure 4-2-5, 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 I 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) Iightly 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 1 HSB51 5409-1 00 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. Tum 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
(<\----l
1 Closing coil
2 Locking lug
I I t
3 Roller, closing catch gear
4 Cam disc 6
5 Stop roller
6 Armature
7 Operating lever
820008
Figure 4-25. Operating mechanism, slow manual operation
1HSB5'15409-100 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 "HandlMotor" switch on the drive

unit to the "Motor" position.
6t
+
3. Reset the direct-on-line starters. t
o)
6l
4. Turn the "Local/Remote/Disconnect"
switch on the control panel to the
"Remote" position.
5. Make a test operation.

820021
Figure 4-26. Check dimension, closing springs
30 1HSB515409-100 en 8
t
tl nn
ttI,l,
2005-08-1 2
SE-77180 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 78 20 00
Telefax: +46 (0) 240 78 23 20
SFo Circuit-Breaker HPL 245-550B.2 and
mechanism BLG 1002A
1-pole operation
1HSB4454O9-202 en 9
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Article number:
1 HSB445409-202 en 9
Approvaldate:
2006-12-11
LIST OF CONTENTS
2. Safety. 3
2.1 Warningtext................ , ..)
2.2 Safety directives.......... .4
3. Overhaul, general 7
7
3.2 Gas handling equipment........ 7
3.3 Personal safety equipment.... 7
3.4 Cleaningequipment.... 7
3.5 Spare parts. 8
3.6 Testequipment............ 8
3.1 Premises 8
4. Dismantling the circuit-breaker....... 9

4.1 General...... ,.9
4.2 Gas............ r0
4.3 Cleaning and waste disposal ll
4.4 Unloading the pull rod in the tripping mechanism..... t2
4.5 Dismantling the brezking unit for transport..... l4
4.6 Dismantling the breaking unit............. l6
5. Contact and puffer replacement 19

5.I Replacing the upper main circuit .19
5.2 Replacing the lower current path .24
5.3 Replacing the puffer.... ....21
6. Overhaul of the T-mechanism 22
7. Assembling the breaking unit 23

7.1 Treatment of contact surfaces ...23
7.2 Treatment of sealing surfaces and seals...... ...24
7.3 Assembling the breaking unit ..................... ...25
8. Dismantling the post insulator and mechanism for

transport ............32
8.1 Dismantling the post insulator ..... JJ
8.2 Unloading the tripping mechanism pull rod ..... -1J
8.3 Removing the post insulator .....34
1 HSB445409-202 en 9
9. Overhaul of the mechanism............ 36
lO.Assembling the post insulator. 37

10.1 Assembling the tripping mechanism pull rod on the
operating lever 39
10.2 Gas filling 40
1 l.Assembling and commissioning 41
ii 1HS8445409-2O2 en I
FIGURES
Figure 4-1. Unloading the pull rod ............ ................12

Figure 4-2. Removing the operating interlocking, disconnecting circuit-
breakers I3
Figure 4-3. Unloading the pull rod, disconnecting circuit-breakers
Figure 4-4. Dismantling the brezking unit ............ t4
Figure 4--5. Assembling the transport cover .........
Figure 4-6. Breaking unit with assembly tool ............ l6

Figure 4-7. Breaking unit with pre-insertion resistor and capacitor
Figure 4-8. Dismantling the breaking unit ............ l8

Figure 5-1. Upper current path .......... l9
Figure -5-2. Lower current path ........... 20
Figure 5-3. Puffer 2t
Figure 6-1. T-mechanism .. 22
Figure 7-1. Assembling the ,;;";;;;;;;;;;;; 25
Figure 7-2. Assembling the breaking unit ........... 26
Figure 7-3. Assembling the absorption agent and cover ....... 27
Figure 7-4. Assembling the locking washer 28
Figure 7 -5. Assembling the pre-insertion resistor 29
Figure 7 -6. Assernbling the capacitors 30
Figure 7-7. Assembling the corona rings 3r

Figure 8-1. Dismantling the post insulator 32
Figure 8-2. Unloading the pull rod ...... 33
Figure 8-3. Dismantling the post insulator 34
Figure 8-4. Dismantling the insulating rod .......... 35
Figure 9-1. Mechanism housing 36
Figure l0-1. Assembling the insulating rod ....... 37
Figure l0-2. Assembling the post insulator ................. ......38
Figure l0--i. Assembling the tripping mechanism pull rod on the

operating lever ..39
\
1 H58445409-202 en 9
\
iv 1HS8445409-202 en 9
Overhaul lnstructions General
1. General
This Overhaul instruction applies to the SF6 circuit- breaker HPL 245-55082 and
HPL 245-550T82, I -pole operation. It 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.
1 H58445409-202 en 9 1
General Overhaul lnstructions
2 1HS8445409-202 en 9
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. used for hazards that may only result in damage to the installation.
1 H58445409-202 en g
3
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.
insulators should be carried out at reduced gas pressure,0.125 MPa (abs).
WARNING
insulators should be carried out at reduced gas pressure, 0. 125 MPa (abs).
WARNING
Do not operate the mechanism unloaded!
connected and trimmed with the associated pressurized circuit-breaker.
The standard operating sequence is O - 0.3 s - CO - 3 min. - CO. The time between
1 HS8445409-202 en 9
4
WARNING
Work requires training and product knowledge and may only be carried
out by authorised personnel.
Risk Measure
Working next to high voltage. lsolate and earth close to the work
place. lf 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
Risk of crushing in the operating Operate the circuit-breaker to the

mechanism and link system. open position. lsolate and earth the
There is stored energy in the high voltage side. Uncharge the
opening and closing springs. The springs by switching off the motor
mechanism can be tripped by heavy current and perform a Close-Open
vibrations or by unintentional contact operation or move the operating
with mechanical latch components. mechanism drive shaft backwards by
hand (see the Overhaul lnstructions
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 circuit-breaker's

insulators. insulators that may result in damage
The normal working pressure is up to to the porcelain must not take place
0.8 MPa (abs). Damage to the until the gas pressure has been
porcelain can result in splintering. reduced to max. 0.'125 MPa (abs.).
1H58445409-202 en I 5
6 1 HS8445409-202 en 9
Overhaul lnstructions 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 A normal set of tools and torque wrenches (9-550 Nm).
a 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.
a Assembly tool, ABB Art. No. lHSB 630030-R.
3.2 Gas handling equipment

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

. Full face mask with filter for fine particles and acid 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 957o (vol), C2HsOH, for cleaning inside surfaces.
. Heavy duty plastic sheet and plastic bags to prevent the ingress of moisture and
to protect cleaned components before assembly.
1 HSB445409-202 en I 7
Overhaul, general Overhaul lnstructions
3.5 Spare parts

a Set of contactsl
a Set of sealsl
a Absorption agentl
o Lubricants, see Lubricants Instruction for the names of suppliers and brands
Grease "G": ABB Art. No. ll7l
4014-407
Grease "K": ABB Art. No. 1263 0011-102
Grease "M": ABB Art. No. llTl
4016-612
Grease "N": ABB Art. No. ll7l
4016-607
Grease "S": ABB Art. No. ll71 4014-406
Grease "P": ABB Art. No 1171 50ll-102.
a Anti-corrosion agent
Valvoline Tectyl 506, ABB Art. No. 1241 0011-108.
a Locking fluid.
Loctite 270, ABB Art. No. 1269 0014-408.
a SF6 gas.
a Nitrogen gas.
a Protective cover, circlip and tensioning tool from the assembly.
Protective cover for breaking unit ABB Art. No. 1HSB442186-5.
Protective cover for post insulator, ABB Art. No. 1 HSB442l 58- I .
Locking ring, ABB Art. No. 2171 835-D.
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 unit 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.
Under no circumstances may the breaking unit be removed or dismantled during
rain or other unsettled weather conditions, nor when the relative humidity is 807o or
higher.
l. According to the spare parts lists for the breaker in question.
8 1HSB445409-202 en 9
Overhaul lnstructions D ism antl i ng th e ci rcu it-b reake r
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 Instructions must be read and
followed.
Check and make a note of 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 be carried out separately on:
. The breaking unit.
. The post insulator.
N.B. Removal and assembly of the 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 in the operating mechanism by switching off the
motor current and perform a Close-Open operation.
. Switch off the control voltage and, if necessary, also the heating power.
1 HSB445409-202 en 9 9
D ism antl ing th e ci rcu it-b reake r Overhaul lnstructions
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 pressurized 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 large 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 circuirbreaker is filled again with dry nitrogen until atmospheric
pressure is reached. The breaker is now ready to be dismantled.
10 1 HS8445409-202 en 9
Overhaul lnstructions D is mantli n g the ci rcu it-b reake r
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 lace mask with
a fine particle and acidic gas filter must be worn when cleaning 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.
1 HS8445409-202 en 9 11
D i sm antl i ng th e ci rcu it-b reake r Overhaul lnstructions
4.4 Unloading the pull rod in the tripping mechanism

Before the breaking unit is dismantled for transport, the circuit-breaker must be
taken out of service, see Chapter 4.1 . l, the gas removed, see Chapter 4.2.1 and the
pull rod in the tripping mechanism unloaded.
4.4.1 Unloading the tripping mechanism pull rod

For disconnecting circuit-breakers, see Chapter 4.4.2.
L Operate the circuit-breaker slowly towards the Closed position by cranking the
operating mechanism by hand. This is described in the Overhaul Instructions
for the operating mechanism. Stop cranking when the dimension L= 187 mm
(for circuit-breakers with breaking capacity 31.5-50 kA) or L=199 mm (for
circuit-breakers with breaking capacity 63 kA) has been reached.
2. Remove the bottom cover (1) to the tripping mechanism.
3. Remove the bolt (2) and fit the tensioning tool (3) I HSB44638 1 -A, see also the
circuit-breaker Assembly Instructions.
4. Tension the adjuster screw (4) to unload the tripping mechanism pull rod (5)
L
e
Item
1 Bottom cover
2 Bolt M16x30 1 pcs.
Washer 2 pcs.
5 6
3 Tool 1HS8446381-A
4 Adjuster screw
5 Pull rod
6 Operating lever
1 2
810098 4
Figure 4-1. Unloading the pull rod
12 1HS8445409-202 en 9
Overhaul lnstructions D is mantli n g the ci rcu it-b reake r
4.4.2 Unloading the pull rod, disconnecting circuit-breakers

l. Disconnect the blocking disc ( l) from the rod piston (2) on the operating
mechanism AD 100 by removing the cotter pin (4) and the cylindrical
pin (3).
2. Dismantle the operating interlocking with the glass cover (3) and the protective
plates (5) from the tripping mechanism by loosening the bolts (2).
3
1
Item L-_-_
2
1 Blocking disc
2 Rod piston
I
r____-1_a
3 Cylindrical pin 1 pc.
4 Cotter pin 1 pc.

Washers 10.5x20x2 8 pcs
7
b Glass cover
6
7 Protective plates 2 pcs 5
Figure 4-2. Removing the operating interlocking, disconnecting circuit-breakers
3. Operate the circuit-breaker slowly towards the Closed position by cranking the
operating mechanism by hand. This is described in the Overhaul Instructions
for the operating mechanism. Stop cranking when the dimension L= 187 mm
has been reached.
4. Fit the guiding block (2) with the bottom cover (1).
5. Tension the adjuster bolt (3) to unload the tripping mechanism pull rod (4)
Item
1 Bottom cover with spacing rod *
5
2 Guiding block *
3 Adjuster screw *
J 4
4 Pull rod
5 Operating lever
,
. lncluded in tensioning tool 1 HSB446381-D

1 2
3
Figure 4-3. Unloading the pull rod, disconnecting circuit-breakers
1 H58445409-202 en 9 13
Dismantl ing th e ci rcu it-breake r Overhaul lnstructions
4.5 Dismantling the breaking unit for transport

l. Dismantle the cover (3) from the breaking unit (I ).
2. Fit the locking washer (5) so that the contacts in the breaking unit are held in
the right position.
3. Dismantle the circlip (6) and pin (7).

4. Place a lifting sling around the breaking unit (l) and prepare to lift it.
5. Undo the bolts (8) against the post insulator and carefully lift the breaking unit
straight up.
I @
Item
@
1 Breaking unit
2 Post insulator
2
3 Cover with two O-rings
4 Bolts M10x25 4 pcs. 4 6,7

Washers 10.5x22x2 4 pcs. NB! On the back
5 Locking washer
of the T-mechanism
6 Circlip
7 Pin

Nuts M12 4 pcs.
B1 0093
Figure 4-4. Dismantling the breaking unit
14 1 HSB445409-202 en 9
Overhaul lnstructions D i smantli n g the ci rcu it-b reake r
6. Assemble the cover (3) on the breaking unit using the bolts and washers (4),
tighten by hand.
7. Fit the breaking unit's transport cover (l) with associated O-ring.
8. Fit the transport cover (3) with associated O-ring on the post insulator.
9. Fillthe post insulator with SF6 gas or nitrogen gas to a pressure of
0.125 MPa abs.
Item

Nuts M12 8 pcs.
3 Transport cover with O-ring 1 2
B1 0090
Figure 4-5. Assembling the transport cover
10. Place the breaking unit on a suitable transport base so it cannot tip over.
The breaking unit is now ready for transportation to the workshop for an overhaul.
1 H58445409-202 en I 15
D i sm antl i ng the ci rcu it-breake r Overhaul lnstructions
4.6 Dismantling the breaking unit

Plan the dismantling work so that it can be carried out quickly and without long
delays to prevent moisture in the air coming into lengthy contact with the dust in the
breaking unit and on the inside and outside of the breaking chamber insulator.
N.B. Use personal safety equipment such as overalls, protective gloves and face
mask.
Collect the decomposition products in the breaking unit, in the form of powder, as
the breaking unit is successively opened. First use a vacuum cleaner and thereafter
carefully wipe the dismantled components.
Dismantling and assembly are facilitated by placing the breaking unit on an
assembly tool, ABB Art. No. IHSB 630030-R, with a mechanism for operating the
contacts.
I . Lift the breaking unit ( I ) from

the transport base and dismantle the transport
cover (2), but let the O-ring remain in position.
2. Place the assembly tool (4) on the transport base and position the
breaking unit (l).
3. Connect the mechanism in the assembly tool to the breaking unit by fitting the
pin (5) and circlip (6).
4. Screw a bolt, M8, into the threaded hole in the locking washer (7) and pull it out.
!tem
1 Breaking unit
3 Bolts M12x80 4 pcs. 2 4

Nuts M12 4 pcs.
4 Assembly tool Art.No. l HSB 630030-R 7

5,6
5 Pin
@
6 Circlip
7 Locking washer
3
B1 0099
Figure 4-6. Breaking unit with assembly tool
16 1HSB445409-202 en 9
Overhaul lnstructions D i smantl i n g the ci rcuit-b reake r
5. Remove the corona rings (if applicable).
6. Remove the capacitors (6) by loosening bolts (7) and (8) (if applicable).
7. Remove the pre-insertion resistors (if applicable).

Loosen stay (2) by removing bolts (3).
Remove bolts (4) next to the spacer (5).
Pull the pre-insertion resistor (l) straight out so the operating shaft is
released from the T:-mechanism housing.
!tem
'l
Pre-insertion resistor
2 Stay
3 Bolts M 12x60 4 pcs.

6 8 54 1
Washers 13x28x3 4 pcs. 2

3
5 Spacer
6 Capacitor \ 7
810202
Spring washer 4 pcs.

Spring washers 4 pcs.
Figure 4-7. Breaking unit with pre-insertion resistor and capacitor
1 H58445409-202 en 9 17
D i sm antl i ng th e ci rcu it-b reake r Overhaul lnstructions
8. Dismantle the covers (1) and lift out the absorption agent containers (2).
N.B. Place the bags with absorption agent in a vessel for chemical waste.
9. tvtait ttre flanges on the breaking chamber insulators (5) so that they can be
reassembled in the same position.
10. Dismantle the upper current paths (3) with the upper terminal flange.
I l. Place a lifting sling on the breaking chamber insulator as shown in Figure 4-8
and remove the insulators (5) from the mechanism housing (4).
N.B. For composite insulators: Place the lifting sling as close to the terminal flange
as possible and not on the rubber surface.
12. Carefully lift straight out so that the puffer (6) and lower current path (7) are
not damaged.
13. Dismantle the lower current paths (7).

14. Operate the puffer (6) outwards using a spanner on the shaft (8) and dismantle
the puffer by removing the pin (9) on the lower end of the puffer pull rod.
I
2
5
4763
Item
1 Cover I 810100
2 Absorption agent container
3 Upper current path
5 Breakin g chamber insu lator
6 Puffer
7 Lower current path
8 Shaft with 24 mm spanner head
I Pin
Figure 4-8. Dismantling the breaking unit

The main components of the breaking unit are now accessible for inspection,
cleaning and replacement of burnt or damaged parts.
18 '1HS8445409-202 en 9
Overhaul lnstructions Contact and puffer replacement
5. 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.
5.1 Replacing the upper main circuit

The entire current path (3) with terminal flange (1) and puffer should be replaced if
the upper current path's fixed arcing contact (4), Figure 5-1, has been burnt so that
the distance to the reference surface is more than 9 mm, or if the outside has been
severely burnt. Replace the entire upper current path if the silver on the current
path's contacts is wom so that the copper is visible.
Tighten the bolted joints (2) with a tightening torque of 22.5 Nm.
4
Item max.9 mm
1 Upper terminal flange 1

Spring washers 12 pcs
4 Arcing contact
Reference _t
surface
-l
--lt -
TIGHTENING TORQUE
22.5 Nm
3 2
810'101
Figure 5-1. Upper current path
1 H58445409-202 en 9 19
Contact and puffer replacement Overhaul lnstructions
5.2 Replacing the lower current path

Remove the current path from the T-mechanism housing. Lift off the puffer and
check that there is no wear on the pull rod's sliding surfaces in the puffer guide.
Check that the silver on the lower current path contacts is not worn so that the
copper is visible. If there are signs of wear, replace the entire lower current path.
Tighten the bolts (2) with a tightening torque of 22.5 Nm.
Item 1 2 3

Spring washers 12 pcs e@

22
4 Puffer
5 Puffer guide
t lc
6 Teflon band
TIGHTENING TORQUE
564
81 01 02
22.5 Nm
Figure 5-2. Lower current path
20 1HSB445409-202 en I
Overhaul lnstructions Contact and puffer replacement
5.3 Replacing the puffer

Check that the nozzle (l) is not punctured. Also check that the contact surfaces on
the puffer cylinder (3) are not burnt or worn so that the copper is visible. Check that
there is no wear on the pull rod's sliding surfaces.
N.B. If the upper curent path has been replaced because the fixed arcing contact is
burnt, the puffer must also be replaced.
Replace the entire puffer if it has bumt or worn surfaces.
Item 1
1 Nozzle
2 Pull rod
3 Puffer cylinder
4 Bolt M8x16 8 pcs.

Washer 8.4x16x1.6 I pcs.
3 Contact surface
TIGHTENING TORQUE
22.5 Nm
2
?
g
T
+
B'10025
Figure 5-3. Puffer
1 HS8445409-202 en I 21
Overhaul of the T-mechanism Overhaul lnstructions
6. Overhaul of the T-mechanism

Check that the T:mechanism is not heavily contaminated with decomposition
products.
Replace all O-rings and coat them with grease "G" and all pins with grease "M", if
the mechanism needs to be dismantled and cleaned.
Item
2
1 Pull rod, upper section
2 Support collar
3 O-ring
4 Bushing
5 O-ring 3
4
81 0't 03 5
Figure 6-l - T-mechanism
22 1HS8445409-202 en 9
Overhaul lnstructions Assembling the breaking unit
7. Assembling the breaking unit

To re-assemble the breaking unit, follow the dismantling instructions in the reverse
order, see Chapter 4.6.
N.B. When re-assembling the breaking unit, all O-rings should be new. Careful
cleaning and treatment of sealing surfaces is required.
7.1 Treatment of contact surfaces

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

a Silver-plated surfaces
Ifnecessary, 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. I l7l 5011-102).
N.B. Grease should be applied within five minutes of cleaning and the joint should
be fitted within 15 minutes.
7.1.2 Moving contact surfaces

a Silver-plated surfaces
If necessary, clean silver-plated moving contact surfaces, using a soft cloth and
solvent (alcohol).
a 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.
a Greasing
Apply Grease "N" (ABB Art. No. 1171 40t6-607) in a covering, but very thin
layer to the male contacts and the puffer cylinder surfaces. Carefully wipe off
all excess grease.
1 H58445409-202 en I 23
Assembling the breaking unit Overhaul lnstructions
7.2 Treatment of sealing surfaces and seals

Clean, degrease and inspect all sealing surfaces in connection with assembly
N.B. Sealing grooves and other sealing surfaces must not have lateral scratches.
Any small scratches on sealing surfaces can be polished 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 terminal
flanges in the gas chamber must not occur.
Coat terminal flange surfaces outside the outer seal with a thin, well-covering layer
of anti-corrosion agent matched to the terminal flange material, usually Grease "G"
(ABB Art. No. I171 4014-407).
Degreasing and cleaning material:
. Alcohol.
Greases for seals:

a Grease "G" for static seals
Grease "S" for moving seals, e.g. shaft seals.
24 1HSB445409-2O2 en 9
7.3 Assembling the breaking unit

1 . Fit the puffers ( I ) on the puffer guides. When the puffer starts to go down over
the Teflon band, carefully turn it so that the Teflon band is not damaged.
N.B. Thke care so that the Teflon band on the piston is not damaged when the
puffer is moved down.
2. Connect together the puffer pull rods (2) and links (3) with the pins (4).
3. Fit the lower current paths (5) over the puffers and puffer guides. Tighten the
bolts (6) with a tightening torque of 22.5 Nm.
4
2
TIGHTENING TORQUE
22.5 Nm
Item 5 1
1 Puffer
2 Pull rod 3
3 Link
4 Pin
@
Washers 8.4x20x2 12 pcs.
Spring washers '12 pcs.
B1 01 04
6
Figure 7-1. Assembling the puffer and lower current path
1 H58445409-202 en I 25
4. Carefully clean the sealing surfaces for the O-rings ( I ) and the outside surface
on the T:mechanism housing (2) and coat well with grease "G". Place the
O-rings (1) on the mechanism housing and carefully lift the breaking chamber
insulators (3) into position. Tighten by hand with the bolts (4).
5. Carefully clean the sealing surfaces for the O-rings (5) and the surface outside
the upper terminal flanges (6) and coat well with grease "G". Place the O-rings
(5) on the upper terminal flanges (6) and assemble with the upper current path
(7). Tighten the upper current path by hand with bolts (8).
Item 4 1 5 8
1 O-ring 2
2 T-mechanism housing 3
3 Breaking chamber insulator
5 O-ring
e€D- F-
6 Upper terminal flange
8 Bolts M12x5O 8 pcs
97 6
9 Puffer
10
10 Spanner 8101 05
Figure 7-2. Assembling the breaking unit
6. Slowly operate the puffers (9) towards their Closed position using the spanner
(10). Align the fixed contacts so that they are centred with each other by
moving the upper terminal flanges (6) and, if necessary, also the breaking
chamber insulators (3).
7. Tighten the bolts (4) and (8) with a tightening torque of 60 Nm.
TIGHTENINC TORQUE
60 Nm
26 1 HSB445409-202 en 9
8. Clean the sealing surfaces on the upper terminal flanges (1) and the outside
surface and coat with grease "G". Place the O-rings (2) on the upper terminal
flanges.
9. Open the new absorption agent package and place the agent in the absorption
agent containers (3).
10. Fit the absorption agent containers (3) and the covers (4) and tighten the bolts
with a tightening torque of 45 Nm.
TIGHTENING TORQUE
-1-5 Nnt
I l. Fit the cover (-5) with the O-ring
2
Item
1 Upper terminal flange
2 O-ring 4
3 Absorption agent container
4 Upper cover
5 Cover
6 Spanner
3
1
6
810106
- 5
Figure 7-3. Assembling the absorption agent and cover
12. If the circuit-breaker is equpped with pre-insertion resistors, see Chapter 7.3.1 .
13. Operate the breaking unit until it is virtually in the Closed position using the
spanner (6).
14. Fill the breaking unit 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 to atmospheric pressure. Allow to stand for a few hours or
overnight.
c. Vacuum pump again down to lfi) Pa and fill with pure SF6 gas to a
pressure of 0.125 MPa (abs).
Store filling hoses so that they are not exposed to moisture or contamination.
They must not be used for other than their intended purpose.
1 HSB445409-202 en I 27
I 5. Check, using a detector, around all covers and insulator flanges that the
breaking unit does not leak.
1 6. Turn the shaft with the spanner ( I ) so that the slot on the end of the shaft is
vertical and the breaking unit is in the sealed position.
17. Dismantle the cover (2), circlip (3) and pin (4) and fit the locking washer (5).
18. Fit the cover (2).
19. If the circuit-breaker is equipped with capacitors, see Chapter 7 .3.2.
20. If the circuit-breaker is equipped with corona rings, see Chapter 7.3.3.
21. Lift off the breaking unit from the assembly tool and fit the transport cover (6).
22. Place the breaking unit on a suitable transport base.
5
4,3
Item
(E
2
1 Spanner
2 Cover
3 Circlip
IlIlilil iililllltIIIiiiilrII
4 Pin
5 Locking washer
6 Transport cover with O-ring 1
1
Washers 13x28x3 I pcs.
Nuts M12 4 pcs.
6
7
B10099
Figure 7-4. Assembling the locking washer
28 1 HS8445409-202 en 9
7.3.1 Assembling pre-insertion resistors (if applicable)

1 . Carefully clean the sealing surface for the O-ring and the surface outside of the
T:mechanism housing (1) and coat well with grease "G". Place the O-ring on
the mechanism housing and lift the pre-insertion resistor (2) into place.
2. Align the pre-insertion resistor's operating shaft in the T:mechanism.

3. Tighten the bolts for the spacer (3) by hand.
4. Fit the stay (4) using the bolts (5).
5. Tighten all bolts (3) and (5) with a tightening torque of 45 Nm.
Repeat points 1-5 to fit the other pre-inse(ion resistor.
Item
T-mechanism housing
32
'1
2 Pre-insertion resistor 4
3 Bolts M12x40 4 pcs 5
4 Stay

B1 0203 1
TIGHTENING TORQUE
45 Nm
Figure 7-5. Assembling the pre-insertion resistor
1H58445409-202 en 9 29
7.3.2 Assembling the capacitors (if applicable)

I. Fit the capacitor brackets ( 1 ) on the capacitors. Tighten the bolts (2) by hand.
2. Attach a lifting device on the capacitor and lift it into position.
3. Fit the bracket against the terminal flange, separated by the spacer washer (5),
and tighten the bolts (4) by hand.
4. Fit the bracket on the T:mechanism housing (3) using the bolts (4).
5. Tighten the bolts (2)with a tightening torque of 79 Nm.
TIGHTENINC TORQUE
79 Nm
&\
TIGHTENING TORQUE
60 Nm
Repeat points 2-6 to fit the other capacitor.
5
Item
1 Capacitor brackets 2 pcs
Spring washer 4 pcs
3
Spring washer 4 pcs. 4
5 Spacer washer 4
1 2
B1 01 20
Figure 7-6. Assembling the capacitors
30 1HS8445409-202 en 9
7.3.3 Assembling the corona rings (if applicable)

I . Dismantle the bolts (I ) that hold the terminal flange against the breaking
chamber isolator.
2. Liftthe corona ring (3) into position and fit the bolts (l). Tighten the bolts by
hand.
3. Fit the bolts (3) with washers and nuts.

4. Tighten all bolts (1 and 3) with a tightening torque of 60 Nm.
TIGHTENING TORQUE
60 Nm
Repeat points I -4 to fit the other corona rings
3
2
%9.P
o o
1
3
3
4 3
HPL 245-550T82 HPL 245-55082
810212 B10'121
Figure 7-7. Assembling the corona rings
Item
2 Corona ring
3 Bolt M10x35 1 or 3 pcs.
Washers 10.5x25x4 2 or 6 pcs.
Nut M10 1 or 3 pcs.

1H58445409-202 en I 31
Dismantling the post insulator and mechanism Overhaul lnstructions
8. Dismantling the post insulator and mechanism for transport

Before the post insulator is dismantled, the gas must be emptied, see Chapter 4.2.1 .
The density monitor must be dismantled and the sealing cap (l) should be fitted to
the non-return valve (2).
l. Dismantle the pull rod between the operating mechanism and the circuit-
breaker.
2. Place alifting sling under the post insulator's upper flange as shown in
Figure 8-l and prepare to lift with a crane.
3. Now loosen the post insulator (5), removing the four bolts (3) on the frame and
the four bolts (4) on the protective tube.
N.B. For composite insulators: Place
the lifting sling as close to the
terminal flange as possible and
not on the rubber surface 1
4. Lift up the post insulator and

carefully lay it down on a
transport carriage. Block up the
post insulator so it lies 2
horizontally. The blocks (6) under
the post insulator should be of an
elastic material, e.g. wood or
rubber. 5
N.B. If possible, keep the supports

supplied on delivery for this
purpose.
3
Transport to the workshop or a new
site should take place with care so as
not to damage the post insulator. 4
Item
1 Sealing cap
2 Non-return valve

Nuts M20 4 pcs.

Nuts M12 4 pcs
Washers 13x24x2.5 8 pcs
5 Post insulator
6 6
810110
6 Blocks
Figure 8-1. Dismantling the post insulator
32 1 HSB445409-202 en 9
Overhaul lnstructions Dismantling the post insulator and mechanism
8.1 Dismantling the post insulator

The post insulator is set up ve(ically on a suitable frame, e.g. circuit-breaker frame
or a frame on the floor of the workshop.
8.2 Unloading the tripping mechanism pull rod

l. If the tripping mechanism should be dismantled, measure and make a note of a
reference dimension, e.g. "Y", so that the opening spring (l) can be refitted to
the same tension using the nut (2).
Y=............. mm date................
2. Remove the pin (3).
N.B. At reassembly the clamp nut (4) shall be replaced.
Item
1 Opening spring
2 Locking nut
3 Pin
4 Clamp nut
1
2
81 01 07
Figure 8-2. Unloading the pull rod
1 H58445409-202 en I 33
Dismantling the post insulator and mechanism Overhaul lnstructions
8.3 Removing the post insulator

Plan the work to remove and clean 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.
If the circuit-breaker is eqiupped with composite insulators the two post insulator
units are replaced with one unit.
N.B. Use personal safety equipment such as overall, protective gloves and face
mask.
1. Dismantle the transport cover (l ) and the upper guide (2).
2. Fit a lifting sling from the top of the post insulator (4) 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.
3. Remove the bolts (5) between the upper (4) and the lower post insulator
unit (7).
4. Lift the upper post insulator unit (4) straight up until the insulating rod (9) is
released. Hold the insulating rod (9) when lifting the post insulator (4).
5. Remove the sealing washer (6).
6. Remove the bolts (8) between the lower post insulator unit (7) and the
mechanism housing.
7. Lift the lower post insulator unit (7) straight up until the insulating rod (9) is
released. Hold the insulating rod (9) when lifting the post insulator (7).
N.B. Take care not to damage the insulating rod (9).
2
1
Item \..,=
1 Transporl cover
2 Upper guide

4
5
Upper post insulator unit
Bolts M16x70 8 pcs.

9 \s
Washers 17x3Ox3 16 pcs. 6
Nuts M16 8 pcs.
5
6 Sealing washer 8
7 Lower post insulator unit 7

B't 0108
9 lnsulating rod
Figure 8-3. Dismantling the post insulator
34 1HS8445409-202 en 9
Overhaul lnstructions Dismantling the post insulator and mechanism
8. Mark the insulating rod so that it is positioned correctly when re-assembling.

Dismantle the insulating rod by removing the circlip ( I ), washer (2) and
pin (3).
3
Item
1 Circlip 1
2 Washer
3 Pin
B1 01 09
Figure 8-4. Dismantling the insulating rod
9. Carefully clean the insulating rod and protect it using a plastic sheet.
10. Carefully clean the post insulator units, inside and outside, and protect them
using a plastic sheet.
1H58445409-202 en I 35
Overhaul of the mechanism Overhaul lnstructions
9. Overhaul of the mechanism

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 Tectyl506, ABB Art. No. l24l 0011-108.
l. The operating shaft (2) isjournalled on a large bearing (4) on the outside ofthe
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
I
2
(M5), which are screwed into
the holes at the end of the
bushing. Replace the O-rings lnner mechanism
(7, 8) in the bushing (6) and
coat with grease "S".
5. Check that the bearing (9)

rotates easily.
3
Item zru
1
2
Mechanism housing
Operating shaft
L
Outer mechanism
3 Operating lever
964
4 Bearing
2
5 Circlip
6 Bushing
7 X-ring 69.2x5.7
I O-ring 89.1x5.7
I Bearing 5
7g
B'too27
Bearings and O-rings
Figure 9-1. Mechanism housing
36 1HS8445409-202 en 9
Overhaul lnstructions Assembling the post insulator
10. Assembling the post insulator

If the circuit-breaker is equipped with composite insulators the two post insulator
units are replaced with one unit.
I . Turn the operating lever ( 1) and link (2) over the edge of the mechanism
housing and fit the insulating rod (3) using the pin (4), washer (5) and
circlip (6).
N.B. Fit the pin so that the circlip (6) faces towards the large bearing.
2. Place the O-ring on the mechanism housing (9) and lift on the lower post
insulator unit (7), tighten the bolts (8) with a tightening torque of 79 Nm.
TIGHTENING TORQUE
79 Nm
3
Item 4
1 Operating lever
6
2 Link
3 lnsulating rod
4 Pin
7
5 Washer 5
6 Circlip I
7 Lower post insulator unit 2
8 Bolts M16x5O 8 pcs.

Washers 17x30x3 I pcs.
1
I Mechanism housing
B1 01 09 9
Figure l0-1. Assembling the insulating rod
1 H58445409-202 en 9 37
Assembling the post insulator Overhaul lnstructions
3. Place the sealing washer (l) with the O-rings on the lower post insulator unit
(2) and lift on the upper post insulator unit (3). Tighten the bolts (4) with a
TIGHTENING TORQUE
190 Nm
4. Fit the upper guide (5) and tighten the bolts (6) with a tightening torque of
60 Nm.
TIGHTENING TORQUE
60 Nm
5. Fit the transport cover (7)
Item 5 7
1 Sealing washer
2 Lower post insulator unit -/

3 Upper post insulator unit
4 Bolts M16x70 B pcs. 3

Washers 17x30x3 1 6 pcs.
Nuts M16 8 pcs. '.S

5 Upper guide
1
6 Bolts M't2x40 4 pcs.
Washers'13x28x3 4 pcs. 4
7 Transport cover
2
B1 01 08
Figure l0-2. Assembling the post insulator
38 1 HSB445409-202 en 9
Overhaul lnstructions Assembling the post insulator
10.1 Assembling the tripping mechanism pull rod on the operating lever
l. Turn the operating lever (3) anti-clockwise towards the Open position and
connect it to the pull rod (5). 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 O0l4-408
(Loctite 270).
TIGHTENING TORQUE
22,5 Nm
\
2. If the nut (8) has moved out of position, adjust it to the dimension Y, see
Chapter 8.2.
3. If the opening spring settings is changed or the tripping mechanism have been
dismantled the clamp nut (11) should be replaced.
Item
1 Bottom cover
3 Operating lever
4 Pin
5 Pull rod 3
5 4
6 Spring housing
6
11
7 Opening spring
7
8
B Locking nut
I Tool 1HSB44638'l-A
Y
10 Adjuster screw 9
11 Clamp nut
810107 10 1
Figure l0-3. Assembling the tripping mechanism pull rod on the operating lever
a Set the dimension L= 187 mm (for circuit-breakers with breaking capacity

31.5-50 kA) or L=199 mm (for circuit-breakers with breaking capacity 63 kA)
using the adjuster screw (10). For disconnecting circuit-breakers, see
Chapter 4.4, Figure 4-3.
1 HSB445409-202 en I 39
Assembling the post insulator Overhaul lnstructions
10.2 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).
Storefilling hoses so that they are not exposed to moisture or contamination.

They must not be used for other than their intended purpose.
The post insulator is now ready for transport.
40 1 H58445409-202 en 9
Overhaul lnstructions Assembling and commissioning
11. 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
Closing time coil I MS MS MS
Closing time coil ll MS MS ms
Opening time coil I MS MS MS
Opening time coil ll MS MS MS
Close-Open times(1) MS MS MS
Lowest controlvoltage closing coil I V V V
Main circuit resistance po pA pa

(1) The circuit-breaker must nol be operated Open-Close without a time delay of 300 ms.
(2) Filling pressure according to rating plate.
Check carried out on the
1 H58445409-202 en I 41
Assembling and commissioning Overhaul lnstructions
Second overhaul
Measured values
Check the following
Closing time coil I MS MS MS
Closing time coil ll MS MS MS
Opening time coil I ms MS MS
Opening time coil ll MS ms MS
Close-Open times(1) MS MS MS
Lowest control voltage closing coil I V V V
Main circuit resistance pa pa pA

(1) The circuit-breaker must not be operated Open-Close without a time delay of 300 ms.
(2) Filling pressure according to rating plate.
Check carried out on the
42 1HS8445409-202 en 9
ll ll ll
,lI,l,
Circuit-breaker Unit
2006-12-11
SE-771 80 LUDVIKA
SWEDEN
Telephone: +a6 (0) 240782000
Telefax: +a6 (0) 24O 78 23 20
SFo Circuit-Breaker Circuit-Breakers HPL and LTB
SF6-gas
1 HSB445 409-2 en 3
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ment.
The document, or pafts thereof, may not be reproduced or copied without prior permission from ABB
Power Technologies AB. lt may not either be impaded to third party or otherwise be used without aut-
Article number:
1HSB445409-2 en 3
Approvaldate:
2004-08-20
SF6-gas
LIST OF CONTENTS
1 HSB44540g-Z en 3
SF6-gas
ii 1 HS8445409-2 en 3
SF6-gas
FIGURES
Figure l-1. Impulse voltage withstand, kV, 10 mm gap ... 1
Figure I -2. Contribution to the greenhouse effect in per cent
1HS8445409-2 en 3 iii
SF6-gas
iv 1 HS8445409-2 en 3
SF6-gas SFO gas
1. SFo 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
I
approx. 2.5 times better than air.

The SF6 gas is usually used at a 2SO
pressure of 0.3-0.5 MPa and then
insulates approximately l0 times 2OO
better than atmospheric air. These
characteristics are utilised to
150
construct small. compact units that
give an all around low
environmental impact. 1oo
The gas is strongly electronegative, 50

i.e. the gas molecules capture free
electrons, and form heavy negative
ions with low mobility. This is (EG
f=Iu?fs
E
effective against the occurrence of o o
electron avalanches, which can (E
oo
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.
1 HSB445409-2 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 207o. 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 ot

fo
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
0
COz CHc Others SFo
Figure I -2. Contribution to the greenhouse ffict 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 1 HS8445409-2 en 3
ll Iltl
tlI,r,
ABB Power Technologies AB 1 H58445409-2 en 3
Ci rcuit-Breaker Division
2004-08-20
SE-771 80 LUDVIKA
SWEDEN
Telephone: +a6 (0) 240 78 20 OO
Telefax: +a6 (0) 240 78 23 20
SFo Circuit-Breaker Circuit-breakers HPL and LTB
Disposal and recycling

1HS8445409-3 en 3
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ABB Power Technologies AB is not responsible for damage incurred due to the misuse oI this docu-
ment.
The document, or pafis thereof, may not be reproduced or copied without prior permission from ABB
Article number:
1 HS8445409-3 en 3
Approvaldate:
2004-o8-20
LIST OF CONTENTS
1. Disposal and recycling ...... 1
l.l General ................1

1.2 Taking care of spent equipment ........................... I
1.3 The circuit-breaker's component parts .......... .... . ... 1
l.-5 Porcelain.... .,......,2

1.6 Electronics. 2
1.7 MetaIs......... )
L8 Plastics 2
1.9 Oils and greases ...........3
Ll0 Rubber....... -)
1.11 Other materiaIs............... 3
1 HS8445409-3 en 3
1 HS8445409-3 en 3
Disposaland 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

Wom-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-breakeq almost 707o, is porcelain. The
remaining 30Vo is mainly metal, primarily iron, steel and aluminium. Rubber and
different plastics make up approximately 0.57o each and chemicals and gas less than
0.5Vo.
1.4 SF5-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 ofin 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.
1 HS8445409-3 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 1 HS8445409-3 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.
1 HS8445409-3 en 3 3
4 1 HSB445409-3 en 3
Ir IIII
,lI,l,
it-Breaker Division
Ci rcu
SE-771 80 LUDVIKA 2004-08-20
SWEDEN
Telephone: +a6 (0) 240 78 20 OO
Telefax: +46 (0) 240 78 23 20
SFo Circuit-Breaker HPL 245-55082 and
mechanism BLG 1002A
1-pole operation
Spare Parts
1 HSB445 409-302 en 5
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Article number:
1 HS8445409-302 en 5
Approval date:
2006-09-22
Spare Parts
LIST OF CONTENTS
1. General 1
2. Circuit-breaker. 3
2.1 Circuit-breakerpole 3
2.2 Breaking unit............. 4

2.3 Set of contacts........ -5
2.4 T-mechanisrn.......,., 5
2.5 Postinsulator.......... 6
2.6 Mechanism 7
3. Accessories 8
3.1 Absorption agent container 8
3.2 Density monitor....... 8
3.3 Set of seals ........... 9

3.4 Assembly sets............. I
3.5 Non-returnvalve.......... 9
3.6 Capacitor(if applicable)..... ....10
3.7 Pre-inserlion resistor (if applicable)....... .... l0
3.8 Corona ring (if applicable). ....10
1.1 Protective cover...........

4.2 Tools lbr unloading the tripping mechanism
4.3 Lubricants........ .....................12
1H58445409-302 en 5
Spare Parts
ii 1 HSB445409-302 en 5
Spare Parts
FIGURES
Figure l -1 . Circuit-breaker HPL 42A82 and HPL550TB2 .... 1
Figure 2-1. Circuit-breaker pole ......3

Figure 2-2. Breaking unit 4
Figure 2-3. Set of contacts 5
Figure 2-4. T-mechanism 5
Figure 2-5. Post insulator .......... 6
Figure 2-6. Mechanism housing .....7

Figure 2-7. Tripping mechanism 7
Figure 3-1. Absorption agent container 8
Figure 3-2. Density monitor 8
Figure 3-3. Non-return valve 9
Figure 3-4. Capacitor ......10

Figure 3-5. Pre-insertion resistor t0
Figure 3-6. Corona ring ................ 10
Figure 4-1. Tensioning tools ll
1HS8445409-302 en 5 iii
Spare Parts
iv 1 HS8445409-302 en 5
Spare Parts General
1. General
spare parts for the sF6 circuit-breaker HPL245-55082 or HpL245-550T82 with
operating mechanism BLG 1002A are supplied by:
SE-771 80 Ludvika
Sweden
Tel: +46 (0)240-78200O
Spare parts recommended to be kept in stock are marked with an R. With more that
ten circuit-breakers in operation, the spare parts marked with RR are also
recommended to be kept in stock. To be able to make quick replacements and avoid
long periods of downtime, the parts marked by RRR can also be stocked.
2 1
3
3
4
4
5
5
81lre
HPL 550T82 with capacitor and HPL 420B.2 without capacitor and
Figure I -1. Circuit-breaker HPL 42082 and HPL550TB2

Item Designation Note
1 Breaking unit without capacitor and pre-insertion resistor RRR
2 Breaking unit with capacitor and pre-insertion resistor RRR
3 Post insulator RRR
4 Operating mechanism RRR
5 Frame
Please state the type designation and serial number with all enquiries and orders of spare
parts. Please also state the order number if possible.
1HS8445409-302 en 5 1
General Spare Parts
2 1 HS8445409-302 en 5
Spare Parts Circuit-breaker
2, Circuit-breaker
2.1 Circuit-breaker pole
810't't2
Figure 2-1. Circuit-breaker pole
Item Designation Note
1 Breaking unit
2 Post insulator
3 Mechanism
4 Tripping mechanism
Please state the type designation and serial number with all enquiries and orders of
spare parts. Please also state the order number if possible.
1H58445409-302 en 5 3
Circuit-breaker Spare Parts
2.2 Breaking unit

2.2.1 Breaking unit
2 4 5 3
1
&
B'10'113
Figure 2-2. Breaking unit
Item Qtv Designation Note
1 2 Breaking chamber insulator RR
2 1 T- mechanism
3 2 Upper current path lncluded in set of contacts

4 2 Lower current path lncluded in set of contacts
5 2 Puffer lncluded in set of contacts
4 1HSB445409-302 en 5
2.3 Set of contacts
rll
a
Upper current path Lower current path
Qty Designation Note

1 Set of contacts R
Puffer
Figure 2-3. Set ofcontacts
2.4 T-mechanism 1
1 1 T-mechanism RR
B'10115
Figure 2-4. T-mechanism
1HS8445409-302 en 5 5
Circuit-breaker Spare Parts
2.5 Post insulator

1 1 Upper post insulator unit RR
1
2 1 Lower post insulator unit RR
'l
3 lnsulating rod RR
4 1 Upper guide
5 1 Flange
If the circuit-breaker is
equipped with composite
insulators the two insulator \
units are replaced by one
insulator unit.
2
5
3
810116
Figure 2-5. Post insulator
6 1 HS8445409-302 en 5
2.6 Mechanism
2.6.1 Mechanism housing
1
Item Qtv Designation Note 6
1 1 Mechanism RR H
a*/,
81 001 2
Figure 2-6. Mechanism housing
2.6.2 Tripping mechanism

'l
1 Tripping mechanism RR
81 01 07
Figure 2-7. Tripping mechanism
1H38445409-302 en 5 7
Accessories Spare Parts
3. Accessories
3.1 Absorption agent container 2 1

1 1 Absorption agent container
2 1 Absorption agent R
810117
Figure 3-1. Absorption agent container
3.2 Density monitor
Item Qty Designation Note

1 1 Density monitor, R
temperature compensated -
reference volume
2 1 Density monitor, R 3
bimetal
(Old design)
3 1 Density monitor, R
bimetal
(New design) B1 0052
Figure 3-2. Density monitor
8 1 HS8445409-302 en 5
Spare Parts Accessories
3.3 Set of seals

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

1 Set of seals 1 HS8446309-D R
3.4 Assembly sets

Set of bolts for a circuit-breaker pole.

1 Set of bolts 1 HS8446309-E R
Set of pins for a complete circuit-breaker pole.

1 Pins with circlips 1 HS8446309-F R
3.5 Non-return valve

1
810053
Figure 3-3. Non-return valve
Qty Designation Article number Note

1 Non-return valve 1HS8442541-C RR
1 HS8445409-302 en 5 I
Accessories Spare Parts
3.6 Capacitor (if applicable)

3
2 1
2
Item Qty Designation Note
1 1 Capacitor
2 2 Bracket
3 1 Spacer washer
Bt0t18
Figure j-4. Capacitor
3.7 Pre-insertion resistor (if applicable)

1

1 1 Pre-insertion resistor
81 01 99
Figure 3-5. Pre-insertion resistor
3.8 Corona ring (if applicable)
Item Qtv Designation Note 1
1 1 Corona ring (for circuit-

breaker with capacitor)
2 1 Corona ring (for circuit- 810119
breaker with capacitor and
pre-insertion resistor) 2
B1 021 8
Figure 3-6. Corona ring
10 1 HS8445409-302 en 5
Spare Parts Tools and lubricants
4. Tools and lubricants

4.1 Protective cover
Item Qtv Designation Article number Note

1 1 Protective cover for breaking unit 1HS8442186-5 B
2 1 Protective cover for post insulator 1 HSB4421 58-1 R
4.2 Tools for unloading the tripping mechanism
Item Qty Designation Article number Note

1 1 Tensioning tool, circuit-breaker 1HS8446381-A R
2 1 Tensioning tool, disconnecting 1 HS8446381 -D R

circuit-breaker
1
2
810054
Figure 4-1. Tensioning tools
1H58445409-302 en 5 11
Tools and lubricants Spare Parts
4.3 Lubricants
For individual grease and oil, see lubricant instruction 1HSB445409- l.
12 1 HS8445409-302 en 5
ll Illl
'TI,I'
Circuit-Breaker Divison
SE-771 80 LUDVIKA 2006-09-22
SWEDEN
Telephone: +a6 (0) 240 78 20 00
Telefax: +a6 (0) 240 78 23 20
SFo Circuit-Breaker Operating mechanism
BLG 1OO2A
Spare Parts
1 HS8515409-200 en 7
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ABB Power Technotogi@s AB is not r6spons.b,€ tor da,mas€
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PowerTechnologiesAB.,lmaynota.the.be.dpaft€d
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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 Auxil iary contact........ 7
2.5 Heating element...... 8
2.6 Electrical equipment 9
1HS8515409-2oo en 7
Spare Parts
ii 1 HSB51 5409-200 en 7
Spare Parts
FIGURES
Figure I -l . Operating mechanism I
Figure 2-1. Drive unit J
Figure2-2. Closing damper ........ 4

F'igure 2-3. Opening damper ......., 5
Figure 2-4. Catch gear 6

n
Figure 2-6. Heating element ........ 8
tsigure 2-7 . Electrical equipment 9
1 HSBS1 5409-200 en 7 iii

Spare Parts
IV 1HS8515409-200 en 7
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.
spare parts or tools. Please also state the order number, if possible.
1
ff- + -I
It
i,
i,
Ir 'll
4 i,
5 I
Ir
ll
3
tl
- __I
---.:---__tl
H:rr lo
@ @ 'o::
t
---'-----j--x
cover removed
Figure I -1. Operating mechanism
Item
1 Drive unit
2 Mechanism
Control panel
4 Spring battery
5 Heating element (behind protection plate)
1HS8515409-200 en 7 1
General Spare Parts
2 1HSB51 5409-200 en7

Spare Parts Components
2. Components
2.1 Drive unit
820031
Type of drive unit(l) Article number

1 Motor, 220 V 0-60H2 2361 113-AU
2 Motors, 220 V 0-60 Hz 2361 113-AV
1 Motor, 110 V 0-60H2 2361 113-AS
2 Motors, 110 V 0-60 Hz 2361 113-AT
(1) See wiring diagram
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.
1HSBs15409-200 en 7 3
Components Spare Parts
2.2 Damper
2.2.1 Closing damper
820032
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 1HS8515409-200 en 7
2,2.2 Opening damper
B20033
Figure 2-j. Opening damper
Designation Adicle number

Opening damper HPLxxxAl, 3-pole 5256 707-BP
HPLxxxBl, 3-pole
HPLxxxA4
HPLxxxB4
HPLxxx82 5256 707-BH
HPLxxxA'l ,1-pole 5256 707-BR
HPLxxxBl, 1-pole
HPLxxxA2
HPL B1 , 1-pole 5256 707-BS
HPL 81, 3-pole 5256 707-BV

HPL 83
HPL 81, 1-pole, Hl-speed 5256 707-BY
HPL 82, 84'50 KA" 5256 707-Br
HPL 82, 84 -63 KA' 5256707-BZ

HPL 82, Hi-speed 5256 707-CD
LTB E1, 3-pole 52s6707-BX
LTB E2 5256707-BU
LTB E, USiGS 5256 707-CC
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.
1 HSB51 5409-200 en 7 5
2.5 Heating element
0
a
6 54
321
820036
Designation Voltage range Article number

Heating element 110-127 V AC, 70 W 5291 800-R
220-254 V AC, 70 W 5291 800-5
110-127 V AC, 70+140 W 5291 800-U
220-254 V AC,70+140 W 5291 800-V

110-127 V AC, 529't 800-X
70+140+140 W
220-254V AC, 5291 800-Y
70+140+140 W
8
1HS8515409-200 en 7
820035
Designation Article number

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 54
321
B20036
Designation Voltage range Article number

Heating element 110-127 V AC, 70 W 5291 800-R
220-254 V AC,70 W 5291 800-5
110-127 V AC, 70+140 W 5291 800-U
220-254 V AC, 70+140 W 5291 800-V

110-127 V AC, 529't 800-X
70+140+140 W
220-254V AC, 5291 800-Y
70+140+140 W
I 1 HSB51 5409-200 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
ffifi -
110-130V, 50/60 Hz 5351 749-4
220-250 V DC 5351 749-1 ffi
1_J1
l
220-250 V, 50/60 Hz 5351 749-3 .l
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 Relay, 3-pole 42-48V DC 5619 758-4
110 V DC 5619 758-2
125 V DC 5619 758-8
220V DC 561 I 758-1
250 V DC 5619 758-7
Relay, 4-pole 42-48V DC 5619 750-4

E
110 V DC 5619 750-2

1
125 V DC 5619 750-8
220V DC 561 9 750-1
250 V DC 5619 750-10
4 Counter 42-48V DC 5692 965-13
110-'125 v DC 5692 965-1 2
220-250v Dc 5692 965-11
s2l.02.
Figure 2-7. Electrical equiPment
and orders of spare

Please state the type designation and serial number with all enquiries
parts or tools. Please also state the order number if possible'
9
1 HSB51 5409-200 en 7
Spare Parts
Lubricants
3. Lubricants
For individual grease and oil, see lubricant instruction 1HSB445409-1
10 1HSB515409-200 en 7

Abb HPL 245-550B2 & HPL 2450550TB2 BLG 1002a

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Abb HPL 245-550B2 & HPL 2450550TB2 BLG 1002a

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SFo Circuit-Breaker HPL 245-550Ei2 and

HPL 245-55OTB2 with operating

&"ea eG*a.s aearfu

O ABB Power Technologies AB

l.l Design of the circuit-breaker....... I

Figure l -1. Circuit-breaker, HPL 245-55082 and 245--550T82 ........... .............2

Figure I -2. Circuit-breaker pole, Opening - Closing .......

1.1 Design of the circuit-breaker

1.2 Weights for the circuit-breaker parts

Figure I -1. Circuit-breaker HPL 245-55082 and 245-550T82

Item Part Weight

1.3 The breaking principle

Figure I -2. Circuit-breaker pole, Opening - Closing

1.4 Function of the operating mechanism

The normal operating sequence is:

O - 0.3 s- CO - 3 min - CO (according to IEC) orCO - 15 s - CO (according to

O ABB Power Technologies AB

l.l Design of the operating mechanism.............. I

1.2 Normal operating mode 2

1.4 Closing operation ..................4

2.3 Open operation.............. 6

Figure I -1. Operating mechanism I

Figure l-2. Normal operating mode 2

Figure 1-3. Opening operation 3

Figure 1-4. Closing operation ... 4

Figure 2-1. Remote/Local operation 5

Figve2-2. 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

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

1 .1 Design of the operating mechanism

3 Control panel ilt

Figure I -l . Operating mechanism

1.2 Normal operating mode

Figure I -2. Normal operating mode

1.3 Opening operation

The closing springs are still charged.

Figure l-3. Opening oPeration

1.4 Closing operation

Figure I -4. Closing operation

Local/Remote/D iscon nect switch

2 Open/Close operation switch tr21 M

Figure 2- l. Remote/Local operation

2.2 Close operation

OpeniClose operation switch

Figure 2-2. Close operation

2.3 Open operation

Open/Close operation switch

Figure 2-3. Open operation

2.4 Rapid reconnection

Figure 3-1. Drive unit

3.2 Mechanical interlocking

Figure 3-2. Interlocking mechanism

3.3 Catch gear

The rated standard output of the coils is 200 W.

Figure 3-3. Catch gear

Figure 3-4. Closing and Opening damper

3.5 Auxiliary contact