Ltb-E1 BLK

Product Manual
1HSB435416-1en Rev1
LTB 245E1
BLK 222
1-pole operation
1
2
4
3
5
6
7
8
9
11
10
ABB Switchgear AB
S-771 80 LUDVIKA
PRODUCT MANUAL
PRODUCT DESCRIPTION
- Circuit-Breaker
PRODUCT DESCRIPTION
- Operating Mechanism
ASSEMBLY INSTRUCTIONS
CHECKLIST
OPERATING AND MAINTENANCE
INSTRUCTIONS
LUBRICANTS
MAINTENANCE INSTRUCTIONS
OVERHAUL INSTRUCTIONS
- Circuit-Breaker
SPARE PARTS
- Circuit-Breaker
SPARE PARTS
ABB Switchgear
SF
6
Circuit-Breaker LTB 245E1 with operating
mechanism BLK 222
1-pole operation
1HSB435455-1 enrev1
Product Description
The information in this document is subject to alteration without prior notice and should not be regar-
ded as an undertaking fromABB Switchgear AB. ABB Switchgear AB takes no responsibility for errors
that can occur in the documentation.
ABB Switchgear AB is not responsible for damage incurred due to the misuse of this document.
The document, or parts thereof, may not be reproduced or copied without prior permission from ABB
Switchgear AB. It may not either be imparted to third party or otherwise be used without authorisation.
Infringement hereof will be subject to action in accordance with applicable laws.
ABB Switchgear AB
Article number: 1HSB435455-1 enrev1
Date: 2000-08-04
Product Description
1HSB435455-1 enrev1 i
LIST OF CONTENTS
1. Description.......................................................................... 1
1.1 Design of the circuit-breaker.......................................................... 1
1.2 The circuit-breakers gas system.................................................... 2
1.3 Operating mechanism..................................................................... 3
1.4 Standards........................................................................................ 3
Product Description Description
1HSB435455-1 enrev1 1
1. Description
High voltage circuit-breaker LTB 245E1, with three operating mechanisms type
BLK 222.
1.1 Design of the circuit-breaker
The circuit-breaker is made up of three separate poles. These consist of three main
parts. At the bottom is an operating mechanism in an alloy housing, above this are
hollow post insulators through which the operating insulator runs and at the top is
the breaking unit.
Each breaking unit consists of a breaking chamber insulator, which together with an
upper and lower ange makes up the enclosure, and upper and lower current paths
and puffer. The puffer, which is designed with the lower operating current contacts
integrated, runs on the outside of the lower current path. The upper operating
current contacts are integrated in the upper current path.
The poles are mounted on separate hot-dipped galvanised column frames. The
frame consists of two welded formed plate halves, which are interconnected with
bolted cross stays.
The weights of component parts:
Figure 1-1. Circuit-breaker type LTB 245E1
Item Part Weight, kg
1 Circuit-breaker
pole
See
dimension
drawing
2 Operating
mechanism
210
3 Frame 86-200
2
3
1
B10034
Description Product Description
2 1HSB435455-1 enrev1
1.2 The circuit-breakers gas system
The circuit-breaker poles are permanently lled with SF
6
gas at a pressure of
0.7 MPa abs at 20C on circuit-breakers whose performance is limited by a lowest
ambient temperature of -30C.
On circuit-breakers whose ambient temperature is -40C the circuit-breaker is
lled to a pressure of 0.5 MPa abs at 20C. On breakers whose ambient temperature
is -55C the breaker is lled with a mixture of SF
6
gas and N
2
gas or CF
4
gas at a
pressure of 0.7 MPa abs at 20C. The poles are tted with density monitors to
monitor the pressure.
1.2.1 Opening and closing
The circuit-breaker poles work according to the Auto-Puffer
TM
- principle with the
puffer cylinder (1) divided into two chambers. An Auto-Puffer
TM
section (2) and a
compression section (3).
When the normal operating currents are
cut, the SF
6
gas is compressed in the
compression section to an over-pressure.
When the arcing contacts part, the gas in
the compression section ows out and
extinguishes the arc at the passage trough
zero.
When the short-circuit currents are cut the
requisite extinguishing pressure is built-up
in the Auto-Puffer
TM
section by heating the
arc. In this way a pressure increase is
achieved with energy from the arc and no
extra energy is required fromthe operating
mechanism.
On closing, the puffer cylinder slides
upwards, the contacts engage one another
and the puffer cylinder is relled with gas.
Figure 1-2. Circuit-breaker pole in Close position
1
2
3
1HSB435455-1 enrev1 3
1.3 Operating mechanism
LTB circuit-breaker is operated by a motor-charged spring operating mechanism
type BLK 222.
The operating mechanism is connected to the poles mechanism via a pull-rod
system.
The circuit-breaker is closed by the operating mechanism, which houses the closing
springs. On closing, the opening springs are tensioned, which are permanently
coupled to the poles operating mechanisms. The trip latch in the operating
mechanism keeps the circuit-breaker in the closed position. Opening of the circuit-
breaker only requires the release of the trip latch.
The normal operating cycle is:
O-0.3s-CO-3 min-CO (according to IEC) or CO-15s-CO (according to ANSI).
1.4 Standards
The circuit-breakers comply with the requirements according to IEC Publication
60056 and in most cases also ANSI C37 and are restrike-free when breaking a
capacitive load.
1HSB435455-1 enrev1
0008
ABB Switchgear AB
Head Ofce
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
ABB Switchgear
SF
6
Circuit-Breaker Operating mechanism
type BLK 222
1HSB535432-100 en rev2
Product Description
ded as an undertaking from ABB Switchgear AB. ABB Switchgear AB takes no responsibility for errors
ABB Switchgear AB
Article number: 1HSB535432-100 en rev2
Date: 2000-04-19
Product Description
1HSB535432-100 en rev2 i
LIST OF CONTENTS
1. Description.......................................................................... 1
1.1 Delivery...........................................................................................2
1.2 Unpacking.......................................................................................2
1.3 Storage ............................................................................................3
2. Assembly and connection................................................. 5
2.1 Mechanical connection ...................................................................5
2.2 Electrical connection.......................................................................6
2.3 Loading the closing springs ............................................................7
2.4 Normal operations, the circuit-breaker closed................................8
2.5 Open, the circuit-breaker is open....................................................8
2.6 Closed, the circuit-breaker is closed ...............................................9
3. Operations .........................................................................11
3.1 Remote/local operations................................................................ 11
3.2 Close operation ............................................................................. 11
3.3 Open operation..............................................................................12
3.4 Rapid reconnection .......................................................................12
4. Component parts.............................................................. 13
4.1 Drive mechanism..........................................................................13
4.2 Catch gear .....................................................................................13
4.3 Dashpot .........................................................................................14
4.4 Limit switch with auxiliary contact ..............................................14
4.5 Heater element ..............................................................................15
Product Description
ii 1HSB535432-100 en rev2
FIGURES
Figure 1-1. Operating mechanism BLK 222. .................................................... 1
Figure 1-2. Lifting the operating mechanism. ................................................... 2
Figure 2-1. Operating mechanism. .................................................................... 5
Figure 2-2. Earth clamp connection. ................................................................. 6
Figure 2-3. Electrical loading of the closing spring. ......................................... 7
Figure 2-4. Normal operating position. ............................................................. 8
Figure 2-5. Opening operation. ......................................................................... 8
Figure 2-6. Closing operation. .......................................................................... 9
Figure 3-1. Remote/local operations. ...............................................................11
Figure 3-2. Close operation. .............................................................................11
Figure 3-3. Open operation. ............................................................................ 12
Figure 4-1. Motor. ........................................................................................... 13
Figure 4-2. Catch gear. .................................................................................... 13
Figure 4-3. Dashpot. ........................................................................................ 14
Figure 4-4. Limit switch with auxiliary contact. ............................................. 14
Figure 4-5. Heater element. ............................................................................. 15
1HSB535432-100 en rev2 1
1. Description
The operating mechanism BLK 222 is intended for operating circuit-breakers with
integrated opening springs. Under no circumstances may the operating mechanism
be operated without first being mounted and adjusted for a circuit-breaker.
The operating mechanism consists of an closing spring with associated motor
charging device that automatically charge the closing spring after each closing
operation. A closing interlock holds the tensioned closing spring prepared for the
Closing of the circuit-breaker and the re-tensioning of the opening springs. A
opening interlock holds a closed circuit-breaker prepared for immediate Opening.
The component parts of the operating mechanism are integrated in a cabinet which
also accommodates an operating panel and operating equipment. The cabinets
cover can be removed and the operating panel opened to facilitate service and
overhauling.
The standard operating cycle is O - 0.3 s - CO - 3 min - CO (IEC) or CO - 15s - CO
(ANSI). The time between closing operations should not be less than 1 minute
during the testing of the circuit-breaker and relay systems involving more than 3
closing operations.
Figure 1-1. Operating mechanism BLK 222.
Item
1 Drive unit
2 Operating mechanism
3 Operating panel
4 Closing spring
5 Heater element
1 2
4
3
5
B30200
Description Product Description
2 1HSB535432-100 en rev2
1.1 Delivery
Check on arrival that the delivery corresponds with the order and delivery
documents and that no transport damage has occurred.
If any material is missing or if transport damage has occurred, please report this
immediately to ABB Switchgear AB, Circuit Breaker Division.
1.2 Unpacking
The operating mechanism is packed in a crate. The crate is marked with a case
number and the gross weight. Other information is written on a plywood
board/label, which is attached to two of the crates sides.
The operating mechanism must be lifted using the lifting eyes on top of the cabinet,
see Figure 1-2. Slings must not be placed around the cabinet when lifting.
All packing material can be recycled.
Figure 1-2. Lifting the operating mechanism.
B30079
1HSB535432-100 en rev2 3
1.3 Storage
Avoid storage. If storage is necessary, this must be done indoors or under cover.
The operating mechanism shall preferably be stored indoors in a dry building. When
stored outdoors, the crate should be opened to promote the exchange of air and a
heater should be used to prevent condensation.
An approved storage area is a store consisting of:
roof
a solid floor
humidity less than 50%
temperature +20 C (10 C)
Product Description Assembly and connection
1HSB535432-100 en rev2 5
2. Assembly and connection
The operating mechanism should be positioned in accordance with the circuit-
breakers measurement diagram.
2.1 Mechanical connection
The connection of the pull-rods between the operating mechanism and the circuit-
breaker should be carried out in accordance with the instructions for the circuit-
breaker to be connected to the operating mechanism.
WARNING
Do not operate the mechanism unloaded!
Operations shall take place only after the mechanism has been connected
and adjusted to the associated pressurised circuit-breaker.
On delivery the operating mechanisms closing spring is uncharged.
Figure 2-1. Operating mechanism.
Min.
Max. (Green fieId)
MiddIe position (YeIIow fieId)
1
Item
1 Indication disk
2 Indication pin
B30161
2
2
Min. pos.: No tension on cIosing spring.
N.B. The opening spring is tensioned if the
circuit-breaker is cIosed.
Mid. pos.: Dog against cIosing catch gear.
(YeIIow fieId) CIosing spring tensioning has begun.
N.B. No work permitted on operating mech.
Spring shaII be considered tensioned.
Max. pos.: CIosing spring is fuIIy tensioned.
(Green fieId)
Assembly and connection Product Description
6 1HSB535432-100 en rev2
2.2 Electrical connection
Operation and signal cables are routed through the connection flange at the bottom
of the cabinet. Fit the flange with a suitable cable gland for the cable in question.
Connect the cables to the terminal blocks in accordance with the applicable wiring
diagram. The terminal blocks are of a snap-in type and are designed both for
through wiring with termination of a stranded conductor with a cross-section of
max. 4 mm
2
, and as disconnectable blocks with termination of a stranded conductor
with a cross-section of max. 6 mm
2
intended for motor circuits, AC circuits and
supply circuits.
Connect the earth wire to the earth terminal (1) on the side of the cabinet.
N.B. Cables must not be routed so that they obstruct manual cranking.
Figure 2-2. Earth clamp connection.
1
B30079
1HSB535432-100 en rev2 7
2.3 Loading the closing springs
2.3.1 Electrical loading
Make the motor protection switch (1) so that the motor (2) starts and drives the
spring drum (3) to the tensioned position. The limit switch (4) breaks the contactor
(5) and the motor circuit.
CAUTION
The contactor must not be operated manually so that the limit switch
is bypassed.
Figure 2-3. Electrical loading of the closing spring.
Item
1 Motor protection switch
2 Motor
3 Spring drum
4 Limit switch
5 Contactor
5
3
1
2
4
B30200
Assembly and connection Product Description
8 1HSB535432-100 en rev2
2.4 Normal operations, the circuit-breaker closed
The open spring on the circuit-breaker and the closed spring on the operating
mechanism are tensioned. The circuit-breaker remains in the closed position by the
operating mechanisms opening interlock (1).
Figure 2-4. Normal operating position.
2.5 Open, the circuit-breaker is open
When the circuit-breaker is open the interlock is released from the catch gear (1). In
the end position the movement is dampened by the dashpot (2), which makes up an
end position stop in the OPEN position. The closing spring is tensioned.
Figure 2-5. Opening operation.
Item
1 Open interlock
2 Closed interlock
Item
1 Closing catch gear
2 Dashpot
3 Tripping arm
2
1
B30054
1
2
3
B30057
1HSB535432-100 en rev2 9
2.6 Closed, the circuit-breaker is closed
When closed the closing arm (1) is released from the tripping arm (3) and the
interlock heel (2). The dashpot piston (4) is extended and is prepared once again for
an opening operation. The motor starts and charges the closing spring again so that
the circuit-breaker returns to normal operations.
The operating mechanism is prepared for a new closing operation after opening
(O-CO).
Figure 2-6. Closing operation.
Item
1 Closing arm
2 Interlock heel
3 Tripping arm with interlock heel
4 Dashpot piston
4
2
3
1
B30054
Product Description Operations
1HSB535432-100 en rev2 11
3. Operations
3.1 Remote/local operations
With normal operations the switch (1) is in the Remote position for electrical remote
operations. In the LOCAL position, operations can only be carried out using the
operating switch (2).
The switch (1) has one position for the Shutdown function.
Figure 3-1. Remote/local operations.
3.2 Close operation
A Close operation using the operating switch (2) or electrical remote pulses can
only take place if:
Switch (1) is in the Remote or Local position.
The closing spring is tensioned with a closed ON circuit via the limit switch
(3).
The circuit-breaker is in the open position with a closed ON circuit via auxiliary
contact (4).
The gas density is greater than the blocking level with closed ON circuit via the
density monitor.
Figure 3-2. Close operation.
Item
1 Switch, Local/Remote
2 Operating switch, On/Off
Item
3 Limit contact
4 Auxiliary contact
2 1
B30207
2 1
3
4
B30200
Operations Product Description
12 1HSB535432-100 en rev2
3.3 Open operation
An Open operation with a closed circuit-breaker can be made with the switch (1) in
the LOCAL position and the operating switch (2) in the ON position.
Figure 3-3. Open operation.
3.4 Rapid reconnection
Automatic rapid reconnection, Open-0.3s-Closed-Open can be made if:
The circuit-breaker is closed.
The switch is in the Remote position.
The mechanisms closing spring is fully loaded when the operating cycle is
started.
With automatic rapid reconnection the switchgears relay equipment can give an
immediate Open impulse if the short-circuit still remains in the network. As the
operating circuits are electrically interlocked via the auxiliary contact an Close
operation will always be completed before an Open operation is started. Even if the
Close pulse has been given during a current Open operation.
Item
2 1
B30208
Product Description Component parts
1HSB535432-100 en rev2 13
4. Component parts
4.1 Drive mechanism
The drive mechanism is supplied with a motor for 110 or 220 V DC and
50, 60 Hz AC.
The motor should be capable of loading the spring at 85% of the nominal voltage
(IEC).
Figure 4-1. Motor.
4.2 Catch gear
The operating mechanism has a Closing and an Opening catch gear.
The standard voltage of the magnets is 110 or 220 V DC.
The coils rated power is 200 W.
Figure 4-2. Catch gear.
Item
1 Motor
Item
1 Opening catch gear
1
B30068
1
2
B30062
Component parts Product Description
14 1HSB535432-100 en rev2
4.3 Dashpot
The operating mechanism is fitted with a dashpot to slow the final phase of the
opening movement.
Figure 4-3. Dashpot.
4.4 Limit switch with auxiliary contact
The operating mechanism is fitted as standard with a 12 way auxiliary contact
consisting of twelve normally open and twelve normally closed contacts. Three
normally closing and three normally opening contacts are used for the operating
mechanisms own function. There is also the possibility of supplementing with
twelve extra contacts.
The auxiliary contacts shaft is in direct connection with the operating mechanisms
operating lever and accordingly follows the circuit-breaker contacts movement.
Figure 4-4. Limit switch with auxiliary contact.
Item
1 Dashpot
Item
1 Limit switch
2 Auxiliary contact
1
B30063
2
1
B30200
Product Description Component parts
1HSB535432-100 en rev2 15
4.5 Heater element
The operating mechanism is equipped with a heater element to prevent
condensation and should always be connected.
Figure 4-5. Heater element.
Data
70 W, 220 V: R = 691 Ohm 10%.
140W, 220 V: R = 346 Ohm 10%.
70 W, 110 V: R = 173 Ohm 10%.
140 W, 110 V: R = 86 Ohm 10%.
Item
1 Heater element
1
B30058
1HSB535432-100 en rev2
0004
ABB Switchgear AB
Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
ABB Switchgear
SF
6
Circuit-Breaker LTB 245E1 with three operating
mechanisms BLK 222
1-pole operation
1HSB435410-1 enrev1
Assembly Instructions
Switchgear AB. It may not either be imparted to a third party or otherwise be used without authorisa-
tion. Infringement hereof will be subject to action in accordance with applicable laws.
ABB Switchgear AB
Date: 2000-09-05
1HSB435410-1 enrev1 i
LIST OF CONTENTS
1. General ................................................................................ 1
2. Safety................................................................................... 3
2.1 Warning text ................................................................................... 3
2.2 Safety, general ................................................................................ 4
3. Delivery ............................................................................... 5
3.1 Weights........................................................................................... 5
3.2 Unpacking ...................................................................................... 6
3.3 Storage before assembly ................................................................ 7
4. Assembly............................................................................. 9
4.1 Preparations.................................................................................... 9
4.2 Frame assembly............................................................................ 11
4.3 Assembling the frame on the foundation ..................................... 12
4.4 Assembling the circuit-breaker pole on the frame ....................... 13
4.5 Assembling the operating mechanism......................................... 15
4.6 Final assembly of the circuit-breaker pole................................... 16
4.7 Assembling the pull-rods ............................................................. 17
4.8 Inspecting the bolted joints, etc.................................................... 19
5. Electrical connections ..................................................... 21
5.1 Connection of the operating mechanism...................................... 21
5.2 Assembly of busbars or overhead lines........................................ 21
6. Pressurising the poles..................................................... 23
6.1 Preparations.................................................................................. 23
6.2 Gas lling with SF6 gas ............................................................... 24
6.3 Gas monitoring system................................................................. 27
6.4 Leakage test.................................................................................. 28
6.5 Fitting the signs and cover ........................................................... 28
7. Commissioning................................................................. 29
8. Operating values .............................................................. 31
8.1 Times............................................................................................ 31
8.2 Motor and control circuits............................................................ 31
8.3 Resistance..................................................................................... 31
8.4 Contact stroke............................................................................... 31
ii 1HSB435410-1 enrev1
FIGURES
Figure 3-1. Component parts ............................................................................. 5
Figure 3-2. Lifting the operating mechanism .................................................... 6
Figure 4-1. Assembly markings ........................................................................ 9
Figure 4-2. Foundation .................................................................................... 10
Figure 4-3. Frame assembly ............................................................................ 11
Figure 4-4. Frame assembly on the foundation ............................................... 12
Figure 4-5. Lifting the circuit-breaker pole ..................................................... 13
Figure 4-6. The circuit-breaker poles non-return valve ................................. 13
Figure 4-7. Fitting the circuit-breaker pole on the frame ................................ 14
Figure 4-8. Assembly of the operating mechanism ........................................ 15
Figure 4-9. Circuit-breaker poles on the frame ............................................... 16
Figure 4-10. Dismantling the signs and cover ................................................... 17
Figure 4-11. Assembling the pull-rod ............................................................... 18
Figure 5-1. Operating mechanism ................................................................... 21
Figure 6-1. Gas lling ..................................................................................... 24
Figure 6-2. Density monitor and union nut ..................................................... 26
Figure 6-3. Gas monitoring ............................................................................. 27
Figure 6-4. Fitting the signs and cover ............................................................ 28
Assembly Instructions General
1HSB435410-1 en1 1
1. General
This assembly instruction applies to the SF
6
circuit-breaker type LTB 245E1 with
three operating mechanisms type BLK 222 for 1-pole operation and contain all
essential information for assembly and commissioning.
Read through the entire Assembly Manual before starting the assembly work.
Assembly Instructions Safety
1HSB435410-1 en1 3
2. Safety
2.1 Warning text
Warning text occurs where required and indicates that the text in question should be
observed extra carefully. The warning texts are marked as set out below:
DANGER
indicates an immediate hazardous situation that, if not avoided, will result
in death or serious injury.
WARNING
indicates an immediate hazardous situation that, if not avoided, can result
CAUTION
indicates a hazardous situation that can result in minor or moderate
injury.
N.B. is used for hazards that may only result in damage to the installation.
Safety Assembly Instructions
4 1HSB435410-1 en1
2.2 Safety, general
WARNING
Circuit-breaker with pressurised porcelain insulators.
Mechanical damage on the porcelain can cause it to explode with the
following risk of splintering.
Work on the circuit-breaker that brings about the risk of a mechanical
damage to the insulators should be carried out at a reduced gas pressure,
0.125 MPa (abs).
WARNING
Do not operate the operating mechanism unloaded!
and trimmed with the associated pressurised circuit-breaker.
The standard operating cycle is O - 0.3 s - CO - 3 min.-CO. The time between
closing operations should not be under 1 minute during the testing of circuit-
breakers and relay systems involving more than 3 closing operations.
Assembly Instructions Delivery
1HSB435410-1 en1 5
3. Delivery
Check on arrival that the delivery corresponds with the order and delivery
documents and that no transport damage has occurred.
If any material is missing or if transport damage has occurred, please report this
immediately to ABB Switchgear AB, Circuit Breaker Division.
3.1 Weights
The weights of component parts are as follows:
Figure 3-1. Component parts
Item Part
Weight,
kg
1 Circuit-breaker
pole
stated on
the
applicable
dimension
drawing
for the
order..
2 Operating
mechanism
210
3 Frame 86-200
2
3
1
B10034
Delivery Assembly Instructions
6 1HSB435410-1 en1
3.2 Unpacking
The material is packed in crates and on pallets. The crates are marked with a case
number and the gross weight. Other information is written on a plywood
board/label, which is attached to two of the crates sides.
The operating mechanism must be lifted using the lifting eyes on top of the cabinet,
see Figure 3-2. Slings must not be placed around the cabinet when lifting.
The circuit-breakers must be kept in the transport packaging until just before
assembly.
All packing material can be recycled.
Figure 3-2. Lifting the operating mechanism
B
1
0
0
3
6
Assembly Instructions Delivery
1HSB435410-1 en1 7
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 avsnitt 3.3.5, Spare parts).
Storage in a humid climate, without proper ventilation, can lead to discolouring of
zinc coated surfaces. This discolouring is known as white rust, and consists mainly
of zinc oxide and zinc hydroxide and is a result of a chemical process between pure
zinc on the surface and moisture.
The long term rust protection is not affected because the steel-zinc layer under the
surface remains unaffected. According to Swedish standard the presence of white
rust is no reason to reject goods.
Upon arrival each unit should be checked regarding the following:
The delivery corresponds with the order and shipping documents
Damage due to transport and missing parts
If damage is discovered or suspected the case should be opened and photos taken.
Report damage as well as missing parts.
All components should be rationally stored for easy access. All material should be
stored in an approved store
1
, exceptions are stated below. Dust, smoke, corrosive or
inammable gas, steam or salt must not pollute the surrounding air otherwise the
equipment must be cleaned before construction.
The original cases can be used for storage, but the plastic covering should be
removed. The assembly units coupling pieces as well as connections are provided
with transport covers or protective covers which must not be removed until shortly
before the circuit-breakers are assembled.
3.3.2 Stacking of cases
Cases of different widths shall normally not be stacked (the pressure may destroy
the covers of the lower cases). If cases of different widths need to be stacked, a
framework must be used between the cases in order to distribute the pressure evenly.
Stacking of more than three cases is not allowed. It must be noted that stacking
causes instability sidewise and therefore the cases must be secured, i.e., prevented
from tumbling down or rolling over.
1. An approved store is dened as consisting of:
roof
rm base
humidity below 50%
temperature 20C (10C)
Delivery Assembly Instructions
8 1HSB435410-1 en1
3.3.3 Operating mechanism
The operating mechanism should be unpacked on arrival. If it is not kept in an
approved store, the heating element must be connected and permanently switched
on to prevent the control equipment from corrosion or damage due to freezing.
3.3.4 Circuit-breakers
The circuit-breakers should be stored in their original cases where they are properly
protected from damage. The units shall not stand in water. The circuit-breakers can
be stored outdoors. If this happens they should be protected by at least a tarpaulin.
The tarpaulin must not be so tight that air circulation to zinc coated surfaces is
prevented. Any condense should easily drip off.
The lowest permitted ambient temperature for storage is -30C.
3.3.5 Spare parts
Spare parts shall be kept indoors in an approved store and in their original packing.
This is especially important for rubber components (seals etc.), which must also be
protected fromsunlight to avoid drying. Gaskets have a limited storage life, so avoid
storing them. Frames can be stored outdoors.
Assembly Instructions Assembly
1HSB435410-1 en1 9
4. Assembly
4.1 Preparations
Before starting the assembly, make certain that all requisite tools and documents are
on hand.
Standard tools with torque wrenches (10 - 430 Nm).
Lifting devices and lifting slings.
Lubricant, see Lubricants 1HSB445409-1 for suppliers and brand names.
Grease G: ABB article number1171 4014-407
Grease SV: ABB article number 1171 4016-610.
Contact paste.
Applicable dimension drawings and diagrams for the order.
4.1.1 Assembly markings
On delivery the circuit-breakers are supplied dismantled in transport units. The
component parts are marked to facilitate assembly. The circuit-breaker poles and
operating mechanisms have been tested together.
Check that the assembly markings correspond with Figure 4-1 and that the serial
number on the operating mechanism corresponds with the serial number of the
circuit-breaker.
Figure 4-1. Assembly markings
Item
1 Operating
mechanism A
2 Operating
mechanism B
3 Operating
mechanism C
4 Circuit-breaker
pole A1
5 Circuit-breaker
pole B1
6 Circuit-breaker
pole C1
2 3
1
4 5
6
B10037
Assembly Assembly Instructions
10 1HSB435410-1 en1
4.1.2 Foundation
The circuit-breakers foundation must be at and level. Adjust any deviations using
spacer washers, see Chapter 4.3, Assembling the frame on the foundation. Figure
4-2 shows the permitted deviations in mm for the position of the foundation bolts.
The nominal dimensions are stated on the applicable dimension drawing for the
order.
Figure 4-2. Foundation
Length = >110
1
1
B10038
1HSB435410-1 en1 11
4.2 Frame assembly
The frame is supplied in welded halves with six cross stays and nuts, bolts and
washers.
Bolt the halves together as shown in Figure 4-3. Fit the cross stays according to
the numbering 1-4, using the supplied nuts, bolts and washers.
N.B. Make sure the stays are tted as set out in Figure 4-3 and to the intended
operating mechanism.
Tighten the bolted joints to a torque of 430 Nm.
Figure 4-3. Frame assembly
Item
1 Frame halves 2 pcs.
2 Stays 6 pcs.
3 Bolts M20x60
Nuts M20
Washers 21x37x3
8 pcs.
8 pcs.
16 pcs.
1
2
3
TIGHTENING TORQUE
430 Nm
3
4
2
1
B10039
12 1HSB435410-1 en1
4.3 Assembling the frame on the foundation
Check that the frames are upright and adjust them to the same level using the nuts
(2).
Fill with spacer washers the gap between the lower nut and the foundation, which
should be as small as possible.
Thighten the lower nut against the spacer washers (4). For the nal tightening of the
frame, use the upper nut, which is tightened to a torque of 300-350 Nmfor M24 nut
and 500-550 Nm for M30 nut.
Foundation bolts and spacer washers are not supplied.
Figure 4-4. Frame assembly on the foundation
Item
1 Foundation bolts,
L> 110 mm
(Not supplied)
2 Nuts (Not supplied) 8 pcs.
3 Washers 8 pcs.
4 Spacer washers (Not supplied)
5 Foundations
6 Frame foot
2
0
1
2
6
4
5
3
1
0
1
0
>
1
1
0
2
B10006
300-350 Nm
or
500-550 Nm
TIGTHENINING TORQUE
1HSB435410-1 en1 13
4.4 Assembling the circuit-breaker pole on the frame
Place a lifting sling around the breaking units top as shown in Figure 4-5 and, using
this method, lift the circuit-breaker pole from its horizontal position in the transport
packaging.
Check that the bolts (1) are tightened with tightening torque 60 Nm before lifting
the pole to vertical position
Figure 4-5. Lifting the circuit-breaker pole
Check that the circuit-breaker
pole does not leak before
assembly on the frame.
1. Undo the sealing cap (1).
2. Press the non-return
valves disk (2) inwards
using a rod with a
diameter of about 5 mm.
A clear hissing noise
should be heard from the
pole. If no hissing noise
is heard, the pole leaks.
This must be rectied
before assembly.
3. Fit the sealing cap (1).
Figure 4-6. The circuit-breaker poles non-return valve
B10040
1
2
1
B10008
14 1HSB435410-1 en1
A circuit-breaker pole is tted to each frame according to Figure 4-7. Fit the bolts
(1) and tighten by hand.
N.B. Final tightening is carried out when the operating mechanism has been tted.
Figure 4-7. Fitting the circuit-breaker pole on the frame
Item
1 Bolts M20x70
Nuts M20
Washers 21x36x3
4 pcs.
4 pcs.
8 pcs.
1
B10041
1HSB435410-1 en1 15
4.5 Assembling the operating mechanism
On delivery the operating mechanism has been set and is supplied with the closing
springs correctly adjusted.
Fit the operating mechanism as set out in Figure 4-8.
Fit all bolts and tighten them by hand. Then tighten the bolted joints (1) with a
tightening torque of 79 Nm and the bolted joints (2) with a tightening torque of
190 Nm
Dismantle the operating mechanisms lifting beams (2x2 bolts M8x25) and store
these.
Figure 4-8. Assembly of the operating mechanism
Item
1 Bolts M12x40
Nuts M12
Washers 13x24x2.5
8 pcs
8 pcs
16 pcs
2 Bolts M16x40
Nuts M16
Washers 17x30x3
4 pcs.
4 pcs.
8 pcs.
3 Spring washer 4 pcs.
TIGHTENING TORQUE
79 and 190 Nm
1
2
B10042
3
16 1HSB435410-1 en1
4.6 Final assembly of the circuit-breaker pole
Tighten the poles to the frame with a tightening torque of 300 Nm.
Figure 4-9. Circuit-breaker poles on the frame
TIGHTENING TORQUE
300 Nm
B10043
1HSB435410-1 en1 17
4.7 Assembling the pull-rods
Each pole is supplied set to a basic setting. Adjust the poles to the correct open
position when tting the operating rods between the operating mechanism and the
pole.
Pull-rod assembly takes place in stages:
Preparations for assembling the pull-rods.
Assembling the pull-rods between the operating mechanisms and the poles.
4.7.1 Preparations for assembling the pull-rods
Remove all the pole covers (1)
and the Close-Open signs (2), to
gain the best possible access to
the pole mechanisms.
Figure 4-10. Dismantling the signs and cover
Item
1 Cover
2 Sign
3 Coupling link
1 3 2 B10012
18 1HSB435410-1 en1
4.7.2 Assembling the pull-rod between operating mechanism A and pole A1.
Each pole is supplied set to a basic setting and its Close and Open positions are
determined. Adjustment is made as set out in Figure 4-11.
Move by hand the pull-rod fromthe operating mechanism(2) to the side, as far
that the turnbuckle screw (5) can be placed between the coupling link (4) and
the pull-rod from the operating mechanism. The operating mechanisms pull-
rod must not be slide out so far that it locks in its inner Closed position.
Simultaneously screw the turnbuckle screw (5) in the operating mechanisms
pull-rod (2) (left-hand thread) and the poles coupling link (4) (right-hand
thread).
N.B. Remember the two spring washers (6) under each locking nut (8).
Turn the turnbuckle screw (5) so its length decreases at the same time as
operating lever (3) moves towards its Open position. The turnbuckle screw
(5) is the right length when the operating lever (3) is in its Open position
and the alignment check hole (7) is directly aligned with the predrilled
hole in the mechanismhousing (1). Check the position of the hole using a rod
with a 6 mm diameter. Check that the turnbuckle screw (5) is screwed past the
alignment check holes (9 and 10). The tightening torque for the locking nuts is
190 Nm
Figure 4-11. Assembling the pull-rod
Item
1 Mechanism housing
2 Pull-rod fromoperating
mechanism
3 Operating lever
4 Coupling link, pole
5 Turnbuckle screw
6 Spring washers
7 Alignment check hole
in arm
8 Locking nuts
in pull-rod
in coupling link
6
7
3
9
5
4
1
2
10
8
B10044
TIGHTENING TORQUE
190 Nm
1HSB435410-1 en1 19
Repeat the procedure to assemble the pull-rods between operating mechanism B
and pole B1 and between operating mechanism C and pole C1.
4.8 Inspecting the bolted joints, etc.
Check using a 6 mm diameter rod that the arms alignment check hole is
aligned with the predrilled hole in the mechanism housing.
Check that all bolted joints are tightened to the correct torque in accordance
with the table below.
Bolted joint Tightening torque (Nm)
Frame 430
Foundation 300-350 or 500-550
Circuit-breaker pole 300
Operating
mechanism
79 and 190
Pull-rod 190
Density monitor 10
Protective tube 79
Plates 22,5
Cover 9
Assembly Instructions Electrical connections
1HSB435410-1 en1 21
5. Electrical connections
5.1 Connection of the operating mechanism
Operation and signal cables are routed through the connection ange at the bottom
of the cabinet. Fit the ange with a suitable cable gland for the cable in question.
Connect the cables to terminal blocks in accordance with the applicable wiring
diagram. The terminal blocks are of a snap-in type and are designed both for
through wiring with termination of a stranded conductor with a cross section of
max. 4 mm
2
, and disconnectable block with termination of a stranded conductor
with a cross section of max. 6 mm
2
intended for motor circuits, AC circuits and
supply circuits.
Connect the earth wire to the earth terminal (1) on the side of the cabinet.
Figure 5-1. Operating mechanism
5.2 Assembly of busbars or overhead lines
WARNING
Work must not be carried out on a pressurised circuit-breaker.
High-voltage conductors consisting of aluminium busbars or aluminium connectors
for overhead lines can, after being treated with contact paste, be directly connected
to the breaking units terminal ags 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 tted in the joint. Bimetallic washers
can be supplied by ABB on request.
B10045
1
Electrical connections Assembly Instructions
22 1HSB435410-1 en1
Using contact paste or grease
1. Clean all grease and old paste from the contact surfaces.
2. Rub down the surfaces using an abrasive cloth, e.g. Scotch Brite No. 7447 or
emery cloth.
3. Apply immediately:
- Contact paste on aluminium surfaces.
- Grease SV, ABBs article number 1171 4016-610, on copper surfaces.
4. Fit together the joint with the paste or grease still applied.
5. Wipe off any excess paste or grease.
N.B. Position the bimetallic washers so that the aluminium sides face the
aluminium surfaces and the copper sides are turned towards the copper
surfaces or the silver-plated surfaces.
N.B. The contact paste may only be used on xed joints. It must not be used
inside the breaking unit.
Assembly Instructions Pressurising the poles
1HSB435410-1 en1 23
6. Pressurising the poles
The circuit-breaker poles are supplied vacuum-processed and lled with SF
6
gas at
a pressure of 0.12- 0.13 MPa abs at 20C.
6.1 Preparations
WARNING
When commissioning, the SF
6
gas needs to be relled to the pressure
stated on the rating plate.
Pressurisation takes place directly from a gas cylinder using the gas lling
equipment, ABB article number 1HSB 445439-A.
The gas hose for the lling equipment is supplied vacuum-pumped and lled with
SF
6
gas.
WARNING
To avoid personal injury while relling, 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 relling equipment should be placed in the
same area.
Connect the control cables to the operating mechanisms terminal blocks for
opening and closing. The cables are routed to the control room or protected
area away from the circuit-breaker.
Connect the cables to appropriate pushbutton switches.
Set the operating mechanisms control switch in the remote position.
Switch on the motor starter so the closing springs are tensioned.
Open the terminal blocks to which the density monitor cables are connected
and interrupt the circuit to the interlocking relays.
Pressurising the poles Assembly Instructions
24 1HSB435410-1 en1
6.2 Gas lling with SF
6
gas
Figure 6-1. Gas lling
1. Place the gas cylinder (1) in a protected area.
2. Check the lling pressure on the circuit-breakers rating plate.
3. Fit the regulator (2) on the gas cylinder. Set the right lling pressure,
compensated for the temperature as set out in Table 6-1 on the regulator.
4. Pull the sealing rings off the density monitor (3) with your ngers.
N.B. Do not use a sharp tool.
5. Lubricate the sealing rings thoroughly with grease G and ret them on the
density monitor.
Item
1 Gas cylinder
2 Regulator
3 Density monitor
4 Coupling
5 Valve
6 The circuit-breakers gas valve
7 Hose
8 Adaptor
9 Nipple with union nut
10 Equal union cross
11 Valve
1
3
2
4
7 5
6
8
9
B10016 11
10
1HSB435410-1 en1 25
6. Connect the density monitor (3) to the coupling (4) or the equal union cross
(10). Open valve (5) or alternatively, valve (11). If the density monitor is
connected to coupling (4), then valve (11) must be closed. However, if the
density monitor is connected to the equal union cross (10), then valve (5) must
be closed.
7. Connect coupling (4) to the circuit-breakers gas valve (6).
8. Connect the gas-lled hose (7) to the coupling.
9. Connect the hose to the gas cylinder.
10. Go from the circuit-breaker to the protected area and let the gas ow until the
regulator switches off.
11. Wait until the gas temperature has reached the circuit-breaker temperature level
before reading off the gas pressure on the density monitor. Adjust the pressure
if necessary
12. Dismantle the hose from the coupling on the circuit-breaker.
13. Close the valve to the density monitor.
14. Dismantle the coupling from the circuit-breaker.
15. Release the pressure on the density monitor by opening valve (5) or valve (11).
16. Dismantle the density monitor from the coupling and t it on the circuit-
breaker.
17. Repeat from 4 through to 16 for poles B and C.
N.B. When reading from the precision gauge, correct the lling pressure
depending on the temperature as set out in Table 6-1.
Table 6-1. Filling pressure
Filling pressure in MPa (abs)
stated on the rating plate 0.7
Filling pressure read off on the gauge in
Temp. when
lling C
MPa (abs) bar (abs) MPa (a.op.) bar (a.op.)
+40 0.75 7.5 0.65 6.5
+30 0.72 7.2 0.62 6.2
+20 0.70 7.0 0.60 6.0
+10 0.66 6.6 0.56 5.6
0 0.63 6.3 0.53 5.3
-10 0.61 6.1 0.51 5.1
-20 0.58 5.8 0.48 4.8
26 1HSB435410-1 en1
18. Close the valve on the gas cylinder when all poles have been lled.
19. Disconnect the hose from the gas cylinder and release the pressure in the
regulator by pressing in the non-return valve.
20. Release the regulators adjustment pressure by turning the adjuster valve so
that the wrong pressure is not lled in the next circuit-breaker to be tted.
N.B. When the density monitor (1) is nally tted, tighten the union nut (2) is with
a torque of 10 Nm.
Figure 6-2. Density monitor and union nut
21. Operate the circuit-breaker Close and Open 3 times from the control room.
22. Connect the cables to the density monitors.
23. Reset the circuits for the interlocking relays.
Item
1 Density monitpr
2 Union nut
TIGHTENING TORQUE
10 Nm
1 2
B10017
1HSB435410-1 en1 27
6.3 Gas monitoring system
Drill a 23 mm diameter hole in ange (1) on the bottom of the operating
mechanismand t cable gland (2) with a sealing washer (3) and nut in the hole.
Insert the cable through the cable gland in the operating mechanism and
connect it to the terminal blocks as stated on the applicable operating
mechanisms circuit diagram.
Tighten the cable gland (2) to secure the cable.
Secure the cables to the frames leg using pipe clips (5) and nuts, bolts and
washers (6).
Connect the cable to the density monitors terminal block.
N.B. The cable ends for the density monitor should be as long as necessary so that
the density monitor can be disconnected from the non-return valve without
the need of disconnecting the cable.
Figure 6-3. Gas monitoring
Item
1 Flange
2 Cable gland
3 Sealing washer
4 Pipe clips 4 pcs.
5 Bolts M5x20
Nuts M5
Washers 5.3x10x1
4 pcs.
4 pcs.
8 pcs.
1
3
2
5
4
B10046
28 1HSB435410-1 en1
6.4 Leakage test
Perform a leakage test using a leak detector around the density monitors
connections.
6.5 Fitting the signs and cover
Fit and thighten all Close and Open signs (1) with a torque of 22,5 Nm.
Then t the cover (2) with a tightening torque of 9 Nm.
Figure 6-4. Fitting the signs and cover
Item
1 Sign
2 Cover
3 Bolts M8x16
Washers 8.4x16x1.5
9 pcs.
9 pcs.
1 2
B10012
3
TIGHTENING TORQUE
9 and 22,5 Nm
Assembly Instructions Commissioning
1HSB435410-1 en1 29
7. Commissioning
Before commissioning the circuit-breaker carry out all checks as set out in Check
list for assembling and commissioning 1HSB445410-100 and ll in the
operating values for the installation.
Assembly Instructions Operating values
1HSB435410-1 en1 31
8. Operating values
The operating values in these instruction apply to SF
6
circuit-breakers type
LTB 245E1 with operating mechanism type BLK 222.
8.1 Times
8.2 Motor and control circuits
8.3 Resistance
Main circuit resistance per pole max 49 .
8.4 Contact stroke
Main contact stroke is 160 3 mm.
Closing times < 28 ms
Opening time coil I 17 2 ms
Opening time coil II 17 2 ms
Close-Open time
(1)
(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.
26 3 ms
Charging time for motor max 15 s
Operating voltage opening
coil I
V (according to the rated data plate)
Operating voltage opening
coil II
Operating voltage closing coil
I and II
1HSB435410-1 enrev1
0009
ABB Switchgear AB
Head Ofce
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
ABB Switchgear
SF
6
Circuit-Breaker Circuit-breakers HPL and LTB
1HSB445410-100 en rev1
Check list, assembly
that can occur in the document.
ABB Switchgear AB
Date: 1998-10-28
Check list Check list for assembly and commissioning
1HSB445410-100 en rev1 1
1. Check list for assembly and commissioning
The following checks shall be made and the check list completed before the circuit-
breaker is commissioned. The check list shall be kept in the order binder.
Date:_______________
Installation:______________________________________________
Serial number:_____________________________
Circuit-breaker pole
1. Check that the circuit-breaker and operating mechanism have been assembled
in accordance with the assembly instructions.
2. Check that all bolted joints are tightened to the tightening torques stated in the
assembly instructions.
3. Ensure that all poles are in the open position. The alignment hole in the
operating lever shall align with the predrilled hole in the mechanism housing.
Operating mechanism
4. Make an ocular inspection to check that oil from the oil dashpots has not
leaked in the operating mechanism.
5. Tighten all screws in terminal blocks involved in the assembly work.
Gas lling
6. Connect the operating mechanism for remote control from a protected area in
connection with gas lling and test operations.
Set the control switch to remote.
7. Connect the gas lling equipment for gas lling from the protected area.
8. Fill with gas each pole one after the other and performan operational test three
times as set out in the assembly instructions.
9. Check the heater element.
10. Make sure the thermostat, if provided, is set to 10C
1
.
1. Other thermostat settings may occur.
Check list for assembly and commissioning Check list
2 1HSB445410-100 en rev1
Operating values
11. Check the breakers operating values with the applicable operating values for
the breaker in the Assembly Instructions and note down the measured values in
the table below.
CAUTION
The circuit-breaker must not be switched Open - Close without an
intermediate delay of 300 ms.
.
12. Check carried out by:________________________________
13. If points 1-11 as set out above have been completed, the circuit-breaker can be
commissioned.
Check the following
Measured values
Pole A Pole B Pole C
Closing time coil I ms ms ms
Closing time coil II ms ms ms
Opening time coil I ms ms ms
Opening time coil II ms ms ms
Close-Open time ms ms ms
Lowest control voltage closing coil I V V V
Lowest control voltage closing coil II V V V
Lowest control voltage opening coil I V V V
Lowest control voltage opening coil II V V V
Main circuit resistance
Filling pressure
(1)
(1) Filling pressure in accordance with the rating plate.
MPa (abs) MPa (abs) MPa (abs)
1HSB445410-100 en rev1
9810
ABB Switchgear AB
Head Ofce
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
ABB Switchgear
SF
6
Circuit-Breaker Type LTB E
1HSB435409-100 enrev1
Operating and Maintenance
Instructions
ABB Switchgear AB
Date: 2000-09-04
Operating and Maintenance Instructions
1HSB435409-100 enrev1 i
INNEHLLSFRTECKNING
1. General ................................................................................ 1
1.1 Warning text ................................................................................... 1
1.2 Varning........................................................................................... 2
2. Preventative maintenance ................................................. 3
2.1 Circuit-breaker ............................................................................... 3
2.2 Operating mechanism..................................................................... 5
2.3 Spare parts...................................................................................... 6
3. Inspection intervals............................................................ 7
3.1 Maintenance summary ................................................................... 8
3.2 Maintenance category A ................................................................ 9
3.3 Maintenance category B............................................................... 10
3.4 Maintenance category C............................................................... 12
3.5 Maintenance category D .............................................................. 19
Operating and Maintenance Instructions
FIGURES
Figure 2-1. Number of operations with short-circuit current. ........................... 4
Operating and Maintenance Instructions General
1HSB435409-100 en1 1
1. General
These Operating and Maintenance Instructions apply to the SF
6
circuit-breaker type
LTB E.
The instructions contain recommendations for the care and guidelines for the
maintenance of high-voltage circuit-breakers the LTB E type. The instructions are
divided into four parts:
Inspection intervals
Instructions for preventive maintenance of circuit-breakers
Instructions for preventive maintenance of operating mechanism
Fault correction maintenance
Periodic maintenance must be carried out at the the time or operation intervals
specified.
Fault correction maintenance is related to the faults detected. The fault correction
maintenance described in this Manual involves the replacement of defective units. If
the user chooses to try and repair a defective unit instead, specialist knowledge is
often needed. This will not be found in the Manual.
The equipment must be overhauled in accordance with specied criteria, e.g. after a
certain number of operations. Overhaul of the equipment must be entrusted to
authorised service personnel.
1.1 Warning text
Careful attention must be given to text marked with:
DANGER
in death or serious personal injury.
WARNING
CAUTION
indicates a hazardous situation than can result in minor or moderate
injury.
General Operating and Maintenance Instructions
2 1HSB435409-100 en1
1.2 Varning
WARNING
Circuit -breakers with pressurised porcelain insulators.
Mechanical damage to the porcelain can cause it to explode with the
subsequent risk of splintering. Work on the circuit-breaker that brings
about the risk of mechanical damage to the insulators should be carried
out at a reduced gas pressure, 0.125 MPa (abs).
Operating and Maintenance Instructions Preventative maintenance
1HSB435409-100 en1 3
2. Preventative maintenance
2.1 Circuit-breaker
2.1.1 Circuit-breaker service life
Assuming that the recommended inspection intervals have been adhered to and the
appropriate measures have been implemented, the LTB E circuit-breaker will have a
service life exceeding 30 years or 10,000 mechanical operations.
The following points will ensure a long service life:
1. Burning-off of the arcing contacts is limited.
2. Each breaking unit is equipped with a absorption agent with the service life
equivalent to that of the circuit-breaker.
3. Bearings in the space lled with gas are maintenance-free.
4. The seals have double sealing rings.
Generally speaking, there are only two reasons to open the breaking unit:
if the number of short-circuits x short-circuit current (kA) is approaching
the curve in Figure 2-1
or...
if the number of operations for line, reactor or capacitor switching, as well as
switching of the load current
1
has reached the level specified under the
heading Inspection intervals in the inspection chart.
Other reasons for opening the breaking unit are limited to mechanical
faults/incorrect adjustment of the drive system that may cause damage to
components inside the breaking unit.
N.B. Opening the breaking unit requires special instruction and may only be done
by trained and authorised personnel.
The curve that denes the permissible number of short-circuits can be expressed
approximately as:
for LTB 245E1: n x I
2
= 20000
for LTB 420E2: n x I
1.9
= 20000
where
n = number of short-circuits
I = short-circuit current, kA (RMS)
All short-circuit current levels can be included in the total of the number of short-
circuits x short-circuit current, for example for LTB 245E1, to the power of 2.
For example: LTB 245E1: 10x30
2
+20x20
2
+20x10
2
=19,000.
1. All normal service switched-off and -on load currents are not to be included into this
formula- they are considered only in calculation of total number of mechanical CLOSE /
OPEN operations.
Preventative maintenance Operating and Maintenance Instructions
4 1HSB435409-100 en1
2.1.2 Service life of arcing contacts with short-circuit interruption
The diagram below shows the number of interruptions versus short-circuit current
that the contacts in a LTB E circuit-breaker can manage before the metal losses due
to burning becomes so great that they must be replaced.
Figure 2-1. Number of operations with short-circuit current.
2.1.3 Tightness checking
The circuit-breakers are equipped with density monitors for checking the gas
density. Each density monitor is equipped with an alarm contact that gives an
electric signal in the event of abnormal leakage. Alarmlevel 1 gives an alarmsignal
while alarm level 2 blocks.
N.B. A new or overhauled circuit-breaker should be checked for tightness by
reading the density monitors after about 1 month and then at 1-2 year
intervals in connection with the regular ocular inspections.
5000
2000
1000
20
500
50
100
200
20 10 2 4 5 3 30 40 50 63
n
kA
Number of interruptions
Short-circuit current
LTB 245E1
LTB 420E2
Operating and Maintenance Instructions Preventative maintenance
1HSB435409-100 en1 5
2.1.4 Cleaning the outside
The circuit-breaker insulators must be cleaned from salt and other contaminant
deposits at the same time as the cleaning of the other insulators in the substation.
The time interval for cleaning depends on local conditions, i.e. the amount of
atmospheric pollution.
N.B. All LTB E circuit-breakers are completely hose-proof, , i.e. circuit-breakers
in operation can be cleaned with high-pressure water without any risk of
water entering the circuit-breaker and causing damage to essential parts.
2.1.5 Lubricating the circuit-breaker
Use only the lubricants recommended in the document Lubricants 1HSB445409-1.
This is particularly important in cold climates with temperatures below -25C.
When supplied, the circuit-breaker bearings are lubricated with Grease G
1
and
will not normally need lubricating except during major overhauls.
See the Overhaul instructions applicable for the circuit-breaker, for lubricating
sealing rings.
2.1.6 Rust protection
The opening springs are rust inhibited by painting with two-component paint.
2.2 Operating mechanism
2.2.1 Maintenance
Work on the operating mechanism with the circuit-breaker in the Closed position
and with tensioned closing springs always involves a certain risk. It is therefore
important that the guidelines in the document Product information BLG 1002A
or, Product information BLK 222, Safety regulations, are followed before the
work is started.
2.2.2 Cleaning
Clean the operating mechanism when necessary using a vacuum cleaner.
Check that the lters in the valves are clean. Replace them if they are dirty.
1. See the document Lubricants 1HSB445409-1 for the names of suppliers and brands for
grease and oils.
Preventative maintenance Operating and Maintenance Instructions
6 1HSB435409-100 en1
2.2.3 Lubrication
The ball, roller and needle bearings in the operating mechanism are permanently
lubricated and require no maintenance. Lubrication is therefore limited to shafts in
the latch mechanism; these should be greased after 2000 operations. The wormgear
in the drive unit for BLG 1002A should be lubricated at the same interval. The
sliding surfaces of the spring fork and dashpot must be lubricated with Grease G
1
and the chains with Oil A
1
, in connection with an overhaul.
When supplied the closing and opening dashpots are lled with Oil S
1
.
2.2.4 Rust protection
Certain steel parts in the operating mechanism have manganese phosphate surfaces
and then dipped in a rust inhibiting oil. This applies to latches, gear-wheels and
parts of the link system.
The closing springs are rust inhibited by painting with two-component paint (BLG
1002A) or by manganese phosphate surfaces and then dipped in a rust inhibiting oil
(BLK 222).
When supplied, the operating mechanismis equipped with desiccants for protection
against moisture during transport.
Despite the extensive rust inhibitor treatment, minor corrosion can occur after some
years especially if the circuit-breaker is located in a strongly corrosive environment.
Rust spots should be cleaned and new rust inhibitor applied with a brush or spray.
The recommended rust inhibitor is Grease G
1
or Tectyl 506
(ABB Art. No. 1241 0011-108).
N.B. Tectyl 506 forms a waxy protective skin when it dries and therefore it must
not be sprayed into bearings and latch mechanisms or on to gear-wheels and
chains.
2.3 Spare parts
Spare parts must be stored indoors in an approved storage space
2
and in the original
packaging. This is particularly important for rubber components (seals etc.), which
must also be protected against sunlight to prevent them drying. Seals have a limited
shelf life so avoid storing them. Base frames can be stored outdoors.
1. See the document Lubricants 1HSB445409-1 for the names of suppliers and brands for
grease and oils.
2. Approved storage space:
roof, solid foundation, relative humidity less than 50%, temperature +20
o
C(10C)
Operating and Maintenance Instructions Inspection intervals
1HSB435409-100 en1 7
3. Inspection intervals
Important checkpoints, acceptable tolerances, certain functional values for
adjustments, and recommended inspection intervals can be found in the following
inspection chart.
In corrosive or polluted air and in climates with a high relative humidity, it can be
necessary to halve the inspection intervals.
The specied inspection intervals should be considered as recommended guide
values, which can be increased or decreased depending on local conditions.
Inspection intervals Operating and Maintenance Instructions
8 1HSB435409-100 en1
3.1 Maintenance summary
Explanations:
1. Mech. oper. = Mechanical Close-Open operations.
2. CLOSE/OPEN oper. with el load = Close-Open operations with electrical
loading.
3. Special requirements for resistance check of circuit-breakers operated
< 100 CLOSE/OPEN operations/year.
Type of measure Inspection interval
Explan-
ation
Conditionof
circuit-
breaker
during work
Com-
petence
require-
ments
A Ocular inspection 1-2 years a1 a2
B Preventive maintenance
Intermediate check
Operation test including
timing test
Thermovision check
Greasing of Wormgear
3-6 years or 2,000 mech.
CLOSE/OPEN operations.
1) b1 b2
C Preventive maintenance
General check of circuit-
breaker and operating
mechanism
15 years or 5,000 mech.
1), 3) b1 b2
D Overhaul
Overhaul of breaking
chambers
Line and transformer
circuit-breakers
Capacitor-reactor and lter
circuit-breakers
Not synchronized
Synchronized
Major overhaul
2,500 CLOSE/OPEN op.
with el. load.
5,000 CLOSE/OPEN op.
with el. load.
2)
1)
c1
d1
c2
c2
LTB 245E1:
nxI
2
=20,000
LTB 420E2:
nxI
1.9
=20,000
1HSB435409-100 en1 9
Condition of circuit-breaker during work:
a1) Circuit-breaker in service.
b1) Closing springs unloaded, circuit-breaker open, disconnected and earthed. If
thermovision measurement is included, it shall be done at normal load before
the circuit-breaker is disconnected.
c1) Closing springs unloaded, circuit-breaker open, disconnected and earthed.
Poles/Breaking units dismounted and transported to workshop.
d1) Closing springs unloaded, circuit-breaker open, disconnected and earthed.
Complete circuit-breaker including operating mechanism transported to
workshop.
Competence requirements:
a2) Substation personnel with no special training.
b2) Personnel authorised by ABB to carry out assembly, commissioning and
maintenance work.
c2) Personnel authorised by ABB to carry out assembly, commissioning and
maintenance work. Support from ABB may be necessary in certain cases.
3.2 Maintenance category A
To be inspected Inspection interval Measures / Instructions / Tools
1.
Ocular inspection 1-2 years Check external cleanliness, heater
element function, gas pressure, valves
and drainage holes.
No special tools needed.
See Chapter 2.1.3 and Chapter 2.1.4
and 1HSB515409-100 for BLG 1002A
or 1HSB535409-100 for BLK 222.
10 1HSB435409-100 en1
3.3 Maintenance category B
1.
Ocular inspection 3-6 years or 2,000 mech. CLOSE/
OPEN operations.
Check external cleanliness, heater
and drainage holes.
or 1HSB535409-100 for BLK 222.
2.
Rating plates 3-6 years or 2,000 mech. CLOSE/
OPEN operations.
Make a note of the serial number.
3.
Operation counter 3-6 years or 2,000 mech. CLOSE/
OPEN operations.
Make a note of the number of
operations.
4.
Visual inspection in
operating mechanism
3-6 years or 2,000 mech. CLOSE/
OPEN operations.
Look for loose bolts and nuts, oil leaks
from dashpots.
If leakage replace the complete
dashpot.
No tools necessary.
See Manual 1HSB515409-100 for BLG
1002A or 1HSB535409-100 for BLK
222.
5.
Corrosion inspection
Rust protection
3-6 years or 2,000 mech. CLOSE/
OPEN operations.
Visual inspection.
Rust stains polished off and treated
with rust protection.
See Chapter 2.2.4 .
6.
Greasing 3-6 years or 2,000 mech. CLOSE/
OPEN operations.
Circuit-breaker in open position, closing
springs discharged. Greasing of the
worm gear ( only BLG 1002A) and
shafts in latches in the operating
mechanism with grease M.
See Chapter 2.1.5 ,Chapter 2.2.3 and
Manual 1HSB515409-100 for BLG
1002A or 1HSB535409-100 for BLK
222.
1HSB435409-100 en1 11
7.
Thermovision
measurements
3-6 years or 2,500 mechanical
Close-Open operations.
To be carried out at full load before the
circuit-breaker is taken out of service.
Checking the temperature rise of the
the external parts of the breaking unit.
The maximal allowed temperature
difference between phases is
5 degrees.
Thermovision camera.
The load current must be taken into
consideration during the measurements
as well as large variations in the load
current 3-4 hours before the
measurements.
See manual for the thermovision
camera.
8.
Operational test 3-6 years or 2,500 mechanical
Operational test, if possible in
combination with measurement of
operating times, (incl. Close-Open
times).
12 1HSB435409-100 en1
3.4 Maintenance category C
1.
Ocular inspection 15 years or 5,000 mech. CLOSE/
OPEN operations.
Check external cleanliness, heater
and drainage holes.
or 1HSB535409-100 for BLK 222.
2.
Rating plates 15 years or 5,000 mech. CLOSE/
OPEN operations.
Make a note of the serial number.
3.
Operation counter 15 years or 5,000 mech. CLOSE/
OPEN operations.
Make a note of the number of
operations.
4.
SF
6
gas
Filling of gas (if
necessary)
Dew point at normal
gas pressure in the
circuit-breaker.
15 years or 5,000 mech. CLOSE/
OPEN operations.
Gas lling equipment.
See Assembly instruction for applicable
circuit-breaker, ch 6.
Dew point maximum - 5 C at rated
lling pressure and + 20 C
temperature.
5.
Insulators
Visual inspection and
cleaning.
OPEN operations.
Spray and rub the insulators clean.
Check cementing, bolts and nuts.
Spray equipment, clothes and
wrenches.
See Chapter 2.1.4
1HSB435409-100 en1 13
6.
Main current circuit
Resistance check. 15 years or 5,000 mech CLOSE/
OPEN operations.
Circuit-breakers only operating
<100 CLOSE/OPEN
operations/year after 6-8 years or
2500 mech CLOSE/OPEN
operations.
Check resistance of circuit-breaker.
Resistance bridge, test current min.
200 A DC.
Resistance value as specied in
applicable Assembly instructions for the
circuit-breaker in question.
Higher values allowed for frequent
operation with small currents (400).
Calculation of permissible resistance:
7a.
Contact system
Opening position 15 years or 5,000 mech. CLOSE/
OPEN operations.
Inspection of reference holes in outer

lever and mechanism housing.
See applicable Assembly instructions
for the circuit-breaker in question.
7b.
Operating
characteristics
Opening time
Closing time
Close-Open time
Phase discrepancy
Auxiliary switches
Contact travel
Contact damping.
OPEN operations.
Measurement with electronic timer.
Nominal operating voltage.
For times, see the applicable Assembly
instructions for the circuit-breaker.
Max phase discrepancy between
phases:
at closing 4 ms; at opening 3 ms.
max discrepancy between breaks in the
same phase:
at closing 3 ms; At opening 2 ms.
1002A or 1HSB535409-100 for BLK
222.
R
Rn
2
-------
In
I
-----
1.65
=
R = Permissible increase in
resistance
R
n
= Max. resistance as specied
in operating values
I
n
= Rated current as specied on
rating plate
I = Current for which max.
resistance is calculated.
14 1HSB435409-100 en1
8a.
Operational availability
Pull rod system
Safety release of
operation
Anti-pumping relay
15 years or 5,000 mechanical

Check the tightening torque on bolts in
the pull-rod system.
Torque wrench.
Torque: See applicable Assembly
instructions for the circuit-breaker.
Measurement of minimum operating
voltage.
Closing coil: < 85%IEC ( < 72 %ANSI)
of nominal voltage.
Opening coil: < 70%IEC (< 56 %ANSI)
of nominal voltage.
Variable D.C. voltage source required.
Checking anti-pumping function:
The circuit-breaker in open position, the
operating mechanismcharged, CLOSE
and OPEN impulse given
simultaneously (the close button shall
be pressed).
The circuit-breaker will make a CLOSE-
OPEN operation and may not close
when the operating mechanism is
charged.
The pumping device must stay as long
as the close impulse remain. Lowest
operating voltage of the relay is
measured (85% of nominal).
8b.
Motor current 15 years or 5,000 mechanical
Check the carbon on the motor/motors.
If they are 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 change
up to 30% from value measured at
routine test.
The motor shall be able to charge the
springs at min. 85% of nominal voltage
(IEC).
See 1HSB515409-100 for BLG 1002A
or 1HSB535409-100 for BLK 222.
1HSB435409-100 en1 15
8c.
Dashpot 15 years or 5,000 mechanical
Checking of oil-level or recording of
damping during operation alternatively.
Recording of damping during operation
is made by means of a circuit breaker
analyzer with transducers connected to:
main shaft of the circuit breaker
mechanism when checking the
opening dash-pot
main shaft (cam shaft) of the
operating mechanism when
checking the closing dash-pot.
These measurements are to be carried
out only by specially trained personal.
1002A or 1HSB535409-100 for BLK
222.
8d.
Catch-gears 15 years or 5,000 mechanical
Visual control of the adjustment.
Play of gaps in the catch-gears acc. to
1002A or 1HSB535409-100 for BLK
222.
Greasing of shafts and catch surfaces
with Grease L acc. to 1HSB445409-1.
Change the signal from coil 1 to coil 2.
8e.
Coils 15 years or 5,000 mech CLOSE/
OPEN operations.
The resistances of coils and coil
currents are allowed to differ +/- 10%
from value measured at routine test.
8f.
Mechanical interlocking
Only applicable for BLG
1002A
OPEN operations.
In OPEN position the distance between
the interlocking arm and the
interlocking disc shall be min. 2 mm.
In CLOSE position there must be full
contact between the arm and disc (No
gap is permitted).
See Manual 1HSB515409-100.
16 1HSB435409-100 en1
8g.
Heaters
Operating mechanism 15 years or 5,000 mech. CLOSE/
OPEN operations.
Checking of resistance:
If applicable, check signal for loss of
power.
1002A or 1HSB535409-100 for BLK
222.
8h.
Central control cubicle 15 years or 5,000 mech. CLOSE/
OPEN operations.
Checking of resistance.
Small cubicle:
48 W, 110 V R = 330 Ohms +/- 10%
48 W, 220 V R = 1000 Ohms +/- 10%.
Middle or large cubicle:
140 W, 110 V R = 86 Ohm +/-10%
140 W, 220 V R = 346 Ohm +/- 10%.
8i.
Thermostat 15 years or 5,000 mech. CLOSE/
OPEN operations.
If applicable, check that the thermostat
is adjusted to requested value.
See Manual 1HSB445410-100.
8j.
Terminal blocks 15 years or 5,000 mech. CLOSE/
OPEN operations.
Tightening of screws or clamps.
1002A or 1HSB535409-100 for BLK
222.
8k.
Direct on line motor
starter
OPEN operations.
If applicable, check signal for loss of
power.
1002A or 1HSB535409-100 for BLK
222.
1HSB435409-100 en1 17
9.
Tightness of the SF
6
gas
Density monitoring
OPEN operations.
Check the density switches and
signal/blocking circuits.
Accurancy test of the pressure gauge
must be done at standard reference
atmosphere i.e. +20 C and 101.3 kPa
(1013 mbar).
Remove the density switch from the
circuit-breaker for checking of function.
N.B. Min permissible voltage for test
of the circuits in the density
switch (30 V).
See applicable Assembly Instruction for
the circuit-breaker.
10.
Blocking relays 15 years or 5,000 mech. CLOSE/
OPEN operations.
The relays shall close when a density
switch is pulled out from a pole
pressurized to lling pressure.
11.
Corrosion 15 years or 5,000 mech. CLOSE/
OPEN operations.
Outside:
Visual check, particularly check
protected components in non heated
compartments, pull-rod system, clevis
couplings, springs.
Treat with anti-rust oil if necessary.
See Chapter 2.2.4 and Manual
1HSB515409-100 for BLG 1002A or
1HSB535409-100 for BLK 222.
12a.
Lubrication 15 years or 5,000 mechanical
Inspect and lubricate the latches.
See Chapter 2.1.5 , Chapter 2.2.3 and
1002A or 1HSB535409-100 for BLK
222.
18 1HSB435409-100 en1
12b.
Worm gear 15 years or 5,000 mechanical
For BLG 1002A:
Greasing the operating
mechanisms drive unit with Grease
M.
For BLK 222:
Check the oil level in the worm gear
housing.
See Product information for the
13.
Tightening torque 15 years or 5,000 mech. CLOSE/
OPEN operations
Check of tightening torque on screw
joints.
Tightening torques acc. to Assembly
Instruction and Overhaul Instruction.
Tightening torque for earthing 79 Nm.
1HSB435409-100 en1 19
3.5 Maintenance category D
To be inspected Inspection intervals Measures / Instructions / Tools
1.
Overhaul of breaking
chambers
Line and transformer
circuit-breakers
Capacitor bank circuit-
breakers
Reactor circuit-
breakers
Filter circuit-breakers
All kinds of service.
Not synchronized:
2,500 CLOSE/OPEN operations
with el. load.
Synchronized:
5,000 CLOSE/OPEN operation with
el. load.
Alarming result at diagnostic test.
Gas evacuated, poles/ breaking units
dismounted and transported to a clean
workshop.
Porcelain lift off, contacts and PTFE-
parts replaced with new ones.
See Manual Overhaul Instruction for
actual circuit-breaker.
Standard tools, close tting dust mask,
long sleeved overall, protective plastic
or rubber gloves.
See Manual Overhaul Instruction for
applicable circuit-breaker.
2.
Major overhaul of
complete circuit-
breaker and operating
mechanism
Circuit-breaker.
Disassembly of the poles and
mechanisms. New contacts and PTFE-
components are to be mounted.
Exchange of outer worn out parts.
If the circuit-breaker and operating
mechanism are overhauled for another
2,000 operations, selected worn out
parts are to be exchanged.
If the circuit-breaker and operating
mechanism are overhauled for another
10,000 operations, in principle all
moving parts are to be exchanged.
Protection against decomposed gas as
standard tools above.
Instructions:
For circuit-breaker, see Manual
Overhaul Instructions for actual circuit-
breaker.
Operating mechanism under
supervision from ABB.
3.
Capacitor 30 years or 10,000 mech.
Check of values on:
C = C
N
+5%,-0%
PD < 5 pC
Tan d < 0,2%.
LTB 245E1:
nxI
2
=20,000
LTB 420E2:
nxI
1.9
=20,000
1HSB435409-100 enrev1
0008
ABB Switchgear AB
Head ofce
S-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
ABB Switchgear
SF
6
Circuit-Breaker Circuit-breakers HPL and LTB
1HSB445409-1 en0
Lubricants
that can occur in the document.
ABB Switchgear AB
Article number: 1HSB445409-1 en0
Date: 1997-06-11
Lubricants
1HSB445409-1 en0 i
LIST OF CONTENTS
1. General ................................................................................ 1
1.1 Safety instructions.......................................................................... 1
2. Oil........................................................................................ 3
3. Grease ................................................................................. 5
Lubricants General
1HSB445409-1 en0 1
1. General
As a guide to the selection of oils and greases for circuit-breakers HPL and LTB
with operating mechanisms, a description is given below of the application areas as
well as trade names and suppliers.
1.1 Safety instructions
Protective gloves, long-sleeved overalls and eye protection must be worn when
handling greases and oils.
All spillage shall be covered with an absorption agent and taken care of as chemical
waste according to applicable local directives.
Lubricants
1HSB445409-1 en0 3
2. Oil
Oil A
Thin, fully synthetic lubricating oil for precision components in the operating
mechanism and circuit-breaker. Also used for post lubrication of bearings that
cannot be lubricated with grease G without dismantling, e.g. links and link gears.
Viscosity at 40C: 62-65 cSt
Lowest pour temperature: -52C
Oil D
Breaker oil with a low viscosity ~ 6.0 cSt at 20C. Also used as oil in dashpots.
Dashpots with the letter s punched on the cover shall be lled with oil S.
Oil S
Silicone oil intended for dashpots in heavy-duty operating mechanisms, type BLG.
Only dashpots with the letter s punched on the cover shall be lled with this oil.
SUPPLIER Oil A Oil D Oil S
ABB art. No. 1171 2039-1 1171 3011-102 1173 7011-106
ABB spare part No. 1HSB875318-A 1HSB875318-B 1HSB875318-C
MOBIL MOBIL 1 (481127)
5W-30
Circuit-breaker oil
Univolt 42 (44)
-
CASTROL FORMULA RS
5W-50
- -
SHELL TMO Synthetic
5W-30
NYSWITCHO 3
NYSWITCHO 3X
DC 200 Fluid 200
CS
OK Super-synthetic
4W-40
Circuit-breaker oil
A65
Klte-Schalteroel X
-
Lubricants
1HSB445409-1 en0 5
3. Grease
Grease G
Low-temperature grease for all types of bearings, gearing and worm gears and
valves in air-blast circuit-breakers.
Also used for greasing sealing rings and crevice corrosion protection on breakers
type HPL
Grease K
Molykote grease for lubricating pins in link gears and in earthquake dampers.
Grease N
For lubricating moving contacts and puffer cylinders in SF
6
circuit-breakers. The
grease shall be applied in a very thin layer on the contacts sliding surfaces.
Grease L
Low-temperature grease especially suitable for lubricating precision components,
for example, latch mechanisms in operating mechanisms that shall work in severe
cold.
Grease M
Low-temperature grease for long-term and permanent lubrication of worm gears,
and spur gears and other machine elements. Counteracts wear and corrosion.
Grease P
Vaseline for coating contact surfaces on xed joints on the inside of the breaking
unit.
Grease S
Fluoro-silicone grease for lubricating the EPDM-O-rings and as crevice corrosion
protection on circuit-breakers type ED as well as for lubricating rotating shaft seals
on circuit-breakers types LTB and HPL.
Grease SV
For lubricating moving contacts (opening contacts), silver-plated contacts and
brushed aluminium surfaces on xed joints outdoors
Lubricants
1HSB445409-1 en0 6
.
SUPPLIER Grease G Grease K Grease N Grease L
ABB art. No. 1171 4014-407 1263 0011-102 1171 4016-607 1171 4016-606
ABB spare part No. 5316 381-A 5316 381-M 5316 381-L 5316 381-H
ASEOL AG - - ASEOL SYLITEA
4-018
Dow Corning G-rapid plus
GULF 718EP Synthetic
grease
- -
MOBIL Mobil grease 28 - -
Monteuos S.p.A. - Fomblin OT 20 -
SHELL Aero Shell
Grease 223
- -
SUPPLIER Grease M Grease P Grease S Grease SV
ABB art. No. 1171 4016-612 1171 5011-102 1171 4014-406 1171 4016-610
ABB spare part No. 5316 381-J 5316 381-N 5316 381-G 5316 381-C
Klber Isoex Topas NB
52
-
Dow Corning - - FS-3451 No. 2
Fluortech AB TP55
SHELL - Shell vaseline
8401
Statoil Electrical grease
1HSB445409-1 en0
9808
ABB Switchgear AB
Head Ofce
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
ABB Switchgear
SF
6
type BLK 222
1HSB535409-100 en rev2
Maintenance
ABB Switchgear AB
Date: 2000-04-19
Maintenance Operating Mechanism
1HSB535409-100 en rev2 i
LIST OF CONTENTS
1. General ............................................................................... 1
2. Safety................................................................................... 3
2.1 Warning text ....................................................................................3
2.2 Safety directives..............................................................................4
3. Maintenance, general ......................................................... 7
3.1 Tools................................................................................................7
3.2 Cleaning equipment ........................................................................7
3.3 Spare parts.......................................................................................7
3.4 Test equipment ................................................................................7
4. Maintenance........................................................................ 9
4.1 General ............................................................................................9
4.2 Preparations for maintenance........................................................18
4.3 Cleaning ........................................................................................19
4.4 Corrosion.......................................................................................19
4.5 Lubrication....................................................................................20
4.6 Heater element ..............................................................................20
4.7 Drive unit ......................................................................................21
4.8 Catch gear .....................................................................................23
4.9 Dashpot .........................................................................................25
4.10 Limit switch with auxiliary contact ..............................................26
4.11 Terminal blocks.............................................................................28
Maintenance Operating Mechanism
FIGURES
Figure 4-1. Operating mechanism BLK 222 ..................................................... 9
Figure 4-2. Electrical discharging of the closing springs. ............................... 10
Figure 4-3. Mechanical discharging of the closing spring. ..............................11
Figure 4-4. Mechanical charging .................................................................... 12
Figure 4-5. Switch Local/Remote, motor protection. ..................................... 13
Figure 4-6. Connecting the crank. ................................................................... 13
Figure 4-7. Slow manual Closing operation ................................................... 14
Figure 4-8. Closing catch gears roller ............................................................ 14
Figure 4-9. Switch Local/Remote, motor protection. ..................................... 15
Figure 4-10. Crank connection. ......................................................................... 15
Figure 4-11. Slow manual Open-operation. ...................................................... 16
Figure 4-12. Closing catch gears roller. ........................................................... 16
Figure 4-13. Operating panel. ........................................................................... 18
Figure 4-14. Heater element. ............................................................................. 20
Figure 4-15. Drive unit. ..................................................................................... 21
Figure 4-16. Replacing the motor ..................................................................... 22
Figure 4-17. Catch gear ..................................................................................... 23
Figure 4-18. Checking the play. ........................................................................ 23
Figure 4-19. Replacing the catch gear. .............................................................. 24
Figure 4-20. Dashpot ......................................................................................... 25
Figure 4-21. Limit switch with auxiliary contact. ............................................. 26
Figure 4-22. Time measurement, contact movement. ....................................... 27
Figure 4-23. Electrical equipment. .................................................................... 28
Maintenance Operating Mechanism General
1HSB535409-100 en rev2 1
1. General
This information applies for the spring operating mechanism BLK 222 intended for
operating circuit-breakers with integrated opening springs. Information is provided
in this instruction for maintenance and fault correction maintenance.
Preventive maintenance and overhaul of the mechanism BLK 222 should be carried
out at regular intervals.
Visual inspection at 1-2 years intervals.
Lubrication after 15 years or 2000 mechanical On-Off operations.
Preventive maintenance after 15 years or 5000 mechanical On-Off operations.
Overhaul after 30 years or 10 000 mechanical On-Off operations.
Overhaul and repair work may only be carried out by service personnel authorised
by ABB Switchgear AB.
Maintenance Operating Mechanism Safety
1HSB535409-100 en rev2 3
2. Safety
2.1 Warning text
observed extra carefully. The warning texts are marked as set out below.
DANGER
WARNING
CAUTION
indicates a hazardous situation than can result in minor or moderate
injury.
N.B. used for hazards that may only result in damage to the installation.
Safety Maintenance Operating Mechanism
4 1HSB535409-100 en rev2
2.2 Safety directives
On all types of work on high-voltage circuit-breakers, the risks listed below must be
taken into consideration and corresponding measures must be taken.
WARNING
Circuit-breakers with pressurised insulators.
Mechanical damage to the insulator can cause it to explode with the
Work on the circuit-breaker that brings about the risk of mechanical
0.125 MPa (abs).
WARNING
Do not operate the mechanism unloaded!
and trimmed with the associated circuit-breaker.
The standard operating cycle is O - 0.3 s - CO - 3 min. - CO. The time between
closing operations should not be less than 1 minute during the testing of circuit-
Maintenance Operating Mechanism Safety
1HSB535409-100 en rev2 5
WARNING
Work requires training and product knowledge and may only be carried
out by authorised personnel.
Risk Measure
Working next to high voltage. Isolate and earth close to the work
place. If work must be carried out
close to live installation components,
the safety distance applying in the
countrys applicable safety
regulations must be observed.
Working on ladders and platforms. Work shall be carried out in
accordance with applicable safety
regulations in the country concerned.
Difficult weather conditions that
require short shifts with a great deal
of climbing on ladders and platforms,
should be avoided.
Working with low voltage.
Both alternating (AC) and direct (DC)
current can be routed to the
Switch off the control voltage and if
necessary the heating voltage.
Risk of crushing in the operating
mechanism and link system.
There is stored energy in the
opening and closing springs. The
mechanism can be tripped by heavy
vibrations or by unintentional contact
with mechanical latch components.
Operate the circuit-breaker to the
open position. Isolate and earth the
high-voltage side. Discharge the
springs by switching off the motor
current and perform a Close-Open
operation or move the operating
mechanisms drive shaft backwards
by hand (see the Product Information
for the operating mechanism). For
reasons of safety the closing springs
must be uncharged during
transportation as well as during
assembly and storage.
Working close to pressurised
insulators.
The normal working pressure is up to
0.8 MPa. Damage to the porcelain
can result in splintering.
Work close to the circuit-breakers
insulators that may result in damage
to the insulator, must not be carried
out until the gas has been emptied to
max. 0.125 MPa (abs.) pressure.
Maintenance Operating Mechanism Maintenance, general
1HSB535409-100 en rev2 7
3. Maintenance, general
All requisite equipment should be available before work is started so that
maintenance work can be carried out in the best way.
The following equipment is required.
3.1 Tools
A normal set of tools including a torque wrench (10-100 Nm).
Measuring scale.
Vernier gauge.
Lifting slings.
3.2 Cleaning equipment
Vacuum cleaner.
Drying cloths of a lint-free material.
3.3 Spare parts
Lubricants and oils, see Lubricants, 1HSB445409-1 for suppliers and trade
names.
Grease G: ABB Art. No. 1171 4014-407
Grease L: ABB Art. No. 1171 4016-606
Grease M ABB Art. No. 1171 4016-612
Oil A: ABB Art. No. 1171 2039-1
Anti-corrosion agent.
Valvoline Tectyl 506: ABB Art. No. 1241 0011-108
Grease G: ABB Art. No. 1171 4014-407.
Locking fluid
Loctite 242, ABB Art. No. 1269 0014-410.
Tool to crank the operating mechanism, ABB Art. No. 2172 733-186
3.4 Test equipment
Equipment to record attenuation curves and operating values.
(e.g. Programma or ABB SA10)
Maintenance Operating Mechanism Maintenance
1HSB535409-100 en rev2 9
4. Maintenance
4.1 General
The Operating and Maintenance Instructions for the circuit-breaker should be read and
followed before work on the circuit-breaker is started and while work is in progress.
WARNING
and trimmed with the associated pressurized circuit-breaker.
The component parts of the operating mechanism are integrated in a cabinet which
also contains a control panel with operating equipment. The top of the cabinet can
be removed and the operating panel opened to facilitate service and overhaul work.
Figure 4-1. Operating mechanism BLK 222
Measure all operating values and record them. If the measured values
correspond with the specified values for the circuit-breaker, then only a visual
inspection, cleaning and lubrication are required.
Item
1 Drive unit
3 Operating panel
4 Closing spring
5 Heater element
1 2
4
3
5
B30200
Maintenance Maintenance Operating Mechanism
10 1HSB535409-100 en rev2
4.1.1 Discharging the closing springs
It is important the closing springs are uncharged during maintenance when working
on the circuit-breaker or operating mechanism.
Electrical discharging of the closing springs.
1. Switch off the motor protection (1)
2. Turn the Local/Remote switch (2) on the operating panel to Local.
3. Perform an Open-Closed-Open operation.
4. Check that the spring is uncharged. The spring indicator (3) shows uncharged
spring.
5. The circuit-breaker is in the Open position.
Figure 4-2. Electrical discharging of the closing springs.
The motor protection should be reset when work has been completed.
Item
1 Motor protection
2 Switch Local/Remote
3 Spring indicator
4 Operating switch Closed/Open
2 4
1
B30201

1HSB535409-100 en rev2 11
Mechanical discharging of the closing spring.
1. Unscrew the cover (1) so the motor circuit is cut.
2. Assemble the crank (3) and the crank attachment (4) as in Figure 4-3.
3. Crank anti-clockwise until the spring is fully uncharged.
4. Check that the spring is uncharged. The spring indicator (5) shows uncharged
spring.
Figure 4-3. Mechanical discharging of the closing spring.
Item
1 Cover
2 Screw M6 4 pcs.
3 Crank
4 Crank attachment
5 Spring indicator
2
1 3
4
Mechanism
B30202

12 1HSB535409-100 en rev2
4.1.2 Mechanical charging of the closing spring
The closing spring can be manually charged, if there is no motor voltage available.
Unscrew the cover (1) so that the crank can be inserted. Assemble the crank (2)
and the crank attachment (3) as set out in Figure 4-4.
Crank clockwise until the spring indicator (4) shows a tensioned spring.
Refit the cover.
Figure 4-4. Mechanical charging
Item
1 Cover
2 Crank
3 Crank attachment
4 Spring indicator
1
2
3
Mechanism
B30202
4
1HSB535409-100 en rev2 13
4.1.3 Slow manual Closing and Opening operations
Some service work requires the circuit-breaker to operate slowly.
CAUTION
Slow manual closing and opening operations may only be carried out by
persons that are well conversant with the operation of the mechanism and
circuit-breaker as there is a risk of personal injury and mechanical
damage.
Slow manual closing operation of the operating mechanism
May only be carried out if:
The circuit-breaker is in the
open position.
The switch Local/Remote (1)
on the control panel is in the
Off position.
The motor voltage is cut using
the motor protection (2).
Figure 4-5. Switch Local/Remote, motor protection.
Closing springs uncharged.
1. Assemble the crank (1) and crank attachment (2) as in Figure 4-6
Figure 4-6. Connecting the crank.
Item
2 Motor protection
Item
1 Crank
2 Crank attachment
2 1
B30206
1
2
Mechanism
B30052
14 1HSB535409-100 en rev2
2. Connect the crank and crank anti-clockwise so it is possible to attach the tool
(2) on the heel (3) and dog (1), see Figure 4-7.
3. Crank clockwise until the crank shaft stops against the closing catch gear (4).
Crank a further number of turns so that the roller (5) is under pressure.
4. Press using a screwdriver on the latch (6) for the closing catch gear.
5. Continue to crank clockwise until the link system (7) engages with the Open-
lock (8).
N.B. Check that the link system has engaged with the roller on the Open-lock.
6. Crank the crank 1-2 turns anticlockwise and remove the tool (2) from the dog.
Figure 4-7. Slow manual Closing operation
7. Continue to crank anti-clockwise so
that the dog returns to its original
position. When the dog passes the
closing catch gears roller (5) this is
lifted up with a screwdriver, see
Figure 4-8.
Figure 4-8. Closing catch gears roller
The circuit-breaker is now in the closed position and a normal opening operation
can be made.
Item
1 Dog
2 Tool Art. No. 2172 733-186
3 Heel
5 Roller
6 Latch
7 Link system
8 Open-lock
2
3
5
1
4
6
8
7
B30054
B30056
1HSB535409-100 en rev2 15
Slow manual opening operation
May only be carried out if:
The circuit-breaker is in the
closed position.
The switch Local/Remote (1)
on the control panel is in the
Off position.
The motor voltage is cut using
the motor protection (2).
Figure 4-9. Switch Local/Remote, motor protection.
Closing spring tensioned.
1. Fit the crank (1) and crank attachment (2) as in Figure 4-11 and press in the
back lock with the crank attachment.
Figure 4-10. Crank connection.
Item
2 Motor protection
3 Operating switch Closed/Open
Item
1 Crank
2 Crank attachment
2 1 3
B30206
1
2
Mechanism
B30052
16 1HSB535409-100 en rev2
2. Attach the tool (2) on the heel (3).
3. Crank the crank clockwise until it stops against the closing catch gear. Crank a
further number of turns so that the roller is put under pressure (5).
4. Press the latch (6) for the closing catch gear with a screwdriver.
5. Continue to crank clockwise until the tool (2) is clamped between the heel (3)
and the link system (8).
6. Press with a screwdriver on the latch (7) for the Open-lock.
Figure 4-11. Slow manual Open-operation.
7. Crank anti-clockwise until the tool (2)
is released. If not the link system (8)
follows the closing arm (4) repeat
point 6. When the dog passes the
closing catch gears roller (5) this is
lifted up with a screwdriver, see
Figure 4-12.
Figure 4-12. Closing catch gears roller.
8. Remove the tool (2).
The circuit-breaker is now in the Open position. The spring must be tensioned
before a normal Closing operation can be performed.
Item
1 Dog
2 Tool Art. No. 2172 733-186
3 Heel
4 Closing arm
5 Roller
6 Latch, closing catch gear
7 Latch, Open-lock
8 Link system
2
3
5
1
4
7
6
8
B30057
B30056
1HSB535409-100 en rev2 17
4.1.4 Interlocking system
The following electrical interlocks are integrated in the operating mechanism.
Closing circuit
Closing pulse to the Closing coil can only go through the auxiliary contact
if the circuit-breaker is in the open position.
Closing pulse to the Closing coil can only go through the limit switch if
the closing springs are tensioned.
Closing pulses are prevented when the density of the SF
6
-gas is lower than
the blocking level.
Remaining Closing pulses are cut up by the anti pumping relay after a
completed Closing operation.
Motor circuit
The motor circuit is cut with the switch, with slow Open and Closing
operations.
The motor circuit is cut with manual cranking of the spring.
18 1HSB535409-100 en rev2
4.2 Preparations for maintenance
The following should be done before maintenance is started:
1. Switch the circuit-breaker to the open position.
2. Isolate and earth.
3. Switch of the motor current.
4. Perform an Close-Open operation so that the spring is discharged.
5. Cut the operating voltage and if necessary also the voltage to the heater.
Figure 4-13. Operating panel.
Item
1 Operating panel
2 Operating switch
Close/Open
4 Spring indicator
3 2 1
B30203

1HSB535409-100 en rev2 19
4.2.1 Emptying the gas
Work that involves a risk of damaging the insulators must not be carried out until
the gas has been evacuated to a pressure of max. 0.125 MPa (abs).
WARNING
Unused SF
6
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 SF
6
gas collect in such places, a risk of
asphyxiation may occur due to a lack of oxygen.
The SF
6
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, SF
6
mixed with N
2
or CF
4
,

must not be reused unless the mixture
ratio is under control. (Can be checked with a meter that indicates the
percentage of SF
6
.)
4.3 Cleaning
Clean the inside of the operating mechanism using a vacuum cleaner.
Check that the filters in the valves are clean. If they are heavily soiled they
should be replaced.
4.4 Corrosion
Some of the steel mechanism parts have been surface treated with manganese
phosphate and then rust protected by dipping in oil. This applies to, among others,
latches and components in the link system.
Despite good rust protection small signs of rust attack can appear after a number of
years, especially on circuit-breakers erected in aggressive environments.
Rust spots should be removed and new anti-corrosive agent should be applied
by brush or spray. Recommended anti-corrosive agents are Grease G

or
Tectyl 506.
N.B. After drying Tectyl 506 forms a protective wax-like cover and must not be
sprayed on bearings as well as catch gears and gears.
20 1HSB535409-100 en rev2
4.5 Lubrication
The ball, roller and needle bearings as well as worm gears in the operating
mechanism are permanently lubricated and require no maintenance. Therefore only
the shafts in the catch gears need to be lubricated.
Sliding surfaces for the dashpot should be lubricated during an overhaul with
Grease G.
4.6 Heater element
The operating mechanism is fitted with a heater element to prevent condensation
and should always be connected.
Measure the resistance and check the voltage failure signal, if there is such,
after every 15 years or 2000 operations.
Data
70 W, 220 V: R = 691 Ohm 10%.
140W, 220 V: R = 346 Ohm 10%.
70 W, 110 V: R = 173 Ohm 10%.
140 W, 110 V: R = 86 Ohm 10%.
Item
1 Heater element
1
B30058
1HSB535409-100 en rev2 21
4.7 Drive unit
Measure the motor current at the end of the loading procedure. See the relevant
Assembly Instructions for the circuit-breaker, chapter Operating values.
The motor should be capable of charging the spring at 85% of its nominal
voltage (IEC).
Figure 4-15. Drive unit.
Item
1 Drive unit
B30160

22 1HSB535409-100 en rev2
4.7.1 Replacing the motor
1. Fully discharge the closing spring. The spring indicator should be Green.
2. Crank anti-clockwise so that the closing arm (1) rests against the roller (2).
3. Remove the cover on the operating mechanism cabinet.
4. Loosen the screws (3) and the electrical connection.
5. Fit the new motor. Tighten the screws (3) with tightening torque 9 Nm.
Figure 4-16. Replacing the motor
6. Lock the bolts using locking fluid, Loctite 242, ABB Art. No. 1269 0014-410.
7. Refit the cover.
4.7.2 Start switch
Check that the signal for voltage failure functions, if not replace the start switch.
Item
1 Closing arm
2 Roller
3 Bolts M6x75
Washers 6.4x12x1.5
2 pcs
2 pcs
TIGHTENING TORQUE
9 Nm
1
2
B30168

1HSB535409-100 en rev2 23
4.8 Catch gear
The operating mechanism is fitted as standard with a closing magnet and two
opening magnets, but can, on request, be equipped with double magnets on the
closing side.
Figure 4-17. Catch gear
Check and clean the shafts in the catch gear.
Lubricate these with Grease L at an interval of 15 years or 2000 operations.
Check that the voltage to the magnets does not fall below the minimum
voltage, see the delivery document for the operating mechanism.
Check the play between the magnet arms and the auxiliary catch. The play can
be at least . 1 mm. If the play is outside the stated measurement the entire catch
gear should be replaced.
Figure 4-18. Checking the play.
Item
1 Open catch gear
2 Close catch gear
Item
1 Auxiliary catch
2 Magnet arm
2
1
B30204
1 mm
1
2
B20013
24 1HSB535409-100 en rev2
4.8.1 Replacing the Open or Close catch gear
1. Loosen the bolts (1).
2. Replace the complete Close or Open catch gear
3. Tighten the bolts (1) with a tightening torque 40 Nm and lock with Loctite 242,
ABB Art. No. 1269 0014-410.24
Figure 4-19. Replacing the catch gear.
Item
1 Bolts M8x70 3 pcs
1
1
1
B30062
TIGHTENING TORQUE
40 Nm
1HSB535409-100 en rev2 25
4.9 Dashpot
The operating mechanism is fitted with a dashpot to dampen the final phase of the
opening movement.
Figure 4-20. Dashpot
The oil level should be up to the mark. If necessary, fill up with oil S.
Item
1 Dashpot
1
B30063
26 1HSB535409-100 en rev2
4.10 Limit switch with auxiliary contact
The operating mechanism is fitted as standard with a 12 pole auxiliary contact
consisting of twelve opening and 12 closing contacts. Three closing contacts and
three opening contacts are used for the functioning of the operating mechanism.
The auxiliary contact shaft is in direct connection with the operating lever in the
operating mechanism and accordingly follows the movement of the circuit-breaker
contacts.
Figure 4-21. Limit switch with auxiliary contact.
After 15 years or 2000 operations,check the contact movement by measuring the
times and compare the results with those obtained during commissioning. The
comparison can then be used to check the condition of:
Contact movement
Contact damping.
Item
1 Limit switch
2 Auxiliary contact
2
1
B30200
1HSB535409-100 en rev2 27
1. Connect a time-meter across the signal contacts 10, 19, 121 and 122 in
accordance with the circuit diagram.
2. Measure the times t
1
, t
2
and t
3

3. Turn the switch Local/Remote to the LOCAL position.
4. Connect the time-meter across terminals X1:190 and X1:192.
5. Turn the switch Close/Open to OPEN and then to the CLOSED position.
6. Note down the times t
1
, t
2
and t
3.
7. Disconnect the time-meter.
8. Turn the switch Local/Remote to the REMOTE position.
Figure 4-22. Time measurement, contact movement.
Contact movement
Arcing contact
Closed
Auxiliary contact
Open
t
2
t
3
t
1
Time
t
1
ms Proportional to the contacts opening speed.
t
2
ms Time that determines contact damping.
t
3
ms Proportional to the contacts closing speed.
B20018
Contact
movement
28 1HSB535409-100 en rev2
4.11 Terminal blocks
Check all screws and pins.
Figure 4-23. Electrical equipment.
Item
1 Opening coil
2 Closing coil
3 Motor
5 Operating switch Close/Open
6 Electric counter
7 Limit contact
8 Auxiliary contact
9 Anti-condensation heater
10 Anti pumping relay
11 Interlock relay
12 Interlock relay
13 Motor contactor
14 Motor protection
15 Miniature switch, heater
10
11
12
13
14 15 6
1
2
3
5 4
7
8
9
B30205
1HSB535409-100 en rev2
0005
ABB Switchgear AB
Head office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
ABB Switchgear
SF
6
mechanism BLK 222
1-pole operation
1HSB435409-200 enrev1
Overhaul Instructions
ABB Switchgear AB
Date: 2000-09-05
1HSB435409-200 enrev1 i
LIST OF CONTENTS
1. General ............................................................................... 1
2. Safety................................................................................... 3
2.1 Warning text ................................................................................... 3
2.2 Safety directives ............................................................................. 4
3. Overhaul, general ............................................................... 7
3.1 Tools............................................................................................... 7
3.2 Gas handling equipment................................................................. 7
3.3 Personal safety equipment.............................................................. 7
3.4 Cleaning equipment ....................................................................... 7
3.5 Spare parts...................................................................................... 8
3.6 Test equipment ............................................................................... 8
3.7 Premises ......................................................................................... 8
4. Dismantling the circuit-breaker......................................... 9
4.1 General ........................................................................................... 9
4.2 Gas................................................................................................ 10
4.3 Cleaning and waste handling ....................................................... 11
4.4 Dismantling the circuit-breaker pole for transport....................... 12
5. Dismantling the circuit-breaker pole .............................. 13
5.1 Dismantling the tripping mechanisms pull-rod........................... 13
5.2 Removing the breaking unit ......................................................... 14
5.3 Removing the post insulator......................................................... 15
5.4 Dismantling the breaking unit ...................................................... 16
6. Contact and Auto-PufferTM replacement....................... 17
6.1 Inspection of the upper current path............................................. 17
6.2 Inspection of the Auto-PufferTM................................................. 18
6.3 Inspection of the lower current path............................................. 19
7. Overhaul of the mechanism............................................ 21
8. Assembling the circuit-breaker pole .............................. 23
8.1 Treatment of contact surfaces ...................................................... 23
8.2 Treatment of sealing surfaces and seals ....................................... 24
8.3 Assembling the breaking unit....................................................... 25
8.4 Assembling the post insulator ...................................................... 26
8.5 Assembling the circuit-breaker pole ............................................ 27
8.6 Gas lling ..................................................................................... 28
8.7 Assembling the tripping mechanisms pull-rod on the operating
lever .............................................................................................. 29
9. Dismantling the breaking unit for transport ................... 31
9.1 Assembling the breaking unit after an overhaul ........................... 32
10.Assembling the circuit-breaker and commissioning.... 35
1HSB435409-200 enrev1 iii
FIGURES
Figure 4-1. Dismantling the circuit-breaker pole .............................................12
Figure 5-1. Dismantling the pull-rod ...............................................................13
Figure 5-2. Removing the breaking unit ..........................................................14
Figure 5-3. Removing the post insulator ..........................................................15
Figure 5-4. Dismantling the breaking unit .......................................................16
Figure 6-1. Upper current path .........................................................................17
Figure 6-2. Auto-PufferTM..............................................................................18
Figure 6-3. Lower current path ........................................................................19
Figure 7-1. Mechanism housing ......................................................................21
Figure 8-1. Assembling the breaking unit ........................................................25
Figure 8-2. Assembling the post insulator .......................................................26
Figure 8-3. Assembling the circuit-breaker pole .............................................27
Figure 8-4. Assembling the tripping mechanisms pull-rod on the operating
lever. ..............................................................................................29
Figure 9-1. Dismantling the breaking unit .......................................................31
Figure 9-2. Fitting the breaking unit ................................................................33
Figure 9-3. Mechanism housings sign. ...........................................................34
Overhaul Instructions General
1HSB435409-200 enrev1 1
1. General
This Overhaul Manual applies to the SF
6
circuit-breaker type LTB 245E1, 1- pole
operation. This Manual contains information for overhaul and repair work.
Overhaul and repair work may only be carried out by technicians trained by
ABB Switchgear AB.
Overhaul Instructions Safety
1HSB435409-200 enrev1 3
2. Safety
2.1 Warning text
observed extra carefully. The warning texts are marked as set out below:
DANGER
WARNING
CAUTION
indicates a hazardous situation that can result in minor or moderate
injury.
Safety Overhaul Instructions
4 1HSB435409-200 enrev1
2.2 Safety directives
WARNING
Circuit-breaker with pressurised porcelain insulators.
Mechanical damage on the porcelain can cause it to explode with the
Work on the circuit-breaker that brings about the risk of mechanical
0.125 MPa (abs).
WARNING
and trimmed with the associated pressurised circuit-breaker.
The standard operating cycle is O - 0.3 s - CO - 3 min.-CO. The time between
closing operations should not be under 1 minute during the testing of circuit-
Overhaul Instructions Safety
1HSB435409-200 enrev1 5
WARNING
Work requires training and product knowledge and may only be carried
out by authorised personnel.
Risk Measure
Working close to high voltage. Isolate and earth close to the work-
place. If work must take place close
to live installation components, the
safety distance applying in the
countrys applicable safety
regulations must be observed.
Working on ladders and platforms. Work shall take place in accordance
with applicable safety regulations in
the country concerned. Difcult
weather conditions that require short
shifts with a great deal of climbing on
ladders and platforms should be
avoided.
Working with low voltage.
Both Alternating and Direct Current
can be routed to the operating
mechanism.
Switch of the control voltage and if
necessary the heating voltage.
Risk of crushing in the operating
mechanism and link system.
There is stored energy in both the
closing and opening springs. The
mechanism can be tripped by heavy
vibrations of by unintentional contact
with the mechanical latch
components.
Operate the breaker to the open
position. Isolate and earth the high-
voltage side. Unload the springs by
switching off the motor current and
perform an Close-Open operation or
move the operating mechanisms
drive shaft backwards by hand (see
the Product Information for the
operating mechanism). For reasons
of safety the closing springs must be
unloaded during transportation as
well as during assembly and storage.
Working close to pressurised
insulators.
The normal working pressure is up to
0.8 MPa. Damage to the porcelain
can result in splintering.
Working close to the circuit-
breakers insulators that may result in
damage to the porcelain, must not be
carried out until the gas has been
emptied to max. 0.125 MPa (abs.)
pressure.
Overhaul Instructions Overhaul, general
1HSB435409-200 enrev1 7
3. Overhaul, general
All requisite equipment and spare parts should be on hand, before work is started, to
ensure that the overhaul is carried out under the best possible conditions.
The following equipment is required.
3.1 Tools
A standard tool kit with torque wrenches (10-100 Nm).
Lifting devices and lifting slings. The weights of the circuit-breaker parts to be
lifted can be found on the applicable dimension drawing for the order.
3.2 Gas handling equipment
Gas handling equipment for evacuating, cleaning, compressing and storing the used
SF
6
gas as well as instruments for monitoring the pressure and vacuum.
3.3 Personal safety equipment
Full face mask with lter for ne particles and acidic gases.
Long-sleeved overalls.
Protective gloves of plastic or rubber.
3.4 Cleaning equipment
Vacuum cleaner with micro-lter and plastic nozzle.
Drying cloths of a lint-free material.
Sealed storage containers for waste products and used absorption lter.
Wire brush for contact surfaces of aluminium.
Cleaning pad, e.g. Scotch Brite, for contact surfaces of copper.
Industrial alcohol 95% (vol), C
2
H
5
OH, for cleaning inside surfaces.
Heavy-duty plastic sheet and plastic bags to prevent the ingress of moisture and
to protect cleaned components before assembly.
Overhaul, general Overhaul Instructions
8 1HSB435409-200 enrev1
3.5 Spare parts
Contact set
1
Set of seals
1
Absorption agent
1
Lubricants, see Lubricants, 1HSB445409-1 for supplier and trade names
Grease G: ABB art. No. 1171 4014-407
Grease N: ABB art. No. 1171 4016-607
Grease S: ABB art. No. 1171 4014-406
Grease P: ABB art. No. 1171 5011-102.
Anti-corrosion agent
Valvoline Tectyl 506, ABB art. No. 1241 0011-108.
Locking uid
Loctite 243, ABB art. No. 12690014-429.
SF
6
gas.
Protective cover for the breaking unit, ABB art. No.1HSB445237-1.
Protective cover for post insulator, ABB art. No. 5439 142-A.
3.6 Test equipment
Equipment to record attenuation curves on the operating mechanism.
(e.g. Programma or ABB SA10)
Operating time meter.
Ohmmeter.
Leak detector.
3.7 Premises
The circuit- breaker or breaking units must be opened indoors in a dry and clean
premises.
When the weather is good and settled and outdoor working conditions are similar to
indoor conditions, the breaking units can be removed outdoors and transported to
dry and clean premises for the overhaul.
N.B. Under no circumstances may the breaking unit be removed or dismantled
during rain or other unsettled weather conditions, nor when the relative
humidity is 80% or higher.
1. According to the spare parts lists for the circuit-breaker in question.
Overhaul Instructions Dismantling the circuit-breaker
1HSB435409-200 enrev1 9
4. Dismantling the circuit-breaker
4.1 General
The instructions in the Operating and Maintenance Manual 1HSB435409-100
should be read and observed before the circuit-breaker is dismantled and during the
overhaul:
Check and note down the circuit-breakers operating values before dismantling.
Any deviations from the recommended values indicate that something must be
checked with special care during the overhaul.
The overhaul can take place in two different ways:
First and foremost it is recommended that the entire circuit-breaker is
dismantled for transport to a service workshop, where it can be dismantled in
detail for an overhaul.
Alternatively, and secondly, only the breaking unit is dismantled.
The latter method does not entail so much work, but may only be used when the
weather is settled and the outdoor working conditions are similar to indoor
conditions.
N.B. Removal and assembly of the breaking unit must not be done when the
weather is such that there is a risk of rain.
WARNING
The work requires trained staff with product knowledge and may only be
carried out by authorised personnel.
4.1.1 Preparations for the overhaul
The following must be done before starting the overhaul:
Operate the circuit-breaker to Open position.
Isolate and earth.
Off-load the operating mechanisms spring battery by switching off the motor
current and implementing a Close-Open operation.
Switch off the control voltage and, if necessary, also the heater power.
Dismantling the circuit-breaker Overhaul Instructions
10 1HSB435409-200 enrev1
4.2 Gas
Work on the circuit-breakers insulators or live components as well as transport and
dismantling of complete circuit-breaker poles fromthe frame, may not be done until
the gas has been evacuated to a pressure of max. 0.125 MPa (abs).
Gas shall be emptied fully to atmospheric pressure, when a normal pressurised
space, e.g. a breaking unit, shall be opened.
WARNING
If nitrogen, in those cases where nitrogen is used for cleaning the inside of
the circuit-breaker, is to be emptied into the free air, this shall be done
through a particle and absorption lter. Emptying shall take place
outdoors and at ground level.
WARNING
Unused SF
6
gas is non-toxic, odourless and colourless. It is heavier than
air and can therefore easily collect in low-lying places, e.g. cable trenches,
tanks, etc., if released in larger volumes.
When large quantities of SF
6
gas collect in such places, a risk of
asphyxiation may occur due to lack of oxygen.
4.2.1 Emptying the gas
The SF
6
gas is evacuated and the circuit-breaker should be vacuum pumped using
the gas handling equipment, which cleans and compresses the gas so that it can be
reused or destructed.
After a vacuum has been pumped in the circuit-breaker, it is lled with dry nitrogen
at atmospheric pressure and then vacuum pumped again. In this way freely oating
dust is extracted from the circuit-breaker.
Finally, the circuit-breaker is lled again with dry nitrogen to atmospheric pressure.
The circuit-breaker is now ready for dismantling.
Overhaul Instructions Dismantling the circuit-breaker
1HSB435409-200 enrev1 11
4.3 Cleaning and waste handling
CAUTION
Some decomposition products formed in the breaking unit can, when
coming in contact with moisture, become corrosive and can irritate the
skin, eyes and mucous membranes.
Protective gloves of plastic or rubber, long-sleeved overall and a full face mask with
a ne particle and acidic gas lter must be worn during the cleaning of the inside of
the circuit-breaker.
The dust (decomposition products) that forms in the circuit-breaker can be removed
using a vacuum cleaner tted with a micro-lter and wiped off using a soft cloth
dampened with alcohol.
N.B. All dust, old absorption agent, used cloths, etc., should be collected in a
sealed vessel and treated as chemical waste according to applicable local
directives.
Protective gloves must be worn during all waste handling.
N.B. Protective gloves should be rinsed thoroughly in water after waste handling.
Dismantling the circuit-breaker Overhaul Instructions
12 1HSB435409-200 enrev1
4.4 Dismantling the circuit-breaker pole for transport
Before the circuit-breaker pole is dismantled, the circuit-breaker must be taken out
of service, see Chapter 4.1.1, and the gas emptied, see Chapter 4.2.1. The density
monitor must be dismantled and the sealing cap (1) tted to the non-return valve (2).
1. Dismantle the pull-rod between the operating mechanism and the circuit-
breaker
2. Place a lifting sling under the breaking units upper ange as shown in
Figure 4-1 and prepare to lift with a crane. Now loosen the circuit-breaker pole
(5), removing the four bolts (3) on the frame and the four bolts (4) on the
protective pipe.
3. Lift up the circuit-breaker pole
and carefully lay it down on a
transport carriage. Block up the
circuit-breaker pole so it lies
horizontal. The bottom of the
transport crate can be used. The
blocks (6) under the breaking
units insulator should be of an
elastic material, e.g. wood or
rubber.
N.B. If possible, keep the supports,
supplied on delivery, for this
purpose.
Transport to the workshop or a new
site should take place with care so as
not to damage the insulators.
Figure 4-1. Dismantling the circuit-breaker pole
Item
1 Sealing cap
2 Non-return valve
3 Bolts M20x70
Nuts M20
Washers 21x36x3
4 pcs.
4 pcs.
8 pcs.
4 Bolts M12x50
Nuts M12
Washers 13x24x2.5
4 pcs.
4 pcs.
8 pcs.
5 Circuit-breaker pole
6 Blocks
1
2
B10055
4
3
6 6
5
Overhaul Instructions Dismantling the circuit-breaker pole
1HSB435409-200 enrev1 13
5. Dismantling the circuit-breaker pole
Set uo the circuit-breaker pole is tted vertically on a suitable frame, e.g. circuit-
breaker frame or a frame on the oor of the workshop.
5.1 Dismantling the tripping mechanisms pull-rod
1. Dismantle the protective cover (8) and clean the covers four ventilation slots.
2. Measure and note down a reference, e.g. Y, so that the opening spring (5) can
be retted to the same tension using nut (6) when reassembled.
Y=............. mm date...............
3. Ret the protective cover (8).
Figure 5-1. Dismantling the pull-rod
Item
1 Operating lever
2 Pin
3 Pull-rod
4 Spring housing
5 Opening spring
6 Nut
7 Lock nut
8 Protective cover
9 Bolts M8x20 4 pcs.
Y
7
2
1
3
4
5
6
B10056
9
8
Dismantling the circuit-breaker pole Overhaul Instructions
14 1HSB435409-200 enrev1
5.2 Removing the breaking unit
1. Fit the lifting sling from the top of the breaking unit to the crane or overhead
crane. Tension the lifting sling moderately.
2. Remove the bolts (1) between the post insulator (2) and the breaking unit (3).
3. Lift the breaking unit
75-100 mm.
4. Remove the circlip (4), washer
(5) and pin (6).
Set up the breaking unit vertically on
a suitable surface so that it does not
fall over.
Figure 5-2. Removing the breaking unit
Item
1 Bolts M12x35
Washers
13x24x2.5
8 pcs.
8 pcs.
2 Post insulator
3 Breaking unit
4 Circlips 2 pcs.
5 Washers 2 pcs.
6 Pin
5
4
6
1
B10057
2
3
Overhaul Instructions Dismantling the circuit-breaker pole
1HSB435409-200 enrev1 15
5.3 Removing the post insulator
Plan the work to remove the insulator so that it can be carried out quickly and
without long delays to prevent moisture in the air coming into lengthy contact with
the dust in the post and operating insulators.
N.B. Use personal safety equipment such as overalls, protective gloves and face
mask.
1. Position the lifting sling from the top of the post insulator to the crane or
overhead crane.
2. Remove the post insulators bolts (2) from the mechanism housing (3).
3. Lift the post insulator straight up until the operating insulator (7) is released.
Hold the operating insulator while lifting the post insulator.
N.B. Take care so as not to damage the operating insulator.
4. Remove the operating insulator (7) by removing the circlip (4), washer (5) and
pin (6).
5. Clean the operating insulator carefully and protect it using plastic sheet.
6. Clean the post insulator carefully, inside and outside, and protect it using
plastic sheet.
Figure 5-3. Removing the post insulator
Item
1 Post insulator
2 Bolts M16x50
Washers 17x30x3
8 pcs.
8 pcs.
3 Mechanism housing
4 Circlip
5 Washer
6 Pin
7 Operating insulator
4
6
5
1
3
B10058
2
7
Dismantling the circuit-breaker pole Overhaul Instructions
16 1HSB435409-200 enrev1
5.4 Dismantling the breaking unit
Plan the dismantling work so that it can be carried out quickly and without long
delays to prevent moisture in the air coming into lengthy contact with the dust in the
breaking unit and on the inside and outside of the breaking chamber insulator.
N.B. Use personal safety equipment such as overalls, protective gloves and face
mask.
Take care of the decomposition products, in the breaking unit, in the form of
powder, as the breaking unit is successively opened. First use a vacuum cleaner and
thereafter carefully wipe the dismantled components.
1. Remove the bolts (1) and cover (2) and lift out
the absorption agent container (3).
N.B. Place the bag with absorption agent in a
container for chemical waste.
2. Remove the bolts (4) and upper ange (5) with
the upper current path (6).
3. Remove the bolts (4) and breaking chamber
insulator (7) from the lower ange (8).
4. Rinse the inside of the breaking chamber
insulator with water.
Figure 5-4. Dismantling the breaking unit
The main components of the breaking unit are now accessible for inspection,
cleaning and replacement of burnt or damaged parts.
Item
1 Bolts M12x35
Washers 13x24x2,5
8 pcs.
8 pcs.
2 Cover
3 Absorption agent container
4 Bolts M12x50
Washers 13x24x2.5
16 pcs.
16 pcs.
5 Upper ange
6 Upper current path
7 Breaking chamber insulator
8 Lower ange
B10059
1
6
4
3 2
7
5
8
4
Overhaul Instructions Contact and Auto-PufferTM replacement
1HSB435409-200 enrev1 17
6. Contact and Auto-Puffer
TM
replacement
If the circuit-breaker is not going to be reassembled immediately after the cleaning
of the component parts, protect them against contamination and moisture by
packing them in plastic bags with a desiccant to absorb moisture.
The insulators are suitably protected by tying heavy-duty plastic sheet over the end
surfaces.
Check the upper and lower current paths and the Auto-Puffer
TM
as described below.
If any component is burnt or worn and is replaced, replace also the other
components at the same time.
6.1 Inspection of the upper current path
Replace the entire current path if the upper current paths xed arcing contact,
Figure 6-1, has been burnt so that the distance to the reference surface is more than
6 mm or if the outside surface has been severely burnt. Replace also the upper
current path if the silver on the current paths contacts is worn so that copper is
visible.
Tighten the bolts (2). Tightening torque 22.5 Nm.
Figure 6-1. Upper current path
Item.
1 Flange
2 Bolt M8x20
Retaining washer
Washer
3 Current path
4 Arcing contact
1
3
4
B10060
Reference surface
2
m
a
x
.
6

m
m
TIGHTENING TORQUE
22.5 Nm
Contact and Auto-PufferTM replacement Overhaul Instructions
18 1HSB435409-200 enrev1
6.2 Inspection of the Auto-Puffer
TM
Move the contact spring upwards from position a to b. Lift off the Auto-Puffer
TM
and check that the sliding surfaces on the pull-rod are not worn.
Check that the nozzle is not punctured. Also check that the contact surfaces on the
Auto-Puffer
TM
cylinder are not burnt or worn so that copper is visible.
Replace the entire Auto-Puffer
TM
if it has burnt or worn surfaces or if the nozzle has
been punctured.
Figure 6-2. Auto-Puffer
TM
Item
1 Nozzle
2 Pull-rod
3 Auto-Puffer
TM
cylinder
4 Bolt M8x16
5 Contact springs
1
2
Contact surface
3
B10061
4
5
Contact surface
b
a
TIGHTENING TORQUE
22.5 Nm
Overhaul Instructions Contact and Auto-PufferTM replacement
1HSB435409-200 enrev1 19
6.3 Inspection of the lower current path
Check that the lower current paths sealing ring (5), Teon band (4) and
guide bush (6) are not worn. Also check that the valve washer (7) is at and seals.
Check that the silver on the lower current path is not worn so that copper is visible.
If there are signs of wear, replace the lower current path.
Tighten the bolts (2). Tightening torque 22.5 Nm.
Figure 6-3. Lower current path
Item
1 Flange
2 Bolt M8x20
Retaining washer
Washer
3 Current path
4 Teon band
5 Sealing ring
6 Guide bush
7 Valve washer 2
1
3
5
7
4
B10062
6
TIGHTENING TORQUE
22.5 Nm
Overhaul Instructions Overhaul of the mechanism
1HSB435409-200 enrev1 21
7. Overhaul of the mechanism
Clean the mechanism housing using a vacuum cleaner and then wipe it. Inspect and
lubricate the bearings and sealing rings.
Protect untreated or manganese phosphated steel outside the gas chamber using
Valvoline Tectyl 506, ABB art. No. 1241 0011-108.
1. The operating shaft (2) is journalled on a large ball-bearing (4) on the outside
of the gas chamber. The bearing is visible for inspection and lubrication when
the operating lever (3) and circlip (5) are dismantled.
2. Pull the operating shaft (2) out of the mechanism housing and remove the ball-
bearing (4) from the shaft.
3. Lubricate the ball-bearing (4)
with grease G.
4. Remove the bushing (6) that
holds the sealing rings in
position by means of the two
bolts (M5), which are screwed
into the holes at the end of the
bushing. Replace the sealing
rings (7, 8) in the bushing
behind the ball-bearing and
lubricate with grease S.
5. Check that the ball-bearing (9)
rotates easily.
Figure 7-1. Mechanism housing
Item
1 Mechanism housing
2 Operating shaft
3 Operating lever
4 Ball-bearing
5 Circlip
6 Bushing
7 X-ring 69.2x5.7
8 O-ring 89.1x5.7
9 Ball-bearing
Inner mechanism
1
2
Outer mechanism
3
Bearings and O-rings
9
7
5
4
8
B10027
6
2
Overhaul Instructions Assembling the circuit-breaker pole
1HSB435409-200 enrev1 23
8. Assembling the circuit-breaker pole
To re-assemble the breaking unit follow the dismantling instructions in the reverse
order, see Chapter 5.
N.B. When re-assembling the breaking unit, all sealing rings must be new. Careful
cleaning and treatment of the sealing surfaces is required.
8.1 Treatment of contact surfaces
Before re-assembling the breaking unit, treat the contact surfaces as follows:
8.1.1 Fixed contact surfaces
Silver-plated:
If necessary, clean silver-plated contact surfaces, using a soft cloth and solvent
(alcohol).
N.B. Polishing using Scotch Brite or grinding must not take place.
Copper surfaces
Copper surface must be clean and free from oxide. If necessary, clean with a
polishing cloth, e.g. Scotch Brite.
N.B. After cleaning with Scotch Brite always remove all loose particles from the
surfaces using alcohol.
Aluminium surfaces
Brush clean contact surfaces of aluminium, using a wire brush. Immediately
thereafter carefully clean the surfaces to remove any loose particles with a dry,
clean cloth.. Then coat the surfaces with a thin layer of Vaseline, grease P
(ABB art. No. 1171 5011-102).
N.B. Grease should be applied within ve minutes of cleaning and the joint should
be tted within 15 minutes.
8.1.2 Moving contact surfaces
Silver-plated:
If necessary, clean silver-plated movable contact surfaces, using a soft cloth
and solvent (alcohol).
Lubrication:
Apply grease N (ABB art. No. 1171 4016-607) in a covering, but very thin
layer to the lower current paths silver-plated section, the upper current paths
contact surfaces and the Auto-Puffer
TM
cylinders contact surfaces. Carefully
wipe off all excess grease.
Assembling the circuit-breaker pole Overhaul Instructions
24 1HSB435409-200 enrev1
8.2 Treatment of sealing surfaces and seals
Clean, degrease and inspect all sealing surfaces in connection with the assembly.
N.B. Sealing grooves and other sealing surfaces must not have lateral scratches.
Any small scratches on sealing surfaces can be removed by polishing with a
ne abrasive, e.g. Scotch Brite. Polishing shall take place along the sealing
line and never across this.
When re-assembling the circuit-breaker, replace all seals with new seals.
Lubricate sealing surfaces and seals sparingly to facilitate the seals union against
the surface and as corrosion protection. Excess grease that can squeeze out on
anges in the gas chamber must not occur.
Coat ange surfaces outside the seal with a thin, well-covering layer of anti-
corrosion agent matched to the ange material in question, usually Grease G
(ABB art.No. 1171 4014-407).
Degreasing and cleaning material:
Alcohol.
Lubricating material for seals:
Grease G for static seals
Grease S for moving seals, e.g. shaft seals.
1HSB435409-200 enrev1 25
8.3 Assembling the breaking unit
1. Fit the Auto-Puffer
TM
(1) on the lower current path (2). When the Auto-
Puffer
TM
starts to go down over the Teon band, carefully turn it so that the
Teon band or the Auto-Puffer
TM
cylinders ngers are not damaged.
2. Place the sealing ring on the lower ange (4) and lift on the breaking chamber
insulator (5). Centre it and tighten the bolts (6) to 60 Nm.
3. Fit the upper current path (7) with the
sealing ring in the breaking chamber
insulator (5). Centre the current path in
relation to the Auto-Puffer
TM
(1). Tighten
the bolts (6) to 60 Nm.
First a new absorption agent container in
connection with the assembly of the breaking unit
on the post insulator, see Chapter 8.5.
Figure 8-1. Assembling the breaking unit
Item
1 Auto-Puffer
TM
2 Lower current path
3 Bolt M8x20
Retaining washer
Washer
4 Lower ange
5 Breaking chamber insulator
6 Bolt M12x50
Washer 13x24x2.5
7 Upper current path
TIGHTENING TORQUE
60 Nm
7
5
1
3
2
B10063 4
8
6
TIGHTENING TORQUE
60 Nm
26 1HSB435409-200 enrev1
8.4 Assembling the post insulator
1. Turn the operating lever (1) and link (2) over the edge of the mechanism
housing and t the operating insulator (3) using pin (4), washer (5) and circlip
(6).
N.B. Fit the pin so that the circlip (6) faces towards the large bearing.
2. Place the sealing ring on the mechanism housing (9), lift on the post insulator
(7) and tighten the bolts (8) with the tightening torque 79 Nm.
Figure 8-2. Assembling the post insulator
Item
1 Operating lever
2 Link
4 Pin
5 Washer
6 Circlip
7 Post insulator
8 Bolts M16x50
Washers 17x30x3
8 pcs.
8 pcs.
9 Mechanism
housing
TIGHTENING TORQUE
79 Nm
B10064
6
8
9
4
1
7
5
3
2
1HSB435409-200 enrev1 27
8.5 Assembling the circuit-breaker pole
1. Suspend the breaking unit in the lifting sling and pull out the Auto-Puffer
TM
so
that the pull-rod (1) is accessible for assembly.
2. Carefully clean the sealing surface for the sealing ring on the post insulator (2).
Also clean the lower ange (3) and lubricate well using grease G so that the
sealing ring is held in place during the assembly. Place the sealing ring in its
slot.
3. Slowly lower the breaking unit so that it comes into position to t the pin,
approx. 75-100 mm above the post insulator.
4. Connect the Auto-Puffer
TM
s
pull -rod (1) to the operating
insulator using pin (4), washer
(5) and circlip (6).
Figure 8-3. Assembling the circuit-breaker pole
Item
1 Pull-rod
2 Post insulator
3 Lower ange
4 Pin
5 Washers 2 pcs.
6 Ciirclips 2 pcs.
7 Bolts M12x35
Washers 13x24x2.5
8 pcs.
8 pcs.
8 Upper ange
9 Cover
B10065
1
5
4 3
2
7
6
8
10
9
7
28 1HSB435409-200 enrev1
5. When the pin is tted, lower the breaking unit carefully onto the post insulator
and centre it. Tighten the breaking unit using the bolts (7) with the tightening
torque 60 Nm.
6. Clean the sealing surface on the upper ange (8) and coat with grease G.
Place the sealing ring on top of the upper ange.
7. Open the new absorption agent package and place the agent in the absorption
agent container (10).
8. Fit the absorption agent container (10) and the cover (9) and tighten the bolts
(7) with the tightening torque 45 Nm.
N.B. Put on the cover immediately after the absorption agent container has been
tted.
8.6 Gas lling
Vacuum-pump down to 100 Pa and let the vacuum pumping continue for at
least one hour after this pressure has been reached.
Stop the vacuum pumping and ll the circuit-breaker with dry and pure
nitrogen to atmospheric pressure. Allow it to stand for a few hours or
overnight.
Vacuum-pump again down to 100 Pa and ll with pure SF
6
gas to
0.125 MPa (abs).
Store the lling hoses so that they are not exposed to moisture or contamination.
They must not be used other than for their intended purpose.
TIGHTENING TORQUE
60 Nm
TIGHTENING TORQUE
45 Nm
1HSB435409-200 enrev1 29
8.7 Assembling the tripping mechanisms pull-rod on the operating lever
1. Turn the operating lever (1) anticlockwise towards the open position and
connect it to the pull-rod (3) using the pin (2).
2. Remove the protective cover (8).
3. If the nut (6) has moved out of position adjust it to the dimension Y, see
Chapter 5.1.
4. Tighten the lock nut (7) to 200 Nm and lock it using locking uid, ABB art.
No. 12690014-410 (Loctite 242).
5. Ret the protective cover.
Figure 8-4. Assembling the tripping mechanisms pull-rod on the operating lever.
The circuit-breaker is now ready for transportation.
Item
1 Operating lever
2 Pin
3 Pull-rod
4 Spring housing
5 Opening spring
6 Nut
7 Lock nut
8 Protective cover
9 Bolts M8x20 4 pcs.
Y
6
2
1
3
4
5
7
B10056
9
8
Overhaul Instructions Dismantling the breaking unit for transport
1HSB435409-200 enrev1 31
9. Dismantling the breaking unit for transport
Dismantling of just the breaking unit for overhaul may only be carried out in good
and settled weather conditions and if the relative humidity does not exceed 80%.
1. Take the circuit-breaker out of service.
2. Empty the gas, see Chapter 4.2.1. Fill with nitrogen to atmospheric pressure.
3. Operate the circuit-breaker slowly towards the closed position by cranking the
operating mechanism by hand. This is described in the Overhaul Instructions
for the operating mechanism. Stop cranking when the dimension 230-235 mm
as set out in Figure 9-1 is reached. The coupling link with pin (1) on the
operating insulator (4) is now in the correct position for dismantling.
4. Place a lifting sling around the top section of the breaking unit and prepare to
lift.
5. Remove the bolts (5) and carefully lift the breaking unit (6) a maximum
of 70 mm.
N.B. Do not lift the breaking
unit must not be lifted
more than 70 mm so as
not to damage the
circuit-breakers
interior.
If a large amount of moisture
should enter the post insulator,
ll it immediately with
nitrogen gas and transport it to
a workshop as soon as possible
for dismantling and careful
cleaning.
Figure 9-1. Dismantling the breaking unit
Item
1 Pin
2 Washer
3 Circlip
5 Bolt M12x35
Washer 13x24x2.5
6 Breaking unit
7 Auto-Puffer
TM
pull-rod
8 Post insulator
B10066
2
1
3
4
5
6
230-235
8
7
Dismantling the breaking unit for transport Overhaul Instructions
32 1HSB435409-200 enrev1
6. Disconnect the breaking unit (6) by removing the circlip (3), washer (2) and
pin (1).
N.B. Ensure that neither the circlips nor the washers fall into the post insulator
during the dismantling. Cover the opening, for example, by tying a cloth over
it.
7. Fit the protective cover, ABB art. No. 5439 142-A, with the sealing ring over
the post insulator (8). When the cover has been bolted in position, increase the
nitrogen pressure in the post insulator to 0.125 MPa abs.
8. Slide the Auto-Puffer
TM
pull-rod (7) into the breaking unit (6) and t the
protective cover, ABB art. No. 1HSB445237-1, with the sealing ring.
The breaking unit is now ready for transport.
If the post insulator or breaking unit is left in this condition for a long period
without the breaking unit being re-assembled , the post insulator or breaking unit
should be vacuum-pumped and lled with nitrogen, see Chapter 8.6.
9.1 Assembling the breaking unit after an overhaul
1. Suspend the breaking unit and remove the post insulators protective cover,
ABB art. No. 1HSB445237-1, and pull out the Auto-Puffer
TM
so that the Auto-
Puffer
TM
pull-rod (7) is accessible for assembly.
2. Reduce the nitrogen pressure in the post insulator (8) to atmospheric pressure
and remove the protective cover.
3. Carefully clean the sealing surface of the sealing ring on the post insulator (8)
and coat with grease G. Fit the sealing ring in its slot.
4. Slowly lower the breaking unit (6) so that it sits in position for tting the pin,
approx. 60 - 70 mm above the post insulator.
5. Connect the Auto-Puffer
TM
s pull-rod (7) to the operating insulator (4) using
pin (1).
6. When the pin is tted, lower the breaking unit (6) carefully down towards the
post insulator (8) and centre it. Bolt the breaking unit in position using the bolts
(5), with the tightening torque 60 Nm.
7. Clean the upper ange (9) and coat with grease G. Place the sealing ring on
top of the upper ange.
8. Open the packaging of the new absorption agent and ll the agent in the
absorption agent container (12).
TIGHTENING TORQUE
60 Nm
Overhaul Instructions Dismantling the breaking unit for transport
1HSB435409-200 enrev1 33
9. Fit the absorption agent container (12) and the cover (10) and tighten the bolts
(11) with the tightening torque 45 Nm.
Figure 9-2. Fitting the breaking unit
10. Fill the circuit-breaker pole with gas.
a. Vacuum-pump down to 100 Pa and let the vacuum pumping continue for
at least one hour after this pressure has been reached.
b. Stop the vacuum-pumping and ll the circuit-breaker with dry and pure
nitrogen to atmospheric pressure. Allow it to stand for a few hours or
overnight.
c. Vacuum-pump again down to 100 Pa and ll with pure SF6 gas to
0.125 MPa (abs).
Store the lling hoses so that they are not exposed to moisture or contamination.
They must not be used other than for their intended purpose.
Item
1 Pin
2 Washer
3 Circlip
5 Bolt M12x 35
Washer 13x24x2.5
6 Breaking unit
7 Auto-Puffer
TM
pull-
rod
8 Post insulator
9 Upper ange
10 Cover
11 Bolt M12x35
Washer 13x24x2.5
12 Absorption agent
container
TIGHTENING TORQUE
45 Nm
230-235
2
3
4
7
1
10
11
12
9
6
5
8
B10067
Dismantling the breaking unit for transport Overhaul Instructions
34 1HSB435409-200 enrev1
11. Operate the circuit-breaker slowly towards the open position by cranking the
operating mechanism by hand and check that the alignment check hole,
D=6 mm, for the open position in the operating lever aligns with the hole in the
mechanism housing.
Figure 9-3. Mechanism housings sign.
A
B
A+B
Adjustment of pull-rod in OPEN POSITION
Correct contact position when holes A and B coincide
Check with pin, diameter D=6
Instllning av manverstng i FRN-LGE
Rtt kontaktlge nr hl A och B sammanfaller
Kontrollera med en pinne diameter D=6
B10032
Overhaul Instructions Assembling the circuit-breaker and commissioning
1HSB435409-200 enrev1 35
10. Assembling the circuit-breaker and commissioning
Assembling the circuit-breaker and commissioning are carried out in accordance
with applicable assembly instructions for the circuit-breaker in question.
After assembling the circuit-breaker, check and note down the operating values.
Check carried out on the:________________________________
First overhaul.
Check the following
Measured values
Close-Open times
(1)
(1) The circuit-breaker must not be operated Open-Close without an intermediate delay of 300 ms.
ms ms ms
Lowest control voltage to coil I V V V
Lowest control voltage to coil II V V V
Lowest control voltage from coil I V V V
Lowest control voltage from coil II V V V
Filling pressure
(2)
(2) Filling pressure according to rating plate.
Assembling the circuit-breaker and commissioning Overhaul Instructions
36 1HSB435409-200 enrev1
Check carried out on the:________________________________
Second overhaul.
Check the following
Measured values
Close-Open times
(1)
(1) The circuit-breaker must not be operated Open-Close without an intermediate delay of 300 ms.
ms ms ms
Lowest control voltage to coil I V V V
Lowest control voltage to coil II V V V
Lowest control voltage from coil I V V V
Lowest control voltage from coil II V V V
Filling pressure
(2)
(2) Filling pressure according to rating plate.
1HSB435409-200 enrev1
0009
ABB Switchgear AB
Head Ofce
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
ABB Switchgear
SF
6
mechanism BLK 222
1-pole operation
1HSB435409-300 en0
Spare Parts
ABB Switchgear AB
Article number: 1HSB435409-300 en0
Date: 1997-10-01
Spare Parts
1HSB435409-300 en0 i
LIST OF CONTENTS
1. General ................................................................................ 1
1.1 Circuit-breaker pole ....................................................................... 2
2. Breaking mechanism......................................................... 3
2.1 Breaking mechanism...................................................................... 3
2.2 Contact set ...................................................................................... 4
3. Post insulator...................................................................... 5
4. Mechanism.......................................................................... 7
4.1 Mechanism..................................................................................... 7
4.2 Tripping mechanism....................................................................... 7
5. Accessories ........................................................................ 9
5.1 Absorption agent container ............................................................ 9
5.2 Density monitor.............................................................................. 9
5.3 Set of seals.................................................................................... 10
5.4 Assembly set ................................................................................ 10
5.5 Non-return valve .......................................................................... 10
6. Tools and lubricants......................................................... 11
6.1 Protective cover ............................................................................ 11
6.2 Lubricants..................................................................................... 11
Spare Parts
ii 1HSB435409-300 en0
FIGURES
Figure 1-1. Circuit-breaker pole. ....................................................................... 1
Figure 1-2. Circuit-breaker pole. ....................................................................... 2
Figure 2-1. Breaking unit. ................................................................................. 3
Figure 2-2. Contact set. ..................................................................................... 4
Figure 3-1. Post insulator. ................................................................................. 5
Figure 4-1. Mechanism housing. ....................................................................... 7
Figure 4-2. Tripping mechanism. ...................................................................... 7
Figure 5-1. Absorption agent container. ............................................................ 9
Figure 5-2. Density monitor. ............................................................................. 9
Figure 5-3. Non-return valve. .......................................................................... 10
Spare Parts General
1HSB435409-300 en0 1
1. General
Spare parts for the SF
6
circuit-breaker LTB 245E1 with operating mechanism
BLK 222 are supplied by:
ABB Switchgear AB
Box 700
SE-771 80 Ludvika
Sweden
Tel: +46 (0) 240-78 20 00
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.
Figure 1-1. Circuit-breaker pole.
Please state the type designation and serial number with all enquiries and orders of
spare parts or tools. Please also state the order number if possible.
Item Designation Note
1 Circuit-breaker pole RRR
2 Operating
mechanism
RRR
3 Frame
2
3
1
B10034
General Spare Parts
2 1HSB435409-300 en0
1.1 Circuit-breaker pole
Figure 1-2. Circuit-breaker pole.
Please state the type designation and serial number with all enquiries and orders of spare
parts or tools. Please also state the order number if possible.
Item Designation
1 Breaking unit
2 Post insulator
3 Mechanism
4 Tripping mechanism
2
1
3
4
B10122
Spare Parts Breaking mechanism
1HSB435409-300 en0 3
2. Breaking mechanism
2.1 Breaking mechanism
Figure 2-1. Breaking unit.
Item Qty. Designation Note
1 1 Breaking chamber
insulator
RR
2 1 Upper current path Included in
contact set
3 1 Lower current path Included in
contact set
4 1 Puffer Included in
contact set
B10123
1
2
4
3
Breaking mechanism Spare Parts
4 1HSB435409-300 en0
2.2 Contact set
Figure 2-2. Contact set.
Qty. Designation Note
1 Contact set R
B10124
Spare Parts Post insulator
1HSB435409-300 en0 5
3. Post insulator
Figure 3-1. Post insulator.
1 1 Post insulator RR
2 1 Operating insulator RR
1
2
B10125
Spare Parts Mechanism
1HSB435409-300 en0 7
4. Mechanism
4.1 Mechanism
Figure 4-1. Mechanism housing.
4.2 Tripping mechanism
Figure 4-2. Tripping mechanism.
1 1 Mechanism RR
1 1 Tripping mechanism RR
1
B10012
1
B10126
Spare Parts Accessories
1HSB435409-300 en0 9
5. Accessories
5.1 Absorption agent container
Figure 5-1. Absorption agent container.
5.2 Density monitor
Figure 5-2. Density monitor.
1 1 Absorption agent
container
2 1 Absorption agent R
1 1 Density monitor,
temperature-
compensated - reference
volume
R
2 1 Density monitor,
temperature-
compensated - bimetal
R
1
2
B10127
1
B10052
2
Accessories Spare Parts
10 1HSB435409-300 en0
5.3 Set of seals
Set of seals for a complete circuit-breaker pole.
5.4 Assembly set
Set of bolts for a circuit-breaker pole.
Set of pins for a complete circuit-breaker pole.
5.5 Non-return valve
Figure 5-3. Non-return valve.
Qty. Designation Article number Note
1 Set of seals 1HSB436309-A R
1 Set of bolts 1HSB436309-B R
1 Pins with circlips 1HSB436309-C R
1 1 Non-return valve RR
1
B10053
Spare Parts Tools and lubricants
1HSB435409-300 en0 11
6. Tools and lubricants
6.1 Protective cover
6.2 Lubricants
6.2.1 Oil
6.2.2 Grease
Item Qty. Designation Article number Note
1 1 Protective cover for
breaking unit
1HSB445237-1 R
2 1 Protective cover for
post insulator
5439 142-A R
Oil Article number Note
A 1HSB875318-A
D 1HSB875318-B
S 1HSB875318-C
Grease Article number Note
G 5316 381-A
K 5316 381-M
N 5316 381-L
L 5316 381-H
M 5316 381-J
P 5316 381-N
S 5316 381-G
Sv 5316 381-C
1HSB435409-300 en0
9710
ABB Switchgear AB
Head Ofce
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
ABB Switchgear
SF
6
type BLK 222
1HSB535409-200 en rev1
Spare Parts
ABB Switchgear AB
Date: 2000-04-19
Spare Parts
1HSB535409-200 en rev1 i
LIST OF CONTENTS
1. General ................................................................................ 1
2. Motor ................................................................................... 3
3. Dashpot ............................................................................... 5
4. Catch gear........................................................................... 7
5. Heater element.................................................................... 9
6. Electrical equipment ........................................................ 11
7. Lubricants......................................................................... 13
7.1 Oil..................................................................................................13
7.2 Grease............................................................................................13
Spare Parts
FIGURES
Figure 1-1. Operating mechanism BLK 222. .................................................... 1
Figure 2-1. Motor. ............................................................................................. 3
Figure 3-1. Dashpot. .......................................................................................... 5
Figure 4-1. Catch gear. ...................................................................................... 7
Figure 5-1. Heater element. ............................................................................... 9
Figure 6-1. Electrical equipment, BLK 222. ....................................................11
Spare Parts General
1HSB535409-200 en rev1 1
1. General
Spare parts for the operating mechanism BLK 222 are supplied by:
ABB Switchgear AB
SE-771 80 Ludvika
Sweden
Tel: +46 (0) 240-78 20 00
Replacement modules are supplied complete and fully tested.
Please state the type designation and the serial number with all enquiries and orders
of spare parts. Please also state the order number if possible.

Figure 1-1. Operating mechanism BLK 222.
Item
1 Drive unit
3 Operating panel
4 Closing spring
5 Heater element
1 2
4
3
5
B30200
Spare Parts Motor
1HSB535409-200 en rev1 3
2. Motor
Figure 2-1. Motor.
Please state the type designation and the serial number with all enquiries and orders of spare
parts. Please also state the order number if possible.
Type of motor Article number
1 Motor, 220 -250 V AC/DC 1HSB534460-2
1 Motor, 110 -127 V AC/DC 1HSB534460-1
B30068
Spare Parts Dashpot
1HSB535409-200 en rev1 5
3. Dashpot
Figure 3-1. Dashpot.
Designation Article number
Dashpot 1HSB535256-C
30063
Spare Parts Catch gear
1HSB535409-200 en rev1 7
4. Catch gear
Figure 4-1. Catch gear.
Item Designation Article number
1 Closing catch gear 110 V 1HSB535436B5
220 V 1HSB535436B7
2 Closing coil 1, Y3 60-72 V LA 516 771-AX
3 Opening catch gear 110 V 1HSB535436B3
220 V 1HSB535436B8
4 Opening coil 1, Y1 220-250 V LA 516 771-AY
5 Opening coil 2, Y2 110-125 V LA 516 771-AL
Y2-A, Y2-B 220-250 V LA 516 771-AZ
Double opening coil 110-125 V LA 516 771-AU
3
1
5
4
2
B30062
Spare Parts Heater element
1HSB535409-200 en rev1 9
5. Heater element
Designation Voltage range Article number
Heater element 110-127 V, 70 W 5291 805-1
220-254 V, 70 W 5291 805-2
110-127 V, 140 W 5291 805-3
220-254 V, 140 W 5291 805-4
B30058
Spare Parts Electrical equipment
1HSB535409-200 en rev1 11
6. Electrical equipment
Spare parts for electrical equipment BLK 222
Figure 6-1. Electrical equipment, BLK 222.
Item Designation Voltage range Article number
1 Anti pumping 220-250 V DC 5619 758-1
relay 110-125 V DC 5619 758-2
2 Interlock relay 60-72 V DC 5619 758-3
3 Interlock relay 42-48 V DC 5619 758-4
4 Motor contactor 220-250 V DC 5351 749-1
110-125 V DC 5351 749-2
220-240 V AC 5351 749-3
5 Miniature switch 220-250 V DC 5344 027-40
(1)
(1) K4A 2-pole + auxiliary contact
Motor (MCB) 110-125 V 5344 027-41
(2)
(2) K8A 2-pole + auxiliary contact
6 Miniature switch
Heater (MCB)
110-254 V 5344 027-18
7 Counter 220-250 V DC 5692 965-1
110-125 V DC 5692 965-2
42-48 V DC 5692 965-3
1
2
3
4
5 6 7
B30209
Spare Parts Lubricants
1HSB535409-200 en rev1 13
7. Lubricants
7.1 Oil
7.2 Grease
Oil Article number
A 1HSB875318-A
D 1HSB875318-B
S 1HSB875318-C
Grease Article number
G 5316 381-A
K 5316 381-M
N 5316 381-L
L 5316 381-H
M 5316 381-J
P 5316 381-N
S 5316 381-G
SV 5316 381-C
1HSB535409-200 en rev1
0005
ABB Switchgear AB
Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928

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Product Manual

Inspection of reference holes in outer

15 years or 5,000 mechanical

Maintenance Operating Mechanism Maintenance

Maintenance Maintenance Operating Mechanism

Maintenance Operating Mechanism Maintenance

Maintenance Maintenance Operating Mechanism

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