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Product Manual
1HSB445416-14 en
HPL 245-550B2
BLG 1002A
1-pole operation
PRODUCT MANUAL
PRODUCT DESCRIPTION
- Circuit-Breaker
PRODUCT DESCRIPTION
- Operating Mechanism
ASSEMBLY INSTRUCTIONS
CHECKLIST
1
2
3
4
5
6
7
8
9
10
11
OPERATING AND MAINTENANCE

INSTRUCTIONS
LUBRICANTS
MAINTENANCE INSTRUCTIONS
OVERHAUL INSTRUCTIONS
- Circuit-Breaker
SPARE PARTS
- Circuit-Breaker
ABB Power Technology Products AB
S-771 80 LUDVIKA
SPARE PARTS
SF6 Circuit-Breaker
HPL 245-550B2 with operating

mechanism BLG 1002A
1-pole operation
Product Description
1HSB445455-14 en
ABB Power Technology Products
The information in this document is subject to alteration without prior notice and should not be regarded as an undertaking from ABB Power Technology Products AB. ABB Power Technology Products
AB takes no responsibility for errors that can occur in the documentation.
ABB Power Technology Products 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
Power Technology Products 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.
Article number: 1HSB445455-14 en

Date: 2002-04-04
Product Description
LIST OF CONTENTS
1. Description.......................................................................... 1
1.1
1.2
1.3
1.4
1HSB445455-14 en
Design of the circuit-breaker.......................................................... 1

The circuit-breakers gas system .................................................... 2
Operating mechanism..................................................................... 3
Standards ........................................................................................ 3
Product Description
FIGURES
Figure 1-1. Circuit-breaker type HPL 245-550B2 ............................................ 1

Figure 1-2. Circuit-breaker pole, Opening - Closing ........................................ 2
ii
1HSB445455-14 en
Description
Product Description
1. Description
High-voltage circuit-breaker HPL 245-550B2, with three operating mechanisms
type BLG 1002A.
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 a mechanism in an alloy housing, above this is hollow post
insulators through which the operating insulator runs and at the top is the breaking
unit.
Each breaking unit consists of two breaking chamber insulators, which together
with two flanges and an upper mechanism housing make up the enclosure, and
upper and lower current path with a contact system. The puffer runs in the lower
current path. The fixed contacts are integrated in the upper and lower current path.
In those cases where each pole contains several breaking units in series, the
breaking units can be connected in parallel with grading capacitors. 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.
Weights for component parts:

Item
Part
Weight, kg
Circuit-breaker
pole
See dimension
drawing
Operating
mechanism
465
Frame
86-200
1
2
B10068
Figure 1-1. Circuit-breaker type HPL 245-550B2
1HSB445455-14 en
Description
Product Description
1.2 The circuit-breakers gas system

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

On opening the puffer cylinder (1) is drawn downwards towards the fixed piston and
the enclosed gas is compressed and forced at a high velocity out through the nozzle
(2) and the arcing contacts (3).
1
3 2
Figure 1-2. Circuit-breaker pole, Opening - Closing

When the arcing contacts have separated an arc is produced which at high currents
obstructs the nozzle (2). When the current approaches the passage through zero, the
gas starts to flow out through the puffer cylinder. The specially designed nozzle
ensures that the gas flow is directed towards the arc. The gas is allowed to pass both
both down through the moving arcing contact and up passt the fixed arcing contact.
When the arc has been cooled, it is extinguished and the current is interrupted.
There are separate normal current contacts, which open before and close after the
arcing contacts. They are not affected by the arc on interrruption.
On closing, the puffer cylinder (1) slides upwards, the contacts engage one another
and the puffer cylinder is refilled with gas.
1HSB445455-14 en
Description
Product Description
1.3 Operating mechanism

The HPL circuit-breaker is operated by a motor-charged spring operating
mechanism type BLG.
The operating mechanism is connected to the poles mechanisms via a pull-rod
system.
The breaker is closed by means of the operating mechanism, which houses the
closing springs. On closing, the opening springs are tensioned, which are
permanently fixed to the poles mechanisms. The trip latch in the operating
mechanism keeps the breaker in the closed position. Opening of the circuit-breaker
only requires the release of the trip latch.
The normal operating cycle is:
O-0.3 s-CO-3 min-CO (according to IEC) or CO-15 s-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.
1HSB445455-14 en

Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax:
+46 (0) 240 714 928
1HSB445455-14 en
0204
SF6 Circuit-Breaker
Operating Mechanism
type BLG 1002A
Product Description
1HSB515432-100 en rev3
AB takes no responsibility for errors that can occur in the document.
document.
Power Technology Products AB. It may not either be imparted to a third party or otherwise be used without authorisation. Infringement hereof will be subject to action in accordance with applicable laws.
Article number: 1HSB515432-100 en rev3

Date: 2002-06-10
Product Description
LIST OF CONTENTS
1. Description.......................................................................... 1
1.1
1.2
1.3
Normal operating mode.................................................................. 2

Opening operation.......................................................................... 3
Closing operation ........................................................................... 4
2. Component units ................................................................ 5

2.1
2.2
2.3
2.4
2.5
2.6
1HSB515432-100 en rev3
Drive unit........................................................................................ 5
Mechanical interlock...................................................................... 5
Catch gear....................................................................................... 6
Dashpots......................................................................................... 6
Auxiliary contact............................................................................ 7
Heater element ............................................................................... 8
Product Description
FIGURES
Figure 1-1. Operating mechanism ..................................................................... 1

Figure 1-2. Normal operating mode. ................................................................. 2
Figure 1-3. Opening operation. ......................................................................... 3
Figure 1-4. Closing operation. .......................................................................... 4
Figure 2-1. Drive unit. ....................................................................................... 5
Figure 2-2. Interlocking mechanism. ................................................................ 5
Figure 2-3. Catch gear. ...................................................................................... 6
Figure 2-4. Closing and Opening dashpots. ...................................................... 6
Figure 2-5. Limit switch with auxiliary contact. ............................................... 7
Figure 2-6. Heater element. ............................................................................... 8
ii
1HSB515432-100 en rev 3
Description
Product Description
1. Description
The spring operating mechanism BLG 1002A is intended for operating a circuitbreaker with integrated opening springs. The opening springs are charged
automatically by the mechanism on closing of the circuit-breaker, whereby the
requisite energy for opening is obtained. Under no circumstances may the
mechanism be operated with the spring battery charged, without first being fitted
and trimmed with the associated circuit-breaker.
In principle the operating mechanism consists of a spring battery, which is charged
by a motor fitted with a worm gear, and a mechanism for actuating the opening and
closing action. The spring battery is automatically charged after each closing
operation.
The component parts of the operating mechanism are integrated in a cabinet, which
also contains a control panel with operating equipment. The top and doors of the
cabinet can be removed to facilitate service and overhaul procedures.
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 circuitbreakers and relay systems involving more than 3 closing operations.
2
1
Item
1
Drive unit
Operating
mechanism
Control panel
Spring battery
Heater element
4
5
3
B20001
Figure 1-1. Operating mechanism
1HSB515432-100 en rev3
Description
Product Description
1.1 Normal operating mode

During normal service the circuit-breaker is in the closed position. The opening
spring (14) on the circuit-breaker and the closing springs (7) in the operating
mechanism are charged. The circuit-breaker is kept in the closed position by the
operating mechanisms opening catch gear (1).
1
Item
1
Opening catch gear
Closing springs
14
Opening spring
14
B20028
Figure 1-2. Normal operating mode.
1HSB515432-100 en rev3
Description
Product Description
1.2 Opening operation

The latch in the opening catch gear (1) is released on opening of the circuit-breaker
(1). The opening spring (14) pulls, via the pull-rod (13), the operating lever (4) to
the left. The movement is damped by the opening dashpot (3) at the end position
before the operating lever (4) rests against the cam disc (5).
13
5
1
Item
1
Opening catch gear
Opening dashpot
Operating lever
Cam disc
13
Pull-rod
14
Opening spring
14
B20029
Figure 1-3. Opening operation.
1HSB515432-100 en rev3
Description
Product Description
1.3 Closing operation

On closing of the circuit-breaker, the latch is released in the closing catch gear (2).
The chain section (17) is released and transfers the closing springs (7) energy to the
cam disc (5). The cam disc rotates 360 clockwise and pulls the operating lever (4)
to the right until the opening catch gear (1) engages. The movement is damped in
the end position by the closing dashpot (12). The opening spring (14) is charged via
the pull-rod (13).
The chain section (18) travels up the same path as the chain section (17) travels
down.
13
2
1
Item
1
Opening catch gear
Closing catch gear
Operating lever
Cam disc
Closing springs
12
Closing dashpot
13
Pull-rod
14
Opening spring
17
Chain section
18
Chain section
14
17
18
12
B20031
Figure 1-4. Closing operation.
1HSB515432-100 en rev3
Component units
Product Description
2. Component units
2.1 Drive unit
The drive unit is supplied with one or two motor options for 60, 110 or 220 V DC
and 50, 60 Hz AC.
The motor should be able to charge the springs at 85% of the nominal voltage (IEC).
Item
1
Drive unit
1
B20031
Figure 2-1. Drive unit.
2.2 Mechanical interlock

The interlocking mechanism prevents a closing operation from being carried out if
the circuit-breaker is already in the closed position or if the operating mechanisms
closing springs are uncharged or not fully charged, which can occur, for example, if
the closing catch gear is opened by hand or if a mechanical fault occurs in the catch
gear.
1
2
Item
1
Limit switch
Interlocking lever
Interlocking disc
Cam disc
Operating rod
Operating lever shaft

B20007
Figure 2-2. Interlocking mechanism.
1HSB515432-100 en rev3
Component units
Product Description
2.3 Catch gear

The operating mechanism is fitted as standard with one closing coil and two
opening coils, but on request can be equipped with double coils on the closing side.
The standard voltage of the coil is 110, 220 V DC or AC, but other voltages may
occur.
The rated output of the coils is 200 W as standard. As an option there are coils with
a rated output of 450 W when 2-cycle interruption at 60 Hz is demanded.
Item
1
Catch gear
B20034
Figure 2-3. Catch gear.
2.4 Dashpots
The operating mechanism is equipped with one Closing dashpot to brake the
rotating movement of the cam disc and one Opening dashpot to dampen the final
phase of the opening movement.
Item
1
Closing dashpot
Opening dashpot
1
2
B20024
Figure 2-4. Closing and Opening dashpots.
1HSB515432-100 en rev3
Component units
Product Description
2.5 Auxiliary contact

The operating mechanism is equipped as standard with a 6-pole auxiliary contact
consisting of six opening and six closing contacts. Three closing and one opening
contact are used for the functioning of the operating mechanism. There is a
possibility of supplementing with six or twelve extra contacts.
The shaft of the auxiliary contact is in direct connection with the operating
mechanisms operating lever and accordingly follows the movement of the breaker
contacts.
Item
1
Limit switch
Auxiliary contact
B20035
Figure 2-5. Limit switch with auxiliary contact.
1HSB515432-100 en rev3
Component units
Product Description
2.6 Heater element

The operating mechanism is equipped with a heater element to prevent
condensation from forming and should always be connected.
Item
1
Heater element
6 5 4
3 2
B20036
Figure 2-6. Heater element.
1HSB515432-100 en rev3

Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax:
+46 (0) 240 714 928
1HSB515432-100 en rev3
0206
SF6 Circuit-Breaker
HPL 245-550B2 with

operating mechanism
BLG 1002A
1-pole operation
Assembly Instructions
1HSB445410-14 en
document.

Date: 2002-04-05
LIST OF CONTENTS
1. General ................................................................................ 1
2. Safety................................................................................... 3
2.1
2.2
Warning text ................................................................................... 3

Safety, general ................................................................................ 4
3. Delivery ............................................................................... 5
3.1
3.2
3.3
Weights........................................................................................... 5
Unpacking ...................................................................................... 6
Storage before assembly ................................................................ 7
4. Assembly............................................................................. 9
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
Preparations.................................................................................... 9
Frame assembly............................................................................ 11
Assembling the frame on the foundation ..................................... 12
Assembling the post insulator on the frame................................. 13
Preparations for assembling the operating mechanism................ 14
Assembly of corona ring .............................................................. 15
Assembling the operating mechanism ......................................... 16
Final assembly of the post insulator............................................. 17
Assembling the breaking unit....................................................... 18
Dismantling the off-loading tool .................................................. 24
Assembly the opening device High-speed................................ 25
Assembling the pull-rods ............................................................. 26
Inspecting the bolted joints, etc.................................................... 28
5. Electrical connections ..................................................... 29

5.1
5.2
5.3
Connection of the operating mechanism...................................... 29

Assembly of busbars or overhead lines........................................ 29
Tensioning the closing springs ..................................................... 30
6. Pressurising the poles ..................................................... 31

6.1
6.2
6.3
6.4
6.5
6.6
Preparations.................................................................................. 31
Gas filling with SF6 gas ............................................................... 32
Gas filling with mixed gas............................................................ 35
Gas monitoring system................................................................. 36
Leakage test.................................................................................. 37
Fitting the signs and cover ........................................................... 37
7. Commissioning................................................................. 39
1HSB445410-14 en
8. Operating values ...............................................................41

8.1
8.2
8.3
8.4
ii
Times ............................................................................................ 41
Motor and control circuits ............................................................ 41
Resistance ..................................................................................... 41
Contact stroke............................................................................... 41
1HSB445410-14 en
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 post insulator. ..............................................................13
Figure 4-6. The post insulators non-return valve. ...........................................13
Figure 4-7. Fitting the post insulator on the frame. .........................................14
Figure 4-8. Dismantling the signs and cover. ...................................................14
Figure 4-9. Assembly corona ring ...................................................................15
Figure 4-10. Assembling the operating mechanism. .........................................16
Figure 4-11. Post insulator on the frame. ...........................................................17
Figure 4-12. Dismantling the transport cover. ...................................................18
Figure 4-13. Assembling the breaking unit. .......................................................19
Figure 4-14. Joining together the breaking unit and operating insulator. ..........20
Figure 4-15. Dismantling the locking washer. ...................................................21
Figure 4-16. Assembling the capacitor. .............................................................22
Figure 4-17. Assembling the corona rings. ........................................................23
Figure 4-18. Dismantling the off-loading tool. ..................................................24
Figure 4-19. Assembling the opening device .....................................................25
Figure 4-20. Checking the closing arms locking lug. .......................................26
Figure 4-21. Adjusting the operating mechanism. .............................................26
Figure 4-22. Assembling the pull-rod. ...............................................................27
Figure 5-1. Operating mechanism. ...................................................................29
Figure 5-2. Charging the closing springs. ........................................................30
Figure 6-1. Gas filling. .....................................................................................32
Figure 6-2. Density monitor and union nut. .....................................................34
Figure 6-3. Gas monitoring. .............................................................................36
Figure 6-4. Fitting the signs and cover. ............................................................37
1HSB445410-14 en
iii
General
1. General
This Assembly Instruction Manual applies to the SF6 circuit-breaker type
HPL 245-550B2 with three operating mechanisms type BLG 1002A for 1-pole
operation and contains all essential information for assembly and commissioning
Read through the entire Assembly Manual before starting the assembly work.
1HSB445410-14 en
Safety
2. Safety
2.1 Warning text
Warning text occurs where required and indicates that the text in question should be
observed extra carefully. The warning texts are marked as set out below:
DANGER
indicates an immediate hazardous situation that, if not avoided, will result
in death or serious injury.
WARNING
indicates an immediate hazardous situation that, if not avoided, can result
CAUTION
indicates a hazardous situation that can result in minor or moderate
injury.
N.B. used for hazards that may only result in damage to the installation.
1HSB445410-14 en
Safety
2.2 Safety, general

WARNING
Circuit-breaker with pressurised porcelain insulators.
Mechanical damage to the porcelain can cause it to explode with the
following 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,
0.15 MPa (abs).
WARNING
Do not operate the operating mechanism unloaded!
Operations shall take place only after the mechanism has been connected
and adjusted to the associated pressurised circuit-breaker.
The standard operating cycle is O - 0.3 s - CO - 3 min.-CO. The time between

1HSB445410-14 en
Delivery
3. Delivery
Check on arrival that the delivery corresponds with the order and delivery
documents and that no transport damage has occurred.
If any material is missing or if transport damage has occurred, please report this
immediately to ABB Power Technology Products AB, HV Products/ Circuit
Breaker Division.
3.1 Weights
The weights of the components are as follows:
Item
1
Part
Breaking unit
Post insulator
Weight,
kg
stated on
the
applicable
dimension
drawing
for the
order.
stated on
the
applicable
dimension
drawing
for the
order.
Operating
mechanism
465
Frame
86-200
B10068
Figure 3-1. Component parts.
1HSB445410-14 en
Delivery
3.2 Unpacking
The material are packed in a crates and on pallets. The crate is marked with the case
number and the gross weight. Other information is written on a plywood
board/label, which is attached to two of the 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.
One sling should be attached to the lifting eye and another sling around the bracket
on the bottom when the operating mechanism is supplied in a crate, see Figure 3-2.
The blocking beams should be stored for future maintenance and overhauling.
The circuit-breakers shall be kept in the transport packing until just before
assembly.
All packing material can be recycled.
Supplied in a crate
Supplied on a pallet
B20023
Figure 3-2. Lifting the operating mechanism.
1HSB445410-14 en
Delivery
3.3 Storage before assembly

3.3.1 General
The circuit-breakers are normally delivered in units adapted for transport.
Intermediate storage of these units should be avoided. If intermediate storage can
not be avoided the units should be stored indoors or under a roof. They should also
be stored horizontally above ground level to avoid cracking or water damage. Upon
arrival it is important that the plastic cover is removed in order to prevent corrosion
due to condensation (except for spare parts, see section 3.3.5).
Storage in a humid climate, without proper ventilation, can lead to discolouring of
zinc coated surfaces. This discolouring is known as white rust, and consists mainly
of zinc oxide and zinc hydroxide and is a result of a chemical process between pure
zinc on the surface and moisture.
The long term rust protection is not affected because the steel-zinc layer under the
surface remains unaffected. According to Swedish standard the presence of white
rust is no reason to reject goods.
Upon arrival each unit should be checked regarding the following:
The delivery corresponds with the order and shipping documents
Damage due to transport and missing parts
If damage is discovered or suspected the case should be opened and photos taken.
Report damage as well as missing parts.
All components should be rationally stored for easy access. All material should be
stored in an approved store1, exceptions are stated below. Dust, smoke, corrosive or
inflammable gas, steam or salt must not pollute the surrounding air otherwise the
equipment must be cleaned before construction.
The original cases can be used for storage, but the plastic covering should be
removed. The assembly units coupling pieces as well as connections are provided
with transport covers or protective covers which must not be removed until shortly
before the circuit-breakers are assembled.
3.3.2 Stacking of cases

Cases of different widths shall normally not be stacked (the pressure may destroy
the covers of the lower cases). If cases of different widths need to be stacked, a
framework must be used between the cases in order to distribute the pressure evenly.
Stacking of more than three cases is not allowed. It must be noted that stacking
causes instability sidewise and therefore the cases must be secured, i.e., prevented
from tumbling down or rolling over.
1.
An approved store is defined as consisting of:
roof
firm base
humidity below 50%
temperature 20C (10C)
1HSB445410-14 en
Delivery
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 from sunlight to avoid drying. Gaskets have a limited storage life, so avoid
storing them. Frames can be stored outdoors.
1HSB445410-14 en
Assembly
4. Assembly
4.1 Preparations
Before starting the assembly, make certain that all requisite tools and documents are
on hand.
Standard tools with torque wrenches (9 - 430 Nm).
Lifting device and lifting slings.
Lubricants, see Lubricants 1HSB445409-1 for suppliers and brand names.

Grease G: ABB Art. No. 1171 4014-407
Grease SV: ABB Art. No. 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 two gas-tight transport
units. The component parts are marked to facilitate assembly. The circuit-breaker
poles and operating mechanisms have been tested together. Breaking units and post
insulators having the same marking, e.g., A1, are coupled together. Breaking units
and post insulators only need to be coupled together mechanically and after that
filled with gas.
Check that the assembly markings correspond with Figure 4-1 and that the serial
number on the operating mechanism corresponds with the serial number of the
circuit-breaker.
Item
1
Operating
mechanism A
Operating
mechanism B
Operating
mechanism C
Post insulator A1
Post insulator B1
Post insulator C1
Breaking unit A1
Breaking unit B1
Breaking unit C1
7
8
9
5
1
6
2
3
B10069
Figure 4-1. Assembly markings.

1HSB445410-14 en
Assembly
4.1.2 Foundation
The circuit-breakers foundation must be flat and level. Adjust any deviations using
spacer washers, see Chapter 4.3, Assembling the frame on the foundation. Figure
4-2 shows the permitted deviations in mm for the position of the foundation bolts.
The dimension of the foundation bolts and nuts are stated on the applicable
dimension drawing for the order. The nominal dimensions are stated on the
applicable dimension drawing for the order.
B10004
Length = >110
Figure 4-2. Foundation.
10
1HSB445410-14 en
Assembly
4.2 Frame assembly

The frame is supplied in welded halves with six cross stays and nuts, bolts and
washers.
Bolt the halves together as shown in Figure 4-3. Fit the cross stays according to
the numbering 1-4, using the supplied nuts, bolts and washers.
N.B. Make sure the stays are fitted as set out in Figure 4-3 and to the intended
operating mechanism.
Tighten the bolted joints to a torque of 430 Nm.
Item
1
Frame halves
2 pcs.
Stays
6 pcs.
Bolts M20x60
Nuts M20
Washers 21x37x3
8 pcs.
8 pcs.
16 pcs.
3
2
2
TIGHTENING TORQUE
430 Nm
1
B10005
Figure 4-3. Frame assembly.
1HSB445410-14 en
11
Assembly
4.3 Assembling the frame on the foundation

Check that the frames are upright and adjust them to the same level using the nuts
(2). The dimension of the foundation bolts, washers and nuts are stated on the
applicable dimension drawing for the order.
Fill the gap between the lower nut and foundation with spacer washers; this should
be as small as possible.
Tighten the lower nut against the spacer washers (4). For the final tightening of the
frame, use the upper nut, which is tightened to a torque of 300-350 Nm if M24 or
500-550 Nm if M30.
Foundation bolts, spacer washers and nuts are not supplied.
Item
Nuts (Not supplied)
8 pcs.
Washers (Not supplied)
8 pcs.
Spacer washers (Not supplied)
Foundation
Frame foot
1
20
TIGHTENING TORQUE
300-350 Nm
or
500-550 Nm
>110
Foundation bolts, L > 110 mm

(Not supplied)
10
10
B10006
Figure 4-4. Frame assembly on the foundation.
12
1HSB445410-14 en
Assembly
4.4 Assembling the post insulator on the frame

Place a lifting sling around the top of the post insulator as shown in Figure 4-5 and,
using this method, lift the post insulator from its horizontal position in the transport
crate.
Note the position of the lifting sling! If polymeric insulators: Place the lifting sling
as close to the terminal flange as possible and not on the rubber surface.
.
B10086
Figure 4-5. Lifting the post insulator.

Check that the post insulator
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 1
is heard, the post
insulator leaks. This
must be rectified before
assembly.
3.
Fit the sealing cap (1).
B10008
Figure 4-6. The post insulators non-return valve.
1HSB445410-14 en
13
Assembly
Assembly a post insulator on each frame according to Figure 4-7. Fit the bolts (1)
and tighten by hand.
N.B. Final tightening is carried out when the operating mechanism has been fitted.
Item
1
Bolts M20x60
Nuts M20
Washers 21x36x3
4 pcs.
4 pcs.
8 pcs.
B10087
Figure 4-7. Fitting the post insulator on the frame.
4.5 Preparations for assembling the operating mechanism

Remove all the pole covers (1) and
the Close-Open signs (2), to gain
the best possible access to the pole
mechanisms.
Item
1
Cover
Sign
Coupling link
B10012
Figure 4-8. Dismantling the signs and cover.

14
1HSB445410-14 en
Assembly
4.6 Assembly of corona ring

If the circuit-breaker have polymeric insulators assembly the supplied corona ring
as section 4-9.
2
Item
Corona ring
1 pcs
Bracket
4 pcs
Bolts M10
4 pcs
Washer 10,5x20x2
12 pcs
Bolts M10
4 pcs
Nuts M10
4 pcs
4,5,6
TIGHTENING TORQUE
60 Nm
3,4
Figure 4-9. Assembly corona ring
1HSB445410-14 en
15
Assembly
4.7 Assembling the operating mechanism

On delivery the operating mechanism has been set and is supplied with the closing
springs correctly adjusted.
The operating mechanism is fitted as set out in Figure 4-10.
Fit all bolts and tighten them by hand. Then tighten the bolted joints (1) with a
tightening torque of 79 Nm.
2
Item
1
1
Bolts M12
Nuts M12
Washers 13x24x2.5
10 pcs.
10 pcs.
20 pcs.
Spring washer 13x29x3
4 pcs.
TIGHTENING TORQUE
79 Nm
B10088
Figure 4-10. Assembling the operating mechanism.
16
1HSB445410-14 en
Assembly
4.8 Final assembly of the post insulator

Tighten the post insulator to the frame with a torque of 300 Nm.
TIGHTENING TORQUE
300 Nm
B10089
Figure 4-11. Post insulator on the frame.
1HSB445410-14 en
17
Assembly
4.9 Assembling the breaking unit

Place a lift sling around the breaking unit as shown in Figure 4-12 and lift the
breaking unit horizontally out of the transport packaging.
N.B. The breaking unit should be balanced and lifted horizontally.
1.
Dismantle the transport cover (1) and the cover (3) from the breaking unit (5)
and the transport cover (6) on the post insulator (7). Save all the transport
covers for future overhaul work.
N.B. The locking washer (8) under the cover (3) should remain in place so that it
holds the breaking units contact system in the sealed position.
5
Item
1
Transport cover with sealing

ring
Bolts M12x50
Washers 13x28x3
Nuts M12
8 pcs.
16 pcs.
8 pcs.
Cover with 2 sealing rings
Bolts M10x25
Washers 10.5x22x2
Breaking unit

ring
Post insulator
Locking washer
4
3
1
4 pcs.
4 pcs.
8
7
B10090
Figure 4-12. Dismantling the transport cover.
18
1HSB445410-14 en
Assembly
2.
Check that the sealing ring (1) is well-cleaned and apply a layer of grease G.
Also apply a thin layer of grease G on the sealing face for the sealing ring on
the post insulators top flange and a generous layer of grease on the surface
outside of the sealing groove. Place the sealing ring (1) in its groove.
3.
Lower the breaking unit (2) onto the post insulator (3). Centre the breaking unit
on the operating insulator (4). Check that the sealing ring (1) is in position.
N.B. The breaking unit should be lowered straight over the operating insulator.
2
Item
1
Sealing ring
Breaking unit
Post insulator
Operating insulator
B10091
Figure 4-13. Assembling the breaking unit.
1HSB445410-14 en
19
Assembly
4.
Join together the breaking unit (1) and the post insulator (2) by hand using the
nuts, bolts and washers (3).
5.
Fit the pin (4) and circlip (5). Check that the circlip (5) sits correctly in its
groove.
The operating insulator can be adjusted vertically, if necessary, using the
adjuster screw (6) once the nut (7) has been loosened.
1
Item
1
Breaking unit
Post insulator
Bolts M12x70
Washers 13x24 x2.5
Nuts M12
Pin, D= 22 mm
Circlip
Adjuster screw
1 pcs.
Locking nut
1 pcs.
4
4 pcs.
8 pcs.
4 pcs.
5
2
7
6
B10092
Figure 4-14. Joining together the breaking unit and operating insulator.
20
1HSB445410-14 en
Assembly
6.
Screw in a bolt (2), M8, in the threaded hole in the locking washer (1) and pull
it out, see Figure 4-15.
7.
Check that the sealing rings and sealing faces are clean. Apply a layer of grease
G to the sealing rings and sealing faces.
8.
Refit the sealing cover (3) without damaging the sealing face. Tighten the bolts
(4) with a tightening torque of 45 Nm.
TIGHTENING TORQUE
45 Nm
9.
Tighten the breaking unit (5) against the post insulator (6) using the bolts (7),
tightening torque 79 Nm.
TIGHTENING TORQUE
79 Nm
5
Item
1
Locking washer
Bolt M8
Sealing cover
Bolts M10x25
Washers 10.5x22x2
Breaking unit
Post insulator
Bolts M12x70
Washers 13x24 x2.5
Nuts M12
1
2
4 pcs.
4 pcs.
4
3
4 pcs.
8 pcs.
4 pcs.
B10093
Figure 4-15. Dismantling the locking washer.
1HSB445410-14 en
21
Assembly
4.9.1 Assembling the capacitors

In those cases where capacitors are supplied, assemble them as follows:
1.
Fit the capacitor brackets (1) on the capacitors. Tighten the bolts (2) by hand.
2.
Attach a lifting device on the capacitor and lift it into position.
3.
Fit the bracket against the flange, separated by the spacer washer (5), and
tighten the bolts (4) by hand.
4.
Fit the bracket on the upper mechanism housing (3) using the bolts (4).
5.
Tighten the bolts (2)with a tightening torque of 79 Nm.
TIGHTENING TORQUE
79 Nm
6.
Tighten the bolts (4) with a torque of 60 Nm.
TIGHTENING TORQUE
60 Nm
Repeat points 2-6 to fit the other capacitor.

5
Item
1
Capacitor brackets
2 pcs.
Bolts M12x35
Spring washer
4 pcs.
4 pcs.
Upper mechanism housing
Bolts M12x30
Washers 13x28x3
Spacer washer
4 pcs.
4 pcs.
3
4
4
1
2
B10120
Figure 4-16. Assembling the capacitor.
22
1HSB445410-14 en
Assembly
4.9.2 Assembling the corona rings

In those cases where corona rings are supplied, assemble them as follows.
1.
Remove the bolts (1) that hold the flange against the breaking chamber
insulator.
2.
Lift the corona ring (2) into position and refit the bolts (1). Tighten the bolts by
hand.
3.
Fit the bolt (3) with washers and nut.
4.
Tighten all bolts (1 and 3) with a tightening torque of 60 Nm.
TIGHTENING TORQUE
60 Nm
Repeat points 1-4 to fit the other corona rings.
Item
1
Bolts M12x50
Washers 13x28x3
Corona ring
Bolt M10x30
Washers 10.5x20x2
Nut M10
2 pcs.
2 pcs.
1
1 pcs.
2 pcs.
1 pcs.
1
3
B10121
Figure 4-17. Assembling the corona rings.
1HSB445410-14 en
23
Assembly
4.10 Dismantling the off-loading tool
Off-load the spring pressure using the adjuster screw (4) before dismantling the
bottom cover (1) and the tool (3).
Refit the bottom cover (1) and tighten the bolts (2) with a
TIGHTENING TORQUE
45 Nm
Fit the bolt (5) and washer in the bottom cover (1) and tighten the bolts with a
TIGHTENING TORQUE
79 Nm
Item
1
Bottom cover
Bolts M10x50
Tool 1HSB446381-A
Adjuster screw
Bolt M16x30
Washer 17x30x3
4 pcs.
1 pcs.
1 pcs.
B10095
Figure 4-18. Dismantling the off-loading tool.
24
1HSB445410-14 en
Assembly
4.11 Assembly the Opening device High-speed

Deassemble the bolt, washer and pin (1).
Mount the complete Opening device High-speed(2), seal the surface between the
opening device and the mechanism housing with silicone.Fit the bolts,washers and
nuts (3) and tighten with tightening torque 79 Nm.
TIGHTENING TORQUE
79 Nm
Fit the coupling link (4) from the opening device and the coupling link from the
operating mechanism (5) in the operating lever (6). Fit the pin,washer and bolt (1).
Tighten with tightening torque 22,5 Nm. Secure with Loctite 270.
TIGHTENING TORQUE
22,5 Nm
Seal the slots (7) in the opening device with silicone. The slot facing downwards
shall be open for drainage.
3
Item
1
Bolt M8x16
Washer
Pin
Opening device
High-speed
Bolt M12x50
Washers 13x24x2.5
Nuts M12
Coupling link
1 pcs.
1 pcs.
1pcs.
4 pcs.
4 pcs.
4pcs.
4
5
Coupling link
Operating lever
Slots
Figure 4-19. Assembling the Opening device High-speed
1HSB445410-14 en
25
Assembly
4.12 Assembling the pull-rods

Each pole is supplied set to a basic setting. Adjust the poles to the correct Open
position when fitting the operating rod between the operating mechanism and the
pole.
Pull-rod assembly takes place in stages:
Preparations for assembling the pull-rods.
Assembling the pull-rods between the operating mechanisms and the poles.
4.12.1 Preparations for assembling the pull-rods
Check that the closing arms (1) locking lug rests against the closing latch (2)
roller.
2
B10013
Figure 4-20. Checking the closing arms locking lug.
Adjust the operating mechanism as set out in Figure 4-21. Press down the
locking lug (1) on the operating lever by inserting a tool, for example, a large
screwdriver, in the hole (2). Insert a screwdriver in hole (3) and press the
operating lever to the right.
2
B10035
Figure 4-21. Adjusting the operating mechanism.
26
1HSB445410-14 en
Assembly
4.12.2 Assembling the pull-rod between the operating mechanism A and pole A1
Each pole is supplied set to a basic setting and its Closed and Open positions are
determined. Adjustment is made as set out below (see Figure 4-22).
Move the operating lever (3) and the pull-rod (2) from the operating
mechanism by hand, towards its Closed position sufficiently far so that the
pull-rod (5) can be placed between the coupling link (4) and the pull-rod from
the operating mechanism.
Simultaneously screw the pull-rod (5) into the operating mechanisms pull rod (2)
(right-hand thread) and the poles coupling link (4) (left-hand thread).
N.B. Remember the two spring washers (6) under each locking nut (8).
Turn the pull-rod (5) so its length decreases at the same time as the operating
lever (3) moves towards its Open position. The pull-rod (5) is the right length
when the operating lever (3) is in its Open position and the alignment
check hole (7) is directly aligned with the predrilled hole in the mechanism
housing (1). Check the position of the hole using a 6 mm diameter rod. Check
that the pull-rod (5) is screwed past the alignment check holes (9 and 10). The
tightening torque for the locking nuts is 430 Nm.
5
Item
1
Mechanism housing
Pull-rod from operating

mechanism
Operating lever
Coupling link, pole
Pull-rod (turnbuckle screw)
Spring washers
Alignment check hole in arm
Locking nuts
Alignment check hole in pull-rod
10
Alignment check hole in

coupling link
10
9
TIGHTENING TORQUE
430 Nm
8
7
B10014
Figure 4-22. Assembling the pull-rod.

Repeat the procedure to assemble the pull-rods between the operating mechanism B
and pole B1 and between operating mechanism C and pole C1.
1HSB445410-14 en
27
Assembly
4.13 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
Frame
Foundation
430
300-350 or 500-550
Operating mechanism
79
Post insulator before lifting
60
Post insulator
300
Sealing cover
45
Breaking unit
79
Mechanism housing
79
Capacitor upper mechanism

housing
60
Corona ring
60
Bottom cover
45
Bottom cover center bolt
79
Pull-rod
430
Density monitor
10
Close and Open mechanism

Mechanism cover
28
Tightening torque, Nm
22,5
9
1HSB445410-14 en
Electrical connections
5. Electrical connections
5.1 Connection of the operating mechanism
Operation and signal cables are routed through the connection flange at the bottom
of the cabinet. Fit the flange with a suitable cable gland for the cable in question.
Connect the cables to the terminal blocks in accordance with the applicable wiring
diagram. The terminal blocks are of a snap-in type and are designed both for
through wiring with termination of a stranded conductor with a cross-section of
max. 4 mm2, and as disconnectable blocks with termination of a stranded conductor
with a cross-section of max. 6 mm2 intended for motor circuits, AC circuits and
supply circuits.
Connect the earth wire to the earth terminal (1) on the side of the cabinet.
B10015
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 flags, which are also made of aluminium.
However, if copper busbars or copper connectors are used for the overhead lines,
grease should be used and a bimetallic washer fitted in the joint. Bimetallic washers
can be supplied by ABB on request.
1HSB445410-14 en
29
Electrical connections
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 Art. No. 1171 4016-610, on copper surfaces.
4.
Assemble the joint with the paste or grease still applied.
5.
Wipe off any excess paste or grease.
N.B. Position the bimetallic washers so that their aluminium sides face the
aluminium surfaces and the copper sides face the copper surfaces or the
silver-plated surfaces.
N.B. The contact paste may only be used on fixed joints. It must not be used
inside the breaking units.
5.3 Tensioning the closing springs

The circuit-breaker is closed and the motor is started to charge the closing springs
(7). The drive sprocket (11) rotates anticlockwise and pulls up the chain section (15)
so that the spring yoke (19) is lifted and charges the closing springs. The chain
section (16) runs down, while the chain sections (17) and (18) do not move.
Item
7
Closing springs
11
Drive sprocket
15
Chain section
16
Chain section
11
17
Chain section
18
Chain section
19
Spring yoke
18
15
17
16
19
B20027
Figure 5-2. Charging the closing springs.
30
1HSB445410-14 en
Pressurising the poles
6. Pressurising the poles

The circuit-breaker poles are supplied vacuum-processed and filled with SF6 gas at
a pressure of 0.12- 0.13 MPa abs at 20C.
6.1 Preparations
WARNING
During commissioning, the SF6 gas or the gas mixture needs to be refilled
to the pressure stated on the rating plate. Different gas pressures can occur,
depending on different requirements with regard to the lowest ambient
temperature.
Pressurisation takes place directly from a gas cylinder using the gas filling
equipment, article number 1HSB 445439-A for SF6 gas and 1HSB 445439-B for
gas mixture.
The gas hose for the filling equipment is supplied vacuum-pumped and filled with
SF6 gas.
WARNING
To avoid personal injury while refilling, due to possible transport damage
to the porcelain, assembly personnel must exercise great care and stay in a
protected and safe area (with regard to splintering) away from the circuitbreaker. The gas cylinder and refilling equipment should be placed in the
same area.
1HSB445410-14 en
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 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.
31
6.2 Gas filling with SF6 gas
3
Item
6
5
Gas cylinder
Regulator
Density monitor
Coupling
Valve
The breakers gas valve
Hose
Adaptor
Nipple with union nut
10
Equal union cross
11
Valve
2
10
B10016
11
Figure 6-1. Gas filling.
1.
Place the gas cylinder (1) in a protected area.
2.
Check the filling pressure and any gas mixture (at ambient temperatures lower
than -40 C) on the circuit-breakers rating plate.
3.
Fit the regulator (2) on the gas cylinder. Set the right filling pressure,
compensated for the temperature as set out in Table 6-1 or Table 6-2, on the
regulator.
4.
Pull the sealing rings off the density monitor with your fingers (3).
N.B. Do not use sharp tools.

5.
32
Lubricate the sealing rings thoroughly with grease G and refit them on the
density monitor.
1HSB445410-14 en
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) should be closed. However, if the
density monitor is connected to the equal union cross (10), then valve (5)
should be closed.
7.
Connect coupling (4) to the circuit-breakers gas valve (6).
8.
Connect the gas-filled hose (7) to the coupling.
9.
Connect the hose to the gas cylinder.
10. Go from the breaker to the protected area and let the gas flow until the regulator
switches off.
11. Wait until the gas temperature has reached the circuit-breaker temperature level
before reading off the gas pressure on the density monitor. Adjust the pressure
if necessary.
12. Dismantle the hose from the coupling on the circuit-breaker.
13. Close the valve to the density monitor.
14. Dismantle the coupling from the circuit-breaker.
15. Release the pressure at the density monitor by opening valve (5) or valve (11).
16. Dismantle the density monitor from the coupling and fit it on the circuitbreaker.
17. Repeat from 4 through to 16 for poles B and C.
N.B. When reading off from the precision gauge, correct the filling pressure
depending on the temperature as set out in Table 6-1.
Table 6-1. Filling pressure
Filling pressure in MPa (abs)
stated on the rating plate
0.5
0.7
0.5
0.7
Filling pressure read off the gauge in
1HSB445410-14 en
Temp. when
filling C
MPa
(abs)
bar
(abs)
MPa
(abs)
bar
(abs)
MPa
bar
MPa
bar
(a.op) (a.op) (a.op) (a.op)
+40
0.54
5.4
0.75
7.5
0.44
4.4
0.65
6.5
+30
0.52
5.2
0.72
7.2
0.42
4.2
0.62
6.2
+20
0.50
5.0
0.70
7.0
0.40
4.0
0.60
6.0
+10
0.48
4.8
0.66
6.6
0.38
3.8
0.56
5.6
0.46
4.6
0.63
6.3
0.36
3.6
0.53
5.3
-10
0.44
4.4
0.61
6.1
0.34
3.4
0.51
5.1
-20
0.42
4.2
0.58
5.8
0.32
3.2
0.48
4.8
-30
0.40
4.0
0.30
3.0
33
18. Close the valve on the gas cylinder when all poles have been filled.
19. Disconnect the hose from the gas cylinder and release the pressure in the
regulator by pressing in the non-return valve.
20. Release the set pressure in the regulator by turning the adjuster valve so that the
next circuit-breaker to be assembled is not filled with the wrong pressure.
N.B. When the density monitor (1) is finally fitted, tighten the union nut (2) with a
torque of 10 Nm.
Item
1
Density monitor
Union nut
TIGHTENING TORQUE
10 Nm
B10017
Figure 6-2. Density monitor and union nut.
21. Operate the breaker Close and Open 3 times from the control room.
22. Connect the cables to the density monitors.
34
1HSB445410-14 en
6.3 Gas filling with mixed gas

A mixture of SF6 and N2 or CF4 gas is used at low temperatures below -40 C, to
prevent condensation of the SF6 gas. See the rating plate if this should be done.
N.B. When filling with mixed gas always fill the SF6 gas first.
The proportions of gas for pressurisation should be 52% SF6 and 48% N2 or CF4.
Example.
For a circuit-breaker with a filling pressure of 0.70 MPa abs (+20 C), first fill SF6
gas to 0.52 x 0.7 = 0.36 MPa abs (+20 C) and then N2 or CF4 gas to
0.70 MPa abs (+20 C).
N.B. When reading off from the precision gauge, correct filling pressure depending
on the temperature as set out in Table 6-2.
Gas filling takes place otherwise as set out in Chapter 6.2.
Table 6-2. Filling with mixed gas.

Filling pressure in MPa (abs)
stated on the rating plate.
SF6
Total filling
pressure
SF6
Total filling
pressure
Filling pressure read off on the gauge in
1HSB445410-14 en
Temp. when
gas filling
C
MPa
(abs)
bar
(abs)
MPa
(abs)
bar
(abs)
+40
0.39
3.9
0.75
7.5
0.29
2.9
0.65
6.5
+30
0.37
3.7
0.72
7.2
0.27
2.7
0.62
6.2
+20
0.36
3.6
0.70
7.0
0.26
2.6
0.60
6.0
+10
0.34
3.4
0.66
6.6
0.24
2.4
0.56
5.6
0.33
3.3
0.63
6.3
0.23
2.3
0.53
5.3
-10
0.32
3.2
0.61
6.1
0.22
2.2
0.51
5.1
-20
0.30
3.0
0.58
5.8
0.20
2.0
0.48
4.8
-30
0,29
2,9
0,57
5,7
0,19
1,9
0,47
4,7
MPa
bar
MPa
bar
(a.op) (a.op) (a.op) (a.op)
35
6.4 Gas monitoring system
Drill a 23 mm diameter hole in flange (1) on the bottom of the operating

mechanism and fit a cable gland (2) with a sealing washer (3) and nut (4) 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 cable to the frames leg using pipe clips (5) and nuts, bolts and
washers (6).
Connect the cable to the density monitors terminal blocks.
N.B. The cable ends for the density monitor should be as long as necessary so that
the density monitor can be disconnected from the non-return valve without
the need of disconnecting the cable.
Item
Flange
Cable gland
Sealing washer
Nut
Pipe clips
4 pcs.
Bolts M5x20
Nuts M5
Washers 5.3x10x1
4 pcs.
4 pcs.
8 pcs.
1
2
3
B10018
Figure 6-3. Gas monitoring.
36
1HSB445410-14 en
6.5 Leakage test

Perform a leakage test using a leak detector around the density monitors
connections.
6.6 Fitting the signs and cover

Fit and tighten all Close and Open signs (1) with a tightening torque of 22,5 Nm.
Then fit the cover (2) with a tightening torque of 9 Nm.
Item
1
Sign
Cover
Bolts M8x16
Washers 8.4x16x1.5
9 pcs.
9 pcs.
TIGHTENING TORQUES
9 and 22,5 Nm
2
B10012
Figure 6-4. Fitting the signs and cover.
1HSB445410-14 en
37
Commissioning
7. Commissioning
Before commissioning the circuit-breaker, carry out all the checks as set out in
Check list for assembling and commissioning 1HSB445410-100 and fill in the
operating values for the installation.
1HSB445410-14 en
39
Operating values
8. Operating values
The operating values in these instructions apply to SF6 circuit-breakers type
HPL 245-550B2 with operating mechanism type BLG 1002A.
8.1 Times
Closing times
< 65 ms
Opening time coil I
17 2 ms
Opening time coil II
17 2 ms
Close-Open time(1)
<47 ms
(1) The Close-Open time refers to the time the main

contacts are closed during a closing operation when
a tripping pulse is simultaneously connected via the
auxiliary contact.
8.2 Motor and control circuits
Charging time for motor
max. 20 s
Operating voltage opening

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

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

coils I and II
V (according to
the rating plate)
8.3 Resistance
Main circuit resistance per breaking unit < 40 .
8.4 Contact stroke

Main contact stroke is 208 4 mm.
1HSB445410-14 en
41

Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax:
+46 (0) 240 714 928
1HSB445410-14 en
0204
SF6 Circuit-Breaker
Circuit-breakers HPL and LTB
Check list, assembly

1HSB445410-100 en rev2
document.

Date: 2002-02-14
Check list for assembly and commissioning
Check list
1. Check list for assembly and commissioning

The following checks shall be made and the check list completed before the circuitbreaker is commissioned. The check list shall be kept in the order binder.
Date:_______________
Installation:______________________________________________
Serial number:_____________________________
Circuit-breaker pole
1.
Check that the circuit-breaker and operating mechanism have been assembled
in accordance with the assembly instructions.
2.
Check that all bolted joints are tightened to the tightening torques stated in the
assembly instructions.
3.
Ensure that all poles are in the open position. The alignment hole in the
operating lever shall align with the predrilled hole in the mechanism housing.
Operating mechanism
4.
Make an ocular inspection to check that oil from the oil dashpots has not
leaked in the operating mechanism.
5.
Tighten all screws in terminal blocks involved in the assembly work.
Gas filling
6.
Connect the operating mechanism for remote control from a protected area in
connection with gas filling and test operations.
Set the control switch to remote.
7.
Connect the gas filling equipment for gas filling from the protected area.
8.
Fill with gas each pole one after the other and perform an operational test three
times as set out in the assembly instructions.
9.
Check the heater element.
10. Make sure the thermostat, if provided, is set to 10C 1.
1.
1HSB445410-100 en rev2
Other thermostat settings may occur.
Check list for assembly and commissioning
Check list
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.
.
Measured values
Check the following

Pole A
Pole B
Pole C
Closing time coil I
ms
ms
ms
Closing time coil II
ms
ms
ms
Opening time coil I
ms
ms
ms
ms
ms
ms
Close-Open time
ms
ms
ms
Lowest control voltage closing coil I
Lowest control voltage closing coil II
Lowest control voltage opening coil I
Lowest control voltage opening coil II
MPa (abs)
MPa (abs)
MPa (abs)
Main circuit resistance

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

13. If points 1-11 as set out above have been completed, the circuit-breaker can be
commissioned.
1HSB445410-100 en rev2

Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax:
+46 (0) 240 714 928
1HSB445410-100 en rev2
0202
SF6 Circuit-Breaker
Type HPL
Operating and Maintenance

Instructions
1HSB445409-102 en
document.
The document, or parts of it, may not be reproduced or copied without prior permission from ABB
Power Technology Products 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.

Date: 2002-06-10
Operating and Maintenance Instructions
TABLE OF CONTENTS
1. General ................................................................................ 1
1.1
1.2
Warning text ................................................................................... 1

Warning .......................................................................................... 2
2. Preventive maintenance .................................................... 3

2.1
2.2
2.3
Circuit-breaker ............................................................................... 3
Operating mechanism..................................................................... 5
Spare parts...................................................................................... 6
3. Inspection intervals............................................................ 7
3.1
3.2
3.3
3.4
3.5
1HSB445409-102 en
Maintenance summary ................................................................... 8

Maintenance category A ................................................................ 9
Maintenance category B............................................................... 10
Maintenance category C............................................................... 12
Maintenance category D .............................................................. 18
FIGURES
Figure 2-1. Arcing contacts and PTFE insulation ............................................. 4
ii
1HSB445409-102 en
General
1. General
These operating and maintenance instructions apply to the SF6 circuit-breaker type
HPL with operating mechanism of type BLG 1002A.
The instructions contain recommendations for the care and guidelines for the
maintenance of high-voltage circuit-breakers of the HPL type. The instructions are
divided into four parts:
Inspection intervals
Instructions for preventive maintenance of circuit-breakers
Instructions for preventive maintenance of operating mechanisms
Fault correction maintenance.
Periodic maintenance must be carried out at the time or operation intervals

specified.
Fault correction maintenance is related to the faults detected. The fault correction
maintenance described in this Manual involves the replacement of defective units. If
the user chooses to try and repair a defective unit instead, specialist knowledge is
often needed. This will not be found in the Manual.
The equipment must be overhauled in accordance with specified criteria, e.g. after a
certain number of operations. Overhaul of the equipment must be entrusted to
authorised service personnel.
1.1 Warning text

Careful attention must be given to text marked with:
DANGER
WARNING
CAUTION
injury.
N.B. is used for hazards that may only result in damage to the installation.
1HSB445409-102 en
General
1.2 Warning
WARNING
Circuit-breakers with pressurised porcelain insulators.
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, 0.15 MPa (abs.)
1HSB445409-102 en
Preventive maintenance
2. Preventive 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 HPL circuit-breaker will have a
service life exceeding 30 years or 10,000 operations.
The following points will ensure a long service life:
1.
Burning-off of the arcing contacts is limited
2.
Each breaking unit is equipped with an absorption agent with a service life
equivalent to that of the circuit-breaker
3.
Bearings in the space filled with gas are maintenance-free
4.
The seals have double 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 on Figur 2-1, page 4
or...
if the number of operations for line-, reactor-, or capacitor- switching, as

well as switching of the load current1 has reached the level specified under
the heading Inspection intervals in the inspection chart.
Other reasons for opening the breaking unit are limited to mechanical
faults/incorrect adjustment of the drive system that may cause damage to
components inside the breaking unit.
N.B. Opening the breaking unit requires special instructions and may only be done
by trained and authorised personnel.
The curve that defines the permissible number of short-circuits can be expressed
approximately as:
n x I1.8 = 20,000
where
n = number of short-circuits
I = short-circuit current, kA (RMS).
All short-circuit current levels can be included in the total of the number of shortcircuits x short-circuit current to the power 1.8,
e.g. 20x301.8+30x201.8+40x101.8=18,230.
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.
1HSB445409-102 en
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 an HPL circuit-breaker can manage before the metal losses due
to burning becomes so great that they must be replaced.
Number of interruptions
N
5,000
2,000
1,000
500
200
100
50
20
2
10
20
30 40 50 63
kA
Short-circuit current
Figure 2-1. Arcing contacts and PTFE insulation
2.1.3 Tightness checking

The circuit-breakers are equipped with density monitors for checking the gas
density. Each density monitor is equipped with an alarm contact that gives an
electric signal in the event of abnormal leakage. Alarm level 1 gives an alarm signal,
while alarm level 2 blocks.
N.B. A new or overhauled circuit-breaker should be checked for tightness by
reading the density monitors after about 1 month and then at 1-2 year
intervals in connection with the regular ocular inspection.
1HSB445409-102 en
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 the local conditions, i.e. the amount of
atmospheric pollution.
N.B. All HPL 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 G1 and
will not normally need lubricating except during major overhauls.
See the Overhaul Instructions applicable for the circuit-breaker, for lubricating
sealing rings.
The worm gear in the drive unit is lubricated with Grease M1.
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,
Safety regulations, are followed before the work is started.
2.2.2 Cleaning
Clean the operating mechanism when necessary using a vacuum cleaner.
Check that the filters in the valves are clean. Replace them if they are dirty.
1. See the document Lubricants 1HSB445409-1 for the names of suppliers and brands for
grease and oils.
1HSB445409-102 en
2.2.3 Lubrication
The ball, roller and needle bearings in the operating mechanism are permanently
lubricated and require no maintenance. Lubrication is therefore limited to shafts in
the latch mechanisms and the worm gear in the drive unit. These should be greased
after 2,000 operations. In connection with overhauls, the sliding surfaces of the
spring fork and dashpot must be lubricated with Grease G1 and the chains with
Oil A1.
When supplied, the bearings in the operating mechanism are lubricated with Grease
G1 and will not normally need to be lubricated except during major overhauls.
When supplied the closing and opening dashpots are filled with Oil S1.
2.2.4 Rust protection

Certain steel parts in the operating mechanism have manganese phosphate surface
treatment and are then dipped in a rust inhibiting oil. This applies to latches, gear
wheels, parts of the link system, etc.
The closing and opening springs are rust inhibited by painting with two-component
paint.
When supplied, the operating mechanism is equipped with anti-corrosion vapour
phase inhibitors. These inhibitors are only for protection 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 G1or Tectyl 506
(ABB Article No. 1241 0011-108).
N.B. Tectyl 506 forms a waxy protective skin when it dries and therefore it must
not be sprayed into bearings and latch mechanisms or on to gear-wheels and
chains.
2.3 Spare parts

Spare parts must be stored indoors in an approved storage space2 and in the original
packaging. This is particularly important for rubber components (seals etc.), which
must also be protected against sunlight to prevent them drying. Seals have a limited
shelf life so avoid storing them. Base frames can be stored outdoors.
1. See the document Lubricants 1HSB445409-1 for the names of suppliers and brands for
greases and oils.
2. Approved storage space:
roof, solid foundation, relative humidity less than 50%, temperature +200C(10C)
1HSB445409-102 en
3. Inspection intervals
Inspection of HPL circuit-breakers with operating mechanisms of type BLG 1002A.
Important checkpoints, acceptable tolerances, certain functional values for
adjustments, and recommended inspection intervals can be found in the following
inspection chart.
In corrosive or polluted air and in climates with a high relative humidity, it can be
necessary to halve the inspection intervals.
The specified inspection intervals should be considered as recommended guide
values, which can be increased or decreased depending on the local conditions.
1HSB445409-102 en
3.1 Maintenance summary
Type of measure
Inspection interval
Explanation
Condition of
circuitbreaker
during work
Competence
requirements
Ocular inspection
1-2 years
a1
a2
Intermediate check
Operation test including
timing test
Thermovision check
Greasing of Wormgear
3-6 years or 2,000 mech. 1)

CLOSE/OPEN operations.
b1
b2
15 years or 5,000 mech.

1), 3)
b1
b2
2)
c1
c2

CLOSE/OPEN operations. 1)
d1
c2
General check of circuitbreaker and operating
mechanism
Overhaul
Overhaul of breaking
chambers
Line and transformer
circuit-breakers
Capacitor-reactor and filter

circuit-breakers
Not synchronized
Synchronized
Major overhaul
nxI1.8 =20,000
2,500 CLOSE/OPEN op.

with el. load.
5,000 CLOSE/OPEN op.
with el. load.
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.
1HSB445409-102 en
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
1.
Ocular inspection
1HSB445409-102 en
Inspection interval
1-2 years.
Measures / Tools/ Instructions
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.
3.3 Maintenance category B
To be inspected
1.
Ocular inspection
Inspection interval
3-6 years or 2,000 mech. CLOSE/

OPEN operations.

and drainage holes.
See Chapter 2.1.3 and Chapter 2.1.4.

OPEN operations.
Make a note of the serial number.

OPEN operations.
Make a note of the number of

operations.
4.
Visual inspection in
operating mechanism

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.
5.
Corrosion inspection
Rust protection

OPEN operations.
Visual inspection.
Rust stains polished off and treated
with rust protection.
See Chapter 2.2.4.
15 years or 2,000 mech. CLOSE/

OPEN operations.
Circuit-breaker in open position, closing

springs discharged. Greasing of the
worm gear and shafts in latches in the
operating mechanism with grease M.
See Chapter 2.1.5, Chapter 2.2.3 and
Manual 1HSB515409-100.
2.
Rating plates
3.
Operation counter
6.
Greasing
10
1HSB445409-102 en
To be inspected
7.
Thermovision
measurements
8.
Exchange pullrod
9.
Measurement spring
charging
10.
Operating test
1HSB445409-102 en
Inspection interval

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.
2,000 mech. CLOSE/ OPEN

operations.
Exchange the pullrod between the

operating mechanism and the breaker
pole.
See the Assembly Instruction for
applicable circuit-breaker.

OPEN operations.
Measure the dimension between the

spring bridge and frame foot.

OPEN operations.
Operating test, if possible in

combination with measurement of
operating times (incl. Close-Open
times).
See the Assembly Instruction for
11
3.4 Maintenance category C

To be inspected
1.
Ocular inspection
2.
Rating plates
3.
Operation counter
4.
SF6-gas
Inspection interval

OPEN operations.

and drainage holes.
See Chapter 2.1.3 and Chapter 2.1.4
and Manual 1HSB515409-100.

OPEN operations.
Make a note of the serial number.

OPEN operations.
Make a note of the number of

operations.

OPEN operations.
Gas filling equipment.
Filling of gas (if

necessary)
Dew point at normal
pressure in circuitbreaker.
5.
Insulators
Visual inspection and
cleaning.
See Assembly instruction for applicable

circuit-breaker, ch 6.
Dew point maximum - 5 C at rated
filling pressure and + 20 C
temperature.

OPEN operations.
Spray and rub the insulators clean.

Check cementing, bolts and nuts.
Spray equipment, clothes and
wrenches.
See Chapter 2.1.4.
12
1HSB445409-102 en
To be inspected
6a.
Main current circuit
Resistance check.
Inspection interval
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 specified in
applicable Assembly instructions for the
circuit-breaker in question.
Higher values allowed for frequent
operation with small currents (400 ).
Calculation of permissible resistance:
Rn In
R = ------- ----2 I
1.65
R=
Permissible increase in
resistance
Rn = Max. resistance as specified
in operating values
In = Rated current as specified on
rating plate
I=
Current for which max
resistance is calculated.
7a.
Contact system
Opening position
7b.
Operating
characteristics
Opening time
Closing time
Close-Open time
Phase discrepancy
Auxiliary switches
Contact travel
Contact damping.
1HSB445409-102 en

OPEN operations.
Inspection of reference holes in outer

arm and mechanism housing.
See applicable Assembly instructions
for the actual circuit-breaker.

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.
13
To be inspected
Inspection interval
8a.
Operation availability
Pull rod system
15 years or 5,000 mechanical

Close-Open operations.
Checking of the tightening torque of

nuts on pull rods.
Wrench size: 36 mm.
Torque: 300 Nm.
See applicable Assembly instruction for
actual circuit-breaker.
Safety of release of
operation

Measurement of minimum operating

voltage.
Closing coil: < 85% of nominal voltage.
Opening coil: < 70% of nominal voltage.
Variable D.C. voltage source required.
Anti-pumping device.

Checking anti-pumping function:

The circuit-breaker in open position, the
operating mechanism charged, CLOSE
and OPEN impulse given
simultaneously (the close button shall
be pressed).
The circuit-breaker will make a CLOSEOPEN 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).

OPEN operations.
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 1HSB 515409-100.
8b.
Motor current
14
1HSB445409-102 en
To be inspected
8c.
Dash-pots
8d.
Catch-gears.
Inspection interval

OPEN operations.
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.

OPEN operations.
Visual control of the adjustment.

Play of gaps in the catch-gears acc. to
Greasing of shafts and catch surfaces
with Grease L acc. to 1HSB445409-1.
Change the signal from coil 1 to coil 2.
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.

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).

OPEN operations.
Checking of resistance:
If applicable, check signal for loss of
power.
8e.
Coils
8f.
Mechanical interlocking
8g.
Heaters
Operating mechanism
1HSB445409-102 en
15
To be inspected
8h.
Central control cubicle
8i.
Thermostat
8j.
Terminal blocks
8k.
Direct on line motor
starter
Inspection interval

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%.

OPEN operations.
If applicable, check that the thermostat

is adjusted to requested value.

OPEN operations.
Tightening of screws or clamps.

See Manual 1HSB 515409-100.

OPEN operations.
If applicable, check signal for loss of

power.
See Manual 1HSB 515409-100.

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.
9.
Tightness of SF6-gas
Density monitoring.
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
16

OPEN operations.
The relays shall close when a density

switch is pulled out from a pole
pressurized to filling pressure.
1HSB445409-102 en
To be inspected
11.
Corrosion
12.
Lubrication
13.
Tightening torque
1HSB445409-102 en
Inspection interval

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.

OPEN operations.
Operating mechanism sliding surfaces

of spring bridge with Grease M and
chains with Oil A.
See Chapter 2.1.5, Chapter 2.2.3 and

OPEN operations
Check of tightening torque on screw

joints.
Tightening torques acc. to Assembly
Instruction and Overhaul Instruction.
Tightening torque for earthing 79 Nm.
17
3.5 Maintenance category D

To be inspected
1.
Overhaul of breaking
chambers
Line and transformer
circuit-breakers
nxI1.8 =20,000
Capacitor bank circuitbreakers

Reactor circuitbreakers
Filter circuit-breakers
Not synchronized:
2,500 CLOSE/OPEN operations
with el. load.
Synchronized:
5,000 CLOSE/OPEN operation with
el. load.
All kinds of service.
Alarming result at diagnostic test.
2.
Major overhaul of
complete circuitbreaker and operating
mechanism
3.
Capacitor
18
Measures / Instructions / Tools
Gas evacuated, poles/ breaking units

dismounted and transported to a clean
workshop.
Porcelain lift off, contacts and PTFEparts replaced with new ones.
See Manual Overhaul Instruction for
actual circuit-breaker.
Standard tools, close fitting dust mask,
long sleeved overall, protective plastic
or rubber gloves.
See Manual Overhaul Instruction for

Circuit-breaker.
Disassembly of the poles and
mechanisms. New contacts and PTFEcomponents 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 circuitbreaker.
Operating mechanism under
supervision from ABB.

Check of values on:

C = CN+5%,-0%
PD < 5 pC
Tan d < 0,2%.
1HSB445409-102 en

Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax:
+46 (0) 240 714 928
1HSB445409-102 en
0206
SF6 Circuit-Breaker
Circuit-breakers HPL and LTB
Lubricants
1HSB445409-1 en1
The information in this document is subject to alteration without prior notice and should not be
regarded as an undertaking from ABB Power Technology Products AB. ABB Power Technology Products AB takes no responsibility for errors that can occur in the document.
document.
Power Technology Products AB. It may not either be imparted to a third party or otherwise be used
without authorisation. Infringement hereof will be subject to action in accordance with applicable laws.
Article number: 1HSB445409-1 en1

Date: 2002-02-14
Lubricants
LIST OF CONTENTS
1. General ................................................................................ 1
1.1
Safety instructions.......................................................................... 1
2. Oil........................................................................................ 3
3. Grease ................................................................................. 5
1HSB445409-1 en1
General
Lubricants
1. General
As a guide to the selection of oils and greases for circuit-breakers, Combined,
Compact 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.
1HSB445409-1 en1
Lubricants
2. Oil
Oil A
Thin, fully synthetic lubricating oil for precision components in the operating
mechanism and circuit-breaker. Also used for post lubrication of bearings that
cannot be lubricated with grease G without dismantling, e.g. links and link gears.
Viscosity at 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 filled with oil S.
Oil S
Silicone oil intended for dashpots in heavy-duty operating mechanisms, type BLG.
Only dashpots with the letter s punched on the cover shall be filled with this oil.
SUPPLIER
1HSB445409-1 en1
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
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 and for moving contacts (opening contacts9 for disconnectors.
Grease K
Molykote grease for lubricating pins in link gears and in earthquake dampers.
Grease N
For lubricating moving contacts and puffer cylinders in SF6 circuit-breakers. The
grease shall be applied in a very thin layer on the 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. Also
for lubricating moving contacts (opening contacts) for earthing switches.
Grease P
Vaseline for coating contact surfaces on fixed joints on the inside of the breaking
unit.
Grease S
Fluoro-silicone grease for lubricating the EPDM-O-rings and as crevice corrosion
protection on circuit-breakers type ED as well as for lubricating rotating shaft seals
on circuit-breakers types LTB and HPL.
Grease SV
For lubricating moving contacts (opening contacts) for disconnectors, silver-plated
contacts and brushed aluminium surfaces on fixed joints outdoors
1HSB445409-1 en1
Lubricants
.
SUPPLIER
Grease G
Grease K
Grease N
Grease L
ABB art. No.
1171 4014-407
1263 0011-102
1171 4016-607
1171 4016-606
ABB spare part No.
5316 381-A
5316 381-M
5316 381-L
5316 381-H
ASEOL AG
ASEOL SYLITEA
4-018
Dow Corning
G-rapid plus
GULF
718EP Synthetic
grease
MOBIL
Mobil grease 28
Montefluos S.p.A.
Fomblin OT 20
SHELL
Aero Shell
Grease 223
SUPPLIER
Grease M
Grease P
Grease S
Grease SV
ABB art. No.
1171 4016-612
1171 5011-102
1171 4014-406
1171 4016-610
ABB spare part No.
5316 381-J
5316 381-N
5316 381-G
5316 381-C
Klber
Isoflex Topas NB
52
Dow Corning
Fluortech AB
SHELL
Statoil
1HSB445409-1 en1
FS-3451 No. 2
TP55
Shell vaseline
8401
Electrical grease

Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax:
+46 (0) 240 714 928
1HSB445409-1 en1
0202
SF6 Circuit-Breaker
Operating Mechanism
type BLG 1002A
Maintenance
1HSB515409-100 en rev3
document.

Date: 2002-10-06
Maintenance Operating Mechanism
LIST OF CONTENTS
1. General ............................................................................... 1
2. Safety................................................................................... 3
2.1
2.2
Warning text ................................................................................... 3

Safety directives ............................................................................. 4
3. Maintenance, general ......................................................... 7

3.1
3.2
3.3
3.4
Tools ............................................................................................... 7
Cleaning equipment ....................................................................... 7
Spare parts...................................................................................... 7
Test equipment ............................................................................... 7
4. Maintenance........................................................................ 9
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
1HSB515409-100 en rev3
General ........................................................................................... 9
Preparations for maintenance....................................................... 12
Cleaning ....................................................................................... 13
Corrosion...................................................................................... 13
Lubrication ................................................................................... 14
Heater element ............................................................................. 15
Drive unit...................................................................................... 16
Catch gear..................................................................................... 17
Dashpots....................................................................................... 18
Link system and spring battery .................................................... 20
Auxiliary contact.......................................................................... 20
Terminal blocks ............................................................................ 22
Slow closing and opening operations........................................... 23
Maintenance Operating Mechanism
FIGURES
Figure 4-1. Operating mechanism ..................................................................... 9

Figure 4-2. Interlocking mechanism ............................................................... 10
Figure 4-3. Releasing the interlock ................................................................. 11
Figure 4-4. Check dimension, closing springs. ............................................... 11
Figure 4-5. Control panel ................................................................................ 12
Figure 4-6. Heater element .............................................................................. 15
Figure 4-7. Drive unit ...................................................................................... 16
Figure 4-8. Catch gear ..................................................................................... 17
Figure 4-9. Checking the clearance. ................................................................ 17
Figure 4-10. Closing and Opening dashpots. .................................................... 18
Figure 4-11. Damping curve, Closing dashpot. ................................................ 19
Figure 4-12. Damping curves, Opening dashpot. .............................................. 19
Figure 4-13. Limit switch with auxiliary contact. ............................................. 20
Figure 4-1. Time measurement, contact travel. ............................................... 21
Figure 4-2. Electrical equipment. .................................................................... 22
Figure 4-3. Switch Local/Remote, direct-on-line starter ................................ 23
Figure 4-5. Fitting the blocking beams ........................................................... 24
Figure 4-6. Interlocking, circuit-breaker open and closing springs uncharged. ..
25
Figure 4-7. Operating mechanism, slow closing operation. ............................ 26
Figure 4-8. Switch Local/Remote, dirct-on-line starters. ................................ 27
Figure 4-10. Fitting the blocking beams. .......................................................... 28
Figure 4-11. Interlocking, circuit-breaker closed and closing springs uncharged.
29
Figure 4-12. Operating mechanism, slow opening operation. .......................... 30
Figure 4-13. Check dimension, closing springs. ............................................... 31
ii
1HSB515409-100 en rev3
Operating Mechanism Maintenance
General
1. General
This information applies to the spring operating mechanism BLG 1002A intended
for operating circuit-breakers with integrated opening springs. Information
regarding maintenance is provided in these instructions.
Preventive maintenance and overhaul work on the operating mechanism BLG
1002A should be carried out at regular intervals.
Visual inspection at intervals of 1-2 years.
Lubrication after 3-6 years or 2,000 mechanical Close-Open operations.
Preventive maintenance after 15 years or 5,000 mechanical Close-Open

operations.
Overhaul after 30 years or 10,000 mechanical Close-Open operations.
Overhauling and repair work may only be carried out by authorised ABB Power
Technology Products AB service personnel.
1HSB515409-100 en rev3
Safety
2. Safety
2.1 Warning text
observed extra carefully. The warning texts are marked as set out below:
DANGER
WARNING
CAUTION
injury.
1HSB515409-100 en rev3
Safety
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
Breakers with pressurised insulators.
Work on the circuit-breaker that risk mechanical damage to the insulators
should be carried out at a reduced gas pressure, 0.125 MPa (abs).
WARNING
Do not operate the mechanism unloaded!
Operations shall take place only when the mechanism has been connected
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 when circuit-breakers and relay
systems are tested with more than 3 closing operations.
1HSB515409-100 en rev3
Safety
WARNING
The work requires training and product knowledge and may only be
carried out by authorised personnel.
Risk
1HSB515409-100 en rev3
Measure
Working next to high voltage.
Isolate and earth next to the work

place. If work must be carried out
next 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 heater voltage.
Risk of crushing in the operating

mechanism and link system.
There is stored energy in both the
opening and the closing springs. The
mechanism can be tripped by heavy
vibrations or by unintentional contact
with the catch 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 drive shaft on
the operating mechanism backwards
by hand. For reasons of safety the
closing springs must be uncharged
during transportation as well as
during assembly and storage.
Working next to pressurised

insulators.
The normal working pressure is up to
0.8 MPa. Damage to the porcelain
can result in splintering.
Work next 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.
Maintenance, general
3. Maintenance, general
All requisite equipment should be available before work is started so that
maintenance work can be carried out in the best way.
The following equipment is required.
3.1 Tools
A normal set of tools including torque wrenches (10-100 Nm).
3.2 Cleaning equipment
Vacuum cleaner.
Drying cloths of a lint-free material.
Lubricants and oils, see Lubricants, 1HSB445409-1 for suppliers and trade
names.
3.3 Spare parts

Grease M: ABB Art. No. 1171 4016-612.
Oil A:
ABB Art. No. 1171 2039-1
Anti-corrosion agent.
Valvoline Tectyl 506: ABB Art. No. 1241 0011-108
Grease G: ABB Art. No. 1171 4014-407.
3.4 Test equipment
1HSB515409-100 en rev3
Equipment to record attenuation curves and operating values.

(e.g. Programma or ABB SA10).
Maintenance
4. Maintenance
4.1 General
The Operating and Maintenance Instructions for the circuit-breaker should be
studied and followed before work on circuit-breaker is started and while work is in
progress.
WARNING
Do not operate the operating mechanism unloaded!
and trimmed with the associated pressurised 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 and doors of the
cabinet can be removed to facilitate service and overhaul procedures.
2
Item
Drive unit
Operating
mechanism
Control panel
Spring battery
Heater element
4
5
3
B20001
Figure 4-1. Operating mechanism
1HSB515409-100 en rev3
Measure all operating values and note them down. If the measured values
correspond with the specified values for the circuit-breaker, then only a visual
inspection, cleaning and lubrication are required.
Maintenance
4.1.1 Mechanical interlock

The mechanical interlock prevents a closing operation if the circuit-breaker is
already in the closed position or if the closing springs in the operating mechanism
are uncharged or not completely charged, which can occur if, for example, the
closing catch has been opened by hand or if a mechanical fault has occurred in the
interlocking mechanism.
Check the position of the interlocking arm in relation to the outside of the
interlocking disc. The interlocking arm should lie 2 mm above this.
Check that the closing circuit is closed when the arm rests on the outside of the
interlocking disc.
1
Item
Limit switch
Interlocking arm
Interlocking disc
Cam disc
Operating rod
2 mm
3
4
5
B20019
Figure 4-2. Interlocking mechanism
10
1HSB515409-100 en rev3
Maintenance
Releasing the interlock

If the movement of the cam disc is stopped by the interlocking arm, it is not possible
to carry out a closing operation until the cam disc has been returned to its normal
position.
1.
Manual discharging of the closing springs.

a.
Turn the switch Local/Remote on the control panel to the STOP position.
b.
Switch off the motor voltage with the direct-on-line starters.
c.
Turn the switch on the drive unit to the HAND position so that the shaft
for manual cranking is released. Put the crank on the shaft.
2.
Press the reverse catch button in hard using a screwdriver and crank clockwise,
see Figure 4-3a, until the locking lug on the operating lever (1) is well past the
roller (2).
3.
Rectify the cause of the fault.
4.
Crank anticlockwise, see Figure 4-3b, until the locking lug on the operating
lever (1) rests against the roller (2) in the closing catch gear.
1
Item
1
Operating lever
Roller, Close
B20020
Figure 4-3. Releasing the interlock
4.1.2 Electrical interlock
294 +2
Check by measuring between the bridge and the

frame foot. Dimension according to figure.4.4
B20021
Figure 4-4. Check dimension, closing springs.
1HSB515409-100 en rev3
11
Maintenance
4.2 Preparations for maintenance

The following should be done before maintenance is started:
1.
Switch the circuit-breaker to the open position.
2.
Isolate and earth.
3.
Switch off the motor current.
4.
Perform a Close-Open operation so that the spring battery in the operating

mechanism is discharged.
5.
Switch off the control voltage and, if necessary, also the heater voltage.
Item
1
Control panel
Control switch On/Off
Switch Local/Remote
Electric counter
Spring indicator
B20009
Figure 4-5. Control panel
12
1HSB515409-100 en rev3
Maintenance
4.2.1 Emptying the gas

Work that involves a risk of damaging the insulators must not be carried out until the
gas has been evacuated to a pressure of max. 0.125 MPa (abs).
WARNING
Unused SF6 gas is non-toxic, odourless and colourless. It is heavier than
air and can therefore easily collect in low-lying places, e.g. cable trenches,
tanks, etc., if released in large volumes
When large quantities of SF6 gas collect in such places, a risk of
asphyxiation may occur due to a lack of oxygen.
The SF6 gas is evacuated by using gas handling equipment, which cleans and
compresses the gas so that it can be reused or destructed.
N.B. Mixed gas, SF6 mixed with N2 or CF4, must not be reused unless the mixture
ratio is kept under control. (Can be checked with a meter that indicates the
percentage of SF6.)
4.3 Cleaning
Clean the inside of the operating mechanism using a vacuum cleaner.
Check that the filters in the 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,
catches, gears and components in the link system.
Despite good rust protection, small signs of corrosion can appear after a number of
years, especially on circuit-breakers erected in very aggressive environments.
Rust spots should be removed and new anti-corrosive agent should be applied
by brush or spray. Recommended anti-corrosive agents are Grease G or
Tectyl 506.
N.B. After drying, Tectyl 506 forms a protective wax-like film and must not be
sprayed on bearings, catch gears, gears or chains.
1HSB515409-100 en rev3
13
Maintenance
4.5 Lubrication
The ball, roller and needle bearings in the operating mechanism are permanently
lubricated and require no maintenance. Therefore only the shafts in catch gears and
worm gear in the drive unit need to be lubricated.
Check whether the chains in the operating mechanism are dry and corroded
and, if necessary, lubricate with Grease G or oil A.
Sliding surfaces for the spring yoke and dashpots should be lubricated during an
overhaul with Grease G .
14
1HSB515409-100 en rev3
Maintenance
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 every15 years or 5,000 operations.
Item
1
Heater element
6 5 4
3 2
B20010
Figure 4-6. Heater element
Data
Tabell 4-1. Heater element resistances
-25C
70 W,
220 V, R=691 Ohms 10%
140 W,
220 V, R=346 Ohms 10%
2x140 W, 220 V, R=173 Ohms 10%
70 W,
110 V, R=173 Ohms 10%
140 W,
110 V, R=86 Ohms 10%
2x140 W, 110 V, R=43 Ohms 10%
-40C
-55C
X
X
X
X
70 W heater element permanently connected , 140 W or 2x140 W heater element

(thermostat controlled) extra for temperatures below -25C.
1HSB515409-100 en rev3
15
Maintenance
4.7 Drive unit
Check and clean the shafts in the catch gear and the worm gears in the drive
unit.
Lubricate these with Grease M at intervals of 15 years or 2,000 operations.
Measure the motor current at the end of the spring charging procedure at
intervals of 15 years or 5,000 operations. See the relevant Assembly
Instructions for the circuit-breaker, chapter Operating values.
The motor should be capable of charging the springs at 85% of its nominal voltage
(IEC).
Item
1
Drive unit
B20011
Figure 4-7. Drive unit
4.7.1 Switch Hand-Motor

Check that the signal for voltage failure functions. If not, replace the switch.
16
1HSB515409-100 en rev3
Maintenance
4.8 Catch gear

The operating mechanism is fitted as standard with one closing coil and two
opening coils, but can, on request, be equipped with double coils on the closing
side.
Closing catch gear
Item
1
Catch gear
1
Opening catch gear
B20012
Figure 4-8. Catch gear
Check that the voltage to the coils does not fall below the minimum voltage,
see the delivery document for the operating mechanism.
Check the play between the magnet arm and the auxiliary catch . The play must
be at least 1 mm. If the plays are outside the specified dimensions, replace the
entire catch gear.
1
Item
1
Auxiliary catch
Magnet arm
1 mm
B20013
Figure 4-9. Checking the clearance.
1HSB515409-100 en rev3
17
Maintenance
4.9 Dashpots
The operating mechanism is fitted with a Closing dashpot to brake the rotation of
the cam disc and an Opening dashpot to dampen the final phase of the opening
movement.
Item
1
Closing dashpot
Opening dashpot
2
B20014
Figure 4-10. Closing and Opening dashpots.
18
1HSB515409-100 en rev3
4.9.1 Closing dashpot

Check the oil level in the dashpot by recording the damping effect during operation.
Connect the circuit-breaker analysers sensor to the cam shaft in the operating
mechanism and record a damping curve. Check the damping distance and the
damping time as set out in Figure 4-11. If the measured values for a and b
are outside the specified values, replace the complete dashpot.
a = damping distance 15-25 mm

b = damping time 80-300 ms
B20015
Figure 4-11. Damping curve, Closing dashpot.
4.9.2 Opening dashpot

Check the oil level in the dashpot by recording the damping effect during operation.
B20016
Wrong
Connect the circuit-breaker analysers sensor to the breakers shaft and record a
damping curve. Check the damping distance and the damping time as set out in
Figure 4-12. If the recorded curve differs from the correct curve, replace the
complete dashpot.
Right
Wrong
Figure 4-12. Damping curves, Opening dashpot.
1HSB515409-100 en rev3
19
Maintenance
4.10 Link system and spring battery

Perform a visual check of the spring battery, links and bearings. If necessary,
lubricate the links and bearings with Grease M.
4.11 Auxiliary contact

The operating mechanism is fitted as standard with a 6-pole auxiliary contact
consisting of six opening and six closing contacts. Three closing and one 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.
Item
1
Limit switch
Auxiliary contact
B20017
After 15 years or 5,000 operations, check the contact travel by measuring the times
and compare the results with those obtained during commissioning. The comparison
can then be used to check the condition of:
20
Contact travel
Contact damping
1HSB515409-100 en rev3
1.
Connect a time-meter across the signal contacts 20, 29, 291 and 292 in
accordance with the circuit diagram.
2.
Measure the times t1, t2 and t3
3.
Turn the switch Local/Remote to the LOCAL position.
4.
Connect the time-meter across terminals X1:190 and X1:192.
5.
Turn the switch On/Off to the OFF position and then the ON position.
6.
Note down the times t1, t2 and t3.
7.
Disconnect the time-meter.
8.
Turn the switch Local/Remote to the REMOTE position.
Contact travel
Arcing contact
Closed
Auxiliary contact
Contact travel
Open
t3
t1
Time
t2
t1 ms
Proportional to the contacts opening speed.
t2 ms
Time that determines contact damping.
t3 ms
Proportional to the contacts closing speed.
B20018
Figure 4-1. Time measurement, contact travel.
1HSB515409-100 en rev3
21
4.12 Terminal blocks

Check all screws and pins.
11
1
Item
13
2 limit switches with

auxiliary contacts
Motors
Switch Hand/Motor
Relays
Contactors
Direct-on-line starters
Miniature circuit-breakers
Plug socket
Thermostat
10
Fuses
11
Opening coil
12
Terminal block
13
Closing coil
14
Cover
12
3
14
12
7
4
6
9
4
B20022
10
Figure 4-2. Electrical equipment.
22
1HSB515409-100 en rev3
4.13 Slow closing and opening operations

Some service work requires the circuit-breaker to operate slowly. For example
preparing for overhaul of breaking unit on two chamber breaker.
CAUTION
Slow closing and opening operations may only be carried out by persons
that are well conversant with the operation of the mechanism and circuitbreaker, as there is a risk of personal injury and mechanical damage.
Slow closing of the operating mechanism

May only be carried out if:
1.
The circuit-breaker is in the open position.
2.
The switch Local/Remote (1) on

the control panel is in the Off
position.
3.
The motor voltage is switched

off with the direct-on-line
starters (2), (3).
4.
The switch Motor/Hand (4) is in

the Hand position so that the
shaft for manual cranking is
released.
4
Item
1
Switch Local/Remote
Direct-on-line starter
Switch Motor/Hand
B20002
Figure 4-3. Switch Local/Remote, direct-on-line starter

1HSB515409-100 en rev3
23
5.
The closing springs are uncharged.

a.
Place the crank (1) on the shaft.
b.
Press the reverse catch button (2) in hard using a screwdriver to release the
reverse catch and discharge the springs. Crank clockwise until the spring
yoke has reached the bottom position and rests against the foot of the
frame.
Item
1
Crank
Reverse catch button
Switch Motor/Hand
Direction
of rotation
Direction
of power
Direction
of power
1
2
B20003
6.
Blocking beams fitted.

a.
Fit the blocking beam (1) around the rod so that the fixing hole is facing
out towards the cabinet. Fit the bolt (2) in the blocking beam.
b.
Fit the other beam in the

same way.
Item
1
Blocking beams
2 pcs.
Bolts M8x60
2 pcs.
B20004
1
2
1
2
Figure 4-5. Fitting the blocking beams
24
1HSB515409-100 en rev3
7.
The interlocking mechanism is disengaged.

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

2
4
Item
1
Operating rod
Interlocking arm
Blocking pin
Hole for blocking pin
Open
position
Closed
position
B20005
Figure 4-6. Interlocking, circuit-breaker open and closing springs uncharged.
8.
The blocking beams move against the mechanical end stop.

a.
9.
Crank anticlockwise, normally 6-8 turns, max. 10 turns.
The intermediate catch is released.

a.
Press down the armature on the closing coil (1).
The slow closing operation in progress can be interrupted in any position before the
locking lug engages the roller. Press in the reverse catch button, so that the circuitbreaker runs slowly towards its open position and stops in the required position
when the button is released.
1.
Crank anticlockwise 310 turns. The cam disc (2) then rotates approx. 3/4 of a
turn and actuates the stop roller (3) so that the operating lever (4) slowly moves
the circuit-breaker towards the closed position. Towards the end of the
movement a click is heard when the locking lug (5) on the operating arm
engages behind the roller (6) in the tripping mechanism.
2.
Crank a few more turns anticlockwise, so that the outer most tip on the cam
disc (2) leaves the stop roller (3). The operating lever is drawn quickly towards
the open position by the power of the opening spring until the locking lug (5)
loudly rests against the roller (6).
3.
Crank anticlockwise until the locking lug (7) just rests against the roller (8) so
that the cam disc returns to its normal position and the blocking beams are offloaded.
4.
Remove the blocking beams.
5.
Check that the locking lug (7) rests against the roller (8). Otherwise the cam
disc will come in the wrong position and the operating mechanism can be
damaged during an opening operation.
1HSB515409-100 en rev3
25
6.
Pull the blocking pin out of the hole.
7.
Turn the switch Motor/Hand to the Motor position.
8.
Switch on the motor voltage with the direct-on -line starters.
9.
Set the switch Local/Remote to the Remote position.
The circuit-breaker is now in the closed position and a normal opening operation
can be carried out.
N. B. Check that the blocking beams are dismantled before carrying out an opening
operation.
3
4
Item
1
Closing coil
Cam disc
Stop roller
Operating lever
Locking lug
Roller, Open
Locking lug
Roller, Closed
6
8
B20006
Figure 4-7. Operating mechanism, slow closing operation.
26
1HSB515409-100 en rev3
Slow opening operation

May only be done if:
1.
The circuit-breaker is in the closed position.
2.
The switch Local/Remote (1) on

the control panel is in the Off
position.
3.
The motor voltage is switched

off with the direct-on-line
starters (2), (3).
4.
The switch Motor/Hand (4) is in

the Hand position so that the
hand crank shaft can be released.
Item
1
Switch Local/Remote
Switch Motor/Hand
B20002
Figure 4-8. Switch Local/Remote, dirct-on-line starters.
1HSB515409-100 en rev3
27
5.
The closing springs are uncharged.

a.
Place the crank (1) on the shaft.
b.
Press the reverse catch button (2) in hard using a screwdriver to release the
reverse catch and discharge the springs. Crank clockwise until the spring
yoke has reached the bottom position and rests against the foot of the
frame.
Item
1
Crank
Reverse catch button
Switch Motor/Hand
Direction
of rotation
of
Direction of
power
Direction of
power
1
B20003

6.
Blocking beams fitted.

a.
Fit the blocking beam (1) around the rod so that the fixing hole is facing
out towards the cabinet. Fit the bolt (2) in the blocking beam.
b.
Fit the other beam in the

same way.
Item
1
Blocking beams
2 pcs.
Bolts M8x60
2 pcs.
B20004
1
2
1
2
Figure 4-10. Fitting the blocking beams.

28
1HSB515409-100 en rev3
7.
The interlocking arm (1) is locked by the pin (5) and stops in the horizontal
position against the locking disc (4).
a.
Press the interlocking arm (1) with force upwards.
b.
Insert the blocking pin (2) in the hole (3).

1
3
Item
1
Interlocking arm
Blocking pin
Hole for blocking pin
Locking disc
Pin
Open
position
Closed
position
2
4
5
B20007
Figure 4-11. Interlocking, circuit-breaker closed and closing springs uncharged.

The slow opening operation means that by using the cam disc you fetch the
circuit-breaker and thereafter release the reverse catch and let the operating
mechanism make a slow opening operation.
1.
Place the crank in the manual operation position and crank anticlockwise until
the blocking beams move against the mechanical end stop. It feels like a light
resistance on the crank and takes normally 6-8 turns, max. 10 turns.
2.
Press down the armature on the closing coil (1), Figure 4-12, so that the locking
lug (2) is disengaged from the roller (3).
3.
Turn the crank approx. 300 turns anticlockwise. If the crank is turned too many
turns, a clang is heard when the cam disc (4) passes the stop roller (5) and
returns once again to the position shown in Figure 4-12, top diagram. Make a
new attempt. Follow the instructions from point 1 and crank a few turns less.
4.
Press in the reverse catch button in the drive unit.
5.
Release the crank and let it rotate until it stops.
6.
Release the opening catch gear by tapping the armature (6) lightly with, e.g. a
screwdriver. The switchs opening springs draw the operating lever (7) towards
the open position. The movement is stopped when the stop roller (5) rests
against the cam disc (4).
7.
Keep the reverse catch button held in until the circuit-breaker has been drawn
into the open position by the opening springs. If the spring force is not
sufficient to move the locking lug (2) so it passes and engages in the locked
position against the roller (3), press in the button and turn the crank clockwise.
8.
Dismantle the blocking beams.
1HSB515409-100 en rev3
29
9.
Check that the locking lug (2) rests against the roller (3). Otherwise crank anticlockwise until the locking lug rests against the roller.
10. Pull the blocking pin out of the hole.

11. Turn the switch Motor/Hand to the Motor position.
12. Switch on the motor voltage with the direct-on-line starters.
13. Turn the switch Local/Remote to the Remote position.
The circuit-breaker is now in the open position and a normal closing operation can
be carried out.
N.B. Check that the blocking beams have been dismantled before carrying out an
opening operation.
3
2
5
4
Item
1
Closing coil
Locking lug
Roller, Closed
Cam disc
Stop roller
Armature
Operating lever
B20008
Figure 4-12. Operating mechanism, slow opening operation.
30
1HSB515409-100 en rev3
4.13.1 Manual tensioning of the closing springs

Crank anticlockwise until the closing springs are fully charged. Check by
measuring between the bridge and the frame foot.
2.
Turn the switch on the drive unit to the

MOTOR position.
3.
Reset the direct-on-line starters.
4.
Turn the switch Local/Remote on the

control panel to the REMOTE position.
5.
Make a test operation.
294 +2
1.
B20021
Figure 4-13. Check dimension, closing springs.
1HSB515409-100 en rev3
31

Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax:
+46 (0) 240 714 928
1HSB515409-100 en rev3
0602
SF6 Circuit-Breaker

mechanism BLG 1002A
1-pole operation
Overhaul Instructions
1HSB445409-212 en
ABB Power Technology Products AB is not responsible for damage incurred due to the misuse of
this document.
The document, or parts of it, may not be reproduced or copied without prior permission from ABB
Power Technology Products AB. It may not either be imparted to a third party or otherwise be used
without authorisation. Infringement hereof will be subject to action in accordance with applicable
laws.

Date: 2002-04-05
LIST OF CONTENTS
1. General ............................................................................... 1
2. Safety................................................................................... 3
2.1
2.2
Warning text ................................................................................... 3

Safety directives ............................................................................. 4
3. Overhaul, general ............................................................... 7

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

4.1
4.2
4.3
4.4
4.5
General ........................................................................................... 9
Gas................................................................................................ 10
Cleaning and waste disposal ........................................................ 11
Dismantling the breaking unit for transport ................................. 12
Dismantling the breaking unit...................................................... 16
5. Contact and puffer replacement ..................................... 19

5.1
5.2
5.3
Replacing the upper main circuit ................................................. 19

Replacing the lower current path ................................................. 20
Replacing the puffer ..................................................................... 21
6. Overhaul of the upper mechanism ................................. 23

7. Assembling the breaking unit ......................................... 25
7.1
7.2
7.3
Treatment of contact surfaces ...................................................... 25

Treatment of sealing surfaces and seals ....................................... 26
Assembling the breaking unit....................................................... 27
8. Dismantling the post insulator and mechanism for

transport31
8.1
8.2
8.3
Dismantling the post insulator ..................................................... 32

Off-loading the tripping mechanisms pull-rod............................ 32
Removing the post insulator......................................................... 33
9. Overhaul of the mechanism ............................................ 35

1HSB445409-212 en
10.Assembling the post insulator........................................37

10.1 Assembling the tripping mechanisms pull-rod on the operating
lever .............................................................................................. 39
10.2 Assembly the Opening device High-speed ............................... 40
10.3 Gas filling ..................................................................................... 41
11.Assembling the circuit-breaker and commissioning....43
ii
1HSB445409-212 en
FIGURES
Figure 4-1. Deassemble Opening device High-speed ..................................12

Figure 4-2. Off-loading the pull-rod. ...............................................................13
Figure 4-3. Dismantling the breaking unit. ......................................................14
Figure 4-4. Assembling the transport cover. ....................................................15
Figure 4-5. Breaking unit with assembly tool. .................................................16
Figure 4-6. Dismantling the breaking unit. ......................................................17
Figure 5-1. Upper current path. ........................................................................19
Figure 5-2. Lower current path. .......................................................................20
Figure 5-3. Puffer. ............................................................................................21
Figure 6-1. Upper mechanism. .........................................................................23
Figure 7-1. Assembling the puffer and lower current path. .............................27
Figure 7-2. Assembling the breaking unit. .......................................................28
Figure 7-3. Assembling the absorption agent and cover. .................................29
Figure 7-4. Assembling the locking washer. ....................................................30
Figure 8-1. Dismantling the post insulator. ......................................................31
Figure 8-2. Off-loading the pull-rod. ...............................................................32
Figure 8-3. Dismantling the post insulator. ......................................................33
Figure 8-4. Dismantling the operating insulator. .............................................34
Figure 9-1. Mechanism housing. .....................................................................35
Figure 10-1. Assembling the operating insulator. ..............................................37
Figure 10-2. Assembling the post insulator. ......................................................38
Figure 10-3. Assembling the tripping mechanisms pull-rod on the operating
lever ...............................................................................................39
Figure 10-4. Assembling the Opening device High-speed .............................40
1HSB445409-212 en
iii
General
1. General
This Overhaul Instruction Manual applies to the SF6 circuit- breaker
HPL 245-550B2, 1-pole operation. It contains information for overhaul and repair
work.
Overhaul and repair work may only be carried out by technicians trained by
ABB Power Technology Products AB.
1HSB445409-212 en
Safety
2. Safety
2.1 Warning text
observed extra carefully. The warning texts are marked as set out below.
DANGER
in death or serious personal injury.
WARNING
in death or serious personal injury.
CAUTION
indicates a hazardous situation than can result in minor or moderate
injury.
1HSB445409-212 en
Safety
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 porcelain insulators.
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).
WARNING
Do not operate the mechanism unloaded!
The standard operating cycle is O- 0.3 s - CO - 3 min.-CO. The time between

1HSB445409-212 en
Safety
WARNING
Work requires training and product knowledge and may only be carried
out by authorised personnel.
Risk
1HSB445409-212 en
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. Off-load 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 off-loaded 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 porcelain, must not be carried
out until the gas has been emptied to
max. 0.125 MPa (abs.) pressure.
Overhaul, general
3. Overhaul, general
Before the overhaul work is started, all the necessary equipment and replacement
parts should be made available so that the overhaul work can be carried out in the
best possible way.
The following equipment is needed.
3.1 Tools
A normal set of tools and 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.
Assembly tool, ABB Art. No. 5439 142-E.
3.2 Gas handling equipment

Gas handling equipment for evacuating, cleaning, compressing and storing the used
SF6 gas as well as instruments for monitoring the pressure and vacuum.
3.3 Personal safety equipment
Full face mask with filter for fine particles and acid gases.
Long-sleeved overall.
Protective gloves of plastic or rubber.
3.4 Cleaning equipment
1HSB445409-212 en
Vacuum cleaner with micro-filter and plastic nozzle.
Drying cloths of a lint-free material.
Sealed storage containers for waste products and used absorption filters.
Wire brush for contact surfaces of aluminium.
Cleaning pad, e.g. Scotch Brite, for contact surfaces of copper.
Industrial alcohol 95% (vol), C2H5OH, for cleaning inside surfaces.
Heavy duty plastic sheet and plastic bags to prevent the ingress of moisture and
to protect cleaned components before assembly.
Overhaul, general
3.5 Spare parts
Contact kits1
Set of seals1
Absorption agent1
Lubricants, see Lubricants, 1HSB445409-1 for the names of suppliers and

brands
Grease K: ABB Art. No. 1263 0011-102
Grease M: ABB Art. No. 1171 4016-612
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.
SF6 gas.
Nitrogen gas.
Protective cover, circlip and off-loading tool from the assembly.
Protective cover for breaking unit ABB Art. No. 1HSB442186-5.
Protective cover for post insulator, ABB Art. No. 1HSB442158-1.
Locking ring, ABB Art. No. 2171 835-D.
Off-loading tool for tripping mechanism, ABB Art. No. 1HSB446381-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 unit must be opened indoors in dry and clean
premises.
When the weather is good and settled and outdoor working conditions are similar to
indoor conditions, the breaking units can be removed outdoors and transported to
dry and clean premises for the overhaul.
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 breaker in question.

1HSB445409-212 en
Dismantling the circuit-breaker
4. Dismantling the circuit-breaker

4.1 General
Before the circuit-breaker is dismantled and during the course of the dismantling
work, the directives in the Operating and Maintenance Instructions
1HSB445409-100 must be read and followed:
Check and make a note of the circuit-breakers operating values before dismantling.
Any deviation from the recommended values indicates that something must be
carefully checked during the overhaul.
The overhaul can be carried out separately on:
The breaking unit.
The post insulator.
N.B. Removal and assembly of the breaking units must not be done when the
weather is such that there is a risk of rain.
WARNING
This work requires 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:
1HSB445409-212 en
Operate the circuit-breaker to the Open position.
Isolate and earth.
Off-load the spring battery in the operating mechanism by switching off the
motor current and performing a Close-Open operation.
Switch off the control voltage and, if necessary, also the heater power.
4.2 Gas
Work on the circuit-breakers insulators or other live components as well as
transport and dismantling of complete circuit-breaker poles from the frame, may not
be done until the gas has been evacuated to a pressure of max 0.125 MPa (abs).
Gas shall be emptied fully to atmospheric pressure when a normal pressurised
space, e.g. the breaking unit, shall be opened.
WARNING
When nitrogen gas is used for cleaning inside the circuit-breaker, the gas
may be discharged into the atmosphere, but only via a dust and absorption
filter.The emptying operation must be done outdoors and at ground level.
WARNING
Unused SF6 gas is non-toxic, odourless and colourless. It is heavier than
air and can therefore easily collect in low-lying places, e.g. cable trenches,
tanks, etc., if released in large volumes.
When large quantities of SF6 gas collect in such places, a risk of
asphyxiation may occur due to lack of oxygen.
4.2.1 Emptying the gas:

The SF6 gas is evacuated and the circuit-breaker should be vacuum pumped using
the gas handling equipment. This cleans and compresses the gas so that it can be
reused or destructed.
N.B. Mixed gas, SF6 mixed with N2 or CF4, must not be reused unless the mixture
ratio is under control. (Can be checked with a meter that indicates the
percentage of SF6.)
After vacuum pumping, the circuit-breaker is filled with dry nitrogen gas until
atmospheric pressure is reached and is then vacuum pumped again. In this way any
free-floating dust inside the circuit-breaker will be extracted.
Finally the circuit-breaker is filled again with dry nitrogen gas until atmospheric
pressure is reached. The breaker is now ready to be dismantled.
10
1HSB445409-212 en
4.3 Cleaning and waste disposal

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 overalls and a full face mask
with a fine particle and acidic gas filter must be worn when cleaning the inside of
the circuit-breaker.
The dust (decomposition products) that forms in the circuit-breaker can be removed
using a vacuum cleaner fitted with a micro-filter and wiped off using a soft cloth
dampened with alcohol.
N.B. All dust, old absorption agent, used cloths, etc., should be collected in a
sealed vessel and treated as chemical waste according to applicable local
directives.
Protective gloves must be worn during all waste handling.
N.B. Drying cloths, protective gloves and vacuum cleaner bags should be rinsed
thoroughly in water after waste handling.
1HSB445409-212 en
11
4.4 Dismantling the breaking unit for transport

Before the breaking unit 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.
1.
2.
Loosen the nuts, bolts and washers (2). Deassemble the complete Opening
device High-speed(3).
2
Item
1
Bolt M8x16
Washer
Pin
1 pcs.
1 pcs.
1pcs.
Bolt M12x50
Washers 13x24x2.5
Nuts M12
4 pcs.
4 pcs.
4pcs.
Opening device
High-speed
Figure 4-1. Deassemble Opening device High-speed
12
1HSB445409-212 en
3.
Operate the circuit-breaker slowly towards the Closed position by cranking the
operating mechanism by hand. This is described in the Product Information for
the operating mechanism. Stop cranking when the dimension L= 180 mm has
been reached.
4.
Remove the tripping mechanisms bottom cover (1).
5.
Remove the bolt (2) and fit tool (3) 1HSB446381-A.
6.
Tension the adjuster screw (4) to off-load the tripping mechanisms pull-rod (5)
from the operating lever (6) in the mechanism housing.
Item
1
Bottom cover
Bolt M16x30
Washer
Tool 1HSB446381-A
Adjuster screw
Pull-rod
Operating lever
1 pcs.
1 pcs.
3
B10098
Figure 4-2. Off-loading the pull-rod.
1HSB445409-212 en
13
1.
Dismantle the cover (3) from the breaking unit (1).
2.
Fit the locking washer (5) so that the contacts in the breaking unit are held in
the right position.
3.
Dismantle the circlip (6) and pin (7).
4.
Place a lifting sling around the breaking unit (1) and prepare to lift it.
5.
Undo the bolts (8) against the post insulator and carefully lift the breaking unit
straight up.
1
3
5
Item
8
Breaking unit
Post insulator
Cover with 2 sealing rings
Bolts M10x25
Washers 10.5x22x2
Locking washer
Circlip
Pin
Bolts M12x70
Washers 13x24x2.5
Nuts M12
4 pcs.
4 pcs.
6, 7
4 pcs.
8 pcs.
4 pcs.
B10093
Figure 4-3. Dismantling the breaking unit.
6.
14
Assemble the cover (3) on the breaking unit using the bolts and washers (4),
tighten by hand.
1HSB445409-212 en
1.
Fit the breaking units transport cover (1) with associated sealing ring.
2.
Fit the transport cover (3) with associated sealing ring on the post insulator.
3.
Fill the post insulator with SF6 gas or nitrogen gas to a pressure of
0.125 MPa abs.
Item
1

ring
Bolts M12x50
Washers 13x28x3
Nuts M12

ring
8 pcs.
16 pcs.
8 pcs.
B10090
Figure 4-4. Assembling the transport cover.
4.
Place the breaking unit on a suitable transport base so it cannot tip over.
The breaking unit is now ready for transportation to the workshop for an overhaul.
1HSB445409-212 en
15
4.5 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.
Dismantling and assembly are facilitated by placing the breaking unit on an
assembly tool, ABB Art. No. 5439 142-E, with a mechanism for operating the
contacts.
1.
Lift the breaking unit (1) from the transport base and dismantle the transport
cover (2), but let the sealing ring remain in position.
2.
Place the assembly tool (4) on the transport base and position the
breaking unit (1).
3.
Connect the mechanism in the assembly tool to the breaking unit by fitting the
pin (5) and circlip (6).
4.
Screw a bolt, M8, into the threaded hole in the locking washer (7) and pull it out.
5.
Remove any capacitors and corona rings.

1
Item
1
Breaking unit
Transport cover with sealing ring
Bolts M12x70
Washers 13x28x3
Nuts M12
Assembly tool Art.No. 5439 142-E
Pin
Circlip
Locking washer
4 pcs.
8 pcs.
4 pcs.
7
5, 6
3
B10099
Figure 4-5. Breaking unit with assembly tool.
16
1HSB445409-212 en
1.
Dismantle the cover (1) and lift out the absorption agent containers (2).
N.B. Place the bags with absorption agent in a vessel for chemical waste.
2.
Mark the flanges on the breaking chamber insulators (5) so that they can be reassembled in the same position.
3.
Dismantle the upper current paths (3) with the upper connection flange.
4.
Place a lifting sling on the breaking chamber insulators as set out in Figure 4-6
and undo the breaking chamber insulators (5) from the mechanism housing (4).
Carefully lift straight out so that the puffer (6) and lower current path (7) are
not damaged.
5.
Dismantle the lower current paths (7).
6.
Operate the puffer (6) outwards using a spanner on the shaft (8) and dismantle
the puffer by removing the pin (9) on the lower end of the puffers pull-rod.
9
2
1
5
4
Item
1
Cover
Absorption agent container
Upper current path
Breaking chamber insulator
Puffer
Lower current path
Shaft with 24 mm spanner head
Pin
B10100
Figure 4-6. Dismantling the breaking unit.
The main components of the breaking unit are now accessible for inspection,
cleaning and replacement of burnt or damaged parts.
1HSB445409-212 en
17
Contact and puffer replacement
5. Contact and puffer 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.
5.1 Replacing the upper main circuit

The entire current path (3) with flange and puffer should be replaced if the upper
current paths fixed arcing contact (4), Figure 5-1, has been burnt so that the
distance to the reference surface is more than 9 mm or if the outside has been
severely burnt. Replace the upper current path if the silver on the current paths
contacts is worn so that the copper is visible.
Tighten the bolts (2). Tightening torque 22.5 Nm.
Item
max. 9 mm
Flange
Bolt M8x20
Retaining washer
Washer
Current path
Arcing contact
Reference
surface
TIGHTENING TORQUE
22.5 Nm
B10101
Figure 5-1. Upper current path.
1HSB445409-212 en
19
5.2 Replacing the lower current path

Remove the current path from the upper mechanism housing. Lift off the puffer and
check that there is no wear on the pull-rods sliding surfaces in the puffer guide.
Check that the silver on the lower current path contacts is not worn so that the
copper is visible.
If there are signs of wear, replace the whole lower current path with flange.
Tighten the bolts (2). Tightening torque 22.5 Nm.
1
Item
1
Upper mechanism
housing
Bolt M8x20
Retaining washer
Washer
Current path
Puffer
Puffer guide
Teflon band
5
TIGHTENING TORQUE
22.5 Nm
B10102
Figure 5-2. Lower current path.
20
1HSB445409-212 en
5.3 Replacing the puffer

Check that the nozzle (1) is not punctured. Also check that the contact surfaces on
the puffer cylinder (3) are not burnt or worn so that the copper is visible. Check that
there is no wear on the pull-rods sliding surfaces.
N.B. If the upper current path has been replaced because the fixed arcing contact is
burnt, the puffer must also be replaced.
Replace the entire puffer if it has burnt or worn surfaces.
Item
Nozzle
Pull-rod
Puffer cylinder
Bolt M8x16
TIGHTENING TORQUE
22.5 Nm
Contact surface
B10025
Figure 5-3. Puffer.
1HSB445409-212 en
21
Overhaul of the upper mechanism
6. Overhaul of the upper mechanism

Check that the upper mechanism is not heavily contaminated with decomposition
products.
Replace all sealing rings and coat them with grease G and all pins with grease
M, if the mechanism needs to be dismantled and cleaned.
Item
1
Pull-rod, upper
section
Support collar
Sealing ring
Bushing
Sealing ring
B10103
Figure 6-1. Upper mechanism.
1HSB445409-212 en
23
Assembling the breaking unit
7. Assembling the breaking unit

To re-assemble the breaking unit follow the dismantling instructions in the reverse
order, see Chapter 4.5.
N.B. When re-assembling the breaking unit, all sealing rings should be new.
Careful cleaning and treatment of sealing surfaces is required.
7.1 Treatment of contact surfaces

Before re-assembling the breaking unit, treat the contact surfaces as follows:
7.1.1 Fixed contact surfaces
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 surfaces must be clean and free from oxide. If necessary, clean with a
cloth and solvent (alcohol) or with Scotch Brite.
N.B. After cleaning with Scotch Brite, always remove all loose particles from the
surfaces using alcohol.
Aluminium surfaces
Brush clean contact surfaces of aluminium, using Scotch Brite. Immediately
thereafter carefully clean the surfaces to remove any loose particles with a dry,
clean cloth. Then coat the surfaces with a thin layer of Vaseline, grease P
(ABB Art. No. 1171 5011-102).
N.B. Grease should be applied within five minutes of cleaning and the joint should
be fitted within 15 minutes.
7.1.2 Moving contact surfaces
1HSB445409-212 en
Silver-plated:
If necessary, clean silver-plated moving contact surfaces, using a soft cloth and
solvent (alcohol).
Non-silver-plated:
Clean moving contact surfaces that are not silver-plated in a similar way to
silver-plated surfaces. However, they may also be cleaned with Scotch Brite.
After cleaning with Scotch Brite, always remove all loose particles.
Greasing:
Apply Grease N (ABB Art. No. 1171 4016-607) in a covering, but very thin
layer to the male contacts and the puffer cylinder surfaces. Carefully wipe off
all excess grease.
25
7.2 Treatment of sealing surfaces and seals

Clean, degrease and inspect all sealing surfaces in connection with assembly.
N.B. Sealing grooves and other sealing surfaces must not have lateral scratches.
Any small scratches on sealing surfaces can be polished with a fine abrasive,
e.g. Scotch Brite. Polishing shall take place along the sealing line but never
across it.
When re-assembling the circuit-breaker replace all seals with new ones.
Grease sealing surfaces and seals sparingly to facilitate the seals union against the
surface and as corrosion protection. Excess grease that can squeeze out on flanges in
the gas chamber must not occur.
Coat flange surfaces outside the outer seal with a thin, well-covering layer of anticorrosion agent matched to the flange material in question, usually Grease G
(ABB Art. No. 1171 4014-407).
Degreasing and cleaning material:
Alcohol.
Greases for seals:
26
Grease G for static seals

Grease S for moving seals, e.g. shaft seals.
1HSB445409-212 en
7.3 Assembling the breaking unit

1.
Fit the puffers (1) on the puffer guides. When the puffer starts to go down over
the Teflon band, carefully turn it so that the Teflon band is not damaged.
N.B. Take care so that the Teflon band on the piston is not damaged when the
puffer is moved down.
2.
Connect together the puffers pull-rods (2) and links (3) with the pins (4).
3.
Fit the lower current paths (5) over the puffers and puffer guides. Tighten the
bolts (6) to a torque of 22.5 Nm.
4
TIGHTENING TORQUE
22.5 Nm
Item
Puffer
Pull-rod
Link
Pin
Lower current path
Bolts M8x20
Washers 8.4x20x2
Retaining washers
12 pcs.
12 pcs.
12 pcs.
B10104
Figure 7-1. Assembling the puffer and lower current path.
1HSB445409-212 en
27
4.
Carefully clean the sealing surfaces for the sealing rings (1) and the outside
surface on the upper mechanism housing (2) and coat well with grease G.
Place the sealing rings (1) on the mechanism housing and carefully lift the
breaking chamber insulators (3) into position. Tighten by hand with the bolts
(4).
5.
Carefully clean the sealing surfaces for the sealing rings (5) and the surface
outside the lower top flanges (6) and coat well with grease G. Place the
sealing rings (5) on the lower top flanges (6) and assemble with the upper
current path (7). Tighten the upper current path by hand with bolts (8).
4
Item
1
Sealing ring
Breaking chamber insulator
Bolts M12x50
Washers 13x28x3
Sealing ring
Upper flange
Upper current path
Bolts M12x50
Washers 13x28x3
Puffer
10
Spanner
2
3
8 pcs.
8 pcs.
8 pcs.
8 pcs.
9
10
B10105
Figure 7-2. Assembling the breaking unit.
6.
Slowly operate the puffers (9) towards their Closed position using the spanner
(10). Align the fixed contacts so that they are centred with each other by
moving the upper flanges (6) and, if necessary, the breaking chamber insulators
(3) too.
7.
Tighten the bolts (4) and (8) with a tightening torque of 60 Nm.
TIGHTENING TORQUE
60 Nm
28
1HSB445409-212 en
1.
Clean the sealing surfaces on the upper flanges (1) and the outside surface and
coat with grease G. Place the sealing rings (2) on the upper flanges.
2.
Open the new absorption agent package and place the agent in the absorption
agent containers (3).
3.
Fit the absorption agent containers (3) and the covers (4) and tighten the bolts
with a torque of 45 Nm.
TIGHTENING TORQUE
45 Nm
Item
1
Upper flange
Sealing ring
Absorption agent container
Upper cover
Cover
Spanner
3
1
B10106
Figure 7-3. Assembling the absorption agent and cover.
4.
Fit the cover (5) with the sealing ring.
5.
Operate the breaking unit until it is virtually in the Closed position using the
spanner (6).
6.
Fill the breaking unit with gas.

a.
Vacuum pump down to 100 Pa and let the pumping continue for at least
one hour after this pressure has been reached.
b.
Stop the vacuum pumping and fill the circuit-breaker with dry and pure
nitrogen to atmospheric pressure. Allow to stand for a few hours or
overnight.
c.
Vacuum pump again down to 100 Pa and fill with pure SF6 gas to a
pressure of 0.125 MPa (abs).
Store filling hoses so that they are not exposed to moisture or contamination. They
must not be used other than for their intended purpose.
7.
1HSB445409-212 en
Check, using a detector, around all covers and insulator flanges that the
breaking unit does not leak.
29
1.
Turn the shaft with spanner (1) so that the slot on the end of the shaft is vertical
and the breaking unit is in the sealed position.
2.
Dismantle the cover (2), circlip (3) and pin (4) and fit the locking washer (5).
3.
Fit the cover (2).
4.
Fit any capacitors.
5.
Lift off the breaking unit from the assembly tool and fit the transport cover (6).
6.
Place the breaking unit on a suitable transport base.

5
4, 3
Item
2
1
Spanner
Cover
Circlip
Pin
Locking washer
Transport cover with sealing ring
Bolts M12x50
Washers 13x28x3
Nuts M12
1
1
4 pcs.
8 pcs.
4 pcs.
B10099
Figure 7-4. Assembling the locking washer.
The breaking unit is now ready for assembling on the post insulator.
30
1HSB445409-212 en
Dismantling the post insulator and mechanism for transport
8. Dismantling the post insulator and mechanism for transport

Before the post insulator is dismantled, the gas must be emptied, see Chapter 4.2.1.
The density monitor must be dismantled and the sealing cap (1) should be fitted to
the non-return valve (2).
1.
Dismantle the pull-rod between the operating mechanism and the circuitbreaker.
2.
Place a lifting sling under the post insulators upper flange as shown in Figure
8-1 and prepare to lift with a crane. Now loosen the post insulator (5),
removing the four bolts (3) on the frame and the four bolts (4) on the protective
tube.
3.
Lift up the post insulator and

carefully lay it down on a
transport carriage. Block up the
post insulator so it lies
horizontal. The blocks (6) under
the post 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 post insulator.
Item
4
Sealing cap
Non-return valve
Bolts M20x60
Nuts M20
Washers 21x36x3
4 pcs.
4 pcs.
8 pcs.
Bolts M12x40
Nuts M12
Washers 13x24x2.5
4 pcs.
4 pcs.
8 pcs.
Post insulator
Blocks
B10110
Figure 8-1. Dismantling the post insulator.

1HSB445409-212 en
31
8.1 Dismantling the post insulator

The post insulator is set up vertically on a suitable frame, e.g. circuit-breaker frame
or a frame on the floor of the workshop.
8.2 Off-loading the tripping mechanisms pull-rod

1.
If the tripping mechanism shall be dismantled, measure and make a note of a

reference dimension, e.g. Y, so that the opening springs (1) can be refitted to
the same tension using the nut (2) at some time in the future.
Y=............. mm
2.
date................
Remove the pin (3).
Item
1
Opening spring
Lock nut
Pin
B10107
Figure 8-2. Off-loading the pull-rod.
32
1HSB445409-212 en
8.3 Removing the post insulator

Plan the work to remove and clean the insulator so that it can be carried out quickly
and without long delays to prevent moisture in the air coming into lengthy contact
with the dust in the post and on the operating insulators.
N.B. Use personal safety equipment such as overalls, protective gloves and face
mask.
1.
Dismantle the transport cover (1) and the upper guide (2).
2.
Fit a lifting sling from the top of the post insulator to the crane or overhead
crane.
3.
Remove the upper post insulator units bolts (5) from the lower
post insulator (7).
4.
Lift the upper post insulator unit (4) straight up until the operating insulator is
released. Hold the operating insulator when lifting the post insulator.
5.
Remove the sealing washer (6).
6.
Remove the lower post insulator units bolts (8) from the mechanism housing.
7.
Lift the lower post insulator unit (7) straight up until the operating insulator is
released. Hold the operating insulator when lifting the post insulator.
N.B. Take care so as not to damage the operating insulator.

2
Item
1
Transport cover
Upper guide
Bolts M12x40
Washers 13x28x3
Upper post insulator unit
Bolts M16x70
Washers 17x30x3
Nuts M16
4 pcs.
4 pcs.
8 pcs.
16 pcs.
8 pcs.
6
5
Sealing washer
Lower post insulator unit
Bolts M16x50
Washers 17x30x3
8 pcs.
8 pcs.
B10108
Figure 8-3. Dismantling the post insulator.
1HSB445409-212 en
33
8.
Mark the operating insulator so that it is positioned correctly when reassembling. Dismantle the operating insulator by removing the circlip (1),
washer (2) and pin (3).
3
Item
1
Circlip
Washer
Pin
B10109
Figure 8-4. Dismantling the operating insulator.
9.
Carefully clean the operating insulator and protect it using plastic sheet.
10. Carefully clean the post insulator units, inside and outside, and protect them
using plastic sheet.
34
1HSB445409-212 en
9. 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 parts outside the gas chamber
using Valvoline Tectyl 506, ABB Art. No. 1241 0011-108.
1.
The operating shaft (2) is journalled on a large ball-bearing (4) on the outside
of the gas chamber. The bearing is accessible for inspection and lubrication
when the operating lever (3) and circlip (5) are dismantled.
2.
Pull the operating shaft (2) out of the mechanism housing and remove the ballbearing (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 (6)
and coat with grease S.
5.
Check that the ball-bearing (9)

rotates easily.
Inner mechanism
Item
1
Mechanism housing
Operating shaft
Operating lever
Ball-bearing
Circlip
Bushing
X-ring 69.2x5.7
O-ring 89.1x5.7
Ball-bearing
Outer mechanism
9
4
2
B10027
7 8
Bearings and O-rings
Figure 9-1. Mechanism housing.
1HSB445409-212 en
35
10. Assembling the post insulator

1.
Turn the operating lever (1) and link (2) over the edge of the mechanism
housing and fit the operating insulator (3) using the pin (4), washer (5) and
circlip (6).
N.B. Fit the pin so that the circlip (6) faces towards the large bearing.
2.
Place the sealing ring on the mechanism housing (9) and lift on the lower post
insulator unit (7), tighten the bolts (8) with a torque of 79 Nm.
TIGHTENING TORQUE
79 Nm
3
Item
Operating lever
Link
Operating insulator
Pin
Washer
Circlip
Bolts M16x50
Washers 17x30x3
Mechanism housing
7
5
8
2
8 pcs.
8 pcs.
1
B10109
Figure 10-1. Assembling the operating insulator.
1HSB445409-212 en
37
Assembling the post insulator
3.
Place the sealing washer (1) with the sealing rings on the lower post insulator
unit (2) and lift on the upper post insulator unit (3). Tighten the bolts (4) with a
torque of 190 Nm.
TIGHTENING TORQUE
190 Nm
4.
Fit the upper guide (5) and tighten the bolts (6) with a torque of 60 Nm.
TIGHTENING TORQUE
60 Nm
5.
Fit the transport cover (7).

6
Item
1
Sealing washer
Upper post insulator unit
Bolts M16x70
Washers 17x30x3
Nuts M16
Upper guide
Bolts M12x40
Washers 13x28x3
8 pcs.
16 pcs.
8 pcs.
4 pcs.
4 pcs.
1
4
Transport cover
2
B10108
Figure 10-2. Assembling the post insulator.
38
1HSB445409-212 en
10.1 Assembling the tripping mechanisms pull-rod on the operating lever

1.
Turn the operating lever (3) anti-clockwise towards the Open position and
connect it to the pull-rod (5) , coat the pin (4) with grease K before assembly.
2.
If the nut (8) has moved out of position, adjust it to the dimension Y,
see Chapter 8.2.
L
Item
1
Bottom cover
Bolts M10x50
Operating lever
Pin
Pull-rod
Spring housing
Opening spring
Lock nut
Tool 1HSB446381-A
10
Adjuster screw
4 pcs.
4
8
Y
B10107
10
Figure 10-3. Assembling the tripping mechanisms pull-rod on the operating lever
3.
1HSB445409-212 en
Set the dimension L= 180 mm using the adjuster screw (10).
39
10.2 Assembly the Opening device High-speed

Mount the complete Opening device High-speed(2), seal the surface between the
Opening device and the mechanism housing with silicone.Fit the bolts,washers and
nuts (3) and tighten with tightening torque 79 Nm.
TIGHTENING TORQUE
79 Nm
Fit the coupling link (4) from the Opening device and the coupling link from the
operating mechanism (5) in the operating lever (6). Fit the pin,washer and bolt (1).
Tighten with tightening torque 22,5 Nm. Secure with Loctite 270.
TIGHTENING TORQUE
22,5 Nm
Seal the slots (7) in the Opening device with silicone. The slot facing downwards
shall be open for drainage.
3
5
Item
1
Bolt M8x16
Washer
Pin
Opening device
High-speed
Bolt M12x50
Washers 13x24x2.5
Nuts M12
1 pcs.
1 pcs.
1pcs.
6
4 pcs.
4 pcs.
4pcs.
4
4
Coupling link
Coupling link
Operating lever
Slots
Figure 10-4. Assembling the Opening device High-speed
1HSB445409-212 en
40
Assembling the post insulator
10.3 Gas filling
Vacuum pump down to 100 Pa and let the pumping continue for at least one
hour after this pressure has been reached.
Stop the vacuum pumping and fill the circuit-breaker with dry and pure
nitrogen to atmospheric pressure. Allow to stand for a few hours or overnight.
Vacuum pump again down to 100 Pa and fill with pure SF6 gas to a pressure of
0.125 MPa (abs).
Store filling hoses so that they are not exposed to moisture or contamination. They
must not be used other than for their intended purpose.
The post insulator is now ready for transport.
1HSB445409-212 en
41
11. Assembling the circuit-breaker and commissioning

The circuit-breaker is assembled and commissioning is carried out in accordance
with applicable assembly instructions for the circuit-breaker in question.
After the circuit-breaker is assembled, check and note down the operating values.
First overhaul.
Measured values
Check the following

Pole A
Pole B
Pole C
Closing time coil I
ms
ms
ms
ms
ms
ms
Opening time coil I
ms
ms
ms
ms
ms
ms
Close-Open times(1)
ms
ms
ms
MPa (abs)
MPa (abs)
MPa (abs)

Filling pressure(2)
(1) The circuit-breaker must not be operated Open-Close without an intermediate delay of 300 ms.
(2) Filling pressure according to rating plate.
Check carried out on the : ________________________________
1HSB445409-212 en
43
Second overhaul.
Measured values
Check the following

Pole A
Pole B
Pole C
Closing time coil I
ms
ms
ms
ms
ms
ms
Opening time coil I
ms
ms
ms
ms
ms
ms
Close-Open times(1)
ms
ms
ms
MPa (abs)
MPa (abs)
MPa (abs)

Filling pressure(2)
(1) The circuit-breaker must not be operated Open-Close without an intermediate delay of 300 ms.
(2) Filling pressure according to rating plate.
Check carried out on the : ________________________________
1HSB445409-212 en
44

Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax:
+46 (0) 240 714 928
1HSB445409-212 en
0204
SF6 Circuit-Breaker

mechanism BLG 1002A
1-pole operation
Spare Parts
1HSB445409-312 en
ABB Power Technology ProductsPower Technology Products AB is not responsible for damage incurred due to the misuse of this document.
Power Technology ProductsPower Technology Products AB. It may not either be imparted to a third
party or otherwise be used without authorisation. Infringement hereof will be subject to action in accordance with applicable laws.

Date: 2002-04-05
Spart Parts
LIST OF CONTENTS
1. General ................................................................................ 1
1.1
Circuit-breaker pole ....................................................................... 2
2. Breaking unit....................................................................... 3
2.1
2.2
2.3
Breaking unit.................................................................................. 3
Contact set...................................................................................... 4
Upper mechanism........................................................................... 4
3. Post insulator...................................................................... 5
4. Mechanism .......................................................................... 7
4.1
4.2
4.3
Mechanism housing ....................................................................... 7

Tripping mechanism....................................................................... 7
Opening device High-speed........................................................ 8
5. Accessories ...................................................................... 11
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Absorption agent container .......................................................... 11

Density monitor............................................................................ 11
Sets of seals .................................................................................. 12
Assembly sets............................................................................... 12
Non-return valve .......................................................................... 12
Capacitor ...................................................................................... 13
Corona ring................................................................................... 13
6. Tools and lubricants......................................................... 15

6.1
6.2
6.3
1HSB445409-312 en
Protective cover ............................................................................ 15

Tool for off-loading the tripping mechanism ............................... 15
Lubricants..................................................................................... 15
Reservdelar
FIGURES
Figure 1-1. Circuit-breaker pole. HPL 245-550B2 ........................................... 1

Figure 1-2. Circuit-breaker pole. ....................................................................... 2
Figure 2-1. Breaking unit. ................................................................................. 3
Figure 2-2. Contact set. ..................................................................................... 4
Figure 2-3. Upper mechanism ........................................................................... 4
Figure 3-1. Post insulator. ................................................................................. 5
Figure 4-1. Mechanism housing. ....................................................................... 7
Figure 4-2. Tripping mechanism. ...................................................................... 7
Figure 4-3. Tripping mechanism. ...................................................................... 8
Figure 5-1. Absorption agent container. .......................................................... 11
Figure 5-2. Density monitor. ........................................................................... 11
Figure 5-3. Non-return valve. .......................................................................... 12
Figure 5-4. Capacitor. ...................................................................................... 13
Figure 5-5. Corona ring ................................................................................... 13
Figure 6-1. Off-loading tool. ........................................................................... 15
ii
1HSB445409-312 en
General
Spare Parts
1. General
Spare parts for the SF6 circuit-breaker HPL 245-550B2 with operating mechanism
BLG 1002A are supplied by:
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.
1
Item
Designation
Note
Breaking unit
RRR
Post insulator
RRR
Operating mechanism
RRR
Capacitor
Frame
B10111
Figure 1-1. Circuit-breaker pole. HPL 245-550B2
Please state the type designation and serial number with all enquiries and orders of
spare parts. Please also state the order number if possible.
1HSB445409-312 en
General
Spare Parts
1.1 Circuit-breaker pole

1
Item
Designation
Breaking unit
Post insulator
Mechanism
Tripping mechanism
4
3
B10217
Figure 1-2. Circuit-breaker pole.
1HSB445409-312 en
Breaking unit
Spare Parts
2. Breaking unit
2.1 Breaking unit
2
B10113
Item
Qty
Designation
Note
Breaking chamber
insulator
Upper mechanism
Upper current path
Included in
contact set
Lower current path
Included in
contact set
Puffer
Included in
contact set
RR
Figure 2-1. Breaking unit.
1HSB445409-312 en
Breaking unit
Spare Parts
2.2 Contact set
Qty
Designation
Contact set
Note
R
B10114
Figure 2-2. Contact set.
2.3 Upper mechanism

1
Item
Qty
Designation
Upper mechanism
Note
RR
B10115
Figure 2-3. Upper mechanism
1HSB445409-312 en
Post insulator
Spare Parts
3. Post insulator
4
Item
Qty
Designation
Note
Upper post insulator RR

unit
Lower post insulator RR

unit
Operating insulator
Upper guide
Sealing ring
RR
2
5
3
B10116
Figure 3-1. Post insulator.
1HSB445409-312 en
Mechanism
Spare Parts
4. Mechanism
4.1 Mechanism housing
1
Item
Qty
Designation
Mechanism
Note
RR
B10012
Figure 4-1. Mechanism housing.
4.2 Tripping mechanism
Item
Qty
Designation
Tripping
mechanism
Note
RR
B10107
Figure 4-2. Tripping mechanism.
1HSB445409-312 en
Mechanism
Spare Parts
4.3 Opening device High-speed
Item
1
Qty
1
Designation
Opening device
High-speed
Note
RR
B10107
Figure 4-3. Tripping mechanism.
1HSB445409-312 en
Spare Parts
Mechanism
1HSB445409-312 en
Accessories
Spare Parts
5. Accessories
5.1 Absorption agent container
1
Item
Qty
Designation
Absorption agent
container
Absorption agent
Note
R
B10117
Figure 5-1. Absorption agent container.
5.2 Density monitor
Item
Qty
Designation
Note
Density monitor,
temperature- compensated reference volume
Density monitor,
temperature- compensated bimetal
B10052
Figure 5-2. Density monitor.
1HSB445409-312 en
11
Accessories
Spare Parts
5.3 Sets of seals

Sets of seals for a complete circuit-breaker pole.
Qty
Designation
Set of seals
Article number
1HSB446309-D
Note
R
5.4 Assembly sets

Set of bolts for a circuit-breaker pole.
Qty
Designation
Set of bolts
Article number
1HSB446309-E
Note
R
Set of pins for a complete circuit-breaker pole.

Qty
Designation
Pins with circlips
Article number
1HSB446309-F
Note
R
5.5 Non-return valve

1
Item
Qty
Designation
Non-return valve
Note
RR
B10053
Figure 5-3. Non-return valve.
12
1HSB445409-312 en
Accessories
Spare Parts
5.6 Capacitor
3
2
Item
Qty
Designation
Capacitor
Bracket
Spacer washer
Note
B10118
Figure 5-4. Capacitor.
5.7 Corona ring

1
Item
Qty
Designation
Note
Corona ring
B10119
Figure 5-5. Corona ring
1HSB445409-312 en
13
Tools and lubricants
Spare Parts
6. Tools and lubricants

6.1 Protective cover
Item
Qty
Designation
Article number
Note
Protective cover for

breaking unit
1HSB442186-5
Protective cover for

post insulator
1HSB442158-1
6.2 Tool for off-loading the tripping mechanism

1
Item
Qty
Designation
Off-loading tool
Article number
1HSB446381-A
Note
R
B10054
Figure 6-1. Off-loading tool.
6.3 Lubricants
6.3.1 Oil
Oil
Article number
1HSB875318-A
1HSB875318-B
1HSB875318-C
Note
1HSB445409-312 en
15
Tools and lubricants
Spare Parts
6.3.2 Grease
Grease
Article number
5316 381-A
5316 381-M
5316 381-L
5316 381-H
5316 381-J
5316 381-N
5316 381-G
SV
5316 381-C
Note
16
1HSB445409-312 en

Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax:
+46 (0) 240 714 928
1HSB445409-312 en
0204
SF6 Circuit-Breaker
Operating mechanism
type BLG 1002A
Spare Parts
1HSB515409-200 en rev3
document.

Date: 2002-06-11
Spare Parts
TABLE OF CONTENTS
1. General ................................................................................ 1
2. Drive unit ............................................................................. 3
3. Dashpots ............................................................................. 5
3.1
3.2
Closing dashpot.............................................................................. 5
Opening dashpot............................................................................. 6
4. Catch gear ........................................................................... 7

5. Auxiliary contact................................................................. 9
6. Heater element.................................................................. 11
7. Electrical equipment ........................................................ 13
8. Lubricants ......................................................................... 15
8.1
8.2
1HSB515409-200 en rev3
Oil................................................................................................. 15
Grease........................................................................................... 15
Spare Parts
FIGURES
Figure 1-1. Operating mechanism. .................................................................... 1

Figure 2-1. Drive unit. ....................................................................................... 3
Figure 3-1. Closing dashpot. ............................................................................. 5
Figure 3-2. Opening dashpot ............................................................................. 6
Figure 4-1. Catch gear ....................................................................................... 7
Figure 5-1. Limit switch with auxiliary contact. ............................................... 9
Figure 6-1. Heater element. ............................................................................. 11
Figure 7-1. Electrical equipment. .................................................................... 13
ii
1HSB515409-200 en rev3
General
Spare Parts
1. General
Spare parts for operating mechanism BLG 1002A are supplied by:
SE-711 80 Ludvika
Sweden
Tel: +46 (0) 240-78 20 00
Replacement modules are supplied complete and tested.
spare parts or tools. Please also state the order number, if possible.
2
Item
1
Drive unit
Operating
mechanism
Control panel
Spring battery
Heater element
4
5
3
B20001
Figure 1-1. Operating mechanism.
1HSB515409-200 en rev3
Drive unit
Spare Parts
2. Drive unit
Type of drive unit(1)
Article number
1 Motor,
220 V 0-60Hz
2361 113-AU
2 Motors,
220 V 0-60 Hz
2361 113-AV
1 Motor,
110 V 0-60Hz
2361 113-AS
2 Motors,
110 V 0-60 Hz
2361 113-AT
(1) See wiring diagram

B20031
Figure 2-1. Drive unit.
Please state the type designation and serial number with all enquiries and orders of spare
parts or tools. Please also state the order number, if possible.
1HSB515409-200 en rev3
Dashpots
Spare Parts
3. Dashpots
3.1 Closing dashpot
Designation
Closing dashpot
Article number
5256 707-BN
B20032
Figure 3-1. Closing dashpot.
1HSB515409-200 en rev3
Dashpots
Spare Parts
3.2 Opening dashpot
Designation
Opening dashpot
HPLxxxA1, 3-pole
Article number
5256 707-BP
HPLxxxB1, 3-pole
HPLxxxA4
HPLxxxB4
HPLxxxB2
5256 707-BH
HPLxxxA1, xxxB1, xxxA2, 5256 707-BR

1-pole
HPL B1, 1-pole
5256 707-BS
B20033
HPL B1, 1-pole, HI-speed 5256 707-BY

HPL B2, B4
5256 707-BT
HPL B1, 3-pole
5256 707-BV
LTB E1, 3-pole
5256 707-BX
LTB E2
5256 707-BU
Figure 3-2. Opening dashpot
1HSB515409-200 en rev3
Catch gear
Spare Parts
4. Catch gear
Designation
Closing catch
gear
Opening catch
gear
Article number
STD 1-coil
5436 009-V
1-coil, interlock
5436 009-AB
2-coils
5436 009-X
2-coils, interlock
5436 009-AC
STD
5436 009-Z
Manual opening
5436 009-AD
Manual opening
69 device
5436 009-AF
B20034
Figure 4-1. Catch gear
1HSB515409-200 en rev3
Auxiliary contact
Spare Parts
5. Auxiliary contact
Designation
Auxiliary contact
Article number
6- or 12-pole
5751 805-F
18-pole
5751 805-H
B20035
1HSB515409-200 en rev3
Heater element
Spare Parts
6. Heater element
Designation
Voltage range
Article number
Heater element 110-127 V AC, 70 W
5291 800-R
220-254 V AC, 70 W
5291 800-S
6 5 4
110-127 V AC, 70+140 W 5291 800-U

220-254 V AC, 70+140 W 5291 800-V
110-127 V AC,
70+140+140 W
5291 800-X
220-254 V AC,
70+140+140 W
5291 800-Y
3 2
B20036
Figure 6-1. Heater element.
1HSB515409-200 en rev3
11
Electrical equipment
Spare Parts
7. Electrical equipment
Spare parts for electrical equipment BLG 1002A.
Item
1
Designation
Voltage range
Contactors
110-125 V DC
Article
number
5351 749-2
110-130V, 50/60 HZ 5351 749-4

220-250 V DC
5351 749-1
220-250 V, 50/60 Hz 5351 749-3

2
Direct-on-line
motor starters
Relay, 3-pole
Relay, 4-pole
Counter
110-125 V, 4-6 A
5576 0760-2
220-250 V, 2.4-4A
5576 0760-1
42-48 V DC
5619 758-4
110 V DC
5619 758-2
125 V DC
5619 758-8
220 V DC
5619 758-1
250 V DC
5619 758-7
42-48 V DC
5619 750-4
110 V DC
5619 750-2
125 V DC
5619 750-8
220 V DC
5619 750-1
250 V DC
5619 750-10
42-48 V DC
5692 965-3
110-125 V DC
5692 965-2
220-250 V DC
5692 965-1
B20002
Figure 7-1. Electrical equipment.
parts or tools. Please also state the order number if possible.
1HSB515409-200 en rev3
13
Lubricants
Spare Parts
8. Lubricants
8.1 Oil
Oil
Article number
1HSB875318-A
1HSB875318-B
1HSB875318-C
8.2 Grease
Grease
Article number
5316 381-A
5316 381-M
5316 381-L
5316 381-H
5316 381-J
5316 381-N
5316 381-G
SV
5316 381-C
1HSB515409-200 en rev3
15

Head Office
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax:
+46 (0) 240 714 928
1HSB515409-200 en rev3
0602

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Product Manual

OPERATING AND MAINTENANCE

ABB Power Technology Products AB

HPL 245-550B2 with operating

ABB Power Technology Products

Article number: 1HSB445455-14 en

Design of the circuit-breaker.......................................................... 1

Figure 1-1. Circuit-breaker type HPL 245-550B2 ............................................ 1

1.1 Design of the circuit-breaker

Weights for component parts:

Figure 1-1. Circuit-breaker type HPL 245-550B2

1.2 The circuit-breakers gas system

1.2.1 Opening and closing

Figure 1-2. Circuit-breaker pole, Opening - Closing

1.3 Operating mechanism

ABB Power Technology Products AB

ABB Power Technology Products

Article number: 1HSB515432-100 en rev3

Normal operating mode.................................................................. 2

2. Component units ................................................................ 5

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

Figure 1-1. Operating mechanism

1.1 Normal operating mode

Opening catch gear

Figure 1-2. Normal operating mode.

1.2 Opening operation

Opening catch gear

Figure 1-3. Opening operation.

1.3 Closing operation

Opening catch gear

Closing catch gear

Figure 1-4. Closing operation.

Figure 2-1. Drive unit.

2.2 Mechanical interlock

Operating lever shaft

Figure 2-2. Interlocking mechanism.

2.3 Catch gear

Figure 2-3. Catch gear.

Figure 2-4. Closing and Opening dashpots.

2.5 Auxiliary contact

Figure 2-5. Limit switch with auxiliary contact.

2.6 Heater element

Figure 2-6. Heater element.

ABB Power Technology Products AB

HPL 245-550B2 with

ABB Power Technology Products

Article number: 1HSB445410-14 en

Warning text ................................................................................... 3

5. Electrical connections ..................................................... 29

Connection of the operating mechanism...................................... 29

6. Pressurising the poles ..................................................... 31

8. Operating values ...............................................................41

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

2.2 Safety, general

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

Figure 3-1. Component parts.

Figure 3-2. Lifting the operating mechanism.

3.3 Storage before assembly

3.3.2 Stacking of cases

3.3.3 Operating mechanism

3.3.5 Spare parts

Standard tools with torque wrenches (9 - 430 Nm).