OPERATION AND INSTALLATION

MANUAL

INSTRUCTION MANUAL BOOK NO. 99-0245HS-Q

HS245 kV- 40/50/63 kA - 2000/3000/3125 A
DUAL RATED ANSI / IEC
GAS CIRCUIT BREAKER

REVISION 2, JUNE 2011

 Table of Contents
PREFACE................................................................................................................................................................ iii

CHAPTER 1. SAFETY............................................................................................................................................1
1.1 INTRODUCTION ............................................................................................................................................1
1.2 GENERAL SAFETY .......................................................................................................................................1
1.3 SPECIFIC SAFETY ........................................................................................................................................1
1.4 SULFUR-HEXAFLUORIDE (SF6) GAS ........................................................................................................2
1.5 sERVICE SAFETY..........................................................................................................................................2

CHAPTER 2. GENERAL INFORMATION.............................................................................................................0

2.1 DESCRIPTION OF BREAKER......................................................................................................................0
2.2 GENERAL CONTROL INFORMATION........................................................................................................7
2.3 BREAKER OPERATION................................................................................................................................8

CHAPTER 3. INSTALLATION................................................................................................................................1
3.1 PACKING SHIPPING and RECEIVING........................................................................................................1
3.2 TOOLS AND TESTING EQUIPMENT ..........................................................................................................2
3.3 STORAGE.......................................................................................................................................................4
3.4 ASSEMBLY INFORMATION .........................................................................................................................5
3.5 INSTALLATION TESTING.............................................................................................................................6
3.6 Installation & ASSEMBLY Check-List........................................................................................................10

CHAPTER 4. SF6 GAS SYSTEM...........................................................................................................................1

4.1 GENERAL INFORMATION ...........................................................................................................................1
4.2 SF6 TEMPERATURE COMPENSATED PRESSURE GAUGE..................................................................1
4.3 Filling with SF6 gas..........................................................................................................................................3
4.4 SF6 LEAK RATE AND LEAK DETECTION ..................................................................................................4
4.5 SF6 TEMPERATURE COMPENSATED GAS MONITORING SYSTEM...................................................4
4.6 TESTING SF6 SYSTEM PRESSURE...........................................................................................................4
4.7 OPTIONAL PRESSURE SYSTEM - INDIVIDUAL PHASE MONITORING...............................................9
4.8 Pulling Vacuum ...............................................................................................................................................9
4.9 O - RingS AND GASKETS Installation.........................................................................................................9
4.10 Swagelok Gas seal system........................................................................................................................10
4.11 Rupture Disk................................................................................................................................................11
4.12. Crankbox rotating o-ring seals ..............................................................................................................12

I
CHAPTER 5. MAINTENANCE..............................................................................................................................1
5.1 SAFETY NOTE ...............................................................................................................................................1
5.2 REPLACEMENT PARTS ...............................................................................................................................1
5.3 GENERAL NOTES.........................................................................................................................................1
5.4 Inspection and Maintenance Schedule .........................................................................................................2

APPENDIX................................................................................................................................................................1
Appendix 1. Torque Value Chart.........................................................................................................................1
Appendix 2. Operation Travel Curves.................................................................................................................2

REVISION HISTORY...............................................................................................................................................1

II
 PREFACE

This manual covers the installation and operation of the HVB AE Power Systems, Inc. 245kV/40/50/63kA gang
operated puffer circuit breaker. These instructions should be reviewed thoroughly to insure proper
understanding prior to performing any work on the equipment.
Prior to performing any work on the circuit breaker, be absolutely sure to review the “SAFETY” section of this
manual and insure that all personnel scheduled to work on the equipment are familiar with the
recommendations of that section.
The illustrations and information provided in this manual are designed to cover the normal customer
requirements. However, this manual may not cover some customer-required special items.
If, for any reason, a problem were to occur which is not covered by this manual, HVB AE Power Systems, Inc.
would request that the following information be available:
Customer/Company Name
Job Site Name (substation)
Circuit Breaker Rating (245kV/40/50/63kA)
Circuit Breaker Serial Number (main nameplate)

To contact HVB, use the following contact information:

HVB AE Power Systems, Inc.
7250 McGinnis Ferry Road
Suwanee, GA 30024
United States of America
Phone: (770) 495-1755
Toll Free: (866) 362-0798
Fax: (770) 623-9214

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 CHAPTER 1. SAFETY

1.1 INTRODUCTION

To the extent required, the products described herein meet applicable ANSI, IEC, IEEE and NEMA standards
as of the time of manufacture but no such assurance is given with respect to local codes and ordinances
because they vary greatly.
The term "breaker" includes all equipment mounted on the circuit breaker foundation.

NOTE: These instructions do not purport to cover all details or variations in equipment nor to provide for every
possible contingency to be met in connection with installation, operation or maintenance. Should further
information be desired or should a particular problem arise which is not covered sufficiently for the purchaser's
purposes, the matter should be referred to HVB AE Power Systems, Inc.

Each user is responsible for instructing all personnel associated with his equipment on all safety precautions
that must be observed.
The following are recommendations to be considered in a user's safety program. These recommendations are
not intended to supplement the user's responsibility for devising a complete safety program and shall not be
considered as such. They are suggestions to cover the more important aspects of personnel safety related to
circuit breakers. HVB AE Power Systems, Inc. neither condones nor assumes any responsibility for user
practices that deviate from these recommendations.

1.2 GENERAL SAFETY

All personnel associated with installation, operation and maintenance of power circuit breakers should be
thoroughly instructed and supervised regarding power equipment in general and also the particular model of
equipment with which they are working. Instruction books and service advisories should be closely studied and
followed.
Maintenance programs must be well planned and carried out consistent with both customer experience and
manufacturer's recommendations, including service advisories and instruction books. Good maintenance is
essential to breaker reliability and safety.
Local environment and breaker application must be considered in such programs, including such variables as
ambient temperatures, actual continuous current, number of operations, type of interrupting duty, and any
unusual local condition, such as corrosive atmosphere or major insect problems.

1.3 SPECIFIC SAFETY

DO NOT work on an energized circuit breaker. If work has to be performed on the breaker, take it out of
service, open the disconnect switches at each side of the breaker, then close the breaker and ground each
phase and capacitor.
DO NOT work on any part of the de-energized breaker until all control and heater power has been
disconnected.
DO NOT disassemble any portion of the gas system of any circuit breaker until system pressure has been
reduced to zero psig by opening the appropriate drain valves. When the gas pressure has been reduced to
zero, cautiously remove covers, tubes, fittings, etc.
CHAPTER 1 SAFETY

If SF6 is to be added to a pressurized system, measures should be taken to protect personnel against sudden
gas release. Upon completion of adding gas to the breaker, the fill valve should be closed. The pressure
should then be relieved between the source and the fill valve prior to removal of transfer tool/filter drier.
Particular care must be exercised to keep personnel clear of all spring-charged mechanisms. Only skilled and
knowledgeable personnel capable of releasing each spring load in a controlled manner must service the
breaker. Information on construction of such mechanisms is provided in this instruction manual.
NOTE: This breaker is spring opened and spring closed. Always ensure that ALL springs are discharged
before working on the breaker.
The gas breaker will hold line-to-ground voltage under positive SF6 pressure on an energized transmission line
where no voltage disturbances are present. Under these conditions, the breaker should be de-energized by
back-up protection breakers and isolated and removed from the system as a safety precaution.
If there is any evidence of deterioration of breaker dielectric capability, the breaker should be de-energized by
back-up protection breakers and isolated from the systems by disconnect switches.
Operational tests and checks should be made on a breaker after maintenance and prior to returning to service
to ensure that it is capable of operating properly. The extent of such tests and checks should be consistent with
the level of maintenance performed.

1.4 SULFUR-HEXAFLUORIDE (SF6) GAS

SULFUR-HEXAFLUORIDE (SF6) gas in its natural state is a colorless, odorless, and tasteless gas with an
extremely low order of toxicity. It is chemically and physiologically inert and non-flammable.
The SF6 gas is approximately 5.5 times heavier than air, and it will displace oxygen. Because of this, care
should be taken when working with SF6 in an enclosed environment. Since it is colorless and odorless, care
should be exercised when handling the gas to provide good ventilation. SF6 gas escaping into a closed room
or pit will float at the lower levels and can cause a possible oxygen shortage.
The SF6 gas, when exposed to electrical arcing, may form toxic decomposition products. These may be
evident as an unpleasant odor and a small amount of very fine powdery material found in the tank.
Before an SF6 tank is entered for maintenance the gas should be evacuated. The tank should then be cleaned
thoroughly with equipment capable of removing very fine dust particles and then flushed with dry air to provide
oxygen to the normal level.
When entering the tank, a respirator mask should be worn. Powder or dust found in the tank should be
removed while wearing gloves. Hands, face, etc. should be carefully washed if they have been exposed to the
powder.

1.5 SERVICE SAFETY

The information provided in this section is designed to give highlights of the information provided in this chapter.
There are three simple and basic rules that will provide safety for anyone working on this type circuit breaker.
Disconnect AC and DC power supplies at the circuit breaker.
With the AC & DC removed from the circuit breaker no powered operation can be done either locally or
remotely. This would prevent accidental operation of the breaker due to, someone pressing the local trip/close
push buttons (optional) or remotely operating the breaker from the control system.
Turn the SF6 test valve to the test position.
With these valves in the test position the circuit breaker control circuits will be opened. The breaker would, in
effect, be in a lockout status due to loss of gas pressure. This also prevents the possibility of someone
restoring the AC & DC power and then operating the circuit breaker. Make sure the all springs are discharged.

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CHAPTER 2 GENERAL INFORMATION

CHAPTER 2. GENERAL INFORMATION

2.1 DESCRIPTION OF BREAKER

The HVB 245kV/40/50kA (Figure 2.1), 245kV/63kA (Figure 2.2), is a high performance dead tank gas circuit
breaker. The breaker ratings are stated on the breaker nameplate. This breaker is a three-phase device rated
to interrupt AC power systems. There is one interrupter assembly per phase, containing moving and stationary
contacts, provided with a single break per phase.
The mechanism is of the stored energy type and is operated by an opening and two closing springs. An DC
motor charges the closing springs. The closing springs are used to close the breaker and at the same time to
charge the opening spring.
Closing and opening operations are controlled electrically by the control switches on the breaker or by remote
relaying. Mechanical handles are provided to manually close and open the breaker.
Electrical insulation is provided by SF6 gas charged to 80 psig at 20 °C (68 °F). The cast aluminum pressure
vessels and both entrance bushings are filled with SF6 gas. A gauge monitors the gas pressure and a
temperature compensated pressure switch. Due to the insulation being provided by the gas, the breaker should
not be operated below the lock out pressure of 72.5 psig. The pressure switch and control system provide the
lockout.
Bushing current transformers (BCT) are usually provided to monitor electrical current passing through the
breaker. The BCT’s are mounted below the entrance bushings inside their own cover.
There are two cabinets mounted to the frame and below the tanks.One cabinet contains the operating
mechanism, interphase linkage, the other contains control system and the customer connections. The cabinets
are heated to keep moisture from damaging the various devices.

Figure 2.1 HS 245 kV 40/50 kA Gas Circuit Breaker

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CHAPTER 2 GENERAL INFORMATION

Figure 2.2 HS 245 kV 63 kA Gas Circuit Breaker

2.1.1 INTERRUPTER
Figure 2.3 shows the interrupter assembly. The single puffer-type interrupter is installed in a grounded tank
filled with SF6 gas at a reference pressure of 80 psig at 20 °C (68 °F).

Figure 2.3 HS 245 kV Interrupter

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CHAPTER 2 GENERAL INFORMATION

NUMBER DESCRIPTION NUMBER DESCRIPTION

1 Stationary Insulator 12 Moving Arc Contact
2 Bolt 13 Shield
3 Stationary Conductor 14 Inner Cylinder
4 Main Sliding Contact 15 Seal
5 Main Moving Contact 16 Seal
6 Interrupter Body 17 Support
7 Outer Cylinder 18 Cover Shield
8 Stationary Arc Contact 19 Moving Conductor
9 Arc Contact Support 20 Actuation Rod
10 Teflon Nozzle 21 Moving Insulator
11 Teflon Cover 22 Support Plate

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CHAPTER 2 GENERAL INFORMATION

2.1.2 PORCELAIN INSULATOR/CONDUCTOR/GAS TANK ASSEMBLY

Figure 2.4 shows the porcelain insulator / conductor assembly installed on each end of the interrupter tank.

Figure 2.4 Porcelain / Conductor assembly installed on Gas Tank

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CHAPTER 2 GENERAL INFORMATION

2.1.3 MECHANISM SPRING-SPRING

The operating mechanism (Figures 2.5, 2.6) is made up of several assemblies including the charging system,
closing spring, tripping linkage and auxiliary switches.

Figure 2.5 Mechanism side view (Breaker Closed / Spring Charged)

Figure 2.6 Mechanism front view

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CHAPTER 2 GENERAL INFORMATION

2.1.3.1 Charging System and Closing Spring

The gear motor drives the charging mechanism that compresses the closing springs. The gear motor turns the
gear train that rotates the charging gear. There are two pawls on the charging gear that turn the charging
camshaft. There is a position switch that detects the position of the charging camshaft and controls the power
to the motor. There are two drums on the camshaft that are attached to links that pull the closing springs to the
charged position. The camshafts and drums compress the closing springs in 180° of rotation. The motor
switch also performs the added function of not allowing the closing coil to operate until the motor has finished
the charge cycle. The interrupter contacts do not move during this operation. This cycle takes less than 15
seconds.

2.1.3.2 Closing Operation

To close the breaker, power is applied to the closing coil. The coil trips the closing latch releasing the closing
spring to drive the breaker contacts closed through a cam. To close the breaker, the spring pulls the closing
links causing the cam to compress the opening spring and close the interrupter contacts. Immediately upon the
discharge of the closing spring the closing spring position switch detects that the spring has discharged then
the motor is activated and starts the charging cycle.

2.1.3.3 Tripping Operation

To trip the breaker, power is applied to the trip coil. This coil trips the latch that is holding the breaker closed.
This releases the opening spring that drives the contacts open with the dashpot controlling the shape of the
stroke curve.

WARNING
The breaker must never be operated in a low gas situation, below the 72.5 psig @ 20°C lockout pressure. This
applies to both manual and electrical operation. The control system defeats electrical operation, there is no
such safety on the mechanical trip and close devices. There are two reasons for not operating below this
value.
1. The breaker has inadequate electrical insulating and arcing extinguishing properties below the lockout
pressure.
2. The mechanism relies on the gas pressure for damping of its motion.
Operating below the lock out will result in mechanical damage to the breaker and can cause catastrophic
damage to the breaker resulting in injury up to and including loss of life to personnel near the GCB.
(This note does not refer to slow opening and closing using the manual operating device on a de-energized
breaker.)

2.1.4 INTERPHASE LINKAGE

The interphase linkage connects the mechanism to the three interrupters. This linkage is made up of a series
of collinear shafts in the crank box. The mechanism controls the position of the interphase linkage through the
main crank therefore controlling the interrupter position.
In the closing action the mechanism pushes on the main crank closing the interrupter contacts. In the opening
action the mechanism pulls on the main crank opening the interrupter contacts.
The gas is sealed by rotating and stationary o-rings.

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CHAPTER 2 GENERAL INFORMATION

2.1.5 CAPACITOR TO BREAKER ASSEMBLY (Figure 2.7), FOR 63kA RATING

WARNING: Don’t remove any plate or cover from capacitor, otherwise the oil will start to leak and the capacitor
have to be send to manufacturer for repair.

Figure 2.7 Capacitor/Breaker Assembly

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CHAPTER 2 GENERAL INFORMATION

2.2 GENERAL CONTROL INFORMATION

2.2.1 INITIAL BREAKER WIRING

2.2.1.1 CONTROL/MECHANISM CABINETS

The Control Cabinet and the Mechanism Cabinet contain both the control system and the mechanism. Bring
the customer’s power leads directly into the control cabinet through the removable panel in the floor of the right
side. Attach the leads to the appropriate terminal boards, per the wiring diagram. The trip coils, close coils, and
auxiliary switches located on the mechanism in the Mechanism Cabinet, are wired into the circuit as needed or
terminated at a terminal block points.

2.2.1.2 CONTROL CIRCUITS

The control circuits of the breaker consist of the components necessary to energize the trip and close coils on
the mechanism, sense the CLOSE / OPEN positions of the breaker, and prevent breaker operation if unsafe or
unsatisfactory conditions exist.
The close or trip signals are normally input from the customer’s power control circuit, but may be input by a local
push button or trip handle (optional) in the control cabinet. The trip handles should be for testing only.

2.2.1.3 CLOSING OPERATION

When the breaker is to be closed, a signal is impressed on the close circuit. Assuming the breaker is open in
normal operational condition, the normal sequence of events is as follows:
1. The closing coil is energized.
2. The closing coil operates releasing the mechanical latches, allowing the closing springs to drive the
interrupters to the closed position. The closing action also charges the opening spring.
3. The auxiliary switch operates.
a) Opening all the 52b contacts.
b) Close coil current is interrupted by one or more 52b contacts.
c) Closing all 52a contacts.
4. The 52Y relay is sealed in through its normally open contacts. This insures no additional close signals
can be applied until this operation sequence is complete.
5. When the close signal is removed, the 52Y relay will be de-energized and the breaker will remain in the
closed position.
6. Close operation is blocked while motor is running to charge the closing springs.
7. Close operation is also blocked when SF6 gas pressure is below certain level.

2.2.1.4 OPENING OPERATION

When the breaker is to be opened, a signal is impressed on either the trip #1 or trip # 2 circuit. Assuming the
breaker is closed and in normal operational condition, the normal sequence of events is as follows:
1. The opening coil is energized.

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CHAPTER 2 GENERAL INFORMATION

2. The opening coil operates releasing the mechanical latches, allowing the opening spring to drive the
interrupters to the opened position.
3. The auxiliary switch operates
a) Opening all the 52a contacts. Open coil current is interrupted by one or more 52a contacts.
b) Closing all 52b contacts.
c) Open operation is blocked when SF6 gas pressure is below certain level.

2.2.1.5 ADDITIONAL CONTROL FEATURES

Anti Pump (52Y)

The anti-pump system allows the closing signal to energize the closing coil only one time for each application of
a close signal. This is accomplished by the 52Y relay that opens the close circuit after the breaker closes and
keeps it open until the close signal is removed. On a trip-free operation the breaker will close then open and
will remain open until the original close signal is removed.
An additional note of interest is that the spring charge control system also blocks the close function until the
motor has finished. Therefore until the motor is finished the anti-pump relay is not the sole device that opens
the close circuit.

2.3 BREAKER OPERATION

The operation of the circuit breaker is covered in the following paragraphs.

2.3.1 MECHANISM
This circuit breaker has a spring-spring mechanism to operate the interrupters.

2.3.2 ARC INTERRUPTION PRINCIPLE

The basic puffer breaker interrupter is shown in Figure 2.7, with an identical unit being used in each SF6 gas
tank. The following sequences describe the Principle of Arc interruption:
Once the trip signal command is issued the insulated operating rod with the puffer cylinder will be pulled rapidly
to the right as the mechanism operates to the open position.
The rapid movement of the cylinder will compress the SF6 from normal pressure to approximately 150 psi. The
gas is prevented from escaping the cylinder by the puffer piston and Teflon nozzle.
The cylinder will continue to move causing increasing gas pressure. The main current path will remain between
the arcing contacts after the main contacts are separated.
Further movement of the cylinder will part the contacts and the arc will be established between the arcing
contacts (inside of insulating nozzle).
The blast releasing exhaust ports, at the nozzle and at the other end of the hollow driving shaft, direct the gas
pressure to the established arc.
The axial nature of the gas blast is effective in stretching and cooling the arc. Total blast time varies from 16 to
25 milliseconds, depending on current being interrupted.
Full interrupting capacity is provided with gas densities corresponding to gas pressures from 72.5 to 80 psig at
20 °C.

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CHAPTER 2 GENERAL INFORMATION

Figure 2.7 Principle of Arc Interruption

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 CHAPTER 3. INSTALLATION

3.1 PACKING SHIPPING AND RECEIVING

Packaging has been planned to support the field erection sequence and provide easy identification of the
components.
The breaker is shipped from the factory on one truck ready for installation. All parts necessary to assemble the
breaker are included as well as additional items required under the purchase contract.
The shipment is broken down into the following main items (crucial to the proper assembly and installation of
the circuit breaker):
• GCB Assembly
• Parts Box
Upon arrival, the entire shipment should be checked for damages or shortages. Shipping papers, including a
packing list along with an instruction manual and a full set of prints, will be in a plastic envelope in the pocket
inside of cabinet door. Additionally, a second copy of this packing list can be found in the parts box normally
shipped with the circuit breaker.

NOTE: It is especially important that any damage incurred during shipping, be reported as soon as possible to
HVB AE Power Systems, Inc. to assure early delivery of replacement parts.

To unload and move the breaker, use the lifting points shown in the below picture:
CHAPTER 3 INSTALLATION

3.2 TOOLS AND TESTING EQUIPMENT

Items actually sent with every shipment may vary in quantity and appearance according to the requirements of
the particular unit or customers contract.

3.2.1 TOOLS
Most of the work on this circuit breaker can be accomplished using standard tools. The hardware on the circuit
breaker are normally metric. The gas piping system is US standard.
1. Special tools are normally required in the purchase contract and shipped with the circuit breaker. One
set of tools is supplied with every five (5) circuit breakers or for every different substation on an order.
Your purchase contract can, of course, affect the amount of tools shipped. The following is a list of
tools normally shipped.
a. Grease – Gleitmo 805 K
b. Grease - Hitalube 280
c. SF6 Gas Transfer Tool
d. Maintenance Operating Screw Assembly, this screw requires a 1 1/8 wrench to operate
(wrench is not supplied).
e. Adapter - GCB Tank to SF6 bottle
f. Manual gear charging closing springs. This device is used to charge the closing springs when
the motor power is temporarily lost (emergency case).
The device should be installed on mechanism plate (above the motor) as shown in Figure 3.1.
There is instruction how to operate it, on mechanism front plate.
To charge the closing springs, use a 17 mm socket and a RATCHET WRENCH (THE
MOTOR POWER MUST BE DISCONNECTED) and follow the direction shown by the
attached indicator. DO NOT CRANK IN OPPOSITE DIRECTION OF ORANGE ARROW.
DO NOT CRANK AFTER THE CHARGING CYCLE IS COMPLETED.

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CHAPTER 3 INSTALLATION

Figure 3.1. Manual Charging Closing Springs Device

2. The following list is intended to include the common METRIC hand tools required to maintain this
circuit breaker. These tools are not supplied with a circuit breaker except as a special order. Metric
tools are not considered “special tools” as they are required for more equipment than this circuit
breaker.
a. Sockets
i. 1/2 inch drive - sizes M10, M13, M17, M19, M30
ii. 3/8 inch drive - sizes M6 through M26

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CHAPTER 3 INSTALLATION

b. Wrenches
i. Combination - sizes M10, M13, M17, M19
c. Scale
i. 150 millimeters - approximately 6 inch
ii. 1000 Millimeters - approximately 3 feet
d. Allen Wrenches
i. Sizes up to M10

3.2.2 TESTING EQUIPMENT

Certain equipment should be available for installation and future maintenance testing of the circuit breaker.
1. Gas handling equipment with a vacuum pump
2. Vacuum gauge capable of reading 1mm of mercury or 1000 microns
3. SF6 Leak Detector
4. Electrolytic Hygrometer - (SF6 Moisture Analyzer)
5. Digital Micro-ohmmeter
6. Megger - 1000 Volt
7. Leak - Tec or equal for gas leak testing
8. Ductor - 100 Amp
9. Motion Analyzer
10. Thermometer
11. Calculator
12. Indicating flashlight with leads

3.3 STORAGE

3.3.1 Breaker Assembly

1. Check to be sure each pole has a slight positive pressure by opening the fill valve. If the breaker
shows zero pressure pull vacuum before filling with SF6, see Chapter 4 for method. For storage set the
gas pressure to 5 to 15 psig. The low of 5 is to ensure that the interrupters and tank internals stay
clean and dry. Storage pressures above 15 psig are not necessary and constitute a safety hazard in
case the bushings are damaged in storage. Check at monthly intervals for positive pressure.
2. Connect all heaters to a proper voltage source. Power leads should enter the control cabinet through
the floor by removing a bolt in the floor. Connection should be made at the heater fuse to supply
heater power. DO NOT LEAVE DOORS PARTIALLY OPEN.
3.3.2 All Parts Boxes
These parts should be kept dry at all times and stored inside a building, if possible. If unable to store inside,
keep off the ground and out of standing water. Cover with canvas or heavy plastic tarpaulin.

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CHAPTER 3 INSTALLATION

3.4 ASSEMBLY INFORMATION

3.4.1 PRELIMINARY INFORMATION

The three poles of the 245kV gas circuit breaker are identical on the standard breaker.
These instructions are supplemented by a set of drawings supplied with the breaker. The types of drawings
furnished include the outline, assembly, electrical elementary, electrical device and ratings list. These
drawings, along with any others that the customer may have requested, are placed with the breaker instruction
book, and stored in a special pocket on the electrical control house door.
The breaker will be located on a reasonably level foundation and properly shimmed and secured with anchor
bolts. The foundation is to provide uniform support to the frame and SF6 gas tanks and to not add any stress.
Space must be provided for opening the control house doors and making the necessary control connections.
Space should be allowed at the end of each pole to allow for possible maintenance of the internal parts of the
breaker. Should flood conditions exist, the foundation must be sufficiently high to assure the control house is
above the high water level.
All standard safety practices, codes and ordinances should be followed during erection and operation of the
breaker.
Prior to any work being done on the subject breaker, the section of this manual on safety should be reviewed
and understood thoroughly.

CAUTION
When working on the gas system open fill valves even though the gauge indicates zero pressure. To ensure
that you do not open a vessel that is under pressure!
DO NOT open interrupter tank when there is a chance of water, dust, or other contaminants entering the
vessel. Internal cleanliness is essential to the successful operation of the circuit breaker. The tanks are
charged to a positive pressure with SF6 gas when delivered. This pressure should be kept in mind when
beginning installation.

SAFETY
Each user, contractor, or installer is responsible for instructing all personnel associated with this equipment on
all safety precautions that must be observed. Read the SAFETY SECTION in this Instruction Manual.

3.4.2 GENERAL ASSEMBLY PROCEDURES

1. The foundation should be of sufficient strength stability to prevent any stress in the SF6 tank due to
ground movement. Foundation to be level within 0.25 inch within support areas. For bolt pattern and
loads see breaker outline drawing. Sling the breaker assembly using the four lifting plates. Use equal
length cables that are 8 feet or longer.
2. Bolt the breaker in place using heavy washers attached to the two ground pads on the support beams.
If necessary, shim between support plates and foundation to insure a direct transmission of loads to
the foundation and prevent stressing the SF6 tanks.
3. Install all ground leads to the frame ground pads as show on customer drawing. Connect the ground
strap at the bottom of the control cabinet to the ground grid.

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CHAPTER 3 INSTALLATION

4. Each pole assembly is factory charged to approximately 5 psig with SF6. Therefore it is not necessary
to pull vacuum on the breaker, simply fill with dry SF6..

3.5 INSTALLATION TESTING

3.5.1 GENERAL
Please see the next section for the Installation Check-List. Timing tests are optional and are not
required. Be sure to follow all manufacturers instructions when using the specialized equipment required in this
section.
1. Fill out owner and circuit breaker information on the first page of the Installation Check-List.
2. Perform the inspections on the first page.
3. SF6 Gas System
a. Record ambient air temperature
b. Record the gauge pressure. The correction factor is calculated from the instruction books
Temperature vs. Gas Pressure chart, see chapter 4.
c. Switch checks. Record the gauge readings for both ON (decreasing pressure) and RESET
(increasing pressure). Use the correction factor to normalize the pressure to a room temp
value. Confirm that the corrected values are within the tolerances in the chart.
d. Leak check the gas system
e. Moisture analysis is recommended. When using gas provided by HVB the gas is guaranteed
by the supplier to have a moisture level below 150 ppm, therefore testing moisture with HVB
gas is optional.

3.5.2 MECHANICAL TESTS

3.5.2.1 External stroke and wipe measurement, (Figure 3.2.)

1. Connect an indicating light, flashlight with leads, to the three poles of the breaker to determine when
the contacts close.
2. Remove the cover on the back of the opening spring and insert the manual charge screw into the
threads. Tighten the screw until it is hand tight. Record the length of threads (A) that is sticking outside
the spring tube. Using a wrench, tighten the screw into the spring tube, ( this will cause the contacts to
move) until the first light lights. Write that value (B) in the column “Contact” for the appropriate pole.
Continue for each of the three lights.
3. Continue to tight the screw. Watch for the trip latch to set. STOP operating the manual screw when the
latch sets. Back off the manual screw to allow the latch to carry the spring load. You will feel the screw
become easier to turn as the latch takes the load. The breaker is now in the closed position. Before
making the final measurement (C) be sure that the screw is hand tight against the open spring.
Calculate the External Stroke (A-C) and Wipes (B-C).
4. Open the breaker by tightening the screw against the spring load again. Press and hold the red open
button to clear the trip latch, then open the breaker by unscrewing the manual operating screw. After
one turn the latch will have cleared and the open button can be released.
5. Remove screw and install back the open spring cover.
6. Calculate the Delta (Phase to Phase) by calculating the difference between the max and min values of
wipe.

3-6
CHAPTER 3 INSTALLATION

3.5.2.2 Circuit breaker operational test

This test can be performed with or without motion analyzing equipment. Performing a motion test with
analyzing equipment is optional. If the transducer is attached to the same location as the external stroke was
measured the transfer function is: 98 mm external stroke / 196 mm internal = 0.5
1. Test for the close, C, and open, O, function by pressing the open and close electrical buttons. If
equipped for dual trip, test both.
2. To test C-O & Anti Pump the breaker must be in the open position. Press both open and close buttons
simultaneously. The breaker should close then immediately open with no delay then lockout the close
function as long as the close button is held in. To properly test hold the close button until after the
motor has stopped charging.
3. For the O-C test the breaker must be in the closed position. Press and release the open button. The
breaker should open. Then press the close button and the breaker should close.
4. SF6 Lockout Function. Before performing this test check the schematic to see if the control circuit is
designed to simply lockout the operation of the breaker or open then lockout. To perform this test turn
the test valve to the test position. Slowly open the purge valve until the gauge reads below 72.5 psi
and the SF6 density monitor has switched for lockout. Then press the open and close buttons. If the
breaker has a simple lockout the mechanism should not operate. If the breaker has an open then
lockout function the breaker should open on low pressure then pressing the buttons should not operate
the mechanism.

Figure 3.2. External Stroke and Wipe Measurement

3-7
CHAPTER 3 INSTALLATION

3.5.3 ELECTRICAL TESTS

3.5.3.1 Contact resistance, (Ductor test)

It measures the integrity of the contact joints in the current path. This measurement can be made on the
breaker before or after gas is in the tanks. The individual poles should be checked using a 100 A Ductor with
100 A flowing. A complete pole unit measured from bushing terminal to bushing terminal should measure
125+/-20 micro ohms or less with the breaker fully closed. Ductor readings taken after gas is in place should
have no noticeable change.

Note: If readings are high, check the connection at the top of the bushing to ensure that the connection is not
adding any additional resistance.

3.5.3.2 Insulation resistance, (1000 V Megger Test)

It measures the integrity of the GCB insulation. For this measurement the breaker should have SF6 gas in the
tanks to a pressure at or above the lockout pressure. The purpose for requiring gas is to insure a moisture free
environment inside of tanks. Note that most of the leakage current will occur on the outside of the bushing
insulator and not inside the gas tank.
1. Test with the breaker in closed position. Put the positive lead on one of the bushing terminals and the
negative on the grounded gas tank. Value must exceed 1000 MΩ.
2. Test with the breaker in open position. Value must exceed 2000MΩ. There are two situations to test:
a. One is from terminal to terminal on each pole.
b. The other is from terminal to ground on each bushing.
3. If measured value is less than noted value, check as follows before concluding there is an internal
problem:
a) Resistance measurements in the ΜΩ range with 1000 V Megger, can be sensitive to lead
position similar to capacitance measuring. Shielded leads should be used for best results.
b) Outside of porcelain should be cleaned and a three-turn guard placed between second and
third petticoat of each bushing and connected to the guard terminal of Megger.
c) Earth lead is connected to good ground on tank. Lead position is not important.
d) The connecting lead from the top of the bushing should be tied to keep lead from touching
outside of bushing or any metal of breaker. Similar to 10 kV capacitance measuring.
e) Remove lead from bushing not connected to Megger, or keep tied to keep free of all parts of
this segment and must not touch ground.
f) Connection to line post of Megger to be as short as possible to connect the test lead.
g) Tie clear of all metal parts or ground.
h) Do not touch earth, lead or Megger case.
i) Do not allow to sag and touch ground.
j) Personnel not to hold or touch leads.
k) Leads twisted together, laid on the ground or touching other possible leakage paths can make
an insulator of 8000 ΜΩ or higher appear to be 500-1000 ΜΩ
l) Let the breaker gas environment reach equilibrium for one week. This will allow the desiccant
to remove all of the moisture and allow the environment to reach steady state conditions.

3-8
CHAPTER 3 INSTALLATION

m) Insulators may have a surface layer of moisture that should disappear within one week when
gas with a dryness less than 150 ppm has been added and new desiccant is in place.

NOTE: Power factor tests are not required on SF6 bushings, these tests provide no useful information on
SF6 filled equipment and are not recommended by HVB AE Power Systems, Inc. for our equipment.

3-9
CHAPTER 3 INSTALLATION

3.6 INSTALLATION & ASSEMBLY CHECK-LIST

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CHAPTER 3 INSTALLATION

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CHAPTER 3 INSTALLATION

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CHAPTER 3 INSTALLATION

3-13
CHAPTER 3 INSTALLATION

3-14
CHAPTER 4 GAS SYSTEMS

CHAPTER 4. SF6 GAS SYSTEM

4.1 GENERAL INFORMATION

For safety considerations, consult Chapter 1 of this instruction manual before proceeding with these
instructions. The SF6 gas system includes monitoring gas pressure, filling the GCB with gas and the gas
sealing O-ring seals.
This chapter covers the standard gas monitoring system, which uses the Qualitrol Temperature Compensated
Pressure Gauge as well as the optional non-temperature compensated monitoring. The craftsperson should
always refer to the breaker specific drawings to confirm which gas monitoring system is installed. Additionally,
in a separate section, specific instructions for non-temperature compensated SF6 monitoring equipment is
described. The customer can choose optional equipment to be used in your monitoring system that is covered
in later sections of this chapter as well.

NOTE: Refer to your circuit breaker drawings to determine which sections of these instructions are relevant
and refer only to those that apply.

NOTE: No maintenance is possible on any pressure/density switches supplied by HVB. No replacement

parts are listed except for replacement of the complete device.

DISCLAMER: This chapter covers the most common gas systems, however due to the customized
nature of the product, there may be differences with regards to customer preference. In which case, if
questions arise due to such differences, it may be advisable to consult HVB AE Power Systems, Inc. to attain
proper gas filling / system information.

4.2 SF6 TEMPERATURE COMPENSATED PRESSURE GAUGE

This GCB uses a Qualitrol SF6 temperature compensated pressure gauge, (Figure 4.1). The temperature
compensated pressure gauge automatically adjusts its operating points higher or lower as a result of ambient
temperature changes. There should be a label on gauge to indicate the part # and contacts settings.
As density changes the dial pointer moves. The switches themselves operate depending on the physical
pointer position and are fixed and stationary. The switch contacts are factory adjusted for each switch value. As
the pointer moves down the scale it contacts each switch in succession.

NOTE: This device and its internal switches ARE NOT field adjustable. If switches appear to be out of
specs., contact HVB.
CHAPTER 4 GAS SYSTEMS

90

80 0.60 MPa 20°C

SF6 0
0.50
70
0.10 10
0.40
60 0.30 0.20
20
50
P.S.I.G. 30

Temperature Compensated Pressure Switch Settings psi

63GDA Closes on Descending Pressure 75.5±2
Opens on Ascending Pressure 77.5±2
63GDC Closes on Descending Pressure 72.5±2
Opens on Ascending Pressure 74.5±2

Figure 4.1 Temperature Compensated Pressure Gauge

4-2
CHAPTER 4 GAS SYSTEMS

4.3 FILLING WITH SF6 GAS

NOTE: Read ALL of the instructions below prior to filling the breaker with SF6 gas.

1. The moisture content of the SF6 gas should be 150ppm, by volume, or less. The cylinder should be
checked with a suitable hygrometer before using in the GCB. If the SF6 gas was supplied with the
circuit breaker it is guaranteed to by dry to less than 150 PPM. Leave the hygrometer on until a reading
of 150 PPM or lower has been obtained. If a reading of 150 PPM or lower cannot be reached, dry the
hygrometer with dry air or nitrogen until below 100 PPM. Immediately recheck.
2. If moisture analysis is to be done on the GCB, use the fill valve for moisture sampling. If a reading of
150 PPM or lower is still not obtained wait one week and recheck during the cool morning hours.
Finally, if a reading of 150 PPM is still not obtained, remove the gas and replace the desiccant in the
tank with fresh bags and dry the gas if its to be re-used. Expected normal value should be under 100
PPM within one week.

NOTE: The filter drier should be replaced after having been used with 50 cylinders of gas. It is suggested a
mark be placed on the filter drier to record each cylinder used. The dryer hose assembly should be capped at
both ends when not in use. An SF6 gas cylinder will weigh about 225 pounds filled, with the gas content being
constant at 115 pounds.

CAUTION: Do not remove the end covers of any SF6 piping until just before connection, this is to keep
moisture out of the vessel and piping. Use dry air or nitrogen to purge the gas lines of moisture or material prior
to connection. Keep dust, dirt, moisture, etc. from entering the lines prior to connection.

3. Close the 3-way test valve (Figure 4.3) between the breaker and the gas density switch, the valve
handle should be aligned 90° to the gas lines to be turned off. Then turn the discharge end of the valve
on the gas cylinder to face the fill valve. Remove the shipping plug from the valve of the cylinder and
the cap on the end of the adapter. Using the adapter with the left-hand threads, attach the filter-dryer to
the valve in the cylinder. The fitting on the hose also has a sealing plug. Install the adapter on the fill
valve. Tighten all connections, and then loosen the nut on the hose at the fill valve end with the valve
closed. Slowly open the valve on the SF6 cylinder for approximately 30 seconds to purge the gas
transfer assembly. Tighten the nut then close the valve on the cylinder. The connection is now filled
with SF6 gas and ready to fill the breaker tank.
4. No regulator is required with the filter-dryer. An orifice with 0.05-inch diameter is installed between the
filter and the gas bottle of the transfer hose to control the flow rate of the gas cylinder. Open the valve
at the breaker, then the cylinder valve. The filling process can be detected by sound or condensation
on the fittings.
5. Approximately 165 lbs of gas will fill the GCB from the vacuum point.. The gas flow may stop due to
chilling.
6. To measure the gas pressure, make sure the valve is in the normal position and allow the gas
pressure to rise while being monitored.
7. During the filling of the breaker, a calibrated gauge need not be used to monitor the phase pressure.
Determine the tank’s body temperature by attaching a thermometer to the shaded side of the tank. Do
not read in less than fifteen minutes after attaching.
8. See breaker nameplate for standard gas system pressure. Fill the GCB till the reading on the gauge
meets the reading on the tank to within ± 3psig.

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CHAPTER 4 GAS SYSTEMS

9. Shut off the fill valve on the GCB gas tank and then the SF6 tank cylinder valve. Slowly loosen the
connection at the cylinder to drain the pressure from the filter-dryer and fill hose.
10. Replace the cap in end of gas transfer tool to keep dirt and air out of the filter - dryer. Replace the
safety cap on the SF6 cylinder and remove the cylinder.
11. Allow the gas pressure to balance for twelve hours and then re-check the pressure. If additional gas is
needed, repeat the steps above.

4.4 SF6 LEAK RATE AND LEAK DETECTION

The maximum permissible design leakage is one psi per year. The rise and fall of pressure should be
observed for a period of one month to determine the loss due to leakage. Remember that the pressure switch
on the breaker is temperature compensated. When checking with a regular gage, changes in pressure due to
temperature fluctuations must be taken into consideration. An allowance equal to about 1 1/2 psig for every five
degrees C should be made for variation in temperature.
If leakage is determined in excess of one psig per year, use an SF6 gas leak detector at all gaskets, bolted and
flared joints. If an SF6 instrument is not available, a high viscosity solution, such as “Leak Tec Formula
277CHV”, can be used. The solution should be cleaned from the surface using a clean damp cloth completes
the leak checking.

4.5 SF6 TEMPERATURE COMPENSATED GAS MONITORING SYSTEM

The temperature compensated gas monitoring system is provided with a three phase common pressure-
monitoring scheme that gangs the pressure of all three phases together to a single temperature compensated
pressure gauge ( Figure 4.4). An optional individual phase monitoring systems is available and described in
later section of this chapter.
The typical system is furnished to provide an alarm circuit when the pressure in the interrupter tank falls bellow
75.5 psig at 20° C. Additional contacts can enable the system to provide a command at 72.5 psig at 20°.
The minimum operating pressure for full dielectric strength and interrupting capacity is 72.5 psig at 20° C.
Below this pressure the breaker should be isolated from the system. Operation of the circuit breaker below this
pressure can result in damage due to reduced backpressure in the puffer cylinder and excessively high
operating speeds and a failure to interrupt due to low dielectric strength caused by insufficient SF6 gas.
SF6 in the gaseous state will show a change in pressure as its temperature is changed. This is represented by
the curve shown in Figure 4.5. The table (Figure 4.2) shows the SF6 Temperature versus Pressure Nameplate
that is normally provided on the cabinet door.

4.6 TESTING SF6 SYSTEM PRESSURE

A valving arrangement to check the SF6 gas pressure alarm switch has been built into the gas system and may
be used in the following manner:
1. Remove all AC and DC connections to the control cabinet. Failure to do the will cause the breaker to
send low gas alarms and the breaker will lockout when testing the lower pressure value
2. Turn test valve off, perpendicular to the direction of gas flow. This isolates the SF6 temperature
compensated pressure gauge from the breaker tank. Very slowly continue to turn the test valve while
watching the pressure gauge. Allow the pressure to drop gradually. The pressure at which the
temperature compensated pressure gauge operates will represent the alarm or command pressure.
3. Return the handle to the initial position, parallel to the gas flow. Failure to do so will leave the switch
isolated from the pressure vessels resulting in a hazardous system with no protection against low SF6
gas pressure.

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CHAPTER 4 GAS SYSTEMS

4. To ensure accurate testing:

a. Check all pressures after the breaker has been de-energized minimum 6 hours
b. Take the readings early in the morning. This is when the gas and metal of the cabinet will be
at the closest temperature.
c. The temperature of the SF6 tank should be checked and used as the gas temperature.
d. See the SF6 Pressure vs. Temperature Table (Figure 4.2.), for pressure at the recorded
temperature.

SF6 Gas Temperature vs. Pressure

Temperature Pressure
In Degree C In Degree F PSIG
-30 -22 62
-20 -4 65
-10 14 69
0 32 73
10 50 76
20 68 80
30 86 84
40 104 87
50 122 91
60 140 95

Figure 4.2. SF6 Gas, Pressure vs. Temperature Table

4-5
CHAPTER 4 GAS SYSTEMS

90
KIHLSTRÖMS
SWEDEN
80 0.60 MPa 20°C
SF 6 0
0.50
70
0.10 10
0.40
60 0.30 0.20
20
50
30
P.S.I.G.

Figure 4.3. Valves In The Gas System

4-6
CHAPTER 4 GAS SYSTEMS

Figure 4.4. Three Phase Common Gas Monitoring System

4-7
CHAPTER 4 GAS SYSTEMS

Figure 4.5. SF6 Pressure Versus Temperature Curve

4-8
CHAPTER 4 GAS SYSTEMS

4.7 OPTIONAL PRESSURE SYSTEM - INDIVIDUAL PHASE MONITORING

An optional SF6 system is used on many of the circuit breakers provided by HVB AE Power Systems, Inc.
Essentially this system is the same as the system covered beginning on page 2 of Chapter 4, with the addition
of lines for each phase’s tank connected to a separate pressure monitor.
This system is available on any model offered by HVB and provides single phase monitoring rather than the
manifold system that monitors the total circuit breaker as a single source of SF6 gas. The three-phase system
provides for command and alarm switches for each pole.
All information regarding adjustment, settings and system pressures should be the same as previously
described for single phase monitoring. The only difference is the number of switches and regular pressure
gauges (3) now would reflect the number of poles.
The customers “Device Sheet” and “Electrical Diagrams” should be referenced to determine the system
provided.

4.8 PULLING VACUUM

In the event that the SF6 gas was removed and the GCB was vented to the atmosphere it is necessary to
replace the gas. Before filling the breaker with SF6 gas it is necessary to replace the desiccant and pull a
vacuum on the GCB. The procedure is as follows:
1. Replace desiccant in the circuit breaker with fresh desiccant. Evacuate each pole until a reading of
1000 microns is reached. This pressure should be held for 2 hours once reaching 1000 microns.

NOTE: For instrument references 1000 microns is equal to one millimeter of mercury and the same as one
Torr.

2. Close the gas-filling valve before attaching the vacuum unit and do not open until the vacuum is
running. Always close the gas-filling valve before stopping the vacuum pump. Failure to close the
gas-filling valve first may result in oil being drawn from the pump into the tank.
3. Normal evacuation equipment will reach 1000 microns within approximately one-half hour.
4. Do not evacuate unless SF6 gas is available and will be added the same day. Enough gas should be
added to a minimum of five psig, but normal operating pressure is recommended.

4.9 O - RINGS AND GASKETS INSTALLATION

O-rings and gaskets are used in the design of the gas circuit breaker and it is important that the O-rings and
gaskets are handled properly to avoid leakage problems. Emphasis must be placed on the importance of using
only factory approved O-rings and gaskets in any location. Considerable research has been conducted to arrive
at the current O-rings an gaskets for the proper application. A second precautionary step is to avoid using
excess lubrication during installation of the O-rings and gaskets. Use only a minimum of the proper lubricant.
The proper installation is described in the following:
1. Inspect the parts on which the O-rings or gaskets is to be assembled to be sure no burrs, sharp edges
or foreign materials are present.
2. The two surfaces, between which the O-ring or gasket will be compressed, should be free of any
visible scratches or sharp changes in surface. If it is deemed necessary to repair an O-ring or gasket
surface the imperfection should be blended into the main surface over a width of approximately one-

4-9
CHAPTER 4 GAS SYSTEMS

quarter inch minimum in order to provide a tight gas seal. This is typically done with a fine emery cloth.
Be sure to clean thoroughly to remove any metal or sandpaper articles.
3. To assemble, place the O-ring or gasket with a minimum force into the groove (DO NOT OVER
STRETCH THE O-RING OR GASKET TO PLACE IT IN THE GROOVE). If stretching was performed
to seat the O-ring or gasket, allow time for it to return to its normal diameter before closing the opening.
O-rings or gaskets should not be twisted. Twisting during installation will occur with a lack of lubrication
and the incorrect ratio of inside diameter to cross-sectional diameter.
4. Assembly of the parts must be accomplished by straight longitudinal motion. Rotary or oscillatory
motion may cause pinching or cutting of the O-ring or gasket seal.
5. Operate the moving parts by hand to be sure there is no binding.
6. If an O-ring or gasket is being removed from a part for examination, never reuse it. A new O-ring or
gasket must be installed upon removal of the original.
7. Extreme care must be exercised when removing an O-ring or gasket for replacement or examination.
Do not use a metallic instrument (i.e., screwdriver, pin, scale, etc.). The proper method to remove an
external O-ring is to grip the piston or part firmly with one hand and with the thumb and the first finger of
the other hand, exert a compressive horizontal force to the sides of the O-ring, causing it to bulge out
sufficiently so that it can be removed from the groove. To remove an internal O-ring, a non-metallic
instrument must be used to prevent scarring of the groove and causing leakage.
8. Recommended procedure for lubricating any O-ring or gasket, is to clean it thoroughly with a clean
cloth (no solvents) and cover the O-ring or gasket completely with a thin film of the prescribed lubricant
before assembling it into the groove. Again, avoid over and under lubricating. Do not apply lubricant
directly from the applicator to the gland, groove, or the installed O-ring or gasket. Excessive grease can
cause contamination problems. Under-lubrication can result in abraded rings, rolling, and increased
friction of the sliding surface. It is very important that the correct lubricant be used on the O-rings or
gaskets. Use of a lubricant, which is not compatible with the O-ring or gasket material, can result in the
deterioration of the O-ring or gasket and leakage at the seal.
9. O-ring or gasket material is Buna-N (black). Hitalube 280 should be used only, for lubrication.

4.10 SWAGELOK GAS SEAL SYSTEM

HVB AE Power Systems, Inc. exclusively uses Swagelok connectors and parts in our gas system.
Figure 4.6. shows an example of Compression Fitting.

Figure 4.6. Swagelok Compression Fitting

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CHAPTER 4 GAS SYSTEMS

4.11 RUPTURE DISK

The rupture disks are located on the end covers (Figure 4.7) of the tanks, opposite the mechanism. The rupture
disk is a reverse buckling style. This is the state of the art in rupture disk technology available today. The
rupture disk is rated to burst at the MAWP (Maximum Allowable Working Pressure) of the gas tank. The rupture
disk is made of Inconel, this is a grade of steel with the corrosion resistance of stainless.
Safety glasses must be worn when working near the rupture disk. If the disk were to burst, the entire gas
pressure of the GCB will burst from the tank in a matter of moments. The force of the blast and the temperature
of the gas would be dangerous and could cause serious injury. To avoid this, a flow diverter is installed in front
of rupture disk and it will direct the gas flow to a safe direction.
Occasionally it may be necessary to inspect the rupture disk. To inspect remove the flow diverter and examine
the disk. The disk should bulge into the tank and be very smooth and symmetrical. Any irregularities or cracks
imply that the disk must be replaced, inspect the ends of the pressed in lines carefully for irregularities. Again
what you are looking for, are irregularities from a symmetrical shape.
The rupture disk is not a serviceable item. In the unlikely event that the rupture disk opens please order a new
one from HVB spare parts and replace it.

Figure 4.7. Rupture Disk Assembled to End Cover

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CHAPTER 4 GAS SYSTEMS

4.11.1 Rupture disk replacement

To replace the rupture disk:
1. Completely remove the SF6 gas.
2. Remove the flow diverter.
3. Remove the rupture disk, (a 13 mm socket wrench is required).
4. Replace the Dessicant by new one.
5. Clean and inspect the O-ring groove.
6. Install a new O-ring, (lubricate it according to the procedure).
7. Carefully install the rupture disk (be sure that it is centered over the opening in the gas tank).
8. Install the flow diverter (be sure the openings of flow diverter are oriented horizontally).Torque all the
M8 bolts to 10 ft-lbs.

CRANKBOX ROTATING O-RING SEALS

The crankbox shafts are sealed by rotating O-rings. The o-rings type and sizes are:

• 1AP100 (Qty. = 6/breaker)

• 1AP65 (Qty = 8/breaker.)

4-12
CHAPTER 5 MAINTENENCE

CHAPTER 5. MAINTENANCE

5.1 SAFETY NOTE

Each user is responsible for instructing all personnel associated with his equipment on all safety precautions
that must be observed. See the section on safety located in the installation manual.

5.2 REPLACEMENT PARTS

This manual does not include a replacement parts section. For replacement parts please see the spare parts
catalog. When parts are required the serial number of the breaker, the part number, and the description should
be given on the purchase order.

5.3 GENERAL NOTES

Dependable service and safety of power equipment is contingent upon the unfailing performance of the power
circuit breaker. To maintain such service, it is recommended that a well-defined inspection and maintenance
schedule be set up and followed, as serious shutdowns can often be avoided by locating potential sources of
trouble in an early stage. A periodic lubrication of parts subject to wear is also vitally important for the
successful operation of the breaker and operating mechanism.
The frequency of periodic inspection should be determined by each operating company on the basis of the
number of operations (including switching), magnitude of currents interrupted, and any unusual operations that
occasionally occur. Operating experience will soon establish a maintenance schedule that will give assurance
of proper breaker condition. Schedule periods may be shortened or lengthened after the customer determines
the condition of the breaker during the first few maintenance checks.
The following recommendations to be observed during either a routine or periodic inspection.
1. Review the SAFETY SECTION at the front of the book. Note items that will be involved during
intended inspection.
2. Be sure the breaker and its mechanism are disconnected from all electrical power, both high voltage
and operating controls, before inspecting or repairing.
3. Apply ground leads to all entrance bushings.
4. Use the connection diagram accompanying the breaker in all cases when testing and connecting the
controls.
5. Before any work is attempted on the operating mechanism, ALL of the springs (Opening and Closing)
must be discharged.
6. After making any adjustments on the breaker, operate the apparatus by hand before attempting
electrical operations.
7. When the breaker interrupter is to be inspected, the SF6 gas should be removed with proper gas
handling equipment.

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CHAPTER 5 MAINTENANCE

5.4 INSPECTION AND MAINTENANCE SCHEDULE

It is assumed that the safety instructions have been reviewed and fully understood before any detail
maintenance is attempted. The detail instructions will include only safety notes that may apply to the part being
discussed.
The HVB AE Power Systems, Inc. gas circuit breaker has been designed for simplicity and minimum
maintenance requirements. It is expected, due to the low number of yearly operations of high voltage breakers,
that the time factor and not number of operations or interruption duty will normally determine the maintenance
schedules.
The inspection and maintenance can be separated into three types: Patrolling, Routine and Periodic (Table
5.1). See the installation chapter for the tool list required for inspections and maintenance.

Assemblies Installation Patrolling Routine Periodic

Monthly 3Y or 500 12Y or
Operations 2000Operations
SF6
Compensate Pressure X X X
Gauge
Compensate Pressure X X X
Switch + Regular
Pressure Gauge
Gas Piping X X X
Moisture Level X X X
Mechanical
Timing Tests X X X
External Stroke X X X
Operational tests X X X
Electrical
Contact Resistance X X X
Insulation X X X
Bushings
Dirt X X X
Damage X X X
Cabinet
Wiring Secure X X X
Aux. Sw. Links secure X X X
Fuse Blocks, Switches X X X
Secure

5-2
CHAPTER 5 MAINTENANCE

Relay Contacts X X X
Heaters Energized X X X
Heaters Thermostat X X X
Motor Gear Train and X X X
Mech. Links
Unusual Noise
SF6 Gas X X X
Electrical Noise X X X
Record
Mechanism Counter X X X
Gas Pressure X X X
Ambient Temp X X X
Dashpot
Oil Leak X X X
Oil Level X X
Oil Replacement X
Aux. Switch
Links X X
Wiring Secure X X
Counter X X
Mechanism
Close, Trip, Latches X X
Charging System X X
Coils Resistance X X
Mech./Crankshaft X X
Connection
Touch up Paint X X
And Caulk
Interrupter
Arcing Contacts X
Teflon Nozzles and X
Teflon Covers
Crankbox O-ring Replacement X
Seals

Table 5.1. Inspections and Maintenance Schedule

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CHAPTER 5 MAINTENANCE

5.4.1 Patrolling Inspection and Maintenance

5.4.1.1 GENERAL

Interval: weekly-to-monthly as best suits the customer's conditions.

This is an observation and data recording inspection that can be expected to limit emergency maintenance
requirements by noting possible problems and arranging a planned time for corrections. These recordings must
be analyzed to derive full benefit from them and keep the breaker utilization at a high level.
The Patrolling Inspection is done under following conditions:
1. Breaker NOT removed from service.
2. SF6 gas NOT removed
3. Breaker in ANY position open or closed.
4. If any of the inspections indicate the GCB is not to specifications refer to either the Routine
Maintenance Section or the specific section that covers the out of specification item.

5.4.1.2 PATROLLING INSPECTION AND MAINTENANCE DETAILS

1. Interval one week to one month, as best suits the customer’s conditions, but should be regular.
2. Visual inspection for unusual conditions.
a. Entrance Bushings
i. Excessive dirt
ii. External damage
b. Cabinet
i. All wiring appears secured
ii. Drive links to auxiliary switch
iii. All fuse blocks or switches appear tight or normal.
iv. Relay contacts show no excessive arcing
v. The 160-watt heaters (located on the upper left side of cabinet) should be energized
at all time, depending on customer requirement
vi. Check the settings of the thermostat heaters
vii. Inspect motor gear train and mechanism links. To do this a mirror will be helpful.
c. External
i. Inspect Dashpot for oil leaks.
d. Unusual Noise
i. SF6 gas system, leaks
ii. Electrical noise in entrance bushing area or internal to the gas tanks.
e. Record
i. Mechanism counter

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CHAPTER 5 MAINTENANCE

ii. Gas pressure. If the pressure is 5 psig below normal, check for leaks at a planned
outage or next routine maintenance. For patrolling inspection it is suggested the plus
or minus error, at normal pressure, be marked on the face with a marking pencil.
iii. Ambient temperature
f. Dashpot
g. Inspect for Oil Leak

5.4.2 Routine Inspection and Maintenance

5.4.2.1 GENERAL

Interval: 500 operations or 3 years interval whichever comes first.

During this inspection are checked: the electrical current path, the SF6 gas system, the control relays and the
mechanism.
The Routine Inspection is done under following conditions:
1) Breaker removed from service
2) SF6 gas NOT removed
3) Breaker in open position and ALL springs discharged
4) If any of the inspections indicate the GCB is not to specifications refer to either the Periodic Maintenance
Section or the specific section that covers the out of specification item

5.4.2.2 ROUTINE INSPECTION AND MAINTENANCE DETAILS

1) All patrolling items

2) Contact resistance measurement
3) Insulation resistance check
4) Check gas pressure devices
5) Check all gas piping for tightness or leaks
6) SF6 gas moisture check. Performed on a new breaker or periodic inspection refill
a) Moisture should be under 150 ppm, by volume
b) Check after 24 hours. If moisture is under 300 ppm but greater than 150 ppm, proceed to next step
c) Check at one week. If under 150 ppm proceed. If above 150 ppm remove gas for drying and replace
desiccant
d) Check moisture at one month - if satisfactory omit checks until routine inspection

7) Check Dashpot for oil leak and oil level

a) Check oil level by taking out the bolt located at the up end of Dashpot. The oil level should be at lower
side of the bolt hole.
8) Check Auxiliary Switch

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CHAPTER 5 MAINTENANCE

a) Check the linkage from the output crank to the auxiliary switch linkage. Be sure all screws, nuts,
cotter pins and retaining rings are in place and tight. If any need to be tightened use red Loctite 271 to
secure the fasteners.
b) Check all wires to auxiliary switch for tightness.
c) Check that the counter functions properly.

9) Check and lubricate (apply a small amount of Gleitmo 805 K) the Mechanism

NOTE: There is no adjustment in the Mechanism. During breaker duty time, if any mechanism malfunction
observed, contact immediately HVB AE Power Systems, inc.

a) Lubricate close and trip latches (Figure 5.2) and check cotter pins and retaining rings
i) Check the free motion of the latch shafts ensure that the spring return is working
ii) Check the free rotation of the latch rollers also look for damage to the rollers
b) Check charging system. Operate breaker several times by opening and closing the interrupter using
the push buttons. Observe the operation of the motor and gear train system. Check the following
conditions:
i) Motor is securely mounted
ii) Gear train is running smoothly
iii) Inspect the gap between the pawls and the gear. There should always be a minimum gap of 1
mm after the motor stops
iv) Time the charging operation; a second hand on a wristwatch is adequate. Ensure that the
charging cycle completes in 15 seconds or less. If the motor stops before complete charging
cycle, open and close the motor circuit by control power breakers/fuse blocks/knife
switches, to reset the motor overrun relay.
v) Lubricate the gears
c) Measure the resistance of the Trip and Close Coils, (125 VDC; 20+10% ohms, at 68 F)
d) Measure the coils gap (all), 2.0 mm+/-0.2 mm.
e) Check the lock nuts for the mechanism rod connected to crankshaft. If any of these nuts are loose the
linkage must be readjusted and the timing must be rechecked. The Red Loctite 271 should be used to
secure the fasteners.

10) Mechanical Tests

a) Timing Test (Operating curves) - Appendix 2. Can be observed the over travel value at closing
operation.
b) External stroke. When power-operating curves cannot be obtained then a mechanical stroke test
should be made using the manual handle located above motor (3/4” or 19 mm hexagon end shaft).
c) Operational test. When all other work is completed a close, open and trip-free check curves should be
taken at normal pressure and voltage.

11) Touch up paint and caulk as found necessary.

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CHAPTER 5 MAINTENANCE

Routine inspection may also indicate the necessity of an internal inspection if:
• The contact resistance is high or inconsistent between phases.
• Insulator resistance low.
• Contact parting times out of tolerance as indicated by operating curves. Assuming routine inspections are
stable and interruption duty is light, the interruption inspection as determined by these facts may well
exceed 20 years. It is therefore recommended that at least one breaker in a yard be inspected at the first
12 year periodic maintenance to verify the interrupter is stable. The customer can then adjust the
interrupter inspection period as indicated by this inspection.

Figure 5.2. Mechanism’s Latches

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CHAPTER 5 MAINTENANCE

5.4.3 Periodic Inspection and Maintenance

5.4.3.1 GENERAL

Interval: 2000 operations or 12 years whichever comes first. During this inspection and maintenance the
operating mechanism will be lubricated. The interrupter may need to be inspected depending on number of
operations. The interrupter inspection is normally determined by the interruption duty (Table 5.3.)

Current Interrupted Number of Operations

Between Inspections
20,000 to 40,000 Amps 10
15,000 to 20,000 Amps 30
5,000 to 15,000 Amp 100
Rated Load Current 2,500 Amp 2000

Table 5.3. Number of Operations between Inspections

The Periodic Inspection is done under following conditions:

1) Breaker removed from service.
2) SF6 gas removed.
3) Breaker in open position and ALL springs discharged.
4) If any of the inspections indicate the GCB is not to specifications refer to either the Periodic
(1) Maintenance Section, or the specific section that covers the out of specification item.

5.4.3.2 PERIODIC INSPECTION AND MAINTENANCE DETAILS

1) All Patrolling Inspections

2) All Routine Inspections
3) Interrupter Inspection, (Figure 2.2)
The Periodic Inspection should proceed as follows:
a) Perform timing tests before the Interrupter Inspection
b) Discharge both closing and opening springs
c) Remove power from the motor circuit by opening control power breakers, fuse blocks or knife switches
d) Close and open the breaker using the push buttons until all springs are discharged
e) Then remove control power from entire control circuit
f) Remove and store SF6 gas
g) Remove end covers (desiccant covers)
h) Inspect the inside of the tank for white powder and other arc debris. Small fine powder material is to be
expected. Long slivers or whiskers are not acceptable. Contact HVB if there is any question about the
material found.

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CHAPTER 5 MAINTENANCE

i) Remove and inspect the arcing contacts:

• Inspect the surface at end for excessive burning. Remove all high spots with a fine file. Measure
total length and replace if it does not meet the following specs:
NEW - 187 mm MINIMUM -184 mm

• Also replace if difference between peaks and valleys exceeds three mm

• When arcing tip shows almost no damage, inspect moving contacts with a mirror, through the
nozzle. If internal parts look good do not disassemble
• Contact tip may show slight galling. Polish lightly with #400 paper to remove high spots. This is a
current carrying surface and will need to be replaced when excessive galling is present.
j) Remove and inspect teflon nozzles and teflon covers:
• Inspect the tapered entrance of the teflon nozzle for damage, in the fully closed position. Black
oval marks around the small inside diameter will indicate contact hitting during operations.
• The slope leading into the diameter may show black marks or slight depressions due to contact
hitting the surface during re-closing operations. Clean and lightly polish with fine paper to remove
black mark, but depressions do not have to be removed. The internal diameter will also have black
rub marks from the contact. Clean only, do not polish or the life of the nozzle will be reduced.
• Nozzle inside diameter at smallest diameter should be checked. Replace if it does not meet the
following specs:

NEW - 28 mm MAXIMUM - 29 mm

• Check end diameter in teflon cover. Replace if it does not meet the following specs:
NEW - 26 mm MAXIMUM - 27 mm

k) All parts should be cleaned with 99% isopropyl alcohol only and lint free wipes before re-assembly
l) Check all other interrupter parts for tightness then clean with 99% isopropyl alcohol and lint free wipes
m) Install the teflon nozzles, teflon covers, arc contacts
n) Contact resistance check per ROUTINE INSPECTION. This may be performed with or without SF6
gas
o) Add new desiccant to containers and reattach desiccant covers using new “O” rings. See spare parts
book for part number
p) Recharge with SF6 gas per SF6 GAS SYSTEM
q) Check for gas leaks per the INSTALLATION SECTION
r) Final operating curves per ROUTINE INSPECTION.
4) Crankbox O-rings Replacement
The rotating O-ring seals should be replaced. Refer to Chapter 4, Figure 4.8, for the rotating O-ring
locations, part# and quantity. No special tools and jigs are required to replace these O-rings.

5) Dashpot oil Replacement

The oil dashpot and the O-ring seals should be replaced. The HVB approved oil is:
SHELL SPECIAL FLUID.
The internals parts of the Dashpot are not user serviceable.

5-9
APPENDIX

APPENDIX 1. TORQUE VALUE CHART

THREAD SIZE STEEL INTO STEEL STEEL INTO ALUMINUM / COPPER/

BRASS
[lbf-ft] [N X cm] [lbf-ft] [N X cm]
M6 5 490 2 294
M8 10 1177 6 784
M10 15 1961 10 1177
M12 35 4413 25 2942
M16 70 9316 45 5884
M20 130 17652 80 10787
M24 300 41188 140 18633
M30 505 68647 275 37265
M36 870 117680 475 64724
M42 1450 196133 795 107873
APPENDIX

APPENDIX 2. OPERATION TRAVEL CURVES

2.1. CLOSE

A-2
APPENDIX

A-3
APPENDIX

A-4
APPENDIX

A-5
APPENDIX

2.2. OPEN

A-6
APPENDIX

A-7
APPENDIX

A-8
APPENDIX

A-9
APPENDIX

2.3. TRIP FREE

A-10
APPENDIX

A-11
APPENDIX

A-12
APPENDIX

2.4. RECLOSE

A-13
APPENDIX

A-14
APPENDIX

A-15
 REVISION HISTORY
REVISION 2: ECO 110048: ADDED LIFTING POINTS PICTURE ON SHEET 3-1.