ABB LTB Manual

Product Manual
1HSB425416-30 en rev0
LTB 72.5-170D1/B
2-column frame
BLK 222
3-pole operation
PRODUCT MANUAL
PRODUCT DESCRIPTION
- Circuit-Breaker 1
PRODUCT DESCRIPTION
- Operating Mechanism 2
ASSEMBLY INSTRUCTIONS
3
CHECKLIST
4
OPERATING AND MAINTENANCE
INSTRUCTIONS 5
LUBRICANTS
6
MAINTENANCE INSTRUCTIONS
OVERHAUL INSTRUCTIONS
- Circuit-Breaker 8
SPARE PARTS
- Circuit-Breaker 9
ABB Power Technology Products AB
S-771 80 LUDVIKA
SPARE PARTS
11
SF6 Circuit-Breaker LTB 72.5-170D1/B
with operating mechanism
BLK 222
3-pole operation
Product Description
1HSB425455-30 en rev1
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 applica-
ble laws.
© ABB Power Technology Products AB
Article number: 1HSB425455-30 en rev1
Date: 2002-05-03
Product Description
TABLE OF CONTENTS
1. Description.......................................................................... 1
1.1 Design of the circuit-breaker.......................................................... 1
1.2 Circuit-breaker gas system ............................................................. 2
1.3 Operating mechanism..................................................................... 4
1.4 Standards ........................................................................................ 4
1HSB425455-30 en rev1 i
Product Description Description
1. Description
High-voltage circuit-breaker LTB 72.5-170D1/B, with operating mechanism type
BLK 222.
1.1 Design of the circuit-breaker

The circuit-breaker is made up of three separate poles. These consist of three main parts.
At the bottom is 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 one breaking chamber insulator, which together with
an upper and a lower flange make up the enclosure, and upper and lower current
path and a puffer. The puffer, which is designed with integrated lower operating
current contacts, runs outside of the lower current path. The upper operating current
contacts are integrated in the upper current path.
The poles are mounted on a pole beam or on a separate hot-dipped galvanised
column frame. The frame consists of two welded formed plate halves, which are
interconnected with bolted cross stays.
The weight of component parts:
Item Part Weight, kg

1
1 Circuit-breaker pole see dimension drawing
2 Operating see dimension drawing

mechanism
3 Pole beam with gas see dimension drawing

pipe 2
4 Gas pipe see dimension drawing Från
5 Frames,
two column frame see dimension drawing 3
three column frame
5
Från
4
B30259
5
Figure 1-1. Circuit-breaker type LTB 72.5-170D1/B.
1HSB425455-30 en rev1 1
Description Product Description
1.2 Circuit-breaker gas system

The circuit-breaker poles are as standard design, permanently filled with gas to the
following pressure at +20°C:
• for LTB 72.5-145D1/B, 50 Hz:
– 0.5 MPa abs, SF6 gas for circuit-breakers operating down to -40°C
ambient temperature
– 0.7 MPa abs, SF6 gas mixed with N2 gas or CF4 gas for circuit-breakers
operating down to -50°C ambient temperature.
• for LTB 72.5-145D1/B, 60 Hz:
ambient temperature
• for LTB 170D1/B, 50 and 60 Hz:
ambient temperature
2 1HSB425455-30 en rev1
1.2.1 Opening and closing

The circuit-breaker poles work in accordance with the Auto-PufferTM- principle with
a puffer cylinder (1) that is divided into two chambers. An Auto-PufferTM- section
(2) and a compression section (3).
When breaking normal operating currents
the SF6-gas is compressed in the
compression section to an overpressure.
When the arcing contacts separate the gas in
the compression section flows out and
extinguishes the arc at the zero crossing.
When breaking the short-circuit currents the
requisite extinguishing pressure is built up
in the Auto-PufferTM- section through the
heat from the arc. In this way a pressure 1
increase is obtained using energy from the 2
arc and no extra energy from the operating
mechanism is needed. 3
On closing, the puffer cylinder slides
upwards, the contacts engage and the puffer
cylinder is refilled with gas.
B30033
Figure 1-2. Circuit-breaker pole in the Closed position.
1HSB425455-30 en rev1 3
1.3 Operating mechanism

The LTB circuit-breaker is operated by a motor-charged spring operating
mechanism type BLK 222.
The operating mechanism is connected to the circuit-breaker poles’ mechanisms via
a pull-rod system.
The circuit-breaker is closed by means of the operating mechanism, which houses
the closing springs. On closing, the opening spring is tensioned, which is intgrated
in the pull rod system between the poles. The tripp latch in the operating mechanism
keeps the circuit-breaker in the closed position. Opening of the circuit-breaker only
requires the release oft the tripp 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.
4 1HSB425455-30 en rev1
ABB Power Technology Products AB 1HSB425455-30 en rev1
Head Office 0502
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 782 320
SF6 Circuit-Breaker Operating mechanism
type BLK 222
Product Description
1HSB535432-100 en rev4

The information in this document is subject to alteration without prior notice and should not be regar-
ded 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 wit-
hout authorisation. Infringement hereof will be subject to action in accordance with applicable laws.
Date: 2002-03-21
Product Description
LIST OF CONTENTS
1. Description.......................................................................... 1
1.1 Delivery.......................................................................................... 2
1.2 Unpacking ...................................................................................... 2
1.3 Storage............................................................................................ 3
2. Assembly and connection ................................................. 5

2.1 Mechanical connection................................................................... 5
2.2 Electrical connection...................................................................... 6
2.3 Loading the closing springs ........................................................... 7
2.4 Normal operations, the circuit-breaker closed ............................... 8
2.5 Open, the circuit-breaker is open ................................................... 8
2.6 Closed, the circuit-breaker is closed .............................................. 9
3. Operations......................................................................... 11
3.1 Remote/local operations............................................................... 11
3.2 Close operation............................................................................. 11
3.3 Open operation ............................................................................. 12
3.4 Rapid reconnection....................................................................... 12
4. Component parts.............................................................. 13
4.1 Drive mechanism.......................................................................... 13
4.2 Catch gear..................................................................................... 13
4.3 Dashpot ........................................................................................ 14
4.4 Limit switch with auxiliary contact.............................................. 14
4.5 Heater element ............................................................................. 15
1HSB535432-100 en rev4 i
Product Description
FIGURES
Figure 1-1. Operating mechanism BLK 222. .................................................... 1

Figure 1-2. Lifting the operating mechanism. ................................................... 2
Figure 2-1. Operating mechanism. .................................................................... 5
Figure 2-2. Earth clamp connection. ................................................................. 6
Figure 2-3. Electrical loading of the closing spring. ......................................... 7
Figure 2-4. Normal operating position. ............................................................. 8
Figure 2-5. Opening operation. ......................................................................... 8
Figure 2-6. Closing operation. .......................................................................... 9
Figure 3-1. Remote/local operations. .............................................................. 11
Figure 3-2. Close operation. ............................................................................ 11
Figure 3-3. Open operation. ............................................................................ 12
Figure 4-1. Motor. ........................................................................................... 13
Figure 4-2. Catch gear. .................................................................................... 13
Figure 4-3. Dashpot. ........................................................................................ 14
Figure 4-4. Limit switch with auxiliary contact. ............................................. 14
Figure 4-5. Heater element. ............................................................................. 15
ii 1HSB535432-100 en rev4
1. Description
The operating mechanism BLK 222 is intended for operating circuit-breakers with
integrated opening springs. Under no circumstances may the operating mechanism
be operated without first being mounted and adjusted for a circuit-breaker.
The operating mechanism consists of an closing spring with associated motor
charging device that automatically charge the closing spring after each closing
operation. A closing interlock holds the tensioned closing spring prepared for the
Closing of the circuit-breaker and the re-tensioning of the opening springs. A
opening interlock holds a closed circuit-breaker prepared for immediate Opening.
The component parts of the operating mechanism are integrated in a cabinet which
also accommodates an operating panel and operating equipment. The cabinet’s
cover can be removed and the operating panel opened to facilitate service and
overhauling.
The standard operating cycle is O - 0.3 s - CO - 3 min - CO (IEC) or CO - 15s - CO
(ANSI). The time between closing operations should not be less than 1 minute
during the testing of the circuit-breaker and relay systems involving more than 3
closing operations.
2 1
5
3
Figure 1-1. Operating mechanism BLK 222.
Item
1 Drive unit
2 Operating mechanism
3 Operating panel
4 Closing spring
5 Heater element
1HSB535432-100 en rev4 1
1.1 Delivery
Check on arrival that the delivery corresponds with the order and delivery
documents and that no transport damage has occurred.
If any material is missing or if transport damage has occurred, please report this
immediately to ABB Power Technology Products AB, Circuit Breaker Division.
1.2 Unpacking
The operating mechanism is packed in a crate. The crate is marked with a case
number and the gross weight. Other information is written on a plywood
board/label, which is attached to two of the crate’s sides.
The operating mechanism must be lifted using the lifting eyes on top of the cabinet,
see Figure 1-2. Slings must not be placed around the cabinet when lifting.
All packing material can be recycled.
B30079
Figure 1-2. Lifting the operating mechanism.
2 1HSB535432-100 en rev4
1.3 Storage
Avoid storage. If storage is necessary, this must be done indoors or under cover.
The operating mechanism shall preferably be stored indoors in a dry building. When
stored outdoors, the crate should be opened to promote the exchange of air and a
heater should be used to prevent condensation.
An approved storage area is a store consisting of:
roof
a solid floor
humidity less than 50%
temperature +20 ˚C (±10 ˚C)
1HSB535432-100 en rev4 3
Product Description Assembly and connection
2. Assembly and connection

The operating mechanism should be positioned in accordance with the circuit-
breaker’s measurement diagram.
2.1 Mechanical connection

The connection of the pull-rods between the operating mechanism and the circuit-
breaker should be carried out in accordance with the instructions for the circuit-
breaker to be connected to the operating mechanism.
WARNING
Do not operate the mechanism unloaded!
Operations shall take place only after the mechanism has been connected
and adjusted to the associated pressurised circuit-breaker.
On delivery the operating mechanism’s closing spring is uncharged.
2 1
2
Min.
Middle position (Yellow field)
Max. (Green field)
B30161
Min. pos.: No tension on closing spring.
Item N.B. The opening spring is tensioned if the

circuit-breaker is closed.
1 Indication disk
Mid. pos.: Dog against closing catch gear.
2 Indication pin
(Yellow field) Closing spring tensioning has begun.
N.B. No work permitted on operating mech.

Spring shall be considered tensioned.
Max. pos.: Closing spring is fully tensioned.
(Green field)
Figure 2-1. Operating mechanism.
1HSB535432-100 en rev4 5
Assembly and connection Product Description
2.2 Electrical connection

Operation and signal cables are routed through the connection flange at the bottom
of the cabinet. Fit the flange with a suitable cable gland for the cable in question.
Connect the cables to the terminal blocks in accordance with the applicable wiring
diagram. The terminal blocks are of a snap-in type and are designed both for
through wiring with termination of a stranded conductor with a cross-section of
max. 4 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.
N.B. Cables must not be routed so that they obstruct manual cranking.
B30079 1
Figure 2-2. Earth clamp connection.
6 1HSB535432-100 en rev4
2.3 Loading the closing springs
2.3.1 Electrical loading

Make the motor protection switch (1) so that the motor (2) starts and drives the
spring drum (3) to the tensioned position. The limit switch (4) breaks the contactor
(5) and the motor circuit.
CAUTION
The contactor must not be operated manually so that the limit switch
is bypassed.
2
3
B30200 1 5
Item
1 Motor protection switch
2 Motor
3 Spring drum
4 Limit switch
5 Contactor
Figure 2-3. Electrical loading of the closing spring.
1HSB535432-100 en rev4 7
Assembly and connection Product Description
2.4 Normal operations, the circuit-breaker closed

The open spring on the circuit-breaker and the closed spring on the operating
mechanism are tensioned. The circuit-breaker remains in the closed position by the
operating mechanism’s opening interlock (1).
Item
1 Open interlock
2 Closed interlock
B30054
Figure 2-4. Normal operating position.
2.5 Open, the circuit-breaker is open

When the circuit-breaker is open the interlock is released from the catch gear (1). In
the end position the movement is dampened by the dashpot (2), which makes up an
end position stop in the OPEN position. The closing spring is tensioned.
Item 2
1 Closing catch gear
2 Dashpot
3 Tripping arm
3
B30057
Figure 2-5. Opening operation.
8 1HSB535432-100 en rev4
2.6 Closed, the circuit-breaker is closed

When closed the closing arm (1) is released from the tripping arm (3) and the
interlock heel (2). The dashpot piston (4) is extended and is prepared once again for
an opening operation. The motor starts and charges the closing spring again so that
the circuit-breaker returns to normal operations.
The operating mechanism is prepared for a new closing operation after opening
(O-CO).
3
2
Item
1 Closing arm 4
2 Interlock heel
3 Tripping arm with interlock heel
4 Dashpot piston
B30054
1
Figure 2-6. Closing operation.
1HSB535432-100 en rev4 9
Product Description Operations
3. Operations
3.1 Remote/local operations

With normal operations the switch (1) is in the Remote position for electrical remote
operations. In the LOCAL position, operations can only be carried out using the
operating switch (2).
The switch (1) has one position for the Shutdown function.
2 1
Item
1 Switch, Local/Remote
2 Operating switch, On/Off
B30207
Figure 3-1. Remote/local operations.
3.2 Close operation

A Close operation using the operating switch (2) or electrical remote pulses can
only take place if:
• Switch (1) is in the Remote or Local position.
• The closing spring is tensioned with a closed ON circuit via the limit switch
(3).
• The circuit-breaker is in the open position with a closed ON circuit via auxiliary
contact (4).
• The gas density is greater than the blocking level with closed ON circuit via the
density monitor.
Item
3 Limit contact
4 Auxiliary contact 3
B30200 2 1
Figure 3-2. Close operation.
1HSB535432-100 en rev4 11
Operations Product Description
3.3 Open operation

An Open operation with a closed circuit-breaker can be made with the switch (1) in
the LOCAL position and the operating switch (2) in the ON position.
2 1
Item
B30208
Figure 3-3. Open operation.
3.4 Rapid reconnection

Automatic rapid reconnection, Open-0.3s-Closed-Open can be made if:
• The circuit-breaker is closed.
• The switch is in the Remote position.
• The mechanism’s closing spring is fully loaded when the operating cycle is
started.
With automatic rapid reconnection the switchgear’s relay equipment can give an
immediate Open impulse if the short-circuit still remains in the network. As the
operating circuits are electrically interlocked via the auxiliary contact an Close
operation will always be completed before an Open operation is started. Even if the
Close pulse has been given during a current Open operation.
12 1HSB535432-100 en rev4
Product Description Component parts
4. Component parts
4.1 Drive mechanism

The drive mechanism is supplied with a motor for 110 or 220 V DC and
50, 60 Hz AC.
The motor should be capable of loading the spring at 85% of the nominal voltage
(IEC).
1
Item
1 Motor
B30068
Figure 4-1. Motor.
4.2 Catch gear

The operating mechanism has a Closing and an Opening catch gear.
The standard voltage of the magnets is 110 or 220 V DC.
The coils rated power is 200 W.
1 2
Item
1 Opening catch gear
B30062
Figure 4-2. Catch gear.
1HSB535432-100 en rev4 13
Component parts Product Description
4.3 Dashpot
The operating mechanism is fitted with a dashpot to slow the final phase of the
opening movement.
Item
1 Dashpot
B30063
Figure 4-3. Dashpot.
4.4 Limit switch with auxiliary contact

The operating mechanism is fitted as standard with a 12 way auxiliary contact
consisting of twelve normally open and twelve normally closed contacts. Three
normally closing and three normally opening contacts are used for the operating
mechanism’s own function. There is also the possibility of supplementing with
twelve extra contacts.
The auxiliary contact’s shaft is in direct connection with the operating mechanism’s
operating lever and accordingly follows the circuit-breaker contact’s movement.
2 1
Item
1 Limit switch
2 Auxiliary contact
B30200
Figure 4-4. Limit switch with auxiliary contact.
14 1HSB535432-100 en rev4
Product Description Component parts
4.5 Heater element

The operating mechanism is equipped with a heater element to prevent
condensation and should always be connected.
Item
1 Heater element
B30058
Figure 4-5. Heater element.
Data
– 70 W, 220 V: R = 691 Ohm ±10%.
– 140W, 220 V: R = 346 Ohm ±10%.
– 70 W, 110 V: R = 173 Ohm ±10%.
– 140 W, 110 V: R = 86 Ohm ±10%.
1HSB535432-100 en rev4 15
Head Office 0321
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
with two column frame and
operating mechanism BLK 222
3-pole operation
Assembly Instructions
1HSB425410-30 en rev0

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.
Date: 2002-05-02
TABLE OF CONTENTS
1. General ................................................................................ 1
2. Safety................................................................................... 3
2.1 Warning text ................................................................................... 3
2.2 Safety, general ................................................................................ 4
3. Delivery ............................................................................... 5
3.1 Weights........................................................................................... 5
3.2 Unpacking ...................................................................................... 6
3.3 Storage............................................................................................ 6
4. Assembly............................................................................. 7
4.1 Preparations.................................................................................... 7
4.2 Frame assembly.............................................................................. 9
4.3 Assembling the frame on the foundation ..................................... 10
4.4 Assembling the pole beam on the frame ...................................... 11
4.5 Assembling the circuit-breaker poles and protective pipe on the
pole beam ..................................................................................... 12
4.6 Assembling the operating mechanism ......................................... 18
4.7 Final assembly of the circuit-breaker pole and frame .................. 20
4.8 Assembling the pull rods.............................................................. 21
4.9 Gas monitoring system................................................................. 27
4.10 Assembling the current transformers ........................................... 28
4.11 Fitting the covers and sign ........................................................... 32
4.12 Inspecting the bolted joints, etc.................................................... 33
5. Electrical connections ..................................................... 35

5.1 Connection of the operating mechanism...................................... 35
5.2 Assembly of busbars or overhead lines........................................ 35
5.3 Tensioning the closing spring....................................................... 37
6. Pressurising the poles ..................................................... 39

6.1 Preparations.................................................................................. 39
6.2 Gas filling with SF6-gas............................................................... 40
6.3 Gas filling with mixed gas............................................................ 43
6.4 Leakage test.................................................................................. 44
7. Commissioning................................................................. 45
8. Operating values .............................................................. 47
1HSB425410-30 en rev0 i
8.1 Times ............................................................................................ 47

8.2 Motor and control circuits ............................................................ 47
8.3 Resistance ..................................................................................... 47
8.4 Contact stroke............................................................................... 47
FIGURES
Figure 3-1. Component parts LTB 72.5-170D1/B. ............................................5

Figure 3-2. Lifting the operating mechanism. ...................................................6
Figure 4-1. Assembly markings. ........................................................................7
Figure 4-2. Foundation. ......................................................................................8
Figure 4-3. Frame assembly. ..............................................................................9
Figure 4-4. Assembling the frame on the foundation. .....................................10
Figure 4-5. Assembling the pole beam. ...........................................................11
Figure 4-6. The circuit-breaker pole’s non-return valve. .................................12
Figure 4-7. Lifting the circuit-breaker pole. ....................................................12
Figure 4-8. Dismantling signs and covers. .......................................................13
Figure 4-9. Assembling the circuit-breaker pole B1. .......................................13
Figure 4-10. Assembling circuit-breaker pole A1 .............................................14
Figure 4-11. Assembling the protective pipe between pole A1 and pole B1 .....15
Figure 4-12. Assembling circuit-breaker pole C1 ..............................................16
Figure 4-13. Assembling the protective pipe between pole B1and pole C1 ......17
Figure 4-14. Assembling the operating mechanism. .........................................18
Figure 4-15. Assembling the pipe flange. ..........................................................19
Figure 4-16. Circuit-breaker pole on the frame. ................................................20
Figure 4-17. Adjusting the operating mechanism. .............................................21
Figure 4-18. Assembling the pull-rod between pole A1 and the operating
mechanism .....................................................................................22
Figure 4-19. Assembling the pull-rod between pole C1 and pole B1. ...............23
Figure 4-20. Assembling the crank extension. ...................................................24
Figure 4-21. Assembling the pull-rods between pole C1 and pole B1. .............25
Figure 4-22. Alignment check hole, OPEN-position. ........................................26
Figure 4-23. Gas monitoring system. .................................................................27
Figure 4-24. Assembling the current transformer bracket. ................................29
Figure 4-25. Flashover distance. ........................................................................30
Figure 4-26. Connecting the current transformer. ..............................................31
Figure 4-27. Sign. ..............................................................................................32
Figure 4-28. Fitting the covers. ..........................................................................32
Figure 5-1. Operating mechanism. ...................................................................35
1HSB425410-30 en rev0 iii

Figure 5-2. Electrically tensioning the closing spring. ................................... 37

Figure 6-1. Gas filling. .................................................................................... 40
Figure 6-2. Density monitor. ........................................................................... 42
iv 1HSB425410-30 en rev0
Assembly Instructions General
1. General
This Assembly Instruction Manual applies to the SF6 circuit-breaker type
LTB 72.5-170D1/B with two column frame and operating mechanism type
BLK 222 for 3-pole operations and contains all essential information for assembly
and commissioning.
Read through the entire Assembly Manual before starting the assembly work.
1HSB425410-30 en rev0 1
Assembly Instructions 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
in death or serious injury.
CAUTION
indicates a hazardous situation that can result in minor or moderate
injury.
N.B. is used for hazards that may only result in damage to the installation.
1HSB425410-30 en rev0 3
Safety Assembly Instructions
2.2 Safety, general
WARNING
Circuit-breaker with pressurised insulators.
Mechanical damage to the insulator 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,
0.125 MPa (abs).
WARNING
Do not energize, charge or operate the operating mechanism until final
assembly and adjustments on the circuit-breaker are fully completed.
The standard operating cycle is O - 0.3 s - CO - 3 min. - CO. The time between
closing operations should not be less than 1 minute during the testing of circuit-
breakers and relay systems involving more than 3 closing operations.
4 1HSB425410-30 en rev0
Assembly Instructions 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-
breakers.
3.1 Weights
The weights of the component parts are as follows:
Från
B30229
Item Part Weight, kg
1 Circuit-breaker pole see dimension drawing
2 Pole beam with gas pipe see dimension drawing
3 Operating mechanism see dimension drawing
4 Frame see dimension drawing
Figure 3-1. Component parts LTB 72.5-170D1/B.
1HSB425410-30 en rev0 5
Delivery Assembly Instructions
3.2 Unpacking
The material is packed in crates and on pallets. The crates are marked with a case
number and the gross weight. Other information is written on a board/label, which
is attached to two of the crate’s sides.
The operating mechanism must be lifted using the lifting eyes on top of the cabinet,
see Figure 3-2. Slings must not be placed around the cabinet when lifting.
The circuit-breakers shall be kept in the transport packaging until just before
assembly.
All packing material can be recycled.
B30002
Figure 3-2. Lifting the operating mechanism.
3.3 Storage
Avoid prolonged storage, i.e. > 3 months. If storage is necessary, this must be done
indoors or under cover.
The original transport packaging can be used to store the circuit-breakers. The circuit-
breakers are stored flat above the ground to prevent breakage and damage by water.
The operating mechanism shall preferably be stored indoors in a dry building. When
stored outdoors, the crate should be opened to promote the exchange of air and a
heater should be connected to a suitable power supply to prevent condensation
An approved storage area is a store consisting of:
a roof
a solid floor
humidity less than 50%
temperature +20 °C ( ±10 °C).
6 1HSB425410-30 en rev0
Assembly Instructions 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 (10 - 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.
• Test tool, ABB article number 6889 703-1
• Plastic disc, ABB article number 6834 115-1
• Check pin, ABB article number 1HSB539782-1
• Crank extension, ABB article number 1HSB532188-F
• Crank, ABB article number 2188 754-G
• Applicable dimension drawing and diagrams for the order.
4.1.1 Assembly markings

On delivery the circuit-breakers are supplied dismantled in transport units. The
component parts are marked to facilitate assembly. The circuit-breaker poles and
operating mechanisms have been tested together.
Check that the assembly markings correspond with Figure 4-1 and that the serial
number on the operating mechanism corresponds with the serial number of the
circuit-breaker.
Assembly should always be carried out as set out in Figure 4-1 as the circuit-breaker
has been adjusted and tested with the poles in this sequence.
Item 4 3 2
2 Circuit-breaker pole A
1
3 Circuit-breaker pole B
4 Circuit-breaker pole C Från
5 Pole beam with gas

pipe
5
B30229
Figure 4-1. Assembly markings.
1HSB425410-30 en rev0 7
Assembly Assembly Instructions
4.1.2 Foundation
The circuit-breaker’s foundation must be flat and level. Figure 4-2 shows the
permitted deviations in mm for the position of the foundation bolts. For dimensions
of the foundation bolts and nuts, see the dimension drawing.
Adjust any deviations using spacer washers, see “kapitel 4.3, Assembling the frame
on the foundation”. The nominal dimensions are stated on the applicable dimension
drawing for the order.
max. 4 mm
± 2 mm
±1 mm
max. 4 mm
2
±1 mm 1
B30003 M24, Length = >110 mm
Item
1 Foundation for frame 1
2 Foundation for frame 2
Figure 4-2. Foundation.
8 1HSB425410-30 en rev0
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. ssembly the cross stays in order
according to the numbering 1-4, using the supplied nuts, bolts and washers.
Make sure the stays are fitted as set out in Figure 4-3.
Tighten the bolted joints to a torque of 190 Nm.
1
Item
1 Frame halves 2 pcs
2 Cross stay 6 pcs
3 Bolts M16x50 8 pcs

Nuts M16 8 pcs
Washers 17x30x3 16 pcs
3 2
TIGHTENING TORQUE
190 Nm
1
B30258
Figure 4-3. Frame assembly.
1HSB425410-30 en rev0 9
4.3 Assembling the frame on the foundation

The two frames are the same. Orintate the frames as shown in Figure 4-1
Check that the frames are upright and adjust them to the same level using the nuts
(2). For dimensions of foundation bolts, spacer washers and nuts refer to the
dimension drawing.
Fill the gap between the lower nut and foundation with spacer washers; which
should be as small as possible.
Foundation bolts, nuts and spacer washers are not supplied.
N.B. The final tightening of the frame is carried out after alignment and mounting
of the pole beam.
Item
1 Foundation bolts L> 110 mm (not supplied)
2 Nuts (not supplied) 8 pcs
3 Washers 8 pcs
4 Spacer washers (not supplied)
5 Foundation
6 Frame foot
1 2 3
10
6
25
115
4
10
B10006 2
Figure 4-4. Assembling the frame on the foundation.
10 1HSB425410-30 en rev0
4.4 Assembling the pole beam on the frame

On delivery the pole beam and gas pipe are assembled.
The pole beam has three rectangular holes by the poles for the adjustment of the
circuit-breaker and in pole A space for the CLOSED-OPEN sign. The pole beam is
mounted on the frame legs (2). Turn the beam so that the mechanism is in the
correct position for the external electrical connection.
The bolts (3) are tightened with a tightening torque of 430 Nm.
TIGHTENING TORQUE
430 Nm
Tighten the frame finally using nuts (2), Figure 4-4, these are tightened with a
tightening torque of 300 Nm.
TIGHTENING TORQUE
300-350 Nm
Item
1 Pole beam
2 Frame
3 Bolts M20x60 8 pcs B10360

Nuts M20 8 pcs
Figure 4-5. Assembling the pole beam.
1HSB425410-30 en rev0 11
4.5 Assembling the circuit-breaker poles and protective pipe on the pole
beam
The circuit-breaker poles are assembled in the order B1, A1 and finally C1.
1. Check that the bolts (1), Figure 4-7, have a tightening torque of 79 Nm.
2. Check that the circuit-breaker pole is sealed before assembling on the frame.
– Unscrew the sealing cap (1).
– Press the non-return valve’s disk (2) inwards using the test tool (3). A
clear hissing noise should be heard from the pole. If no hissing noise is
heard, the pole leaks. This must be rectified before assembly.
1 3
Item
1 Sealing cap
2 Non-return valve
3 Test tool, Art. No. 6889-703-1
B30231 2
Figure 4-6. The circuit-breaker pole’s non-return valve.
3. Place a lifting sling around the top section of the circuit-breaker pole as set out
in Figure 4-7 and in this way lift the circuit-breaker pole from its horizontal
position in the transport packaging. Start with pole B1.
N.B. Note the position of the sling on the circuit-breaker pole!

When assembling composite insulators the lifting sling should be placed as close to
the connection flange as possible and not on the rubber area.
B30254
Figure 4-7. Lifting the circuit-breaker pole.
12 1HSB425410-30 en rev0
4. Dismantle the covers (1) from each pole and the indicating sign (2) from pole
A1.
5.
OPEN
B30232 1 1 1 2
Item
1 Covers, poles
2 Sign
Figure 4-8. Dismantling signs and covers.
6. Lift the circuit-breaker pole B1 into position and align it on the pole beam, see
Figure 4-9. Fit the bolts (1) and tighten by hand.
N.B. Final tightening is carried out when the operating mechanism is assembled.
Item

Washers 13x24x2.5 8 pcs
Nuts M12 4 pcs
B30261
Figure 4-9. Assembling the circuit-breaker pole B1.
1HSB425410-30 en rev0 13
7. Lift the circuit-breaker pole A1 into position and align it on the pole beam, see
Figure 4-10. Fit the bolts (1) and tighten by hand.
N.B. Final tightening is done when the operating mechanism is assembled.
Item
1 Bolts M12x50 4 pcs.

Washers 13x24x2.5 8 pcs.
Nuts M12 4 pcs.
B30262
Figure 4-10. Assembling circuit-breaker pole A1
14 1HSB425410-30 en rev0
8. Assemble the protective pipe (1) between the circuit-breaker poles A1 and B1.
Tighten the bolts (2), see Figure 4-11, with a tightening torque of 79 Nm.
The nut (3) on the outside of the mechanism housing.
TIGHTENING TORQUE
79 Nm
9. Insert the pull-rod (4) with the fork coupling at one end inside the protective
pipe. Guide the pull-rod into the protective pipe through the mechanism
housing on circuit-breaker pole B with the end fitted with the fork coupling
last.
N.B. Insert the pull-rod facing the right way in the protective pipe.
10. Secure the pull-rod (4) in the operating lever (5) using the pin (6) and the lock
washer (7) in the mechanism housing on pole A, see Figure 4-11.
4 Pole B1 1 Pole A1
Item
1 Protective pipe A A-A

3 Nuts M12 4 pcs.
4 Pull-rod
2 3 A
5 Operating lever pole A 4 5 7 6
B10312
6 Pin D=12
7 Lock washer SL12
Figure 4-11. Assembling the protective pipe between pole A1 and pole B1
1HSB425410-30 en rev0 15
11. Lift the circuit-breaker pole C1 into position and align it on the pole beam, see
Figure 4-12. Fit the bolts (1) and tighten hand tight.
N.B. Final tightening is done once the operating mechanism has been fitted.
1
Item

Nuts M12 4 pcs
Från
B10313
Figure 4-12. Assembling circuit-breaker pole C1
16 1HSB425410-30 en rev0
12. Fit the protective pipe with the opening spring housing (1) between pole C1
and pole B. Mount the opening spring housing end on pole C1.
N.B. Make sure that the drainage grooves in the opening spring housing are turned
downwards when mounting it to pole C1.
13. Tighten the opening spring housing using the bolts (2) onto pole C1 with a
tightening torque of 79 Nm.
TIGHTENING TORQUE
79 Nm
14. Tighten the protective pipe (1) using the bolts (3) onto circuit-breaker pole B1
with a tightening torque of 79 Nm.
TIGHTENING TORQUE
79 Nm
N.B. The nut (4) on the outside of the mechanism housing.
Pole C1 1 Pole B1
Item
1 Protective pipe with opening

spring housing


4 Nuts M12 4 pcs.
2
B10314 4 3
Figure 4-13. Assembling the protective pipe between pole B1and pole C1
1HSB425410-30 en rev0 17
4.6 Assembling the operating mechanism

On delivery the operating mechanism has been set and is supplied with the closing
springs correctly adjusted.
WARNING
• Lift the operating mechanism using the four lifting eyes. Align the operating
mechanism’s mounting bracket (1) vertically with the pole beam (2).
• Tighten the operating mechanism’s mounting bracket (1) using the bolts (3)
against the pole beam (2) on the circuit-breaker pole A1.
2 3 1
Item
1 Mounting bracket
2 Pole beam

Nuts M16 4 pcs
B10315
Figure 4-14. Assembling the operating mechanism.
18 1HSB425410-30 en rev0
• Tighten the pipe flange (3) against the circuit-breaker pole A1’s mechanism
housing (4) using the bolts (1). Tightening torque 79 Nm.
TIGHTENING TORQUE
79 Nm
N.B. The nuts (2) on the outside of the mechanism housing.
1 2
Item 3
2 Nuts M12 4 pcs
3 Pipe flange
4 Mechanism housing
B10316
Figure 4-15. Assembling the pipe flange.
• Tighten the bolted joints (3), Figure 4-14, with a tightening torque of 190 Nm.
TIGHTENING TORQUE
190 Nm
• Dismantle the operating mechanism’s lifting rails.

• Refit the lifting rails’ bolts.
1HSB425410-30 en rev0 19
4.7 Final assembly of the circuit-breaker pole and frame

Secure the circuit-breaker poles by tightening the bolts (1) between the poles and
pole beams with a tightening torque of 79 Nm.
TIGHTENING TORQUE
79 Nm
1
Item

Nuts M12 12 pcs
Från
B10313
Figure 4-16. Circuit-breaker pole on the frame.
20 1HSB425410-30 en rev0
4.8 Assembling the pull rods

On delivery each pole is set and its open position is predetermined.
The pull-rods are supplied factory pre-adjusted to the required length. Even the
opening spring pretension on the pull-rod between pole B1 and pole C1 has been
adjusted correctly. Therefore the nuts on the pull rods must not be loosened during
assembly.
The assembly of the pull-rods takes place in stages, that must be followed in the
order described below.
Assembling the pull-rod between the operating mechanism and

pole A1.
1. Check that the operating mechanism’s link (1) is not latched in its closed
position. The operating mechanism’s link (1) can be released and moved
towards its open position by pressing the spring-charged latch (2) using a
screwdriver, so it passes the roller (3).
3
2
Item 1
1 Operating mechanism link
2 Latch
3 Roller
B30017
Figure 4-17. Adjusting the operating mechanism.
1HSB425410-30 en rev0 21
2. Move the operating mechanism’s pull-rod (1) towards its closed position until
the operating mechanism’s dashpot starts to brake.
3. Move the pull-rod (2) between the poles A1 and B1 towards its open position
as far as possible towards the pull-rod (1) from the operating mechanism.
4. Fit together the pull-rods using pin (3) and lock using the locking washer (4).
Pole A1
Item
2 1
1 Operating mechanism’s pull-rod
2 Pull-rod between pole A1 and B1
3 Pin D=16
4 Lock washer SL16
B
B-B
3 4
B30235
B
Figure 4-18. Assembling the pull-rod between pole A1 and the operating
mechanism
22 1HSB425410-30 en rev0
Assembling the pull-rod between pole C1 and pole B1.

1. Insert the pull-rod (1) inside the protective pipe and the opening spring housing
(2). Insert the pull-rod through the mechanism housing on circuit-breaker pole
C1 with the end fitted with a long nut last. Check that the spring bracket (3)
etc., is correctly located in the opening spring housing, see Figure 4-19.
N.B. Insert the pull-rod into protective pipe facing the right way.
Pole C1
Item
1 3
1 Pull-rod between pole C1
and B1
2 Opening spring housing
3 Opening spring bracket
B30236
2
Figure 4-19. Assembling the pull-rod between pole C1 and pole B1.
1HSB425410-30 en rev0 23
2. Fit the protective cover (1) on circuit-breaker pole C1. Tighten the bolts (2)
N.B. The nuts on the outside of the mechanism housing.
TIGHTENING TORQUE
79 Nm
3. Screw the crank extension (3) into the protective cover (1) so that it enters the
countersink on the end of the coupling link (4). Tighten so that the pull-rod (5)
is clamped in position between the crank extension and the opening spring
bracket (6), see Figure 4-20. The crank extension (3) and crank (7) are supplied
with the operating mechanism.
4. Crank, using the crank (7), in the crank extension so far that the pull-rods meet
in the mechanism housing on pole B1 (a bit further in than the position
corresponding to the open position).
Item Pole C1
1 Protective cover
7 3 1
2 Bolts M12x 50 4 pcs.
Nuts M12 4 pcs.
3 Crank extension, ABB Art. No.

1HSB532188-F
4 Coupling link
5 Pull-rod
6 Open spring bracket
7 Crank, ABB Art. No.

2188 754-G B30237 2 4 5 6
Figure 4-20. Assembling the crank extension.
24 1HSB425410-30 en rev0
5. Fit together the pull-rods using pin (1) and lock using the lock washer (2)
6. Place the operating lever (3) and coupling link (4) in the mechanism housing
on pole B1 so that the pin (5) can be fitted. Lock the pin (5) using the lock
washer (6).
Pole B1
Item
1 Pin D=16
2 Lock washer SL16
3 Operating lever
4 Coupling link
5 Pin D=12 3
B
4
6 Lock washer SL12
A
A-A
B-B
B
B30238 A 6 5 1 2
Figure 4-21. Assembling the pull-rods between pole C1 and pole B1.
7. Crank out the crank extension and return it and the crank in the operating
mechanism.
1HSB425410-30 en rev0 25
8. Place the operating lever (1) and coupling link (1) in the mechanism housing
on pole C1 so that the pin (3) can be fitted. Lock the pin (3) using the lock
washer (4). Check that the circuit-breaker (pole A1, B1 and C1) is in the open
position using the check pin (5), with a diameter of 6 mm. If the check pin does
not fit, contact ABB personnel.
N.B. The check pin must be removed after the check is done.
9. Fit the protective bolt (7) on the protective cover (8). Tighten the protective bolt
TIGHTENING TORQUE
79 Nm
Pole C1
Item
1 Operating lever
8 1
2 Coupling link 7
3 Pin D=12
4 Lock washer SL12
5 Check pin, ABB Art. No.

1HSB539782-1
6 Alignment check hole
7 Protective bolt M16x30

Washer 17x30x3
8 Protective cover
B30239 3, 4 2 5, 6
Figure 4-22. Alignment check hole, OPEN-position.
26 1HSB425410-30 en rev0
4.9 Gas monitoring system

The gas pipes are assembled on delivery. The gas pipes can, if necessary, be bent by
using the supplied plastic disc, ABB Art. No. 6834 115-1 so they can be connected
to respective circuit-breaker pole.
N.B. When assembling the gas monitoring system the greatest possible level of
cleanliness must be observed.
• Connect the gas pipes to the circuit-breaker poles, but only screw the union
nuts (2) to the groove (3) on the non-return valves (4). The connection is now
sealed, but the non-return valve has not opened.
N.B. Make sure that the gas pipes do not rest against the pole beam so not galvanic
corrosion will occur.
• When all of the circuit-breaker poles have been connected in this way the union
nuts (1) can be screwed on fully. Tighten them with a tightening torque of
10 Nm.
TIGHTENING TORQUE
10 Nm
• Connect the density monitor to the rear valve on pole A1. Grease the sealing
rings using grease “G” before assembling.
N.B. Only screw the union nut (2) on to the groove (3) on the non-return valve (4).
The connection will then be sealed, but the non-return valve will not be
opened.
Final tightening of the density monitor is done after gas filling.
• Route the cable from the density monitor in to the terminals on the operating
mechanism and strap the cable to frame.
3
2 4 7
Item
6
1 Density monitor 5
2 Union nut
3 Groove
4 Non-return valve
5 Cable
6 Gas pipe
7 Pipe clamps
B10317
8 Plastic disc, ABB
1
Art. No. 6864115-1
Figure 4-23. Gas monitoring system.
1HSB425410-30 en rev0 27
4.10 Assembling the current transformers
Assembling the bracket

There are two different height positions on the circuit-breaker’s frame legs for
securing beams. Select the height position that brings the current transformer’s
highest earth section level with the height of the circuit-breaker’s highest earth
section. See Figure 4-24.
N.B. The flashover distance between the circuit-breaker and the current
transformer must complie with the values accordning to Figure 4-25.
• Fit the beams (1). Tighten the bolts (2) by hand.
• Fit the stays (3). Tighten the bolts (2) by hand.
• Fit the lengthways securing beams (4) and stays (5).
• Tighten all bolts with a tightening torque of 190 Nm.
TIGHTENING TORQUE
190 Nm
28 1HSB425410-30 en rev0
2
2
3
2
1 5 1
B30264
Item
1 Beams 4 pcs.
Washers 17x30x3 40 pcs.
Nuts M16 20 pcs.
3 Stays 4 pcs.
4 Securing beams 2 pcs.
5 Stays 2 pcs.
U-washers 20 pcs.
Nuts M16 20 pcs.
Figure 4-24. Assembling the current transformer bracket.
1HSB425410-30 en rev0 29
Assembling the current transformer

• Mount the three current transformers on the securing beams (4), Figure 4-24.
• Tighten the bolts (6), Figure 4-24, with a tightening torque of 190 Nm.
TIGHTENING TORQUE
190 Nm
• Check that the flashover distance between the circuit-breaker and the current
transformers complies with the values according to Figure 4-25.
K
According to System voltage, kV
IEC 60071
72 123 145 170
G min. 630 1100 1300 1500
K min. 630 1100 1300 1500
B30263
Figure 4-25. Flashover distance.
30 1HSB425410-30 en rev0
• Connect the electrical conductor between the circuit-breaker poles’ lower

connection flanges and one of the current transformers’ line connection, see
Figure 4-26. Make the connection and contact treatment according to Chapter
5.2.
• Tighten all bolts with a tightening torque of 79 Nm.
1
TIGHTENING TORQUE
79 Nm
3
Item Designation Qty Rated current

> 1200 A W 24000 A
> 2400 A W 3150 A

2
B30256
W 1200 A
1 Bolts M12x80 8 st. X
Bolts M12x60 8 st. X X
Washers 13x34x3 16 st. X X X
Nuts M12 8 st. X X X
2 Singel connection cable X X
3 Double connection cable X X
Figure 4-26. Connecting the current transformer.
1HSB425410-30 en rev0 31
4.11 Fitting the covers and sign
WARNING
Check that the operating mechanism’s closing springs are fully offloaded
and the circuit-breaker is in open position before starting work.1
• Fit the sign (2) on pole A1. Tighten the bolt (3) with a tightening torque of
22.5 Nm.
1
Item 3
1 Mechanism pole A1
2
2 Sign
3 Bolts M8x25 2 pcs

Washers 8.4x16x1.6 2 pcs
CLO
SE
OPEN
TIGHTENING TORQUE
22.5 Nm
B30241
Figure 4-27. Sign.
• Fit the covers (1) on all poles. Tighten the bolts (2) with a tightening torque of
10 Nm.
Item
1 Cover, poles
2 Bolts M6x10 12 pcs OPEN
B30232 1 1 1 2
TIGHTENING TORQUE
10 Nm
Figure 4-28. Fitting the covers.

1. If the closing spring is not offloaded, see the Manual Maintenance of the operating
mechanism how to discharge the closing spring
32 1HSB425410-30 en rev0
4.12 Inspecting the bolted joints, etc.

• Check using a 6 mm diameter rod that the arms’ alignment check hole is
aligned with the predrilled hole in the mechanism housing.
• Check that all bolted joints are tightened to the correct torque in accordance
with the table below.
Bolted joint Tightening torque, (Nm)
Foundation 300
Circuit-breaker pole 79
Operating mechanism 190
Pull-rod 127
Density monitor 10
Current transformer 190
1HSB425410-30 en rev0 33
Assembly Instructions 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.
B30028 1
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 unit’s 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.
Connect all frames to the existing earth network.
1HSB425410-30 en rev0 35
Electrical connections Assembly Instructions
Using 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:
- Grease “SV”, ABB’s Art. No. 1171 4016-610, on aluminium and copper
surfaces.
4. Fit together the joint with the grease still applied.
5. Wipe off any excess grease.
N.B. Position the bimetallic washers so that their aluminium sides face the
aluminium surfaces and the copper sides are turned towards the copper
surfaces or the silver-plated surfaces.
N.B. The contact paste may only be used on fixed joints. It must not be used
inside the breaking units.
36 1HSB425410-30 en rev0
Assembly Instructions Electrical connections
5.3 Tensioning the closing spring
5.3.1 Electrical tensioning

Switch on the motor protection breaker (1) so that the motor (2) starts and drives the
spring drum (3) to the tensioned position. The limit position switch (4) breaks the
contactor (5) and the motor circuit.
CAUTION
The contactor must not be pushed manually so that the limit position
switch is bypassed.
2
3
B30200 1 5
Item
1 Motor protection breaker
2 Motor
3 Spring drum
4 Limit position switch
5 Contactor
Figure 5-2. Electrically tensioning the closing spring.
1HSB425410-30 en rev0 37
Assembly Instructions 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 20˚C.
6.1 Preparations
WARNING
During commissioning, the SF6 gas or the gas mixture needs to be refilled
to the pressure stated on the rating plate. Different gas pressures can occur,
depending on different requirements with regard to the lowest ambient
temperature.
Pressurisation takes place directly from a gas cylinder using the gas filling
equipment, ABB Art. No. 1HSB 445439-A for SF6 gas or 1HSB445439-B for
mixed gas.
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 insulator, assembly personnel must exercise great care and stay in a
protected and safe area (with regard to splintering) away from the circuit-
breaker. The gas cylinder and refilling equipment should be placed in the
same area.
• Connect the control cables to the operating mechanism’s terminal blocks for
opening and closing. The cables are routed to the control room or protected
area away from the circuit-breaker.
• Connect the cables to appropriate pushbutton switches.
• Set the operating mechanism’s control switch in the remote position.
• Switch on the motor starter so the closing spring are tensioned.
• Open the terminal blocks to which the density monitors’ cables are connected
and interrupt the circuit to the interlocking relays.
• Connect the operation testing device with variable control voltage and time
measurement.
1HSB425410-30 en rev0 39
Pressurising the poles Assembly Instructions
6.2 Gas filling with SF6-gas

Non-indicating density monitor Indicating density monitor
3
3
8 Item
5 4 7 6
1 Gas cylinder
2 Regulator
3 Density monitor
4 Coupling
5 Valve
6 Hose
7 Adapter
8 Nipple with union nut
9 Equal union cross
1 10 Valve
2
9 10
B30198
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 -30 ˚C) on the circuit-breaker’s 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. Connect an (accurate) pressure gauge on the coupling (4) or the equal union
cross (9). Open valve (5) or, alternatively, valve (10). If the pressure gauge is
connected to coupling (4), then valve (10) must be closed. However, if the
pressure gauge is connected to the equal union cross (9), then valve (5) must be
closed.
40 1HSB425410-30 en rev0
5. Connect coupling (4) to the circuit-breaker’s rear gas valve on pole C1.
6. Connect the gas-filled hose (6) to the coupling (4).
7. Connect the gas-filled hose(6) to the gas cylinder (1) via the regulator (2).
8. Go from the circuit-breaker to the protected area and let the gas flow until the
regulator switches off.
9. Wait until the gas temperature is the same as the breaker’s temperature before
reading off the gas pressure on the density monitor. Adjust the pressure if
necessary.
N.B. When reading off from the precision gauge, correct the filling pressure
depending on the temperature as set out in Table 6-1.
10. Dismantle the hose (6) from the coupling (4) on the circuit-breaker.
11. Close the valve to the pressure gauge.
12. Dismantle the coupling from the circuit-breaker.
13. Release the pressure on the pressure gauge by opening valve (5) or valve (10).
14. Dismantle the pressure gauge from the coupling...
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
Temp. when MPa bar MPa bar MPa bar MPa bar
filling ˚C (abs) (abs) (abs) (abs) (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 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
1HSB425410-30 en rev0 41
15. Close the valve on the gas cylinder.

16. Disconnect the hose from the gas cylinder and release the pressure in the
regulator by pressing in the non-return valve.
17. Release the regulator’s adjustment pressure by turning the adjuster valve so
that wrong pressure is not filled in the next circuit-breaker to be assembled.
N.B. When the density monitor (1) is finally fitted, tighten the union nut with a
torque of 10 Nm.
1
Item
1 Density monitor
B30199
TIGHTENING TORQUE
10 Nm
Figure 6-2. Density monitor.
18. Operate the breaker Close and Open 3 times from the control room.
42 1HSB425410-30 en rev0
6.3 Gas filling with mixed gas

A mixture of SF6 and N2 or CF4 gas is used at low temperatures below -40 ˚C at
0.5 MPa or -30 ˚C at 1.7 MPa, 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
0.52 x 0.7 = 0.36 MPa abs (+20 ˚C) SF6 gas and then N2 or CF4 gas to
0.70 MPa abs (+20 ˚C)
N.B. When reading off from the precision gauge, correct the filling pressure
depending on the temperature as set out in Table 6-2.
Gas filling takes place one pole at a time, otherwise as set out in Chapter 6.2. Once
all poles have been filled with gas, the gas monitoring system is fitted as set out in
Chapter 4.9 before the circuit-breaker is operated.
Table 6-2. Filling with mixed gas.

Filling pressure in MPa (abs)
stated on the rating plate.
SF6 Total filling SF6 Total filling
pressure pressure
Filling pressure read off on the gauge in
Temp. when
MPa bar MPa bar MPa bar MPa bar
gas filling
(abs) (abs) (abs) (abs) (a.op) (a.op) (a.op) (a.op)
˚C
+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 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
1HSB425410-30 en rev0 43
6.4 Leakage test

Perform a leakage test using a leak detector around all gas valves (2 per mechanism
housing).
44 1HSB425410-30 en rev0
Assembly Instructions 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.
Reset all the controll circuits according to applicable circuit diagrams and check
that all terminal blocks are tightened.
Put the tools in the appropriate holders in the operating mechanism.
1HSB425410-30 en rev0 45
Assembly Instructions Operating values
8. Operating values
The operating values in this instruction apply to the SF6 circuit-breaker type
LTB 72.5-170D1/B with operating mechanism type BLK 222.
8.1 Times
Closing time coil I (and II) max. 40 ms
Opening time coil I 22-26 ms
Opening time coil II 22-26 ms
Close-Open time(1) max. 42 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. 15 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 pole:
LTB 72D1/B <40 µΩ
LTB 145D1/B <40 µΩ
LTB 170D1/B <46 µΩ
8.4 Contact stroke

The contact stroke is 120 +4/-0 mm.
1HSB425410-30 en rev0 47
Head Office 0502
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 782 320
SF6 Circuit-Breaker Circuit-breakers HPL and LTB
Check list, assembly

1HSB445410-100 en rev2

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

The following checks shall be made and the check list completed before the circuit-
breaker is commissioned. The check list shall be kept in the order binder.
Date:_______________
Installation:______________________________________________
Serial number:_____________________________
Circuit-breaker pole
1. Check that the circuit-breaker and operating mechanism have been assembled
in accordance with the assembly instructions.
2. Check that all bolted joints are tightened to the tightening torques stated in the
assembly instructions.
3. Ensure that all poles are in the open position. The alignment hole in the
operating lever shall align with the predrilled hole in the mechanism housing.
Operating mechanism
4. Make an ocular inspection to check that oil from the oil dashpots has not
leaked in the operating mechanism.
5. Tighten all screws in terminal blocks involved in the assembly work.
Gas 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 10°C 1.
1. Other thermostat settings may occur.
1HSB445410-100 en rev2 1
Check list for assembly and commissioning Check list
Operating values
11. Check the breaker’s 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
Opening time coil II ms ms ms
Close-Open time ms ms ms
Lowest control voltage closing coil I V V V
Lowest control voltage closing coil II V V V
Lowest control voltage opening coil I V V V
Lowest control voltage opening coil II V V V
Main circuit resistance µΩ µΩ µΩ
Filling pressure(1) MPa (abs) MPa (abs) MPa (abs)
(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.
2 1HSB445410-100 en rev2
Head Office 0202
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
SF6 Circuit-Breaker Type LTB D with
Operating and Maintenance

Instructions
1HSB425409-130 en rev0

document.
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: 2002-03-11
Operating and Maintenance Instructions
TABLE OF CONTENTS
1. General ................................................................................ 1
1.1 Warning text ................................................................................... 1
1.2 Warning .......................................................................................... 2
2. Preventative maintenance ................................................. 3

2.1 Circuit-breaker ............................................................................... 3
2.2 Operating mechanism..................................................................... 8
2.3 Spare parts...................................................................................... 9
3. Inspection intervals.......................................................... 11
3.1 Maintenance summary ................................................................. 12
3.2 Maintenance category A .............................................................. 13
3.3 Maintenance category B............................................................... 14
3.4 Maintenance category C............................................................... 16
3.5 Maintenance category D .............................................................. 21
1HSB425409-130 en rev0 i
Operating and Maintenance Instructions
FIGURES
Figur 2-1. Number of operations with short-circuit current. ........................... 4

Figure 2-2. Switch Local/Remote, motor protection. ....................................... 5
Figure 2-3. Connecting the crank. ..................................................................... 6
Figure 2-4. Slow manual Closing operation. ..................................................... 6
Figure 2-5. Reference measurement contact burn off. ...................................... 7
Figure 2-6. Closing catch gear’s roller. ............................................................. 7
Operating and Maintenance Instructions General
1. General
These Operating and Maintenance Instructions are applicable for the
SF6 circuit-breaker type LTB D.
The instructions contain recommendations for handling and guidelines for the
maintenance of high-voltage circuit-breakers of the LTB D type. The instructions
are divided up into four parts:
• Inspection intervals
• Instruction for preventive maintenance of circuit-breakers
• Instruction 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
in death or serious personal injury.
WARNING
CAUTION
indicates a hazardous situation than can result in minor or moderate injury.
N.B. used for hazards that may only result in damage to the installation.
1HSB425409-130 en rev0 1
General Operating and Maintenance Instructions
1.2 Warning
The risks set out below must be observed and corresponding measures followed
with all work on high-voltage circuit-breakers.
WARNING
Circuit -breakers with pressurised insulators.
Mechanical damage to the porcelain can cause it to explode with the
subsequent risk of splintering. Work on the circuit-breaker that brings
about the risk of mechanical damage to the insulators should be carried
out at a reduced gas pressure, 0.125 MPa (abs).
Risk Measure
Working next to high voltage. Isolate and earth close to the work place. If work must
be carried out close to live installation components, the
safety distance applying in the country's 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. Switch off the control current and, if necessary, the
Both alternating (AC) and direct heating current too.
(DC) current can be routed to the
operating mechanism.
Risk of crushing in the operating Operate the circuit-breaker to the open position. Isolate
mechanism and link system. and earth the high-voltage side. Off-load the springs by
There is stored energy in the switching off the motor current and perform a Close-
opening and closing springs. The Open operation or move the operating mechanism's
mechanism can be tripped by drive shaft backwards by hand (see the Product
heavy vibrations or by unintentional Information for the operating mechanism). For reasons
contact with mechanical latch of safety the closing springs must be off-loaded during
components. transportation as well as during assembly and storage.
Working close to pressurised Work close to the circuit-breaker's insulators that may
insulators. result in damage to the insulator, must not be carried
The normal working pressure is up out until the gas has been emptied to
to 0.8 MPa. Damage to the max. 0.125 MPa (abs.) pressure.
porcelain can result in splintering.
2 1HSB425409-130 en rev0
Operating and Maintenance Instructions Preventative maintenance
2. Preventative maintenance
2.1 Circuit-breaker
2.1.1 Circuit-breaker service life

Assuming that the recommended inspection intervals have been adhered to and
appropriate measures have been implemented, the LTB D circuit-breaker will have a
service life exceeding 30 years or 10,000 mechanical operations.
The following points will ensure a long service life:
1. Burning-off of the arcing contacts is limited.
2. Each breaking unit is equipped with 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, 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 Figure 2-1
or...
– if the number of operations for line, reactor or capacitor switching, as well as
switching of load current1 has reached the level specified under the heading
“Inspection intervals” in the inspection chart, see Chapter 3.1.
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:
Σ n x I2 = 20000
where
n = the number of short-circuits
I = short-circuit current kA (RMS)
All short-circuit current levels can be included in the total of the number of short-
circuits x short-circuit current to the power 2.
e.g. 10x302+20x202+20x102=19000
1. Load currents from normal Closing and Opening operations should not be included in
the formula. These are only included when calculating the total number of mechanical
CO operations.
1HSB425409-130 en rev0 3
Preventative maintenance Operating and Maintenance Instructions
2.1.2 Service life of arcing contacts with short-circuit interruption

The diagram below shows the number of interruptions versus short-circuit current
that the contacts in a LTB D circuit-breaker can manage before the metal losses due
to burning becomes so great that they must be replaced.
Number of operations
n
5000
2000
1000
500
200
100
50
20
kA
2 3 4 5 10 20 30 40 50 63
Short-circuit current
Figur 2-1. Number of operations with short-circuit current.
4 1HSB425409-130 en rev0
2.1.3 Inspection of contact burn off

Measurement of the burn off on arcing contacts can be carried out without the need
of dismantling the breaking chamber. There is a score mark on the mechanism
housing indicating the contact position when the circuit-breaker pole was new. The
score mark is made in line with the operating lever.
WARNING
Manual operation of the circuit-breaker may only be carried out by
specially trained personnel to prevent damage to the circuit-breaker and
personal injury.
Perform a slow manual operation of the circuit-breaker.

• The circuit-breaker is in the
open position.
• The switch Local/Remote (1)
on the control panel is in the
Off position.
• The motor voltage is cut
using the motor protection
(2).
Item
1 Switch Local/Remote
2 Motor protection
B30206
2 1
Figure 2-2. Switch Local/Remote, motor protection.
• Connect a buzzer across the main breaking point to check the position of the
contacts when the contacts are made.
1HSB425409-130 en rev0 5
• The Closing spring is uncharged.

– Assemble the crank (1) and crank attachment (2) as set out in Figure 2-3.
Operating
mechanism
Item
1 Crank 2
2 Crank attachment B30052 1
Figure 2-3. Connecting the crank.
– Connect the crank and crank anti-clockwise so it is possible to attach the

tool (2) on the heel (3) of the dog (1), see Figure 2-4.
– Turn the crank attachment around and crank clockwise until the crank
shaft stops against the closing catch gear (4). Crank a further number of
turns so that the roller (5) is under pressure.
– Press using a screwdriver on the latch (6) for the closing catch gear.
– Continue to crank clockwise until the link system (7) moves toward the
Open latch (8).
N.B. The link system must not engage with the roller on the Open latch.
8 2 3
Item 1
1 Dog
2 Tool art. no. 2172 733-186 6

3 Heel

5 7
5 Roller
4
6 Latch
7 Link system
8 Open latch
B30054
Figure 2-4. Slow manual Closing operation.
6 1HSB425409-130 en rev0
• Crank the crank until the operating lever (1) aligns with the score mark on the
mechanism housing (2), see Figure 2-5.
– Place a small square against the mechanism housing to get the correct
position and measure horizontally the measurement "d".
– Continue to crank towards the Closed position until the buzzer indicates
electrical contact in the circuit-breaker pole.
– If the horizontal measurement "d" has increased by 6 mm or more, the
circuit-breaker pole should be overhauled and the contacts replaced.
2
Item
1 Outer operating lever
2 Mechanism housing
1
Score mark
d
B30242
Figure 2-5. Reference measurement contact burn off.
• Continue to crank the crank clockwise after reading off the reference
measurement until the link system (7) engages with the Open latch (8).
OBS Check that the link system has engaged with the roller on the Open latch.
• Turn the crank attachment (2), Figure 2-3, around and crank the crank 1-2 turns
anti-clockwise and remove the tool (2), Figure 2-4, from the dog.
• Continue to crank anti-clockwise
until the dog returns to its original
position. When the dog passes the
closing catch gear’s roller (5) this is
lifted up with a slotted head
B30056
screwdriver, see Figure 2-6.
Figure 2-6. Closing catch gear’s roller.
The circuit-breaker is now in the closed position and a normal opening operation
can be performed.
1HSB425409-130 en rev0 7
2.1.4 Leakage control

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.
2.1.5 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 LTB D 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.
2.1.6 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 -25˚C.
When supplied, the circuit-breaker bearings are lubricated with Grease “G”1 and
will not normally need lubricating except during major overhauls.
See the Overhaul instructions applicable for the circuit-breaker, for lubricating
sealing rings.
2.1.7 Rust protection

The closing and opening springs are rust inhibited by painting with two-component
paint.
2.2 Operating mechanism
2.2.1 Maintenance
WARNING
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 “Maintenance for BLK
222”, Safety regulations, are followed before the work is started.
1. See the document “Lubricants” 1HSB445409-1 for the names of suppliers and brands for
grease and oils.
8 1HSB425409-130 en rev0
2.2.2 Cleaning
Clean the operating mechanism when necessary using a vacuum cleaner.
2.2.3 Lubrication
The ball, roller and needle bearings as well as the worm gear in the operating
mechanism are permanently lubricated and require no maintenance. Shafts in the
latch mechanisms should be greased after 2,000 operations using Grease “L”1 . The
sliding surfaces on the dashpot should be lubricated using Grease “G”1 .in
connection with an overhaul.
When supplied the dashpot is filled with Oil “S”1.
2.2.4 Rust protection

Certain steel parts in the operating mechanism have manganese phosphate surfaces
and are then dipped in a rust inhibiting oil. This applies to latches and parts of the
link system.
When supplied, the operating mechanism is equipped with absorbent agent for
protection against moisture during transport.
Despite the extensive rust inhibitor treatment, minor corrosion can occur after some
years especially if the circuit-breaker is located in a strongly corrosive environment.
Rust spots should be cleaned and new rust inhibitor applied with a brush or spray.
The recommended rust inhibitor is Grease “G”1 or Tectyl 506
(ABB Art. No. 1241 0011-108).
N.B. Tectyl 506 forms a waxy protective skin when it dries and therefore it must
not be sprayed into bearings and latch mechanisms or on to gear-wheels.
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. Frames can be stored outdoors.
1. See the document “Lubricants” 1HSB445409-1 for the names of suppliers and brands for
grease and oils.
2. Approved storage space:
roof, solid foundation, relative humidity less than 50%, temperature +20oC
1HSB425409-130 en rev0 9
Operating and Maintenance Instructions Inspection intervals
3. Inspection intervals
Important checkpoints, acceptable tolerances, certain functional values for
adjustments, and recommended inspection intervals can be found in the following
inspection chart.
In corrosive or polluted air and in climates with a high relative humidity, it can be
necessary to halve the inspection intervals.
The specified inspection intervals should be considered as recommended guide
values, which can be increased or decreased depending on local conditions.
1HSB425409-130 en rev0 11
Inspection intervals Operating and Maintenance Instructions
3.1 Maintenance summary
Condition of Com-
Explan- circuit- petence
Type of measure Inspection interval
ation breaker require-
during work ments
A Ocular inspection 1-2 years a1 a2
B Preventive maintenance
Intermediate inspection
• Operation testing including 3-6 years, 2 000 mech. 1) b1 b2
time checks oper.
• Thermovision inspections
C Preventive maintenance After 15 years or 5 000 1), 3) b1 b2

• General inspection of the mech. oper.
circuit-breaker and
D Overhaul
• Overhaul of the breaker 2) c1 c2
chamber ΣnxI2=20 000
• Line breaker ΣnxI2=20 000
• Transformer breaker
• Capacitor bank
Reactor breaker
Filter breaker
• Non-synchronised 2 500 el. oper.
• Synchronised 5 000 el. oper.
• Complete overhaul. after 30 years or

10 000 mech oper.
Explanation:
1) Mech. oper. =Mechanical Close-Open operations.
2) El. oper. = Close-Open operations with electrical load.
3) Special demands on resistance inspections for circuit-breakers operated
> 100 Close and Open operations/year.
12 1HSB425409-130 en rev0
Condition of the circuit-breaker during work:

a1) Circuit-breaker in operation.
b1) Closing spring untensioned, circuit-breaker open, disconnected and earthed.
Circuit-breaker poles removed and transported indoors.
c1) Closing spring untensioned, circuit-breaker open, disconnected and earthed.
Poles/breaking unit dismantled and transported to the workshop.
d1) Closing spring untensioned, circuit-breaker open, disconnected and earthed.
Complete circuit-breaker including operating mechanism transported to the
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. In certain cases, with instructions from ABB.
3.2 Maintenance category A
To be inspected Inspection interval Measures / Instructions / Tools
1.
Ocular inspection 1-2 years Check external cleanliness, heater
element function, gas pressure, valves
and drainage holes.
No special tools needed.
See Chapter 2.1.4 and Chapter 2.1.5.
1HSB425409-130 en rev0 13
3.3 Maintenance category B
1.
Ocular inspection 3-6 years or 2,000 mechanical Check external cleanliness, heater
Close-Open operations. element function, gas pressure, valves
and drainage holes.
See Chapter 2.1.4 and Chapter 2.1.5.
2.
Rating plates 3-6 years or 2,000 mechanical Make a note of the serial number.
Close-Open operations.
3.
Operation counter 3-6 years or 2,000 mechanical Make a note of the number of
Close-Open operations. operations.
4.
Ocular inspection of 3-6 years or 2,000 mechanical Check that there are no loose bolts or
operating mechanism Close-Open operations. nuts. Make sure there is no oil leakage
from the dashpots.
In the event of leakage change the
complete dashpot.
No tools needed.
See Manual Maintenance of the
5.
Corrosion inspection 3-6 years or 2,000 mechanical Ocular inspection.
Rust protection Close-Open operations. Remove patches of rust and treat with a
rust inhibitor
See Chapter 2.2.4
6.
Lubrication 3-6 years or 2,000 mechanical The circuit-breaker is in the Open
Close-Open operations. position and the closing spring is off-
loaded. Grease the latches on the
operating mechanism using Grease "L".
See Chapter 2.1.6, Chapter 2.2.3 and
the Manual Maintenance of the
14 1HSB425409-130 en rev0
7.
Thermovision 3-6 years or 2,000 mechanical Carried out at full load before shutdown
measurements Close-Open operations. of the circuit-breaker.
Check on temperature increase in the
outer parts of the circuit-breaker.
The highest permitted temperature
difference between the phases is 5˚C.
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 the Manual for the Thermovision
camera
8.
Operating test 3-6 years or 2,000 mechanical Operation test, if possible in
Close-Open operations. combination with measurement of the
operating times (including Close-Open
times).
See the Assembly Instructions for the
circuit-breaker in question.
1HSB425409-130 en rev0 15
3.4 Maintenance category C
1.
Ocular inspection 15 years or 5,000 mechanical Check external cleanliness, heater
Close-Open operations. element function, gas pressure, valves
and drainage holes.
2.
Rating plates 15 years or 5,000 mechanical Make a note of the serial number.
3.
Operation counter 15 years or 5,000 mechanical Make a note of the number of
Close-Open operations. operations.
4.
SF6 Gas 15 years or 5,000 mechanical Gas filling equipment.
• Gas filling. Close-Open operations. See the applicable Assembly
Instructions for the circuit-breaker in
question.
Dew point measuring instrument.
• Dew point at normal
gas pressure in the Dew point max. -5oC at stated filling
circuit-breaker. pressure and +20˚C.
5.
Insulators
• Ocular inspection and 15 years or 5,000 mechanical Clean the insulators by spraying and
cleaning. Close-Open operations. rubbing. Check the bolts and nuts.
Spraying equipment, drying cloths,
torque wrenches.
See Chapter 2.1.5.
16 1HSB425409-130 en rev0

6.
Main current circuit 15 years or 5,000 mechanical
• Resistance Close-Open operations. Check resistance of circuit-breaker.
measurement Resistance bridge, test current min.
200 A DC.
Circuit-breakers that are only Resistance value as specified in
operated >100 Close-Open applicable Assembly instructions for the
operations/year after 6-8 years or circuit-breaker in question.
2,500 mechanical Close-Open Higher values allowed for frequent
operations. operation with small currents (≤400A).
Calculation of allowed resistance:
In 1, 65
R = Rn -----
I
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.
Mechanism 15 years or 5,000 mechanical Inspection of reference holes in outer
Open position. Close-Open operations. lever and mechanism housing. See
applicable Assembly Instructions for the
7b.
Operating times 15 years or 5,000 mechanical Measurement with electronic timer.
• Opening time Close-Open operations. Nominal operating voltage.
• Closing time For times, see the applicable Assembly
• Close-Open time Instructions for the circuit-breaker in
question.
• Deviation between
phases Maximum time deviation between
phases 4 ms when closing and 3 ms
• Connection times
when opening.
• Contact dampening
See the Manual Maintenance of the
1HSB425409-130 en rev0 17
8a.
Operational availability
• Pull rod system 15 years or 5,000 mechanical Check tightening torque on bolts in the
Close-Open operations. pull-rod system.
See applicable Assembly instructions
for the circuit-breaker.
15 years or 5,000 mechanical Measurement of min. operating voltage.

• Operational safety
Close-Open operations. Closing time for coil: < 85% of nominal
value.
Opening time for coil: < 70% of nominal
value.
Variable DC power supply unit.
• Anti-pumping relay 15 years or 5,000 mechanical It must be possible to perform one

Close-Open operations. Close-Open operation at the rated
voltage with a closing impulse that lasts
for 30 s without “pumping” occurring,
i.e. when the circuit-breaker repeatedly
Opens and Closes.
The lowest operational voltage of the
relay should be measured.
8b.
Motor current 15 years or 5,000 mechanical The motor current shall be measured
Close-Open operations. towards the end of the tensioning
stroke. See applicable Assembly
Instructions for the circuit-breaker
Max. tensioning time: 15 s.
The motor must be able to tension the
springs at 85% of the nominal voltage
(IEC).
8c.
Dashpot 15 years or 5,000 mechanical Inspection of oil level.
Close-Open operations. The oil level can be checked by
removing the dashpot or by means of
an ultrasonic test.
18 1HSB425409-130 en rev0

8d.
Catch gears 15 years or 2,000 mechanical Visual inspection of settings.
Close-Open operations. See the Manual Maintenance of the
Lubrication of surfaces on the shafts
and latches using Grease "L".
8e. 15 years or 2,000 mechanical The resistance and current of the coils
Coils Close-Open operations. is permitted to fluctuate 10% of the
obtained measurement value taken
during routine testing.
8f.
Limit switch 15 years or 2,000 mechanical The closing circuit must be closed
Close-Open operations. before the motor current is switched off,
in the final phase of tensioning of the
spring package.
See Maintenance for the operating
mechanism.
8g.
Heater element 15 years or 2,000 mechanical Resistance measurement:
Close-Open operations. • for BLK 222
70 W, 220v: R = 691 Ohm ±10%.
140W, 220V: R = 346 Ohm ±10%.
Check the signal for voltage failure, if
there is such a signal.
8h.
Terminal blocks 15 years or 5,000 mechanical Check the screws and clamps.
8i.
Motor starter 15 years or 5,000 mechanical Check the signal for voltage failure, if
Close-Open operations. there is such a signal.
1HSB425409-130 en rev0 19
9.
Tightness of the SF6
gas 15 years or 5,000 mechanical Check the pressure sensor and
• Density monitoring Close-Open operations. signal/break contacts on the density
monitors. Pressurise the density
monitors with air or nitrogen, reduce the
pressure slowly and take readings of
the pressure.
If the density monitor is not equipped
with a pressure gauge, the pressure
must be recorded using a separate
gauge.
Min. permissible voltage during check:
30 V.
Permissible deviation from filling
pressure at 20oC:
• Pressure gauge: - 0.02/ + 0.05 MPa.
• Density monitor: 0.015 MPa
Difference between signal and blocking
pressure: >0.01 MPa
See Assembly Instruction för the for the
10.
Blocking relays 15 years or 5,000 mechanical The relays shall break when a density
Close-Open operations. monitor is removed from a circuit-
breaker pole pressurised to filling
pressure. (Must be done when the
circuit-breaker is not operational.)
11.
Corrosion 15 years or 5,000 mechanical External ocular inspection.
Close-Open operations. Treat with rust inhibitor when
necessary.
mechanism.
12a.
Lubrication 15 years or 2,000 mechanical Inspect and lubricate the latches.
Close-Open operations. See Maintenance for the operating
mechanism.
12b.
Worm gear 15 years or 2,000 mechanical • For BLK 222:
Close-Open operations. Check the oil level in the worm gear
housing
mechanism
13.
Operating test 5 years or in accordance with the Operating test, if possible in
customer’s routines combination with measurement of
operating times, (incl. Close-Open
times).
20 1HSB425409-130 en rev0
3.5 Maintenance category D
1.
Overhaul of the
breaking unit
• Line and transformer ΣnxI 2 =20,000. Gas evacuation, dismantling of the
breaker circuit-breaker poles and mechanism.
Transport to a clean workshop.
• Capacitor battery Non synchronised: Insulator removed, replacement of
breaker 2,500 electric Close-Open contacts and PTFE components.
• Reactor breaker operations. Standard equipment, well-fitting face
• Filter breaker Synchronised: mask for dust protection, long sleeve
5,000 electric Close-Open overall, plastic or rubber protective
operations. gloves.
See the Overhaul Instructions for the
• All types of Alarm with diagnostic testing.
maintenance
2.
Overhaul of complete 30 years or 10,000 mechanical Removal of circuit-breaker pole and
circuit-breaker and Close-Open operations. mechanism. Fitting new contacts and
operating mechanism PTFE components. Replacement of
other worn parts.
If the overhaul of the circuit-breaker
and operating mechanism is being
done for a further 10,000 operations,
all moving parts should be replaced.
If the overhaul of the circuit-breaker
and operating mechanism is being
done for a further 2,000 operations,
certain worn parts shall be replaced.
Protection against decomposition
products in accordance with standard
equipment above.
See the Overhaul Instructions for the
Directions and instruction from ABB for
the operating mechanism
3.
Capacitor 30 years or 10,000 mechanical Check the values:
Close-Open operations. C = CN +5%, -0%
PD < 5 pC
Tan d < 0.2%.
1HSB425409-130 en rev0 21
Head Office 0302
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 782 320
SF6 Circuit-Breaker Circuit-breakers HPL and LTB
Lubricants
1HSB445409-1 en1

regarded as an undertaking from ABB Power Technology Products AB. ABB Power Technology Prod-
ucts 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 i
Lubricants General
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 1
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 40˚C: 62-65 cSt
Lowest pour temperature: -52˚C
Oil “D”
Breaker oil with a low viscosity ~ 6.0 cSt at 20˚C. 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 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) Circuit-breaker oil -

5W-30 Univolt 42 (44)
CASTROL FORMULA RS - -
5W-50
SHELL TMO Synthetic NYSWITCHO 3 DC 200 Fluid 200
5W-30 NYSWITCHO 3X CS
OK Super-synthetic Circuit-breaker oil -

4W-40 A65
Kälte-Schalteroel X
1HSB445409-1 en1 3
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 contact’s 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 5
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
Klüber Isoflex Topas NB -

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

8401
Statoil Electrical grease
1HSB445409-1 en1 6
ABB Power Technology Products AB 1HSB445409-1 en1
Head Office 0202
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
type BLK 222
Maintenance
1HSB535409-100 en rev4

ded as an undertaking from ABB Power Technology Products AB. ABB Power Technology Pro-
ductsPower Technology Products AB takes no responsibility for errors that can occur in the
documentation.
document.
Date: 2002-03-21
Maintenance Operating Mechanism
LIST OF CONTENTS
1. General ............................................................................... 1
2. Safety................................................................................... 3
2.1 Warning text ................................................................................... 3
2.2 Safety directives ............................................................................. 4
3. Maintenance, general ......................................................... 7

3.1 Tools ............................................................................................... 7
3.2 Cleaning equipment ....................................................................... 7
3.3 Spare parts...................................................................................... 7
3.4 Test equipment ............................................................................... 7
4. Maintenance........................................................................ 9
4.1 General ........................................................................................... 9
4.2 Preparations for maintenance....................................................... 18
4.3 Cleaning ....................................................................................... 19
4.4 Corrosion...................................................................................... 19
4.5 Lubrication ................................................................................... 20
4.6 Heater element ............................................................................. 20
4.7 Drive unit...................................................................................... 21
4.8 Catch gear..................................................................................... 23
4.9 Dashpot ........................................................................................ 25
4.10 Limit switch with auxiliary contact.............................................. 26
4.11 Terminal blocks ............................................................................ 28
1HSB535409-100 en rev4 i
Maintenance Operating Mechanism
FIGURES
Figure 4-1. Operating mechanism BLK 222 ..................................................... 9

Figure 4-2. Electrical discharging of the closing springs. ............................... 10
Figure 4-3. Mechanical discharging of the closing spring. ............................. 11
Figure 4-4. Mechanical charging .................................................................... 12
Figure 4-5. Switch Local/Remote, motor protection. ..................................... 13
Figure 4-6. Connecting the crank. ................................................................... 13
Figure 4-7. Slow manual Closing operation .................................................... 14
Figure 4-8. Closing catch gear’s roller ............................................................ 14
Figure 4-9. Switch Local/Remote, motor protection. ..................................... 15
Figure 4-10. Crank connection. ......................................................................... 15
Figure 4-11. Slow manual Open-operation. ...................................................... 16
Figure 4-12. Closing catch gear’s roller. ........................................................... 16
Figure 4-13. Operating panel. ........................................................................... 18
Figure 4-14. Heater element. ............................................................................. 20
Figure 4-15. Drive unit. ..................................................................................... 21
Figure 4-16. Replacing the motor ..................................................................... 22
Figure 4-17. Catch gear ..................................................................................... 23
Figure 4-18. Checking the play. ........................................................................ 23
Figure 4-19. Replacing the catch gear. .............................................................. 24
Figure 4-20. Dashpot ......................................................................................... 25
Figure 4-21. Limit switch with auxiliary contact. ............................................. 26
Figure 4-22. Time measurement, contact movement. ....................................... 27
Figure 4-23. Electrical equipment. .................................................................... 28
Maintenance Operating Mechanism General
1. General
This information applies for the spring operating mechanism BLK 222 intended for
operating circuit-breakers with integrated opening springs. Information is provided
in this instruction for maintenance and fault correction maintenance.
Preventive maintenance and overhaul of the mechanism BLK 222 should be carried
out at regular intervals.
• Visual inspection at 1-2 year’s intervals.
• Lubrication after 15 years or 2000 mechanical On-Off operations.
• Preventive maintenance after 15 years or 5000 mechanical On-Off operations.
• Overhaul after 30 years or 10 000 mechanical On-Off operations.
Overhaul and repair work may only be carried out by service personnel authorised
by ABB Power Technology Products AB.
1HSB535409-100 en rev3 1
Maintenance Operating Mechanism Safety
2. Safety
2.1 Warning text

observed extra carefully. The warning texts are marked as set out below.
DANGER
WARNING
CAUTION
indicates a hazardous situation than can result in minor or moderate
injury.
1HSB535409-100 en rev3 3
Safety Maintenance Operating Mechanism
2.2 Safety directives

On all types of work on high-voltage circuit-breakers, the risks listed below must be
taken into consideration and corresponding measures must be taken.
WARNING
Circuit-breakers with pressurised insulators.
0.125 MPa (abs).
WARNING
Do not operate the mechanism unloaded!
and trimmed with the associated circuit-breaker.
The standard operating cycle is O - 0.3 s - CO - 3 min. - CO. The time between
4 1HSB535409-100 en rev3
Maintenance Operating Mechanism Safety
WARNING
Work requires training and product knowledge and may only be carried
out by authorised personnel.
Risk Measure
Working next to high voltage. Isolate and earth close to the work
place. If work must be carried out
close to live installation components,
the safety distance applying in the
country’s 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. Switch off the control voltage and if
Both alternating (AC) and direct (DC) necessary the heating voltage.
current can be routed to the
Risk of crushing in the operating Operate the circuit-breaker to the

mechanism and link system. open position. Isolate and earth the
There is stored energy in the high-voltage side. Discharge the
opening and closing springs. The springs by switching off the motor
mechanism can be tripped by heavy current and perform a Close-Open
vibrations or by unintentional contact operation or move the operating
with mechanical latch components. mechanism’s drive shaft backwards
by hand (see the Product Information
for the operating mechanism). For
reasons of safety the closing springs
must be uncharged during
transportation as well as during
assembly and storage.
Working close to pressurised Work close to the circuit-breaker’s

insulators. insulators that may result in damage
The normal working pressure is up to to the insulator, must not be carried
0.8 MPa. Damage to the porcelain out until the gas has been emptied to
can result in splintering. max. 0.125 MPa (abs.) pressure.
1HSB535409-100 en rev3 5
Maintenance Operating Mechanism 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 a torque wrench (10-100 Nm).
• Measuring scale.
• Vernier gauge.
• Lifting slings.
3.2 Cleaning equipment

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

• Lubricants and oils, see Lubricants, 1HSB445409-1 for suppliers and trade
names.
Grease “G”: ABB Art. No. 1171 4014-407
Grease “L”: ABB Art. No. 1171 4016-606
Grease “M” ABB Art. No. 1171 4016-612
Oil “A”: ABB Art. No. 1171 2039-1
• Anti-corrosion agent.
Valvoline Tectyl 506: ABB Art. No. 1241 0011-108
Grease “G”: ABB Art. No. 1171 4014-407.
• Locking fluid
Loctite 242, ABB Art. No. 1269 0014-410.
• Tool to crank the operating mechanism, ABB Art. No. 2172 733-186
3.4 Test equipment

• Equipment to record attenuation curves and operating values.
(e.g. Programma or ABB SA10)
1HSB535409-100 en rev3 7
Maintenance Operating Mechanism Maintenance
4. Maintenance
4.1 General
The Operating and Maintenance Instructions for the circuit-breaker should be read and
followed before work on the circuit-breaker is started and while work is in progress.
WARNING
Do not operate the operating mechanism unloaded!
and trimmed with the associated pressurized circuit-breaker.
The component parts of the operating mechanism are integrated in a cabinet which
also contains a control panel with operating equipment. The top of the cabinet can
be removed and the operating panel opened to facilitate service and overhaul work.
2 1
5
3
B30200
Item
1 Drive unit
3 Operating panel
4 Closing spring
5 Heater element
Figure 4-1. Operating mechanism BLK 222
• Measure all operating values and record them. If the measured values
correspond with the specified values for the circuit-breaker, then only a visual
inspection, cleaning and lubrication are required.
1HSB535409-100 en rev3 9
Maintenance Maintenance Operating Mechanism
4.1.1 Discharging the closing springs

It is important the closing springs are uncharged during maintenance when working
on the circuit-breaker or operating mechanism.
Electrical discharging of the closing springs.

1. Switch off the motor protection (1)
2. Turn the Local/Remote switch (2) on the operating panel to Local.
3. Perform an Open-Closed-Open operation.
4. Check that the spring is uncharged. The spring indicator (3) shows uncharged
spring.
5. The circuit-breaker is in the Open position.
1 4 2
Item
1 Motor protection
3 Spring indicator 3
4 Operating switch Closed/Open
B30201
Figure 4-2. Electrical discharging of the closing springs.
The motor protection should be reset when work has been completed.
10 1HSB535409-100 en rev3
Mechanical discharging of the closing spring.

1. Unscrew the cover (1) so the motor circuit is cut.
2. Assemble the crank (3) and the crank attachment (4) as in Figure 4-3.
3. Crank anti-clockwise until the spring is fully uncharged.
4. Check that the spring is uncharged. The spring indicator (5) shows uncharged
spring.
Mechanism
Item
1 Cover
2 Screw M6 4 pcs.
3 Crank 4 2
4 Crank attachment
5 Spring indicator 3 1
B30202
Figure 4-3. Mechanical discharging of the closing spring.
1HSB535409-100 en rev3 11
4.1.2 Mechanical charging of the closing spring

The closing spring can be manually charged, if there is no motor voltage available.
• Unscrew the cover (1) so that the crank can be inserted. Assemble the crank (2)
and the crank attachment (3) as set out in Figure 4-4.
• Crank clockwise until the spring indicator (4) shows a tensioned spring.
• Refit the cover.
Mechanism
Item
1 Cover
2 Crank
3 Crank attachment 3 1
4 Spring indicator
B30202
Figure 4-4. Mechanical charging
12 1HSB535409-100 en rev3
4.1.3 Slow manual Closing and Opening operations

Some service work requires the circuit-breaker to operate slowly.
CAUTION
Slow manual closing and opening operations may only be carried out by
persons that are well conversant with the operation of the mechanism and
circuit-breaker as there is a risk of personal injury and mechanical
damage.
Slow manual closing operation of the operating mechanism

May only be carried out if:
open position.
Off position.
• The motor voltage is cut using
the motor protection (2).
Item
2 Motor protection
B30206
2 1
• Closing springs uncharged.

1. Assemble the crank (1) and crank attachment (2) as in Figure 4-6
Mechanism
Item
1 Crank 2
2 Crank attachment 1
B30052
Figure 4-6. Connecting the crank.
1HSB535409-100 en rev3 13
2. Connect the crank and crank anti-clockwise so it is possible to attach the tool
(2) on the heel (3) and dog (1), see Figure 4-7.
3. Crank clockwise until the crank shaft stops against the closing catch gear (4).
Crank a further number of turns so that the roller (5) is under pressure.
4. Press using a screwdriver on the latch (6) for the closing catch gear.
5. Continue to crank clockwise until the link system (7) engages with the Open-
lock (8).
N.B. Check that the link system has engaged with the roller on the Open-lock.
6. Crank the crank 1-2 turns anticlockwise and remove the tool (2) from the dog.
8 2 3
Item 1
1 Dog
2 Tool Art. No. 2172 733-186 6

3 Heel

5 7
5 Roller
4
6 Latch
7 Link system
8 Open-lock
B30054
Figure 4-7. Slow manual Closing operation
7. Continue to crank anti-clockwise so

that the dog returns to its original
position. When the dog passes the
closing catch gear’s roller (5) this is
lifted up with a screwdriver, see B30056
Figure 4-8.
Figure 4-8. Closing catch gear’s roller
The circuit-breaker is now in the closed position and a normal opening operation
can be made.
14 1HSB535409-100 en rev3
Slow manual opening operation

May only be carried out if:
closed position.
Off position.
• The motor voltage is cut using
the motor protection (2).
Item
2 Motor protection
3 Operating switch Closed/Open
2 3 1
B30206
• Closing spring tensioned.

1. Fit the crank (1) and crank attachment (2) as in Figure 4-11 and press in the
back lock with the crank attachment.
Mechanism
Item
2
1 Crank
2 Crank attachment B30052 1
Figure 4-10. Crank connection.
1HSB535409-100 en rev3 15
2. Attach the tool (2) on the heel (3).

3. Crank the crank clockwise until it stops against the closing catch gear. Crank a
further number of turns so that the roller is put under pressure (5).
4. Press the latch (6) for the closing catch gear with a screwdriver.
5. Continue to crank clockwise until the tool (2) is clamped between the heel (3)
and the link system (8).
6. Press with a screwdriver on the latch (7) for the Open-lock.
2 3
Item
1
1 Dog
2 Tool Art. No. 2172 733-186 7

3 Heel 6
4 Closing arm
5 Roller
5
6 Latch, closing catch gear
7 Latch, Open-lock
B30057 8
4
8 Link system
Figure 4-11. Slow manual Open-operation.
7. Crank anti-clockwise until the tool (2)

is released. If not the link system (8)
follows the closing arm (4) repeat
point 6. When the dog passes the
closing catch gear’s roller (5) this is B30056
lifted up with a screwdriver, see
Figure 4-12.
Figure 4-12. Closing catch gear’s roller.
8. Remove the tool (2).

The circuit-breaker is now in the Open position. The spring must be tensioned
before a normal Closing operation can be performed.
16 1HSB535409-100 en rev3
4.1.4 Interlocking system

The following electrical interlocks are integrated in the operating mechanism.
• Closing circuit
– Closing pulse to the Closing coil can only go through the auxiliary contact
if the circuit-breaker is in the open position.
– Closing pulse to the Closing coil can only go through the limit switch if
the closing springs are tensioned.
– Closing pulses are prevented when the density of the SF6-gas is lower than
the blocking level.
– Remaining Closing pulses are cut up by the anti pumping relay after a
completed Closing operation.
• Motor circuit
– The motor circuit is cut with the switch, with slow Open and Closing
operations.
– The motor circuit is cut with manual cranking of the spring.
1HSB535409-100 en rev3 17
4.2 Preparations for maintenance

The following should be done before maintenance is started:
1. Switch the circuit-breaker to the open position.
2. Isolate and earth.
3. Switch of the motor current.
4. Perform an Close-Open operation so that the spring is discharged.
5. Cut the operating voltage and if necessary also the voltage to the heater.
1 2 3
Item
1 Operating panel
4
2 Operating switch
Close/Open
4 Spring indicator
B30203
Figure 4-13. Operating panel.
18 1HSB535409-100 en rev3
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 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,
latches and components in the link system.
Despite good rust protection small signs of rust attack can appear after a number of
years, especially on circuit-breakers erected in aggressive environments.
• Rust spots should be removed and new anti-corrosive agent should be applied
by brush or spray. Recommended anti-corrosive agents are Grease “G” or
Tectyl 506.
N.B. After drying Tectyl 506 forms a protective wax-like cover and must not be
sprayed on bearings as well as catch gears and gears.
1HSB535409-100 en rev3 19
4.5 Lubrication
The ball, roller and needle bearings as well as worm gears in the operating
mechanism are permanently lubricated and require no maintenance. Therefore only
the shafts in the catch gears need to be lubricated.
Sliding surfaces for the dashpot should be lubricated during an overhaul with
Grease “G”.
4.6 Heater element

The operating mechanism is fitted with a heater element to prevent condensation
and should always be connected.
• Measure the resistance and check the voltage failure signal, if there is such,
after every 15 years or 2000 operations.
1
Item
1 Heater element
B30058
Data
– 70 W, 220 V: R = 691 Ohm ±10%.
– 140W, 220 V: R = 346 Ohm ±10%.
– 70 W, 110 V: R = 173 Ohm ±10%.
– 140 W, 110 V: R = 86 Ohm ±10%.
20 1HSB535409-100 en rev3
4.7 Drive unit

• Measure the motor current at the end of the loading procedure. See the relevant
Assembly Instructions for the circuit-breaker, chapter Operating values.
The motor should be capable of charging the spring at 85% of its nominal
voltage (IEC).
Item
1 Drive unit
B30160
Figure 4-15. Drive unit.
1HSB535409-100 en rev3 21
4.7.1 Replacing the motor

1. Fully discharge the closing spring. The spring indicator should be Green.
2. Crank anti-clockwise so that the closing arm (1) rests against the roller (2).
3. Remove the cover on the operating mechanism cabinet.
4. Loosen the screws (3) and the electrical connection.
5. Fit the new motor. Tighten the screws (3) with tightening torque 9 Nm.
TIGHTENING TORQUE
9 Nm
1
Item
1 Closing arm
2 Roller
3 Bolts M6x75 2 pcs

2
3 3
B30168
Figure 4-16. Replacing the motor
6. Lock the bolts using locking fluid, Loctite 242, ABB Art. No. 1269 0014-410.
7. Refit the cover.
4.7.2 Start switch

Check that the signal for voltage failure functions, if not replace the start switch.
22 1HSB535409-100 en rev3
4.8 Catch gear

The operating mechanism is fitted as standard with a closing magnet and two
opening magnets, but can, on request, be equipped with double magnets on the
closing side.
1
Item
1 Open catch gear
2 Close catch gear
B30204
Figure 4-17. Catch gear
• Check and clean the shafts in the catch gear.

• Lubricate these with Grease “L” at an interval of 15 years or 2000 operations.
• Check that the voltage to the magnets does not fall below the minimum
voltage, see the delivery document for the operating mechanism.
• Check the play between the magnet arms and the auxiliary catch. The play can
be at least . 1 mm. If the play is outside the stated measurement the entire catch
gear should be replaced.
Item
1 Auxiliary catch
2 1 mm
2 Magnet arm
B20013
Figure 4-18. Checking the play.
1HSB535409-100 en rev3 23
4.8.1 Replacing the Open or Close catch gear

1. Loosen the bolts (1).
2. Replace the complete Close or Open catch gear
3. Tighten the bolts (1) with a tightening torque 40 Nm and lock with Loctite 242,
ABB Art. No. 1269 0014-410.24
TIGHTENING TORQUE
40 Nm
Item
1 Bolts M8x70 3 pcs
B30062 1 1
Figure 4-19. Replacing the catch gear.
24 1HSB535409-100 en rev3
4.9 Dashpot
The operating mechanism is fitted with a dashpot to dampen the final phase of the
opening movement.
Item
1 Dashpot
B30063
Figure 4-20. Dashpot
The oil level should be up to the mark. If necessary, fill up with oil “S”.
1HSB535409-100 en rev3 25
4.10 Limit switch with auxiliary contact

The operating mechanism is fitted as standard with a 12 pole auxiliary contact
consisting of twelve opening and 12 closing contacts. Three closing contacts and
three opening contacts are used for the functioning of the operating mechanism.
The auxiliary contact shaft is in direct connection with the operating lever in the
operating mechanism and accordingly follows the movement of the circuit-breaker
contacts.
2 1
Item
1 Limit switch
2 Auxiliary contact
B30200
Figure 4-21. Limit switch with auxiliary contact.
After 15 years or 2000 operations,check the contact movement by measuring the

times and compare the results with those obtained during commissioning. The
comparison can then be used to check the condition of:
• Contact movement
• Contact damping.
26 1HSB535409-100 en rev3
1. Connect a time-meter across the signal contacts 10, 19, 121 and 122 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 “Close/Open” to “OPEN” and then to the “CLOSED” 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 movement
Arcing contact
Closed
Auxiliary contact
Contact
movement
Open
t1 t3 Time
t2
t1 ms Proportional to the contact’s opening speed.

t2 ms Time that determines contact damping.
t3 ms Proportional to the contact’s closing speed.
B20018
Figure 4-22. Time measurement, contact movement.
1HSB535409-100 en rev3 27
4.11 Terminal blocks

Check all screws and pins.
8
Item
1 Opening coil
1
2 Closing coil
3 Motor
2
5 Operating switch Close/Open
6 Electric counter
7 Limit contact
8 Auxiliary contact
9 Anti-condensation heater
10 Anti pumping relay
11 Interlock relay
12 Interlock relay 15 14 6 5 4
13 Motor contactor
14 Motor protection
3 7
15 Miniature switch, heater
12
11
10 9
13
B30205
Figure 4-23. Electrical equipment.
28 1HSB535409-100 en rev3
Head office 0321
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928
SF6 Circuit-Breaker LTB 72.5-170D1/B with
3-pole operation
Overhaul Instructions
1HSB425409-230 en rev0

this document.
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 appli-
cable laws.
Date: 2002-04-26
TABLE OF CONTENTS
1. General ............................................................................... 1
2. Safety................................................................................... 3
2.1 Warning text ................................................................................... 3
2.2 Safety directives ............................................................................. 4
3. Overhaul, general ............................................................... 7

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

4.1 General ........................................................................................... 9
4.2 Gas................................................................................................ 10
4.3 Cleaning and waste disposal ........................................................ 11
4.4 Dismantling the circuit-breaker pole for transport....................... 12
5. Dismantling the circuit-breaker pole .............................. 15

5.1 Removing the breaking unit ......................................................... 15
5.2 Removing the post insulator......................................................... 16
5.3 Dismantling the breaking unit...................................................... 17
6. Contact and puffer replacement ..................................... 19

6.1 Replacing the upper current path ................................................. 19
6.2 Replacing the puffer ..................................................................... 20
6.3 Replacing the lower current path ................................................. 21
7. Overhaul of the mechanism ............................................ 23
8. Assembling the circuit-breaker pole .............................. 25

8.1 Treatment of contact surfaces ...................................................... 25
8.2 Treatment of sealing surfaces and seals ....................................... 26
8.3 Assembling the post insulator ...................................................... 27
8.4 Assembling the breaking unit....................................................... 28
8.5 Assembling the circuit-breaker pole ............................................ 30
8.6 Gas filling ..................................................................................... 32
1HSB425409-230 en rev0 i
9. Dismantling the breaking unit for transport ...................33

9.1 Assembling the breaking unit after an overhaul........................... 36
10.Assembling the circuit-breaker and commissioning....39
FIGURES
Figure 4-1. Preparations for dismantling. ........................................................13

Figure 4-2. Dismantling the circuit-breaker pole. ............................................14
Figure 5-1. Removing the breaking unit. .........................................................15
Figure 5-2. Removing the post insulator. .........................................................16
Figure 5-3. Dismantling the breaking unit.. .....................................................17
Figure 6-1. Diameter of the nozzle throat. .......................................................19
Figure 6-2. Upper current path. ........................................................................19
Figure 6-3. Puffer. ............................................................................................20
Figure 6-4. Lower current path. .......................................................................21
Figure 7-1. Mechanism housing. .....................................................................23
Figure 8-1. Assembling the post insulator. ......................................................27
Figure 8-2. Assembling the breaking unit. .......................................................29
Figure 8-4. Assembling the circuit-breaker pole. ............................................31
Figure 9-1. Tripping mechanism ......................................................................34
Figure 9-2. Dismantling the breaking unit. ......................................................35
1HSB425409-230 en rev0 iii

Overhaul Instructions General
1. General
This Overhaul Instruction applies to the SF6 circuit-breaker type LTB 72.5-
170D1/B with two column frame and operating mechanism type BLK 222 for three
pole operations. 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.
1HSB425409-230 en rev0 1
Overhaul Instructions Safety
2. Safety
2.1 Warning text

observed extra carefully. The warning texts are marked as set out below.
DANGER
WARNING
CAUTION
indicates a hazardous situation than can result in minor or moderate
injury.
1HSB425409-230 en rev0 3
Safety Overhaul Instructions
2.2 Safety directives

On all types of work on high-voltage circuit-breakers, the risks listed below must be
taken into consideration and corresponding measures must be taken.
WARNING
Circuit-breakers with pressurised insulators.
0.125 MPa (abs).
WARNING
The standard operating cycle is O- 0.3 s - CO - 3 min.-CO. The time between

4 1HSB425409-230 en rev0
Overhaul Instructions Safety
WARNING
Work requires training and product knowledge and may only be carried
out by authorised personnel.
Risk Measure
Working close to high voltage. Isolate and earth close to the work
place. If work must be carried out
close to live installation components,
the safety distance applying in the
country’s 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. Switch off the control voltage and if
Both alternating (AC) and direct (DC) necessary the heating voltage.
current can be routed to the
Risk of crushing in the operating Operate the circuit-breaker to the

mechanism and link system. open position. Isolate and earth the
There is stored energy in both the high-voltage side. Discharge the
opening and closing springs. The springs by switching off the motor
mechanism can be tripped by heavy current and perform a Close-Open
vibrations or by unintentional contact operation or move the operating
with mechanical latch components. mechanism’s drive shaft backwards
by hand (see the Product Information
for the operating mechanism). For
reasons of safety the closing springs
must be discharged during
transportation as well as during
assembly and storage.
Working close to pressurised Work close to the circuit-breaker’s

insulators. insulators that may result in damage
The normal working pressure is up to to the insulators, must not be carried
0.8 MPa. Damage to the porcelain out until the gas has been emptied to
can result in splintering. max. 0.125 MPa (abs.) pressure.
1HSB425409-230 en rev0 5
Overhaul Instructions 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.
3.2 Gas handling equipment

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

• Full face mask with filter for fine particles and acid gases.
• Long-sleeved overall.
• Protective gloves of plastic or rubber.
3.4 Cleaning equipment

• Vacuum cleaner with micro-filter and plastic nozzle.
• Drying cloths of a lint-free material.
• Sealed storage containers for waste products and used absorption filters.
• Wire brush for contact surfaces of aluminium.
• Cleaning pad, e.g. Scotch Brite, for contact surfaces of copper.
• Industrial alcohol 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.
1HSB425409-230 en rev0 7
Overhaul, general Overhaul Instructions
3.5 Spare parts

• Contact kits1.
• Set of seals1.
• Absorption agent1.
• Lubricants, see Lubricants, 1HSB445409-1 for the names of suppliers and
brands
Grease “G”:ABB Art. No. 1171 4014-407
Grease “L”:ABB Art. No. 1171 4016-606
Grease “N”:ABB Art. No. 1171 4016-607
Grease “P”:ABB Art. No. 1171 5011-102
Grease “S”:ABB Art. No. 1171 4014-406.
• Anti-corrosion agent.
Valvoline Tectyl 506, ABB Art. No. 1241 0011-108.
• SF6 gas.
• Nitrogen gas.
• Protective cover for breaking unit, ABB Art. No. 5237 736-R.
• Protective cover for post insulator, ABB Art. No. 5439 142-A.
3.6 Test equipment

• Equipment to record attenuation curves on the operating mechanism.
(e.g. Programma or ABB SA10)
• Operating time meter.
• Ohmmeter.
• Leak detector.
3.7 Premises
The circuit-breaker or breaking 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 list for the circuit-breaker in question.
8 1HSB425409-230 en rev0
Overhaul Instructions 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
1HSB425409-100 must be read and followed:
Check and note down the circuit-breaker’s operating values before dismantling.
Any deviation from the recommended values indicates that something must be
carefully checked during the overhaul.
There are two different methods of implementing the overhaul:
• First and foremost it is recommended that the entire circuit-breaker is
dismantled for transport to a service workshop, where it can be dismantled in
detail for an overhaul.
• Alternatively, and secondly only the breaking unit is dismantled.
The latter method does not entail so much work, but it may only be used when the
weather is settled and the outdoor working conditions are similar to indoor
conditions.
N.B. Removal and assembly of 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:
• Operate the circuit-breaker to the Open position.
• Isolate and earth.
• Discharge the closing spring in the operating mechanism by cranking the dog
so that the operating link releases from the Closing catch gear.
• Switch off the control voltage and, if necessary, also the heater power.
1HSB425409-230 en rev0 9
Dismantling the circuit-breaker Overhaul Instructions
4.2 Gas
Work on the circuit-breaker’s 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
must be emptied to the atmosphere 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 circuit-breaker is now ready to be dismantled.
10 1HSB425409-230 en rev0
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 during 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.
1HSB425409-230 en rev0 11
4.4 Dismantling the circuit-breaker pole for transport

Before the circuit-breaker pole is dismantled, the circuit-breaker must be taken out
of service, see Chapter 4.1.1, and the gas emptied, see Chapter 4.2.1.
1. Loosen the pole’s gas connections by unscrewing all three nuts to the groove
(1) on the non-return valve (2). Thereafter all three nuts can be removed and
the sealing caps (3) fitted.
2. Discharge the opening spring (4)
N.B. Do not loosen the locking nut and adjuster screw.

– Loosen the lock washer (5) and dismantle the pin (6) so that the outer
lever (7) in the mechanism housing on pole C 1 is released.
When only circuit-breaker pole C1 is to be dismantled the easiest way to
do this is to loosen the opening spring housing (8). Block up the opening
spring housing (8) to support the weight otherwise the mechanism
housing on pole B1 can break. Dismantle the bolts (9). Now go to point 4.
– When circuit-breaker pole A1 and/or B1 or all poles are to be dismantled,
pull the outer lever (7) in the mechanism housing on pole C1 clockwise
until it reaches its stop position.
– Dismantle the protective bolt (10) and screw the crank extension (11) in
the protective cover (12) so that it enters the countsink on the end of the
coupling link (13). Tighten so that the pull-rod (14) is clamped between
the crank extension and the opening spring bracket (15).
– Crank, using the crank (16), in the crank extension (11) a few turns so that
the pulling force on the pull-rods is offloaded.
– Loosen the lock washers (17) and (19) on the circuit-breaker poles B1
respective A1 and dismantle the pins (18, 20).
– Crank, using the crank (16) out the crank extension (11) to offload the
opening spring.
3. Dismantle the pull-rods and protective pipes between the operating mechanism
and the circuit-breaker pole and between the circuit-breaker poles.
12 1HSB425409-230 en rev0
1 Pole C1
3 2
10 7 8
5, 6
9
4
Poles A1 and B1
Pole C1
12
16 11
B30243
14 15 17, 18 19, 20
13
Item Item
1 Groove 11 Crank extension, ABB Art. No. 1HSB532188-F
2 Non-return valve 12 Protective cover
3 Sealing cap 13 Coupling link
4 Opening spring 14 Pull-rod
5 Lock washer SL12 15 Opening spring bracket
6 Pin, pole C1 D=12 16 Crank, ABB Art. No. 2188 754-G
7 Outer lever 17 Lock washer, pole A1 and B1 SL12
8 Opening spring housing 18 Pin, pole A1 and B1 D=12
9 Bolt M12x40 19 Lock washer, pole A1 and B1 SL16
Washer 13x24x2.5
10 Safety bolt M16x30 20 Pin, pole A1 and B1 D=16
Washer 17x30x3
Figure 4-1. Preparations for dismantling.
1HSB425409-230 en rev0 13
4. Place a lifting sling under the breaking unit’s upper flange as shown in Figure
4-2 and prepare to lift with a crane. Now loosen the circuit-breaker pole (1),
removing the four bolts (2) on the frame.
5. Lift up the circuit-breaker pole and carefully lay it down on a transport
carriage. Block up the circuit-breaker pole so it lies horizontal. The block (3)
under the breaking unit’s 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 new site should take place with care so as not damage
the insulators.
1
Item
2
1 Circuit-breaker pole

Nuts M12 4 pcs
3 Blocks
3
3
B10320
Figure 4-2. Dismantling the circuit-breaker pole.
14 1HSB425409-230 en rev0
Overhaul Instructions Dismantling the circuit-breaker pole
5. Dismantling the circuit-breaker pole

The circuit-breaker pole is fitted vertically on a suitable frame, e.g. circuit-breaker
frame or a frame on the floor of the workshop.
5.1 Removing the breaking unit

1. Turn the operating lever (1) anticlockwise to the closed position of the
contacts.
2. Fit the lifting sling from the top of the breaking unit to the crane or overhead
crane. Tension the lifting sling moderately.
3. Remove the bolts (2) between the post insulator (3) and the breaking unit (4).
4. Lift the breaking unit
110 - max. 120 mm.
5. Remove the lock washer (5)
and pin (6).
Set up the breaking unit vertically 4
on a suitable surface, e.g. on two
beams, so that it does not fall over
A 6
and so the bolts on the underside are
accessible.
2
3 A
A-A
Item
1 Operating lever

Washers 13x28x3 8 pcs 5
Nuts M12 4 pcs
1
3 Post insulator
4 Breaking unit
B30244
5 Lock washer SL12
6 Pin D=12
Figure 5-1. Removing the breaking unit.
1HSB425409-230 en rev0 15
Dismantling the circuit-breaker pole Overhaul Instructions
5.2 Removing the post insulator

Plan the work to remove the insulator so that it can be carried out quickly and
without long delays to prevent moisture in the air coming into contact with the dust
in the post and operating insulators.
N.B. Use personal safety equipment such as overalls, protective gloves and face
mask.
1. Position the lifting sling from the top of the post insulator to the crane or
overhead crane.
2. Remove the post insulator’s bolts (2) from the mechanism housing (3).
3. Lift the post insulator straight up until the operating insulator is released. Hold
the operating insulator when performing the lift.
N.B. Take care so as not to damage the operating insulator.

4. Remove the operating insulator by removing lock washer (4) and the pin (5).
5. Clean the operating insulator carefully and protect it using plastic sheet.
6. Clean the post insulator carefully, inside and outside, and protect it using
plastic sheet.
Item
4 1 Post insulator
A-A
3 Mechanism housing
1 4 Lock washer SL12
5 Pin D=12
5
A
3 A
B30245
Figure 5-2. Removing the post insulator.
16 1HSB425409-230 en rev0
Overhaul Instructions Dismantling the circuit-breaker pole
5.3 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 contact with the dust in the
breaking unit and on the inside and outside of the breaking chamber insulator.
N.B. Use personal safety equipment such as overalls, protective gloves and face
mask.
Take care of the decomposition products in the breaking unit, in the form of powder,
as the breaking unit is successively opened. First use a vacuum cleaner and
thereafter carefully wipe the dismantled components.
1. Remove the bolts (1) and the cover (2) and lift
out the absorption agent container (3). 1 3 2 4 5
N.B. Place the bag with absorption agent in a

container for chemical waste.
2. Remove the bolts (4) and upper flange (5) with 6
the upper current path (6).
3. Remove bolts (9) and breaking chamber
insulator (7) from the lower flange (8). 7
4. Rinse the inside of the breaking chamber
insulator with water.
Item

Washers 10.5x20x2 6 pcs
2 Cover
3 Absorption agent container

Nuts M12 4 pcs 8
5 Upper flange
6 Upper current path
7 Breaking chamber insulator

9
B30033
8 Lower flange

Washers 8.4x16x1.6 2 pcs.
Figure 5-3. Dismantling the breaking unit..
The main components of the breaking unit are now accessible for inspection,
cleaning and replacement of burnt or damaged components.
1HSB425409-230 en rev0 17
Overhaul Instructions Contact and puffer replacement
6. 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.
Check the Teflon nozzle’s burnup. All contacts must be replaced if the diameter in
the nozzle throat is greater than 24 mm. If one of the parts is burnt or worn and is
replaced, all other components should be replaced at the same time.
N.B. All contact surfaces must be treated before assembly, see section 8.1,
Treatment of contact surfaces.
Item
1 Nozzle
B30039 max. 24 mm
Figure 6-1. Diameter of the nozzle throat.
6.1 Replacing the upper current path

1. Loosen the bolts (1) and lift out the upper current path (2) from the upper
connection flange (3).
2. Fit a new upper current path. Tighten the 3
1
bolts (1) with a tightening torque of 22.5 Nm.
Item
1 Bolt M8x16
Washer 8.4x16x1.6 2
3 Upper connection flange
TIGHTENING TORQUE
22.5 Nm B30040
Figure 6-2. Upper current path.
1HSB425409-230 en rev0 19
Contact and puffer replacement Overhaul Instructions
6.2 Replacing the puffer

Check that the nozzle is not punctured. Also check that the contact surfaces on the
puffer cylinder are not burnt or worn so that the copper is visible. Check that there is
no wear on the operating rod’s sliding surfaces.
Replace the entire puffer if it has burnt or worn surfaces.
1
Item
1 Nozzle
2 Operating rod
3 Puffer cylinder
B30246
Figure 6-3. Puffer.
20 1HSB425409-230 en rev0
Overhaul Instructions Contact and puffer replacement
6.3 Replacing the lower current path

Check that the silver on the lower main circuit contacts is not worn so that the
copper is visible.
If there are signs of wear, the whole lower main circuit with flange should be
replaced.
Item
5
1 Flange 4
2 Bolt M6x12
Washer 6.4x12x1.6 3
3 Lower current path
4 Contact element
2
5 Teflon band 1
B30247
Figure 6-4. Lower current path.
1. Assemble the puffer on the puffer guide. When the puffer starts to go down
over the teflon band (5) it should be turned carefully to avoid damaging the
teflon band.
N.B. Exercise care so that the teflon band (5) on the piston is not damaged when
the puffer slides down and that the contact element (4) is held in position
in its groove.
2. Assemble the lower current path (3) above the puffer and puffer guide. Tighten
the bolts (2) with a tightening torque of 10 Nm.
TIGHTENING TORQUE
10 Nm
1HSB425409-230 en rev0 21
Overhaul Instructions Overhaul of the mechanism
7. Overhaul of the mechanism

Clean the mechanism housing using a vacuum cleaner and then wipe it. Inspect and
lubricate the bearings and sealing rings.
Protect untreated or manganese phosphated steel parts outside of the gas chamber
using Valvoline Tectyl 506, ABB Art. No. 1241 0011-108.
1. Loosen the bolt (2) and dismantle the outer lever (3) from the operating shaft
(4).
2. Remove the circlip (5).
3. Pull out the operating shaft (4) and inspect the bearings (6, 7). These shall not
be lubricated.
4. Remove the bushing (8), 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 (9, 10) in the bushing and lubricate with grease “S”.
Fill the space between the sealing rings with grease.
N.B. Turn the bearing’s sealing rings in towards the gas chamber.
5. Refit the shaft (4) through the inner operating lever (11) and press in the
bushing (8) with its sealing rings.
6. Fit the circlip (5), felt washer (12) and outer lever (3).
7. Tighten the bolt (2) with a tightening torque of 45 Nm.
Item 7 6
9
1 Mechanism housing 2 1
3 12
2 Bolt M10x45
Washers 10.5x20x2
3 Outer lever
4 Operating shaft
5 Circlip
6 Bearing
5 8
7 Bearing
10
8 Bushing
11
9 X-ring 44.2x5.7
10 O-ring 89.1x5.7 TIGHTENING TORQUE

11 Inner operating lever 45 Nm
12 Felt washer 4 B30248
Figure 7-1. Mechanism housing.
1HSB425409-230 en rev0 23
Overhaul Instructions Assembling the circuit-breaker pole
8. Assembling the circuit-breaker pole

To re-assemble the breaking unit follow the dismantling instructions in the reverse
order see Chapter 5.
N.B. When re-assembling all sealing rings must be new. Careful cleaning and
treatment of sealing surfaces is required.
8.1 Treatment of contact surfaces

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

• Silver-plated:
If necessary, clean silver-plated contact surfaces, using a soft cloth and solvent
(alcohol).
N.B. Polishing using Scotch Brite or grinding must not take place.
• Copper surfaces
Copper 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.
N.B. Grease should be applied within five minutes of cleaning and the joint
should be fitted within 15 minutes.
8.1.2 Moving contact surfaces

• 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.
1HSB425409-230 en rev0 25
Assembling the circuit-breaker pole Overhaul Instructions
8.2 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 removed by polishing 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 seal’s 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 anti-
corrosion 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:
• Grease “G” for static seals
Grease “S” for moving seals, e.g. shaft seals.
26 1HSB425409-230 en rev0
8.3 Assembling the post insulator

1. Fit the operating insulator (1) on the link gear using pin (2) and fit the lock
washer (3).
2. Place the sealing ring (4) on the mechanism housing (5) and lift the post
insulator (6) into position, tighten the bolts (7) with a tightening torque of
79 Nm.
N.B. Make sure not to damage the operating insulator.
TIGHTENING TORQUE
79 Nm
Item
1 Operating insulator
3 A-A
2 Pin D=12
3 Lock washer SL12 4

6
4 O-ring 169.5x5.6
5 Mechanism housing
6 Post insulator A
2
7
1
5 A
B30245
Figure 8-1. Assembling the post insulator.
1HSB425409-230 en rev0 27
8.4 Assembling the breaking unit

1. Place the lower current path (1) with the puffer (2) and the lower connection
flange (3) on two beams.
2. Place the sealing ring (4) on the lower flange (3) and lift on the breaking
chamber insulator (5). Ensure the lower edges clear the lower current path’s
securing bolts. Fit the two bolts (6) and tighten by hand.
3. Check that the upper current path’s (7) arc contact is centred to within 1mm in
relation to the outer screen.
4. Grease the sealing rings (4) and position under the upper flange (8).
5. Fit the upper current path (7) with the sealing rings in the breaking chamber
insulator (5). Centre the current path in relation to the puffer (2). The edge of
the nozzle must not push against teflon guide.
28 1HSB425409-230 en rev0
9 8
6. Tighten the bolts (6) on the lower flange
(3) with a tightening torque of 22.5 Nm.
TIGHTENING TORQUE
22.5 Nm 7
7. Tighten the bolts (9) on the upper flange 4 5

(8) with a tightening torque of 79 Nm.
TIGHTENING TORQUE
2
79 Nm
Item
1 Lower current path 1
2 Puffer
3 Lower connection flange
4 O-ring 194.6x5.6
3
5 Breaking chamber insulator
Washers 8.4x16x1.6 2 pcs.
6
8 Upper connection flange B30033 4
Nuts M12 4 pcs.
Figure 8-2. Assembling the breaking unit.
1HSB425409-230 en rev0 29
8.5 Assembling the circuit-breaker pole

1. Suspend the breaking unit in the lifting sling and pull down the puffer pull-rod
(1) to its fully extended position so it is accessible for assembly.
2. Carefully clean the sealing surfaces for the sealing rings (2) on the post
insulator (3). Also clean the lower flange (4) and lubricate well using grease
“G” so that the sealing ring is held in place during assembly. Place the sealing
ring in its groove.
3. Slowly lower the breaking unit so that it comes into position to fit the pin (5),
approx. 100-150 mm above the post insulator.
4. Connect the puffer’s pull rod (1)
to the operating insulator using A-A
pin (5) and lock using the lock
washer (6).
Item
6
1 Puffer pull-rod
A 5
2 O-ring 169.5x5.6
4, 7
3 Post insulator
4 Lower flange
5 Pin D=12
2
6 Lock washer SL12 A
1
7 Bolts M12x80
Washers 13x28x3
Nuts M12 3
B30244
5. When the pin is fitted, carefully lower the breaking unit on to the post insulator
and centre it. Tighten the breaking unit using the bolts (7) with a tightening
torque of 79 Nm.
TIGHTENING TORQUE
79 Nm
30 1HSB425409-230 en rev0
6. Clean the sealing surface on the upper flange (1) and coat with grease “G”.
Place the sealing rings (2) on top of the upper flange.
7. Open the new absorption agent package and place the agent into the absorption
agent container (3).
8. Fit the absorption agent container (3) and
5
the cover (4) and tighten the bolts (5) with
a tightening torque of 45 Nm. 3 4
1, 2
TIGHTENING TORQUE
45 Nm
Item
1 Upper flange
2 O-ring 194.6x5.6
4 Cover
5 Bolts M10x30
Washers 10.5x20x2
B30249
Figure 8-4. Assembling the circuit-breaker pole.
1HSB425409-230 en rev0 31
8.6 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 circuit-breaker is now ready for transport.
32 1HSB425409-230 en rev0
Overhaul Instructions Dismantling the breaking unit for transport
9. Dismantling the breaking unit for transport

Dismantling of just the breaking unit for overhaul may only be carried out in good
and settled weather conditions and if the relative humidity does not exceed 80 %.
1. Take the circuit-breaker out of service, see Chapter 4.1.1.
2. Empty the gas, see Chapter 4.2.1. Fill with nitrogen gas to atmospheric
pressure.
3. Discharge the opening spring by holding the spring shaft (1), see Figure 9-1.
N.B. Do not loosen the locking nuts and adjuster screw.

– Loosen the lock washer (2) and dismantle the pin (3) so that the outer
lever (4) in the mechanism housing on pole C 1 is released.
– When only circuit-breaker pole C1 is to be dismantled the easiest way to
do this is to move the pull-rod downwards so that the released lever (4)
can be moved to its closed position. Now go to point 5.
– When circuit-breaker pole A1 and/or B1 or all poles are to be dismantled,
pull the outer lever (4) in the mechanism housing on pole C1 clockwise
until it reaches its stop position.
– Dismantle the protective bolt (5) and screw the crank extension (6) in the
protective cover (7) so that it enters the countsink on the end of the
coupling link (8). Tighten so that the pull-rod (9) is clamped between the
crank extension and the opening spring bracket (10).
– Crank, using the crank (11), in the crank extension (6) a few turns so that
the pulling force on the pull-rods is offloaded.
– Loosen the lock washers (12) and (14) on the circuit-breaker poles B1
respective A1 and dismantle the pins (13), (15).
– Crank, using the crank (11) out the crank extension (6) to offload the
opening spring.
4. Move the outer lever (4) in the mechanism housing to its closed position on the
circuit-breaker pole where the braking unit is to be dismantled.
5. Place a lifting sling around the top section of the breaking unit and prepare to
lift it.
1HSB425409-230 en rev0 33
Dismantling the breaking unit for transport Overhaul Instructions
Pol e C1
5 4
2, 3
Poles A1 and B1
Pole C1
7
11 6
B30243
9 10 12, 13 14, 15
8
Item Item
1 OPening spring 8 Coupling link
2 Lock washer SL12 9 Pull-rod
3 Pin, pole C1 D=12 10 Opening spring bracket
4 Outer lever 11 Crank, ABB Art. No. 2188 754-G
5 Protective bolt M16x30 12 Lock washer, poles A1 and B1 SL12

Washer 17x30x3
6 Crank extension, ABB Art. 13 Pin, poles A1 and B1 D=12
No. 1HSB532188-F 14 Lock washer, poles A1 and B1 SL16
7 Protective cover 15 Pin, poles A1 and B1 D=16
Figure 9-1. Tripping mechanism
34 1HSB425409-230 en rev0
6. Remove the bolts (1) and very carefully lift the breaking unit (2)
100 - max 120 mm.
N.B. Do not lift the breaking unit more than 120 mm so as not to damage the
circuit-breaker’s internal components.
Item
1 Bolts M12x80
Washers 13x28x3 2
Nuts M12
A 4
2 Breaking unit
3 Pin 1
4 Pin
5 Post insulator
A
A-A
5
B30244
Figure 9-2. Dismantling the breaking unit.
If a large amount of moisture should enter the post insulator, fill it immediately with
nitrogen gas and transport it to a workshop as soon as possible for dismantling and
careful cleaning.
7. Disconnect the breaking unit (2) by removing the lock washer (3) and the pin
(4).
N.B. Ensure that neither the circlips nor washers fall into the post insulator
during dismantling. Cover the openings by, for example, tying a cloth over
them.
1HSB425409-230 en rev0 35
Dismantling the breaking unit for transport Overhaul Instructions
8. Push down the insulator rod as far into the support porcelain so that the entire
rod is under the edge. Fit the protective cover,
ABB Art. No. 5439 142-A, with the sealing ring over the post insulator (5), see
Figure 9-2. When the cover has been bolted in position, increase the nitrogen
pressure in the post insulator to 0.125 MPa (abs).
9. Slide the puffer pull-rod (4) in the breaking unit (2) and fit the protective cover,
ABB Art. No. 5237 736-R, with the sealing ring, see Figure 9-2.
The breaking unit is now ready for transport.
If the post insulator or breaking unit is left in this condition for a long period
without the breaking unit being re-assembled, vacuum pump the post insulator or
breaking unit and fill with nitrogen gas, see Chapter 8.6.
9.1 Assembling the breaking unit after an overhaul

1. Suspend the breaking unit, remove the post insulator’s protective cover,
ABB Art. No. 5237 736-R, and pull out the puffer so that its pull-rod (1) is
accessible for assembly.
2. Reduce the nitrogen pressure in the post insulator (2) to atmospheric pressure
and remove the protective cover. The protective covers must be dismantled
from all poles simultaneously.
3. Move the outer lever (13) in the mechanism housing to its closed position on
the circuit-breaker pole where the breaking element is to be assembled.
4. Carefully clean the sealing surfaces for the sealing rings (3) on the post
insulator (2). Also clean the lower flange (4) and lubricate well using grease
“G” so that the sealing ring is held in place during assembly. Place the sealing
ring in its groove.
5. Slowly lower the breaking unit (4) so it sits in position for fitting the pin (5).
6. Connect the puffer pull-rod (1) to the operating insulator using the pin (5) and
lock using the lock washer (12).
7. When the pin (5) is fitted, lower the breaking unit (4) carefully down towards
the post insulator (2) and centre it. Bolt the breaking unit in position using the
bolts (6) and tighten to a torque of 79 Nm.
TIGHTENING TORQUE
79 Nm
8. Clean the upper flange (7) and coat with grease “G”. Place the sealing rings (8)
on top of the upper flange.
9. Open the packaging of the new absorption agent and fit the agent into the
absorption agent container (9).
36 1HSB425409-230 en rev0
10. Fit the absorption agent container (9) and the cover (10) and tighten the bolts
(11) to a torque of 45 Nm.
TIGHTENING TORQUE
45 Nm
11
10
Item
9
1 Puffer pull-rod 7, 8
2 Post insulator
3 O-ring 169.5x5.6
4
4 Breaking unit 1
A
5 Pin
6 Bolts M12x80 4 pcs 6
Nuts M12 4 pcs
5
A
7 Upper flange
8 O-ring 194.6x5.6 3
A-A
10 Cover 2

Washers 10.5x20x2 6 pcs 12
12 Lock washer
13 Outer lever B30250
13
Repeat points 1-10 for all poles.

11. Operate the circuit-breaker slowly to the Open position and fit the pin in the
opening arm.
12. Filling the circuit-breaker pole 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 gas to atmospheric pressure. Allow it to stand for a few hours or
over-night.
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.
The circuit-breaker is now ready for gas filling in accordance with the Assembly
Instructions for the circuit-breaker in question.
1HSB425409-230 en rev0 37
Overhaul Instructions Assembling the circuit-breaker and commissioning
10. Assembling the circuit-breaker and commissioning

The circuit-breaker is assembled and commissioned in accordance with the
applicable assembly instructions for the circuit-breaker in question.
Check when the circuit-breaker has been filled with gas that the play between the
closing dashpot and the dashpot buffer is 3-4 mm after a CLOSING operation.
After assembling the circuit-breaker, check and note down the operating values.
First overhaul.
Measured values
Check the following

Close-Open time(1) ms ms ms
(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:________________________________
1HSB425409-230 en rev0 39
Assembling the circuit-breaker and commissioning Overhaul Instructions
Second overhaul.
Measured values
Check the following
Close-Open time(1) ms ms ms
(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:________________________________
40 1HSB425409-230 en rev0
Head Office 0402
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 782 320
with operating mechanism
BLK 222
3-pole operation
Spare Parts
1HSB425409-330 en rev1

this document.
ABB Power Technology Products AB. It may not either be imparted toa third party or otherwise be
used without authorisation. Infringement hereof will be subject to action in accordance with applica-
ble laws.
Date: 2002-04-26
Spare Parts
TABLE OF CONTENTS
1. General ................................................................................ 1
1.1 Circuit-breaker pole ....................................................................... 2
2. Breaking unit....................................................................... 3
2.1 Breaking unit.................................................................................. 3
2.2 Contact set...................................................................................... 4
3. Post insulator...................................................................... 5
4. Mechanism .......................................................................... 7
4.1 Mechanism ..................................................................................... 7
4.2 Tripping mechanism....................................................................... 7
5. Accessories ........................................................................ 9
5.1 Absorption agent container ............................................................ 9
5.2 Density monitor.............................................................................. 9
5.3 Set of seals.................................................................................... 10
5.4 Assembly sets............................................................................... 10
5.5 Non-return valve .......................................................................... 10
6. Tools and lubricants......................................................... 11

6.1 Protective cover ............................................................................ 11
6.2 Lubricants..................................................................................... 11
1HSB425409-330 en rev1 i
Spare Parts
FIGURES
Figure 1-1. Circuit-breaker LTB 72.5-170D1/B ............................................... 1

Figure 1-2. Circuit-breaker pole. ....................................................................... 2
Figure 2-1. Breaking unit .................................................................................. 3
Figure 2-2. Contact set ...................................................................................... 4
Figure 3-1. Post insulator .................................................................................. 5
Figure 4-1. Mechanism housing ........................................................................ 7
Figure 4-2. Tripping mechanism. ...................................................................... 7
Figure 5-1. Absorption agent container ............................................................ 9
Figure 5-2. Density monitor .............................................................................. 9
Figure 5-3. Non-return valve. .......................................................................... 10
Spare Parts General
1. General
Spare parts for the SF6 circuit-breaker LTB 72.5-170D1/B with operating
mechanism BLK 222 mounted on a pole beam or on separate hot-dipped galvanised
column frame are supplied by:
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 than
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.
Please state the type designation and serial number with all enquiries and orders of
spare parts or tools. Please also state the order number if possible.
1
Item Designation Note
1 Circuit-breaker pole RRR
2 Operating RRR
mechanism
3 Pole beam with gas 2
pipe
Från
4 Gas pipe
5 Frame 3
Från
4
B30259
5
Figure 1-1. Circuit-breaker LTB 72.5-170D1/B
1HSB425409-330 en rev1 1
General Spare Parts
1.1 Circuit-breaker pole
Item Designation
1
1 Breaking unit
2 Post insulator
3 Mechanism
B10321
Figure 1-2. Circuit-breaker pole.
Please state the type designation and serial number with all enquiries and orders of spare
parts or tools. Please also state the order number if possible.
2 1HSB425409-330 en rev1
Spare Parts Breaking unit
2. Breaking unit
2.1 Breaking unit
Item Qty Designation Note 1

1 1 Breaking chamber RR
insulator 2
2 1 Upper current path Included in

contact set
3 1 Lower current path Included in
contact set 4
4 1 Puffer Included in
contact set
B30033
Figure 2-1. Breaking unit
1HSB425409-330 en rev1 3
Breaking unit Spare Parts
2.2 Contact set
Qty Designation Article number Note

1 Contact set 72.5-145 kV 1HSB425429-M R
170 kV 1HSB425429-N R
B30251
Figure 2-2. Contact set
4 1HSB425409-330 en rev1
Spare Parts Post insulator
3. Post insulator
Item Qty Designation Note

1 1 Post insulator RR
2 1 Operating insulator RR
1
2
B30072
Figure 3-1. Post insulator
1HSB425409-330 en rev1 5
Spare Parts Mechanism
4. Mechanism
4.1 Mechanism
1

1 1 Mechanism pole A1 RR
1 1 Mechanism pole B1 RR
1 1 Mechanism pole C1 RR
B30252
Figure 4-1. Mechanism housing
4.2 Tripping mechanism

1

1 1 Tripping mechanism
B30253
Figure 4-2. Tripping mechanism.
1HSB425409-330 en rev1 7
Spare Parts Accessories
5. Accessories
5.1 Absorption agent container
1 1 Absorption agent
container
2 1 Absorption agent R B30075
Figure 5-1. Absorption agent container
5.2 Density monitor
1 1 Density monitor, R
temperature-compensated 1
- reference volume
2 1 Density monitor, R
temperature-compensated
- bimetal
B10322
Figure 5-2. Density monitor
1HSB425409-330 en rev1 9
Accessories Spare Parts
5.3 Set of seals

Set of seals for a complete circuit-breaker pole.

1 Set of seals 1HSB422100-AA R
5.4 Assembly sets

Set of bolts for a circuit-breaker pole.

1 Set of bolts for: R
Circuit-breaker 1HSB422100-H R
Pull-rod system 1HSB422100-M R
Incl. pull-rod system 1HSB422100-P R
Frame 1HSB422100-U R
Bracket 1HSB422100-W R
Gas monitoring 1HSB422100-Y R
Set of pins for a complete circuit-breaker pole.

1 Pins with locking for:
Circuit-breaker 1HSB422100-K R
Incl. pull-rod system 1HSB422100-S R
5.5 Non-return valve

1
Item Qty Designation Article number Note

1 1 Non-return valve 1HSB442541-C RR
B30077
Figure 5-3. Non-return valve.
10 1HSB425409-330 en rev1
Spare Parts Tools and lubricants
6. Tools and lubricants
6.1 Protective cover
Item Qty Designation Article number Note

1 1 Protective cover for 5237 736-R R
breaking unit
2 1 Protective cover for 5439 142-A R
post insulator
6.2 Lubricants
6.2.1 Oil
Oil Article number Note

“A” 1HSB875318-A
“D” 1HSB875318-B
“S” 1HSB875318-C
6.2.2 Grease
Grease Article number Note

“G” 5316 381-A
“K” 5316 381-M
“N” 5316 381-L
“L” 5316 381-H
“M” 5316 381-J
“P” 5316 381-N
“S” 5316 381-G
“SV” 5316 381-C
1HSB425409-330 en rev1 11
Head Office 0402
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 782 320
type BLK 222
Spare Parts
1HSB535409-200 en rev3

document.
Date: 2002-03-21
Spare Parts
LIST OF CONTENTS
1. General ................................................................................ 1
2. Motor.................................................................................... 3
3. Dashpot ............................................................................... 5
4. Catch gear ........................................................................... 7
5. Heater element.................................................................... 9
6. Electrical equipment ........................................................ 11
7. Lubricants ......................................................................... 13
7.1 Oil................................................................................................. 13
7.2 Grease........................................................................................... 13
1HSB535409-200 en rev3 i
Spare Parts
FIGURES
Figure 1-1. Operating mechanism BLK 222. .................................................... 1

Figure 2-1. Motor. ............................................................................................. 3
Figure 3-1. Dashpot. .......................................................................................... 5
Figure 4-1. Catch gear. ...................................................................................... 7
Figure 5-1. Heater element. ............................................................................... 9
Figure 6-1. Electrical equipment, BLK 222. ................................................... 11
Spare Parts General
1. General
Spare parts for the operating mechanism BLK 222 are supplied by:
SE-771 80 Ludvika
Sweden
Tel: +46 (0) 240-78 20 00
Replacement modules are supplied complete and fully tested.
Please state the type designation and the serial number with all enquiries and orders
of spare parts. Please also state the order number if possible.
2 1
5
3
B30200
Item
1 Drive unit
3 Operating panel
4 Closing spring
5 Heater element
Figure 1-1. Operating mechanism BLK 222.
1HSB535409-200 en rev3 1
Spare Parts Motor
2. Motor
Type of motor Article number

1 Motor, 220 -250 V AC/DC 1HSB534460-2
1 Motor, 110 -127 V AC/DC 1HSB534460-1
B30068
Figure 2-1. Motor.
Please state the type designation and the serial number with all enquiries and orders of spare
parts. Please also state the order number if possible.
1HSB535409-200 en rev3 3
Spare Parts Dashpot
3. Dashpot
Designation Article number

Dashpot 1HSB535256-C
30063
Figure 3-1. Dashpot.
1HSB535409-200 en rev3 5
Spare Parts Catch gear
4. Catch gear
2
Item Designation Article number

1 Closing catch gear 24 V 1HSB535436-AM
42-48 V 1HSB535436-Y
60-72 V 1HSB535436-AN 3
110-127 V 1HSB535436B5
220-250 V 1HSB535436B7 4
2 Opening catch gear 24 V 1HSB535436-AP
42-48 V 1HSB535436-Z 1
60-72 V 1HSB535436-AR
110-127 V 1HSB535436B3
220-250 V 1HSB535436B8
Opening catch gear, 42-48 V 1HSB535436-AA
with man trip device 110-127 V 1HSB535436-L
220-250 V 1HSB535436-M
3
3 Coils, Y1 and Y3 24 V LA 516 771-AV B30062
42-48 V LA 516 771-AS

60-72 V LA 516 771-AX
110-127 V LA 516 771-AL
220-250 V LA 516 771-AY
4 Double opening coil 110-125 V LA 516 771-AU
Y2
220-250 V LA 516 771-AZ
Figure 4-1. Catch gear.
1HSB535409-200 en rev3 7
Spare Parts Heater element
5. Heater element
Designation Voltage range Article number

Heater element 110-127 V, 70 W 5291 805-1
220-254 V, 70 W 5291 805-2
110-127 V, 140 W 5291 805-3
220-254 V, 140 W 5291 805-4
B30058
1HSB535409-200 en rev3 9
Spare Parts Electrical equipment
6. Electrical equipment
Spare parts for electrical equipment BLK 222
Item Designation Voltage range Article number

1 Relay 220-250 V DC 5619 758-1
110-125 V DC 5619 758-2
60-72 V DC 5619 758-3
42-48 V DC 5619 758-4
2 Motor contactor 220-250 V DC 5351 749-1
110-125 V DC 5351 749-2
220-240 V AC 5351 749-3
5 Miniature switch 220-250 V DC 5344 027-40(1)
Motor (MCB) 110-125 V 5344 027-41(2)
6 Miniature switch 110-254 V 5344 027-18
Heater (MCB)
7 Counter 220-250 V DC 5692 965-1
4 3 5
110-125 V DC 5692 965-2
42-48 V DC 5692 965-3
(1) K4A 2-pole + auxiliary contact

(2) K8A 2-pole + auxiliary contact
1
2
B30209
Figure 6-1. Electrical equipment,
BLK 222.
1HSB535409-200 en rev3 11
Spare Parts Lubricants
7. Lubricants
7.1 Oil
Oil Article number

“A” 1HSB875318-A
“D” 1HSB875318-B
“S” 1HSB875318-C
7.2 Grease
Grease Article number

“G” 5316 381-A
“K” 5316 381-M
“N” 5316 381-L
“L” 5316 381-H
“M” 5316 381-J
“P” 5316 381-N
“S” 5316 381-G
“SV” 5316 381-C
1HSB535409-200 en rev3 13
Head Office 0321
SE-771 80 LUDVIKA
SWEDEN
Telephone: +46 (0) 240 782 000
Telefax: +46 (0) 240 714 928

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Product Manual

ABB Power Technology Products

© ABB Power Technology Products AB

Article number: 1HSB425455-30 en rev1

1.1 Design of the circuit-breaker

Item Part Weight, kg

2 Operating see dimension drawing

3 Pole beam with gas see dimension drawing

Figure 1-1. Circuit-breaker type LTB 72.5-170D1/B.

1.2 Circuit-breaker gas system

1.2.1 Opening and closing

Figure 1-2. Circuit-breaker pole in the Closed position.

1.3 Operating mechanism

ABB Power Technology Products

© ABB Power Technology Products AB

Article number: 1HSB535432-100 en rev4

2. Assembly and connection ................................................. 5

Figure 1-1. Operating mechanism BLK 222. .................................................... 1

Figure 1-1. Operating mechanism BLK 222.

Figure 1-2. Lifting the operating mechanism.

2. Assembly and connection

2.1 Mechanical connection

On delivery the operating mechanism’s closing spring is uncharged.

Min. pos.: No tension on closing spring.

Item N.B. The opening spring is tensioned if the

N.B. No work permitted on operating mech.

Figure 2-1. Operating mechanism.

2.2 Electrical connection

Figure 2-2. Earth clamp connection.

2.3 Loading the closing springs

2.3.1 Electrical loading

1 Motor protection switch

Figure 2-3. Electrical loading of the closing spring.

2.4 Normal operations, the circuit-breaker closed

Figure 2-4. Normal operating position.

2.5 Open, the circuit-breaker is open

Figure 2-5. Opening operation.

2.6 Closed, the circuit-breaker is closed

3 Tripping arm with interlock heel

Figure 2-6. Closing operation.

3.1 Remote/local operations

2 Operating switch, On/Off

Figure 3-1. Remote/local operations.

3.2 Close operation

2 Operating switch, On/Off

Figure 3-2. Close operation.

3.3 Open operation

2 Operating switch, On/Off

Figure 3-3. Open operation.

3.4 Rapid reconnection

4.1 Drive mechanism

Figure 4-1. Motor.

4.2 Catch gear

1 Opening catch gear

2 Closing catch gear

Figure 4-2. Catch gear.

Figure 4-3. Dashpot.

4.4 Limit switch with auxiliary contact

Figure 4-4. Limit switch with auxiliary contact.

4.5 Heater element

Figure 4-5. Heater element.

ABB Power Technology Products

© ABB Power Technology Products AB