IndustrialIT TM

Product Manual
1HYB 800001-25 Rev. A

EDF SK 1-1
with operating mechanism
Type FSA
Product Manual
1
HIGH VOLTAGE CIRCUIT-BREAKER-TYPE
ED 1 H Y B 8 0 0 0 0 1 - 2 6

FUNCTIONAL VALUES
1HYB800001-27
2
LUBRICANTS
1HYB800001-28
3
LOCKING LIQUID FOR THREADS
1HYB800001-29
4
GENERAL INSTRUCTIONS FOR
MAINTENANCE, TRANSPORT & STORAGE
1HYB800001-30
5
GOODS MARKING AND TRANSPORT
1HYB800001-31
6
STORAGE PRIOR TO ERECTION
1HYB800001-32
7
INFORMATION
SF6 GAS AND GAS MIXTURES
1HYB800001-33 8
SAFETY REGULATIONS
1HYB800001-35
9
DISPOSAL AND RECYCLING
1HYB800001-36
10
INSTRUCTIONS FOR ERECTION,
OPERATION AND MAINTENANCE
1HYB800001-37
11
INSTRUCTIONS FOR OPERATION
AND MAINTENANCE OPERATING
MECHANISM TYPE FSA -
1HYB800001-38
12
 1HYB800001-26 Rev. A
Page 1

HIGH VOLTAGE CIRCUIT-BREAKER TYPE ED

The high voltage circuit-breaker type ED is a detached SF6 circuit-breaker for outdoor
erection in open substations.

The circuit-breaker is built up of three separate poles, which consist of three main
parts. At the bottom the mechanism housings made of aluminium. The hollow post
insulators through which operating insulators run and on top the breaking units. Each
breaking unit consists of a hollow insulator which together with an upper and a lower
flange constitute the casing and a lower and an upper current path with a contact
system. The moving contacts are assembled on the lower current path whereas the
fixed contacts are assembled on the upper one.

The circuit-breaker poles to ED SK are permanently filled with SF6 - gas, normally to
the pressure 0.7 MPa absolute at 200C. For monitoring the pressure the circuit-
breaker is equipped with a density monitor. The poles are mounted on a common
supporting frame, consisting of a front and a rear pole beam. The latter is mounted
on two supports which are anchored to the foundations. The beams and supports are
hot-dip galvanized.

The pressure rise and gas flow which are necessary for extinguishing the arc during
the course of breaking are produced partly by compression of the gas, partly by the
energy given from the arc.

At the opening operation the moving contact is pulled downwards over the fixed
piston and the confined quantity of gas is compressed and at high speed forced out
through the springs in the upper end of the cylinder. At the same stage the arcing
contacts are separated and an arc occurs. A specially formed nozzled leads the
outflowing gas towards the arc. The gas is allowed to pass both downwards through
the moving arcing contact and upwards past the fixed arcing contact.

For the continuous current there are separate contacts which are not affected by the
arc at breaking.

At closing operation the moving contact is pushed upwards at which time the con-
tacts engage and the cylinder is filled with gas again.

The ED SK circuit-breaker is operated by a motor-operated spring closing device

type FSA.
 1HYB800001-27 Rev. A
Page 1

Functional Values
SF6 CIRCUIT-BREAKER TYPE ED-SK 1-1 WITH OPERATING MECHANISM TYPE
FSA 1

Closing time max. 60 ms

Opening time max. 35 ms
Close - Open Time *) max. 40 ms

Resistance of the main circuit across the breaking unit :

Max. 50 µW at rated current 2500 A.

*) Close - Open time means the time during which the main contacts are closed at a
closing operation when the tripping impulse is connected in simultaneously, via
the auxiliary contact.
 1HYB800001-28 Rev. A
Page 1

Types of Lubricants for Switching Devices

As a guide to the selection of Lubricants and oils, a description is given below of the
range of applications.
Oil “A” :
Thin lubricating oil for precision parts in operating mechanisms and air-blast circuit-
breakers. Also for relubricating of bearing, which can not be lubricated with grease
G without dismounting -e.g. links and link gears. Viscosity at 400C: 62-65 cSt.
Oil “C”:
Circuit-breaker oil with viscosity~17 cSt at +200C. Suitable only for temperature > -
10 0.
Oil “D” :
Circuit-breaker oil with viscosity~6.0 cSt. at +200C. Shall also be used as oil in
dashpots. For dashpots with the letter “S” stamped on the cover - oil “S” shall be
used.
Oil “S” :
Silicon oil intended for oil dashpots in heavy operating mechanisms. Only dashpots
with the letter “S” stamped on the cover shall be filled with this oil.
1HYB800001-28 Rev. A
Page 2

Grease “G” :
Low temperature grease for all types of bearings, gears and worm gears as well as
valves in air-blast circuit-breakers. Also suitable for lubrication of silverplated con-
tacts in air (e.g. contacts in disconnectors).
Also used when greasing O-rings made from nitrile rubber and as a crevice corrosion
prevention.
Grease “N” :
For lubrication of moving contacts in SF6-insulated circuit breakers (e.g. puffer
cylinders). A very thin layer of the grease shall be rubbed on the sliding surface of
the contacts.
Grease “L” :
Low temperature grease specially suitable for lubricating of fine mechanics-e.g. catch
devices in operating mechanism which shall operate in strong cold.
Grease “M” :
Low temperature grease for long-duration and permanent lubrication of worm gears
and other machine elements. Prevents wear and corrosion.
Grease “P” :

Vaseline for treatment of contact surfaces in current conductor joints.

Grease “R” :

EP-grease for heavily-loaded roller bearings, slide bearings, cam discs and catches
(Lithium grease. Solvent refined mineral oil with lithium soaps and molybdenum
disulphide) in operating mechanisms type FSA.

Grease “S” :

Fluoro-silicone grease for greasing of O-ring made from EPDM and as a corrosion
prevention of gaps in circuit-breakers type ED.

Grease “SV”

Grease for lubricating moving contacts, silver plated connections and brushed
aluminium surfaces in fixed joints outdoors.
1HYB800001-28 Rev. A
Page 3
 1HYB800001-29 Rev. A
Page 1

Locking Liquid For Threads

As guide to selection of locking liquids, a description is given below of the range of
applications.

Pre-treatment of surfaces : The surfaces shall be free from oil, grease, wax, paint and
rust-preventive. Locking Liquids “A”, “B” and “C” are designed for use in only surfaces
also.

Locking Liquid “A” : Weak locking and setting of set screws.

Locking Liquid “B” : Medium strong locking of threads and sealing of screws and
nuts.

Locking Liquid “C” : Strong locking and sealing of studs and bolts up to M36.
Difficult ot dismantle.

Locking Liquid “D” : Locking of fasteners after assembly or adjustment. Sealing

of porous weld joints, castings and sintered materials. The
sealing is very resistant against pressure, solvent and
chemicals. Can only be used on clean, dry surfaces. Oily
goods to be washed with trichloroethylene, preferably steam-
washing.

Locking Liquid “E” : To pre-treat PTFE at locking of a thread connection PTFE/

metal
 1HYB800001-30 Rev. A

General Instructions for Maintenance,

Transport & Storage

Contents :

1. Safety precautions
2. Cleanliness
3. Cleaning
4. Waste disposal
5. Emptying of gas
1HYB800001-30 Rev. A
Page 1

1. Safety precautions
Follow the local high-voltage safety regulations. Put the breaker in the “OPEN”
position.
Disconnect and earth the high voltage side.
Disconnect the operating and heating voltage.
Work on the insulators of the breaker or live parts as well as transport and
dismounting of complete breaking poles may not be done before the breaker is
emptied till a max. pressure of 0.15 MPa abs. Before the opening of the normally
pressurised vessel, it shall be emptied completely till atmospheric pressure. If the
gas will be emptied into the free air, this shall be done through a dust and absorbtion
filter. See under clause “Emptying of gas”.

2. Cleanliness
Very high dielectric requirements are placed on the SF6 gas and on the insulating
parts and correspondingly also on their cleanliness and dryness.
On all work on the open circuit breaker be aware that not only dirt but also air
moisture and hand perspiration are deleterious.
If for any reason gas spaces or parts thereof are exposed to air for longer than 24
hours, the gas spaces are to be closed temporarily and filled with SF6 gas to Pabs =
120 kPa (1.2 bar). Single parts are to be sealed in plastic bags and kept in storage.
Unused SF6 gas is non-poisonous, odourless and colourless. However, it is heavier
than air and with substantial outflow it gathers easily in low situated spaces like
cable trenches, tanks and such.
With large amount of SF6 in these spaces, there is a risk of suffocation due to lack
of oxygen.
- Only perform overhaul work with adequate room ventilation.
- The decomposition products which are formed in the breaking elements are in
combination with humidity corrosive and can cause skin, eye and mucous
memberane irritation. During the opening and internal cleaning of the breaker,
a close fitted mask with a filter against fine dust and acid gases, protective
plastic or rubber gloves and a long sleeved overall shall be used.
The dust (decomposition products), that is formed in the breaker, shall be sucked
with a vacuum cleaner provided with a dust filter and wiped off with a cloth that is
sprinkled with ethanol or toluol.
All the dust as well as the used absorbtion agent is stored in a sealed container and
is disposed off as chemical waste according to the valid provisions. During waste
disposal and handling with decomposition products, it is necessary to wear
protective gloves.
Drying cloths, protective gloves and vacuum cleaner bags shall be rinsed carefully
with plenty of water.
 1HYB800001-30 Rev. A
Page 2

3. Cleaning
A. Insulator with paint-treated plastic outside surface, silicon rubber sheds or porce-
lain insulator.
Rinse the outside surfaces thoroughly with water and let it dry well before the
breaker is opened.
The end and inside surfaces are cleaned with a non fluffy drying cloth soaked with
ethanol.
Cleaned insulators must be touched only with clean protective gloves (plastic or
rubber).
Cover the end surfaces of the insulators with a strong plastic foil to protect from
recontamination.
B. Single parts
Vacuum immediately after disassembly with a vacuum cleaner with a fine dust
filter. Wipe off persistent dust with a non fluffy cloth.
Remove stubbornly adhering dust with a cloth soaked with ethanol.
Cover cleaned details with plastic foil or put in plastic bag.
Details from spaces not filled with SF6 are cleaned with ethanol and then left to
dry in air. Then they are packed in plastic bags.

4. Waste disposal
All the dust as well as the used absorbtion agent is stored in a sealed container and
is disposed off as chemical waste according to the valid provisions. During waste
disposal and handling with decomposition products, it is necessary to wear protective
gloves.

5. Emptying of gas
The breaker is evacuated by means of the gas treatment equipment, that purifies and
compresses the gas, so that it can be reapplied.

Mixed gas - SF6 + N 2 - can only be reapplied if the mixing conditions are under
control.

After the evacuation, the breaker is filled with nitrogen up to atmospheric pressure
and after this evacuated again. In this way the eventual free drifting dust in the
breaker is removed.

Finally the breaker is filled again with dry nitrogen up till atmospheric pressure after
which it is ready for dismounting and transport till the workshop.

NOTE

If work on the circuit-breaker only affects the outside of the breaker, for example
cleaning of the insulators, it is sufficient to empty the breaker down to a pressure of
0.15 MPa abs, normal working pressure.
 1HYB800001-31 Rev. A
Page 1

GOODS MARKING AND TRANSPORT

General
Each case is marked with markings as per Packing list.
In addition they are marked with following :

- Glass, porcelain, handle carefully

- Up

- Put the lifting slings here

DO NOT TILT - It is not allowed to tilt the transport unit more than 45 degrees
MORE THAN 45”

- Centre of gravity

- Must be protected from moisture and rain

Figure 1 Transport unit

The circuit-breaker should be transported in their transport units, and particularly

never be transported unpacked. While choosing conveying equipment the
following should be observed :

• Packing case markings

• The distance and road conditions

The units should be transported in such a way that they are

- Prevented from standing in water

- Not exposed to rough handling and damages
- Covered by atleast tarpaulin, protected against water

Every transport unit must be fixed during the transport. The tying must be so
arranged that the transport units can not move in any direction. Velocity should be
adapted to the road conditions. violent acceleration or retardation can cause damage
to the contents without damaging the packing.
1HYB800001-31 Rev. A
Page 2

Lifting
Before lifting, the symbols on the transport unit (such as centre of gravity, weight
etc.) should be observed. The transport units should be lifted with a lifting machine
provided with forks of slings (see fig. 2). If a crane is utilised slings should be used.
The units may not be rolled or dropped from the conveying or lifting equipment.

Figure 2 Lifting a transport unit

Lifting the operating mechanism out of the transport unit

The operating mechanisms FSA should be lifted by the lifting devices on top of the
cubicle. Lifting slings should never be used around the operating mechanism (see fig.
3)

Figure 3 Lifting the operating mechanism

Lifting the breakers out of the transport units

Lifting the breakers out of the transport units is only necessary just before erection
(see product informatin, which can be found in the cubicle of the operating
mechanism). If they are going to be stored, see “Storage prior to erection”.
 1HYB800001-31 Rev. A
Page 3

Stacking
Transport units with different widths may not be stacked (the pressure may break the
cover of the lower transport units. It should be noted that stacking causes sideways
instability, and therefore the load has to be fixed, i.e. prevented from dropping, rolling
or falling. It is not allowed to stack more than three transport units.

Figure 4 Stacking
 1HYB800001-32 Rev. A
Page 1

Storage prior to erection

General

Circuit breakers intended for outdoor operation are generally delivered in units which
are determined for transport reasons. Intermediate storage of these units should be
avoided. If it is not possible to avoid intermediate storage, they should be stored
indoors or under a roof. They must also be stored above ground level to prevent
water damage. On arrival it is important that plastic sheet are removed in order to
prevent corrosion by condensate water (except for the spare parts).
Storage in a humid climate without proper ventilation may lead to discoloration of the
galvanised surface. This discoloration is commonly known as “white rust” consisting
mainly of zinc oxide and zinc hydroxide and is a result of a chemical process
between the pure zinc on the surface and moisture.
The long term corrosion protection is not influenced, since the iron-zinc layer below
the surface remains unaffected. The presence of white rust is no reason for rejection
of goods.
On arrival, each unit should be checked in the following way :
- delivery is in accordance with order and delivery documents
- any damage in delivery, and material loss
In cases where damages are detected or suspected, the units should be opened and
damages should be photographed. Both damages and shortages should be reported.
All details should be rationally stored so that they are always available. In general, all
material should be stored in an approved storage (note 1), exceptions are given in
the text below. The ambient air should not be heavily contaminated by dust, smoke,
corrosive or combustible gases, vapours or salt, otherwise the equipment has to be
cleaned before erection.
For storage the original transport unit may be used, but the plastic sheeting should
be removed. The coupling joints of the assemblies, as well as all connections, are
fitted with transport covers or protective caps which shall not be removed until
immediately before erection.
Operating mechanism (for circuit breakers)
The operating mechanism should be unpacked on arrival,. If it is not going to be
stored in an approved storage (note 1), the heating elements must be connected and
supplied permanently with power to protect the control equipment from corrosion or
freezing damages.
Circuit Breakers
The breakers should be stored in their original transport unit, where they are well
protected from damages. The units shall be prevented from standing in water. The
breakers may be stored outdoors, except for the EDI-breaker, which should be stored
in an approved store. If the Breakers are stored outdoors they should be covered with
a tarpaulin. (Note 1)
1HYB800001-32 Rev. A
Page 2

The tarpaulin should not be placed directly onto the galvanised surface. An air gap
should be left to prevent condensation. Condensation that may occur should be self-
draining.

For the outdoor breakers the minimum allowed ambient temperature is -300C. For the
indoor breakers the minimum allowed ambient temperature is -50C.

Spare parts

The spare parts shall be stored indoors in an approved storage (note 1), in their
original units. This is in particular valid for rubber parts (sealings etc.), which also
have to be protected against light and sun, in order to prevent them from ageing.
Gaskets can only be stored during limited periods, so avoid storage of these parts.
Structures may be stored outdoors.

Notes 1 :

We define an approved storage as a storage with

- roof
- solid ground
- relative humidity less than 50%
- temperature 200C (+/-100C)
 1HYB800001-33 Rev. A

Information on SF6 Gas and Gas mixture types SF6/CF4

and SF6/N2 when used as breaking and insulation media

Contents :

1. Introduction
2. Thermal and dielectric breaking capacity
3. Chemical reactions in Circuit Breakers
4. Criteria for choice of mixed gas
5. Filling mixed gas
6. Measuring gas mixing proportions
7. Technical data for SF6, CF4 and N 2 gases
8. Safety regulations
8.1 Safety regulations for SF6 gas
8.2 Safety regulations for CF4
8.3 Safety regulations for SF6 and CF 4 gases which
are exposed to arcs
9. Environmental effect.
1HYB800001-33 Rev. A
Page 1

1. Introduction
SF6 gas has become the predominant breaking and insulation media for circuit-
breakers of puffer and Auto-PurrferTM types.

At low ambient temperatures, below - 300 or -400C (depending on filling pressure),

there is a risk for condensation of SF6 gas resulting in drastic density changes. The
temporary condensation at low temperatures is not dangerous but can cause
problems in density monitoring and, temporarily, some reduction of breaking capacity.
One way of avoiding this is to fill sulphur hexafluoride SF6 to a lower density and fill
up to rated density with nitrogen N2 or tetrafluormethane CF4.

Information on characteristics and regulations for SF6 gas, N2 gas and CF4 gas is
stated in this product information.

2. Thermal and Dielectric Breaking Capacity

When breaking short-circuit currents the circuit-breaker must withstand two separate
stresses at somewhat different times, See Figure A.

2. Dielectric region

Figure A.
Stress on a circuit-breaker at breaking moment

Gas flow

Figure B.
Cooling SF6 arc by cold gas mixture
 1HYB800001-33 Rev. A
Page 2

These stresses are :

1. Thermal range

At current zero the hot arc channel shall be cooled down quickly to a temperature
which makes it electrically non-conductive, Figure B. Cooling capacity depends on
how quickly the current decreases towards zero, di/dt, and on the rate-of-rise of the
recovery voltage after current zero, du/dt, Figure A.

2. Dielectric range

After current zero the circuit-breaker must, for a short moment, withstand the full top
value of the transient recovery voltage without dielectric breakdown.

Breaking of terminal fault often gives low rate-of-rise of the recovery voltage and is
often a problem in the dielectric range.

Breaking of distance fault is a problem usually concentrated to the thermal area.

SF6 is an electronegative gas of high density with good characteristics in both the
thermal and dielectric ranges.

Mixed gas filling of SF 6 and N2 gives a somewhat deteriorated thermal breaking

capacity as well as a slightly deteriorated dielectric breaking capacity compared with
only SF6 gas filling. Mixed gas filling with nitrogen often results in a reduction of
breaking capacity, e.g., a rated breaking current of 40 kA is reduced one step to 31.5
kA. The deteriorated dielectric characteristics can be compensated by nitrogen gas
filling to a slightly higher pressure than with only SF6 gas.

Mixed gas filling of SF6 and CF6 results in practically unchanged thermal and
dielectric breaking characteristics. A mixed gas filled circuit-breaker with SF6/CF4
often retains its breaking capacity down to the lowest ambient temperature.

3. Chemical Reactions in Circuit-Breakers

When an arc burns in the arc chamber, part of the SF6 gas decomposes but is
quickly restored to SF6 gas when the temperature falls. Heat from the arc added to
gas, contact material, nozzle material, as well as small amounts of moisture residue,
give chemical reactions. The most important of these are :

Arc in teflon nozzle

Teflon is degraded to pure carbon and CF4 gas.

heat
CF3-(CF2)N - CF3 ➞ CF2 (1)
heat
2CF2 ➞ C + CF4 (2)

Arc in SF6 gas

heat
SF6 ➞ S + 6F (3)
1HYB800001-33 Rev. A
Page 3

The carbon which is formed according to (2) reacts with fluorine atoms which are
produced according to (3) and form CF4 gas, whereby the carbon is bound and
carbonisation is avoided.

4F + C➞ CF4 (4)

CF4, which is an electronegative gas, is therefore formed when the arc affects the
teflon nozzle and SF6 gas.

Chemical reactions between gas formation and possible moisure residue on surfaces
in breaking units.

SF4 + 2H2O ➞ SOF2 + 2HF (5)

SOF2 + H2O ➞ SO2 + 2HF (6)

Reactions between hydrofluoric acid and porcelain

SiO2 + 4HF ➞ SiF4 + 2H2O (7)

Reactions at copper-tungsten contacts

heat
SF6 + Cu ➞ SF4 + CuF 2 (8)

heat
3SF6 + W ➞ 3SF4 + WF6 (9)

Degraded gases which can appear in SF6 breakers after a number of years service
are SOF2, CF4, SiF4 and SO2.

The powder which remains in the breaker poles consists of formation of fluorides.

At gas analysis of mixed gas circuit-breakers with SF6/N2 and SF6/CF4 no other
degraded products than the above mentioned have been identified.

4. Criteria for choice of mixed Gas

By mixed gas is always understood a mixture of SF6 and nitrogen gas or SF6 and
CF4. Nitrogen gas and CF4 are both easily available at gas suppliers. CF4 is
comparatively expensive but it is a natural choice since this gas is formed already
when the arc erodes teflon nozzles in SF6 circuit-breakers. See formulae (2) and (4).

Criteria for choice of gas :

SF6 gas is chosen for ambient temperatures down to -300C or -40 0C

Gas Lowest Filling pressure at +200C Breaking data

ambient absolute pressure
temperature

SF6 -300C 0.7 MPa Depends on type of circuit-

SF6 -400C 0.5 MPa breaker
 1HYB800001-33 Rev. A
Page 4

Mixed gas is chosen for ambient temperatures down to -550C

Gas Lowest Filling pressure at +200C Breaking data in

mixture ambient absolute pressure in comparison
temperature with SF6 filling

SF6/N2 -55 0C 0.36 MPa SF6+0.34 MPa N2=0.7 MPa Reduction one
breaking current step

SF6 /CF4 -55 0C 0.36 MPa SF6+0.34 MPa CF4=0.7 MPa Retains breaking capacity

This table is only for information. It is always the relevant product information for
respective circuit breakers which is valid.

5. Filling mixed Gas

Mixed gas is always filled in such a sequence that SF6 is filled first and then CF4 or
nitrogen gas is filled up to rated pressure at +200C according to the rating plate.

By filling SF6 first a satisfactory gas mixture, without layers of gas, is always
obtained. Otherwise the mixing process takes a long time since it is based on
diffusion and convection. At gas loss, for example due to leakage, refill with correct
mixing proportions and always with SF6 gas first.

6. Measuring Mixing Proportions

Mixing proportions for mixed filling can be measured by DILO “SF6 Percentage
Measuring Device 3-027”.

The instrument measures the sound velocity of the gas mixture and it is calibrated for
SF6/N2 gas. The instrument shows directly on the display the volume of the SF6 part

If the instrument is used to measure SF 6/CF4 gas mixture, the result shown on the
display must be corrected according to figure C. (Example: if 51% is read on the
instrument the SF6 part is 0% and the CF 4 part 100%)

100
SF6 (%)
In 90
SF6/CF4
80

70

60

50

40

30

20

10 DILO

0
50 60 70 80 90 100 DISPLAY
Figure C.
SF6 part in SF6/CF4 gas as a function of
the shown result on the display of DILO 3-027.
1HYB800001-33 Rev. A
Page 5

7. Technical Data for SF6, CF4 and N2 Gases

General SF6 CF 4 N2
information: Max. bottle pressure
at 200 C 2.3 MPa 13.7 MPa 20 MPa

Valve thread (local G5/8A-RH CGA580 G5/8A-RH

& national deviations
can occur)

Material recom- No re- Avoid None

mendation strictions zinc
magnesium

Hygienic limit: 1000 ppm - -

Characteristics: No colour No colour No colour

or smell or smell or smell

Health risks : Suffocating Suffocating Suffocating

Transport: ADR ADR ADR

Class 2.5(a) Class 2.1(a) Class 2.1(a)

Storage: - Group 1A Group 1A

Physical data: Molecular weight 146.05 88.01 28.01

Boiling point
at 1.013 bar 0C -63.8 -127.94 -195.8

Density
(1.013 bar 150C)kg/m3 6.25 3.74 1.185

Vapour pressure
at 00C MPa 1.26 - -

Vapour pressure
at 200C MPa 2.3 - -

Combustible Non-combust. Non-combust. Non-combust.

range in air

Specific volume m3/kg

(1.013 bar, 150C) 0.160 0.268 0.844

Critical temperature 0 C 46

Critical pressure MPa 3.7

 1HYB800001-33 Rev. A
Page 6

8. Safety Regulations
8.1 Safety Regulations for SF6
“SAFETY REGULATIONS FOR SULPHURHEXAFLUORIDE”

HEALTH RISK

Sulphurhexafluoride is considered to be an inert gas.

INHALATION of very high gas content can cause headache, giddiness and
risk for unconsciousness and suffocation due to lack of oxygen.

SPECIAL CHARACTERISTICS AND RISKS

At high temperatures degraded products, which cause irritation, can be formed.

PREVENTIVE MEASURES

Good ventilation
Safeguard gas bottles with chains

PERSONAL PROTECTIVE EQUIPMENT

Inhalation apparatus for use at suffocating gas content.

FIRST AID

Inhalation: fresh air, rest

SPILLAGE AND DEGASSING

Airing

MEASURES AT FIRE

Gas containers near the fire must be removed immediately or cooled with
water.

8.2 Safety Regulations for CF4 gas

“SAFETY REGULATIONS FOR TETRAFLUORMETHANE”

HEALTH RISK

Tetrafluormethane is considered to be an inert gas.

INHALATION of very high gas content can cause headache, giddiness and
risk for unconsciousness and suffocation due to lack of oxygen.

SPECIAL CHARACTERISTICS AND RISKS

At high temperatures degraded products, which cause irritation, can be formed.

PREVENTIVE MEASURES

Good ventilation
Safeguard standing gas bottles with chains
1HYB800001-33 Rev. A
Page 7

PERSONAL PROTECTIVE EQUIPMENT

Inhalation apparatus for use at suffocating gas content.

FIRST AID

Inhalation: fresh air, rest

SPILLAGE AND DEGASSING

Airing

MEASURES AT FIRE

Gas containers near the fire shall be removed immediately or cooled with
water.

8.3 Safety Regulations for SF6 and CF4 gases which are exposed to arc
HEALTH RISK

Air humidity together with degraded products can cause irritation of skin,
eyes, and mucous membrances.

INHALATION of very high gas content can cause headache, giddiness and
risk for unconsciousness and suffocation due to lack of oxygen.

SPECIAL CHARACTERISTICS AND RISKS

Since the gas has been exposed to high temperatures degraded products,
which cause irritation, have been formed.

PREVENTIVE MEASURES

Good ventilation.
Gas from circuit-breakers can be recovered in gas treatment equipment and
reused.

PERSONAL PROTECTIVE EQUIPMENT

Fresh air mask or mask with filter against fine dust and gases with acid content.
Plastic or rubber gloves.
Overalls with long sleeves
Vacuum cleaner with filter for fine dust

FIRST AID

Inhalation: fresh air, rest

Skin and eyes: rinsing with water

 1HYB800001-33 Rev. A
Page 8

SPILLAGE AND DEGASSING

Airing
Dust and filters are stored sealed and handled as chemical refuse according
to local regulations.

MEASURES AT FIRE

Gas containers near the fire must be removed immediately or cooled with
water.

9. Environmental Effect
SF6 and CF4 gases can leak out into the surrounding environment due to leakage in
the circuit-breaker.

CF 4 and SF6 are very stable gases and make no detectable contribution to ozone
destruction and photochemical smog, and they have negligible influence on the green
house effect. The latter applies especially when used in circuit-breakers where, from
the global point of view, gas volumes are small.
 1HYB800001-35 Rev. A
Page 1

Safety Provision and Assembly Instructions for Circuit-

Breakers with Operating Device.
Read carefully the entire Assembly Instruction before starting assembly work.

WARNING TEXTS

Warning texts are stated in 5 different degrees of urgency which should be carefully
observed. These are described below :

DANGER indicates an immediate risk situation that can lead to death or serious
personal injury if not avoided.

DANGER

Warning indicates a risk situation that can lead to death or serious personal injury if
not avoided.
Warning

Caution indicates a risk situation that can lead to small or moderate damage.
Caution

Note Note is used when there is danger that can lead to equipment damage only.

Important Important indicates an operation or a suggestion for handling.

1HYB800001-35 Rev. A
Page 2

1. Safety Regulations
When working on high-voltage circuit-breakers the below-mentioned risks must be
taken into consideration and corresponding safety measures taken.

RISK MEASURE

1. Work next to high-voltage Warning plate placed inside the door to the
operating device

Disconnect and earth near the workplace. If work

must be carried out near energized parts of the
plant, it has to follow local safety regulations of the
organisation responsible for the circuit-breaker.

2. Work on ladders and platforms The work shall follow the directions of the Authority
for occupational safety and health. Avoid work in
severe weather conditions which entails a great
deal of climbing for short periods.

3. Work with low-voltage. Do not connect control or heating voltage until all
Both D. C. and A. C. voltage can have been connection work is completed.
drawn on the operating device.

4. Squeezing risk in operating device and Warning plate is placed on the supporting frame.
link system.
No work must be carried out unless the closing and
The spring operated device has energy opening springs are uncharged and the circuit-
stored in the closing spring. The opening breaker in position OFF “O” disconnect voltage to
spring, which is on the mechanism housing of the motor.
pole C1, or on every pole for one-pole
- The operating device must not be operated
operation, has energy stored. The device can
unless it is connected to the circuit-breaker
be activated by heavy vibrations or
and the electric cables are connected. The
unintentional, slight touch on mechanical
circuit-breaker shall be filled with SF6 gas to
latch parts.
a pressure of 0.7 MPa. The closing springs
should for safety reasons be uncharged
during transport and when the circuit-breaker
is off duty.

5. Work on pressurized porcelain insulators. Work close to the insulators of the circuit-breaker,
Normally, the work pressure is up to 0.7 MPa. which entails risk to damage the porcelain, must
Damage in the porcelain can cause risk for not be carried out until the gas pressure has been
the porcelain to break, lowered to 0.125 MPa absolute pressure.
 1HYB800001-35 Rev. A
Page 3

2. Unpacking
Place the case hoizontally on a flat surface before opening the cover.

Check that all parts are included in the delivery. Check-off on the accompanying
packing list.

Check that no parts have been damaged during transport; especially the porcelain
insulators.

Report any faults immediately to the ABB Representative.

 1HYB800001-36 Rev. A

Disposal and Recycling

Information

The information in this document is subject to alteration without prior notice and should not be regarded as an
undertaking from ABB Limited. ABB Limited takes no responsibility for errors that can occur in the documen-
tation.

ABB Limited 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 Limited.
It may not either be imparted to third pary or otherwise be used without authorisation. Infringement hereof will
be subject to action in accordance with applicable laws.

© ABB Limited
 1HYB800001-36 Rev. A

Contents

1. Disposal and recycling

1.1 General
1.2 Taking care of spent equipment
1.3 The circuit-breaker’s component parts
1.4 SF6-gas
1.5 Porcelain
1.6 Electronics
1.7 Metals
1.8 Plastics
1.9 Oils and greases
1.10 Rubber
1.11 Other materials
 1HYB800001-36 Rev. A
Page 1

1. Disposal and recycling

1.1 General

ABB Limited attempts to minimize environmental impact during the entire product’s
service life. Environment aspects are held in focus during technical and product
development. We always try to consider the eco-cycle while the material’s impact on
the environment and possibilities of recycling are observed. Manufacturing processes
are selected that are as gentle as possible on the environment.

1.2 Taking care of spent equipment

Spent products should be taken out of service in an environmentally correct manner
according to the following instructions.

When discarding used equipment a great deal of material and the energy content of
the material can, after sorting and cleaning, be recycled. The degree of material that
can be recycled varies depending on the technical resources and experience
available in respective countries.

Non-recyclable components shall be left at an approved recycling centre for

destruction or disposal.

1.3 The circuit-breaker’s component parts

A circuit-breaker contains approximately 30 weight % metal. Primarily iron, steel and
aluminium. Rubber and different plastics make up approximately 0.5% each and
chemicals and gas less than 0.5%. The greatest weight share in a circuit-breaker,
virtually 70%, is made up of porcelain.

1.4 SF6-gas
The SF6-gas must be emptied before discarding a circuit-breaker. Care shall be
exercised in accordance with applicable regulations with all handling of SF 6-gas, to
prevent gas leakage. The gas can be taken care of in different ways depending on
the circumstances :

● Regenerated on site, and reused in other equipment

● Sent to a gas supplier for regeneration
● Sent for destruction at a special waste disposal centre

In those cases where the circuit-breaker is filled with mixed gas, the SF6-gas is
separated from the mixture for continued handling as set out above. Alternatively, the
gas mixture can be sent for destruction without being separated.

ABB Limited will willingly take care of the gas when the circuit-breaker is to be
discarded.
1HYB800001-36 Rev. A
Page 2

1.5 Porcelain

Porcelain can, after cleaning, be left for disposal or used for other purposes, for
example, as a filling material.

1.6 Electronics

Leave electronic equipment at an approved recycling company or sort in its

component parts and take care of accordingly.

1.7 Metals

Sort metals according to type and surface finish and leave at an approved recycling
company. After the removal of any paint or other surface treatment the metal can
generally be melted down and used in new products. Many iron, steel and aluminium
parts are large and easy to identify, for example, the frame and mechanism housing.

ABB Limited aims for a reduction in the use of noble metal, or with discharge
environmentally hazardous metals. Recycling of these is extremely important.

Noble metals such as copper and silver are expensive and only occur is small
quantities in the earth’s crust. Copper is primarily used in the current paths, puffer,
contactors and cables. Silver plating of contactors can occur. Some metals can cause
damage if discharged. This applies, among others, to copper, but also to zinc and
nickel which are used sparingly in the form of surface treatment.

1.8 Plastics

Separate different types of plastic and leave at an approval recycling centre or

recycling company. The energy content in thermoplastics and thermosetting plastics
can frequently be recovered through combustion in purpose built installations.
Generally, thermoplastics can be melted down and used again without degrading
quality too much. Composites can be fractionised and used as filling agent in other
materials or be left for disposal.

Composites found in small quantities in isolators, pipes and cable glands consist of
thermosetting plastic. Thermoplastics can be found in components such as guide
rings, belts bushings and support rings. Thermoplastic in ferrules, nozzles, pipe and
collars contains fluorine and is not suitable for recycling, however, it can be disposed
of without the risk of leaking hazardous substances.
 1HYB800001-36 Rev. A
Page 3

1.9 Oils and greases

Empty oils, grease and the like before discarding and leave at an approved recycling
centre or at a recycling company. Oil waste can be separated into oil, water and
different contamination through the use of gravimetric forces. In many cases the oil
can be reused. Alternatively, the oil’s energy content can be recovered through
combustion in purpose built installations.

Oil can be found in dashpots and grease is used as a lubricant.

1.10 Rubber

Rubber can be left at an approved recycling centre either for disposal or reused for
different purpose.

Rubber can be found in seals.

1.11 Other materials

Sort and leave other materials at an approved recycling centre.

 1HYB800001-37 Rev. A

Instructions for Erection,

Operation and Maintenance

Contents :

1. General
2. Construction
3. Function
4. Erection
5. Commissioning
6. Troubleshooting
7. Maintenance
8. Spare Parts
11. Appendix
1HYB800001-37 Rev. A

Contents Page 7.4.1 Taking the circuit breaker out of service 26

7.5 Removal of breaker poles 26
1. General 1 7.5.1 Dismantling of the SF6 gas
1.1 Validity 1 connecting lines 26
1.2 Type designation 1 7.5.2 Removal of breaker poles with crank
1.3 Specification 1 mechanism 26
1.4 Masses 1 7.6 Disassembly of breaker pole 27
1.5 Storage 1 7.6.1 Breaker pole disassembly 27
7.6.2 Disassembly of fixed contact 28
2.. Construction 1
7.6.3 Disassembly of moving contact 28
2.1 Breaker pole 2
7.6.4 Cleaning 28
2.2 SF6 gas supply system 2
7.7 Maintenance of the assemblies 28
3. Function 2 7.7.1 Maintenance of the fixed contact 28
3.1 Control and monitoring 2 7.7.2 Maintenance of moving contact 29
3.2 Switching operations 2 7.7.3 Maintenance of crank mechanism 29
3.2.1 Starting conditions 2 7.8 Assembly of breaker pole 30
3.2.2 “CLOSING” 3 7.9 Erection of breaker poles 32
3.2.3 “OPENING” 3 7.10 Maintenance of spring operated mechanism 32

4. Erection 3 8 Spare parts 33

4.1 General 3 8.1 General 33
4.1.1 Preparations 3 8.1.1 Important notes 33
4.2 Erection procedures 4 8.1.2 Ordering of spare parts 33
4.2.1 Mounting of spring operated mechanism 4 8.2 Spare Parts 33
4.2.2 Fitting of connecting rod 4 8.2.1 Set of contacts 33
4.2.3 Fitting of density monitor and 8.2.2 Set of gaskets, springs & fasteners 33
matching cables 5 8.2.3 Complete set of gaskets for gas supervison 33
4.2.4 High-voltage connections 5 8.2.4 Set of gaskets for crank mechanism 34
8.2.5 Spare parts of spring operated mechanism 34
5. Commissioning 5
8.2.6 Tools for EDF SK 35
5.1 Starting conditions 5
8.2.7 Gas Equipment 35
5.2 Filling of SF6 gas to nominal
8.2.8 Safety Disc unit 36
filling pressure
5.2.2 Filling of mixed gas to nominal filling
11 Appendix 37
pressure 6
11.1 Figures 37
5.3 Function test 7
5.3.1 Trial switching operations 7
5.3.2 Anti-pumping device 8
5.3.3 Check of heaters 8
5.4 Concluding work 8
5.5 Checklist for assembly & commissioning 9

6 Troubleshooting 13
6.1 SF6 gas supply system 13
6.2 Control Circuits 13

7 Inspection intervals 14
7.1 Maintenance concept
7.1.1 Table of parts to be serviced
7.2 Tools, jigs and fixtures and
additional parts 26
7.2.1 Additional parts 26
7.3 Procedures 26
7.3.1 General 26
7.4 Preparations for maintenance 26
 1HYB800001-37 Rev. A
Page 1

1. General
1.1 Validity
These operating instructions are applicable for the high voltage circuit breaker type EDF.

1.2 Type designation E D F SK 1 - 1

SF6 gas insulation

Generation

Outdoor design

Extinction chamber type

Breaker construction

Code BIL Rated voltage

1 = 325 k V = 72.5 kV
Number of chambers

1.3 Specifications
Specifications are contained in the order documentation and on the nameplate (Fig. 1/1)

The diagrams contained in these instructions are schematic diagrams and serve to
illustrate functional relationships.

1.4 Masses
The mass of a 3-pole circuit breaker can be obtained from the order documentation
and the shipping documents.
For internal transport purposes see Fig. 1/2.

1.5 Storage of breaker components before erection

Breakers intended for outdoor operation are generally delivered in units which are
determined by means of transport. Before erection, these units shall be stored
indoors or under a roof as long as possible. If the units will be stored outdoor, they
must be blocked up to prevent them from standing in water pools. With outdoor
storage under long time, the units shall be covered with tarpaulin and the heating
elements of the operating mechanism shall be connected.

2. Construction (Fig. 2/1)

The Circuit breaker type EDF SK 1-1 (10170) is a three-pole SF6 gas circuit breaker and
designed as column type circuit breaker with a spring stored-energy operating mechanism
mounted beneath the middle ople. It consists essentially of :

- Three breaker poles 10171

- Support frame 10172
- Control cubicle with spring operated mechanism and connecting rod 10173
- density monitor 10112
- breaker support 10174.
1HYB800001-37 Rev. A
Page 2

2.1 Breaker pole (Fig. 3/1 a,b)

The breaker pole consists essentially of :
- upper terminal flange, 10099 *)
- insulator for breaking chamber 10106
- fixed contact, compl 10030
- moving contact, compl 10013
- lower terminal flange 10108, post insulator
- crank mechanism 10185

*) On this flange there is a cover that easily can be exchanged to a safety disc
unit if the customer wishes.

The poles are filled with SF6 gas and connected to header block by means of
pipelines. (Fig. 4/1a, c)

2.2 SF6 gas supply system (Fig. 4/1a).

The gas supply system consists of :

- An SF 6 gas density monitor 10112 with header block 10118

- Non return valve 10092

- SF6 gas line 10177/a, 10177/b and 10178.

3. Function
3.1 Control and monitoring (Fig. 3/2)
The schematic diagram of the control shows how the switching commands enter the
circuit breaker control circuit, which monitoring elements are installed to detect any
occurring failures, and which signals are thereby triggered.

The control circuit itself can be seen in the order related circuit diagram.

- Monitoring elements :
SF6 gas density :
The density monitor 10112 (temperature - compensated pressure monitor)
monitors the SF6 gas pressure in the breaker poles and gives a ‘low pressure
alarm’ in case of minor gas losses. If the gas density drops to a value below the
blocking pressure curve according to Fig. 5/1, “CLOSE” and “OPEN” operations
are blocked and an alarm signal is given.

3.2 Switching operations (Fig. 3/1 a, b)

3.2.1 Starting conditions

- Circuit Breaker is filled to nominal gas pressure.

- Operating mechanism in breaker position b 2 (Fig. 2/1), which means closing
spring charged and circuit breaker in open condition.
 1HYB800001-37 Rev. A
Page 3

3.2.2 “CLOSING” (Fig. 3/1b)

- To close the circuit breaker closing coil lever is energised, whereby the closing
spring is released. This moves the moving contact upward, thereby first closing
the arcing contact “g-h”, and then the main current contact “k-l”.

3.2.3 “OPENING” (Fig. 3/1a)

- To open the circuit breaker Trip coil lever is energised, whereby the trip spring
is released. This moves the moving contact downward, thereby first separating
the main current contact “k-l”, and then the arcing contact “g-h”. During this
movement the piston compresses the SF6 gas in the cylinder. The arc between
the contacts increases the compression pressure. In the area of the current
zero a gas flow occurs which extinguishes the arc.

4. Erection
4.1 General
- All adjustments are made in the factory. All moving parts to be coupled are
already positioned correctly and fastened.

- It is advisable to keep the transport packings of the pole columns, thereby

facilitating eventual transport on subsequent overhaul work.

- To prevent the absorption of any moisture, the pole columns are filled with
insulating gas Pabs = 150 kPa (=1.5 bar = 22 lbf/1 in2).

4.1.1 Preparations for erection

The following shall be prepared and provided before erection.

- An erection crane with a carrying capacity of about 850 kg (=1,870 lb) and a
crane hook height of at least 4m (=13 ft) above the floor
- Lifting sling
- Dimension drawing, erection drawings and circuit diagrams
- Circuit breaker material according to the erection drawings
- Torque wrench for a range of 6-200 Nm and socket tool 24 mm (Conn. 3/8”)
- Open-end wrenches for bolts M6-M16 and 1/2” UNC and open-end wrench for
36 mm.
- A thermometer for ambient temperature.
- Gas filling equipment.
- SF6 leak detector.
- SF6 Gas cylinder
1HYB800001-37 Rev. A
Page 4

4.2 Erection procedures

- Lift the complete assembled circuit breaker with the crane, according to Fig 4/2.

- Check SF6 gas pressure by pressing the disc of the check valve inwards with a
pin of approximately f5. A distinct hiss shall then be heard. If there is no
hissing sound the pole has a leak, which must be attended to.

- Place supports 10174 on the prepared foundation. The upper bearing surfaces
for the pole support must be horizontal and must lie in one level. Screw
supports tight to the foundation (Observe MD) (Fig. 2/1).

- The exact location can be obtained from the installation layout plan. During the
erection, make sure that the fixation holes for the earthing connection are
positioned correctly (Fig. 2/1)

- Mount frame 10172 with assembled poles 10171 on supports 10174 with
fasteners 49069, 49622 and 89027. (Observe MD) (Fig. 4/1a)

4.2.1 Mounting of spring operated mechanism FSA I :F 10173 (Fig. 4/1a)

- Place cubicle in correct mounting position between the supports on wooden

underlayments.

- To mount mechanism on the frame lift operating mechanism upward by 4 lifting

bolts, insert staybolts in the holes provided for them and fasten with the
accompanying fasteners “h”. (Observe MD).

Be careful! The pole in the middle must not be damaged by Lifting ropes.

Ensure that there is no washer between frame and stay bolts.

Attention !

During mounting of mechanism ensure that the upper joint head of the connecting rod is
inserted into the fork of the actuating lever 10154.

4.2.2 Fitting of connecting rod

Starting conditions :

Position indicator and spring tension indicator indicate position “b1” and
“Untensioned”. (Fig. 2/1)

- The operating mechanism and the circuit breaker are to be coupled together in
the OPEN position.

- Turn actuating lever on breaker all the way in the direction of the operating
mechanism. For correct position see (Fig. 4/1b).

- The connecting rod is already adjusted in the factory.

- However, if the bores of the actuating lever and joint head do not correspond, the
connecting rod length must be corrected.

- This is done by releasing the lower fasteners “g” (Fig. 4/1a), and by lowering
the cubicle enclosure.

- Release locknuts “h” and “k” of the connecting rod (Fig. 4/1b), turn connecting
rod, hold against turning and tighten locknuts (Observe MD).
 1HYB800001-37 Rev. A
Page 5

- Adjust connecting rod so it can move freely in the joint heads. Treat cylinderical
pin in the upper coupling with grease G (Mobile 28)

- Lift cubicle enclosure and fasten with the lower fasteners “g”.

4.2.3 Fitting of density monitor 10112 (Fig. 4/1a) and cables

- Connect density monitor 10112, cables and possible pressure gauge according
to fig. 2/1, 4/1a, 4/1c.

4.2.4 High-voltage connections (Fig. 4/1a)

The high voltage connection fasteners consist of screws M12 (St. 8.8) and
atleast 1 washer 13/28x3 and 1 lockwasher 13.5/28x1.6 on each side of each
bolt (Observe MD)

5. Commissioning
All data which are checked or measured are to be entered in a commissioning record
and preserved for comparisions.

The SF6 gas pressure can be seen on the circuit breaker nameplate.

5.1 Starting conditions

The erected circuit breaker is isolated from the high-voltage system and earthed
according to regulations. The control current circuits are connected to the low-voltage
system.

5.2.1 Filling of SF 6 gas to nominal filling pressure (Fig. 5/1)

As the circuit-breaker poles are delivered vacuum processed and filled with SF6 gas
at a transport pressure of 0.150 MPa abs (200C), during commissioning only one
filling of SF6 gas is required, to top up pressure up to the filling pressure given on the
rating plate.

It is appropriate to carry out pressuring directly from an SF6 gas bottle. In order to
avoid risks at the first filling, due to possible transport damages to the porcelain, the
gas bottle with filling equipment shall be placed as far from the circuit-breaker as
possible, and preferably behind some shield. Pole columns are connected to the
header block by pipes. Connect the hose from the gas filling equipment to the SF6
gas filling valve on the header block L10118 (Fig. 4/1c).

- SF6 gas filling (Fig. 4/1d)

● Place gas cylinder (1) in a protected area.

● Check the filling pressure and any gas mixture (at ambient temperature
lower than -300C) on the circuit breaker’s rating plate.
● Fit the regulator (3) on the gas cylinder using appropriate coupling (2)
supplied with gas filling device. Use the pressure gauge (9) for filing gas in
circuit brekaer.
● Lubricate the sealing rings supplied with density monitor (7) with grease
“G”.
● Fit the density monitor on the gas valve (8) on the breaker.
1HYB800001-37 Rev. A
Page 6

● Connect coupling (4) supplied loose with gas filling bag to the non-return
valve on the hose of gas filling device.
● Connect above assembly to the circuit breaker’s gas valve (5).
● Open regulator to fill gas in circuit breaker to rated pressure as per fig. 5/1.
● Allow the pressure to stabilise in the circuit breaker for some time. Check
the pressure and adjust if necessary.
● Dismantle the hose coupling assembly from the gas valve on the circuit breaker.
● Close the valve on the gas cylinder.
● Disconnect regulator with hose from gas cylinder.
Breaker is now ready for functional test as per section 5.3.

In the filling process the dependence of the nominal pressure on temperature

(Fig. 5/1) must definitely be taken into account. After a temperature equalization
period of approx. 1 hour, check the pressure and correct if necessary by
adding or releasing gas. Check all sealing joints on the breaker poles and the
gas supply system for leaks with a leak detector. Repair any leaks found
according to chapter 6.

5.2.2 Filling of mixed gas to nominal filling pressure

When the breaker is to be placed in a climate where the temperature goes below
-300C, the circuit-breaker shall be filled up with “mixed gas” instead of pure SF6-gas.

In order to avoid condensation when the temperature is below -30 0C the SF6-gas is
mixed with N2 (Nitrogen gas).

Selection of gas-mixture :

Gas mixture Breaking capacity

Rated breaking current Power frequency

SF6/N2 25 kA 50 Hz
20 kA 60 Hz

The total filling pressure for mixed gas is stated on the breaker’s rating plate. The
circuit-breaker poles are delivered vacuum processed and filled to the pressure
0.150 MPa abs (20 0). At taking into service the SF6-gas-part is to be filled to 0.36
MPa at 200C first and then the N 2-gas part up to the total filling pressure stated on
the rating plate.

Normally the gas filling mixture SF6/N 2 at 200C is :

0.36 MPa SF6 + 0.34 MPa N2 = 0.7 MPa abs.

When filling gas after a possible leak, fill with SF6-gas respective N2-gas in proportion
as above. For instance : a leakage to the blocking level 0.6 MPa gives with SF6/N 2
refilling :
 1HYB800001-37 Rev. A
Page 7

0.36
SF6-gas ● 0.1 = 0.051 MPa SF6 at 200C
0.7

0.34
N2-gas ● 0.1 = 0.049 MPa N2 at 200C
0.7
In the filling process the dependence of the nominal pressure of temperature must
definitely be taken into account.

In Fig 5/1, use graph 4 for SF6 -gas filling and graph 1 for N2-gas filling.

5.3 Function test

Ensure corresponding order documents are available and that the connections have
been made accordingly. Then the trial switching can be performed from a protected
position.

Trial switching may only be performed if :

- the circuit breaker is isolated from the high voltage system and earthed
according to regulations.
- the SF6 gas or mixed gas is at nominal pressure.
- the spring tension indicator of the spring operated mechanism indicates the
position “b2” (Fig. 2/1) “Tensioned”.

5.3.1 Trial switching operations (Fig. 5/2a,b)

The switching times are measured with a time recorder. The diagram of a standard
measuring arrangement is shown in Fig. 5/2a. Every breaker pole has its own
measuring circuit. The time diagrams in Fig 5/2b serve solely for explanation of the
time concepts used.

- Closing (C) (Fig. 5/2b)

The closing time “t1” < 60 ms is the time from the instant the command is
issued until the contacts in the arcing chambers touch. It is to be measured for
each breaker pole. The maximum allowable non-simultaneity between the
breaker poles is Ut 1 < 4 ms.

- Opening (O) (Fig. 5/2b)

The Opening time “t2” < 35 ms is the time from the instant the command is
issued until the contacts in the arcing chambers separate. It is to be measured
for each breaker pole. The maximum allowable non-simultaneity between the
breaker poles is U t2 3 ms.

- CLOSE-OPEN switching (C-O) (Fig. 5/2b)

The close-open time “t3” < 40 ms is the time form the instant the contacts touch
until they separate in the arcing chamber in a “CLOSE-OPEN” switching
operation. For the measurement the terminals “K1” and “K2” on the close-open
switch “M3” (Fig. 5/2a) are short circuited.

- Rapid reclosure (O-C-O)

The rapid reclosure can only be tested with the test equipment of the
installation.
1HYB800001-37 Rev. A
Page 8

5.3.2 Anti-pumping device (Fig. 5/2a)

- Issue a “CLOSE” command by applying a control voltage to terminal 2. Leave

the voltage applied.
- Issue a “OPEN” command by applying a control voltage to terminal 6.

After the interruption by the OPEN command the circuit breaker should not reclose in
spite of the close command still being present.

5.3.3 Check of heaters

Measure resistance or apply voltage and measure the current. When the
thermostat-controlled additional heater is installed, check the adjustment of the
thermostat.

5.4 Concluding work

- Remove all test and measurement equipment.
- Connect the circuit breaker to the high-voltage power lines, making sure that
the safety regulations are observed.
- Take the circuit breaker into service.
 1HYB800001-37 Rev. A
Page 9

5.5 Checklist for assembly and commissioning

1 DATE :
2 PLATE OF INSTALLATION :
SERIAL NUMBER
3 NAME PLATE DETAILS :
Circuit breaker type : eg EDF SK 1-1
Rated voltage : kV Normal Current A
Sr No : Gas Pressure SF6 / 20 deg.C. (abs): bar
Lightning Impulse withstand voltage : kV
Short circuit breaking current : kA
Short time withstand current 3s kA
Line charging breaking current : A
Closing & Opening supply voltage : VDC
Operating sequence : O - 0.3 s - CO - 3 min - CO
First pole to clear factor : 1.5

STORAGE YES NO
1 a Complete material is available as per packing list ?
If NO mention the shortages :
b Instruction manual available ?
c G.A. and erection drawing available ?
d Schematic drawing available ?
2 a Operating drives box stored indoor ?
b Accessories box stored indoor ?
c Was the outdoor equipments stored above HFL (Highest flood level ) ?
d Any equipment damaged during re-transportation / unloading at site ?

ERECTION YES NO
1 Is foundation and location of equipment as per G.A. drawing ?
2 STRUCTURE ERECTION
a Is length of the foundation bolts (projecting outside) sufficient to put checknuts ?
b Is there levelling nut available below structure ?
c Is the top side of the structure base plate as per G.A.. Drawing ?
d Is direction of the structure as per G.A. drawing ?
e Is the structure levelled in x , y and z axis as per G.A. drawing
X = Pole to pole distance (Measuring tape)
Y = Structure Height (Water tube level)
Z = Alignment of all the structures in one line (Line thread)
f Tightness of the nuts and checknuts done ?
g Are the foundation bolts filled with mortar ?
h Are the serial nos of all the equipments matching with the serial numbers
mentioned in the packing list ?
1HYB800001-37 Rev. A
Page 10

3 BREAKER POLES ERECTION : YES NO

a Is there any chipping on the sheds of insulators ?
If YES what is the size of chipping ?
Can erection work proceed further ?
DO NOT PROCEED FURTHER , IF CHIPPING IS UNACCEPTABLE
b Is 0.5 bar positive pressure verified in the breaker poles?
Verification to be done by pressing the gas valve after opening the cover.
c Any damage observed on gas pipe while mounting the breaker poles
on the structure ?
d Any washers left in between the breaker pole channels and the structure ?
DO NOT PROCEED FURTHER BEFORE REMOVING THE WASHERS
e Applicaion of Torque on all the mounting bolts ?
If YES , mention the values :
1. Foundation bolts Nm
2. Structure hardware Nm
3. Pole mounting bolts Nm
4 FIXING OF OPERATING MECHANISM
a Is there any ingress of water found inside the mechanism?
If YES : DO NOT PROCEED FURTHER BEFORE OVERHAULING OF THE MECHANISM.
b Is following procedure adopted for fixing the mechanism?
● Ensure that breaker poles are in fully OPEN position.

● Lift the mechanism and fix the 04 mounting bolts with the pole beam.

● Match the Eye-bolt of the mechanism connecting rod with the lever on pole.

● Apply thin layer of grease on the pin before inserting in the eye bolt.

● After insertion of pin, tighen the locking screw with locking washers.

6 GAS FILLING AND LEAKAGE TEST :

Prerequisite for SF6 gas filling :
● Thermometer

● Temperature v/s pressure chart

● SF6 gas cylinder

● Gas filling kit

● Suitable right / left adaptor (Gas cylinder)

● Spanners

● Cloth

● Cleaning agent

a Presence of positive pressure checked in breaker poles.

If NO , Fill the pressure in that particular pole upto 2.0 bar absolute and sniff
all the pole including gas pipe with the leak detector and find the leakage.
If no leakage is found , continue gas filling and if any leakage is found ,
first ATTEND the leakage point before proceeding further.
b Is the gas monitoring system fixed as per G.A. drawing ?
c CALIBRATION OF DENSITY MONITOR / SWITCH.
AMBIENT TEMPERATURE AT SITE DURING CALIBRATION OF
DENSITY SWITCH & SF6 GAS FILLING IN POLES> DEG.C.
IS THERMOMETER AVAILABLE?
GAS FILLING KIT IS AVAILABLE?
BLOCKING DEBLOCKING

CONTACT / SETTING VALUES IN ABS.BAR

 1HYB800001-37 Rev. A
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REFILL ALARM
OP. BLOCK –I
OP.BLOCK – II
TIME AT WHICH CALIBRATION DONE : AM / PM
e SF6 GAS PRESSURE FILLED AFTER CALIBRATION OF DENSITY SWITCH
● SF6 gas filled in the breaker : Bar
● Temperature at which gas filled . degree C
● Time at which gas filled AM / PM
f SF6 GAS LEAKAGE TEST : YES NO
● Is Leak detector available?
● If NO , do not proceed further till leak detector is arranged.

● Is the complete SF6 gas system in the breaker (which includes pole,

gas pipes & density switch / monitor ) free from any SF6 gas leakage ?
● If NO , describe leakage found from which joints :

7 COMMISSIONING :
a Connection of density switch cables :
●Density switch cable
closing circuit terminals : &__
trip 1 circuit terminals : &__
trip 2 circuit terminals : &__
b Control coil resistance :
CLOSE COIL : W
TRIP COIL - 1 W
TRIP COIL - 2 W
c Requirment of DC control voltage in ideal condition : dc
Measured control voltage dc
SWITCH “ ON “ AC / DC supply.
d Local operation of the breaker ( electrically) :
Local closing operation OK
Local tripping operation for trip coil 1 OK
Antipumping function OK
* Open command provided directly on terminal number :
e Remote operations :
Close command given on terminal number :
Open command (T1) given on terminal number :
Open command (T2) given on terminal number :
f SPARE CONTACTS OF AUXILIARY SWITCH :
● Position of the breaker : TRIP
● Serial number of contacts found NC :

● Serial number of contacts found NO :

● Position of the breaker : CLOSE

● Serial number of contacts found NC :

● Serial number of contacts found NO :

g BREAKER OPERATING TIMES

OPERATION LIMIT PHASE Measured value

CLOSING < 60 milliseconds A ms

B ms

C ms
1HYB800001-37 Rev. A
Page 12

OPENING ( T1 ) < 35 milliseconds A ms

B ms

C ms

OPENING ( T2 ) < 35 milliseconds A ms

B ms

C ms

CO ( through T1 ) < 40 milliseconds A ms

B ms

C ms

CO ( through T2 ) < 45 milliseconds A ms

B ms

C ms

h Are all the space Heaters in operating mechanism working? YES NO

I Tightness of all the electrical terminals verified?

j Is GAS leakage , once again verified after timing and operation?

SF6 GAS PRESSURE AFTER COMPLETION OF JOB : BAR

TIME AT WHICH THE FINAL PRESSURE NOTED : AM / PM

k Operational counter readings as on DATE :

l Are insulators, operating mechanism, pole beam thoroughly cleaned and free
from dust and dirt?
* If NO , clean it thoroughly with dry cloth , before charging.

Check carried out by :

If point 1-7 as set out above have been completed, the circuit-breaker
can be commissioned.
 1HYB800001-37 Rev. A
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6 Troubleshooting
Before any activity is started, the circuit breaker has to be isolated form the high-
voltage system and earthed according to regulations. The control and heating
currents are to be interrupted.

6.1 SF6 gas supply system

- When the signal “Replenishment of SF6 gas” is given the gas pressure has to
be checked and insulating gas added. The correction can also be done while
the breaker is in service. If the density monitor responds inspite of nominal
pressure being present, the density monitor has to be checked.
- If leaks are suspected in the SF6 system, proceed as follows :
- SF6 gas lines :
Check all screwed and brazed joints with a leak detector. Replace faulty
brazings and fittings. Tighten leaking screwed connections.
- Casing details (mechanism housing, flanges etc) :
In the case of minor leaks all sealing joints are to be checked with a leak
detector. In the case of major leaks it is recommended that the leaks are
located using soapy water.
- Crank Mechanism seals :
Leaking crankshaft seals must be replaced according to section 7.7.3.
- Check SF6 gas humidity (dew point).

6.2 Control Circuits

If a switching command is delayed, or executed only partially or not at all, proceed as
follows:
- Switch off control and heating circuit.
- Check the electrical terminals in the control circuits for tightness and proper
connection.
- Compare wiring with wiring diagrams and correct if necessary.
- Check coils of solenoid valve 10006 and if necessary change defective coils.
The cause of the overload has to be established and eliminated.
- Switch on and check control voltage.
- Switching or blocking occurs in the wrong pressure range.
- Check the function of the circuit breaker when the density monitor is
disconnected. When it is confirmed that the density monitor is defective it has
to be replaced.
1HYB800001-37 Rev. A
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7. 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.
 1HYB800001-37 Rev. A
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7.1 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.
• Heat measurements

C Preventive maintenance After 15 years or 5 000 1), 3) b1 b2

• General inspection of the mech. oper.
circuit-breaker and
operating mechanism.
D Overhaul
• Overhaul of the breaker 2) c1 c2
chamber
• Line breaker ΣnxI2=8 000
• Transformer breaker ΣnxI2=8 000
• Capacitor battery breaker
Reactor breaker
Filter breaker
• Non-synchronised 2 000 el. oper.
• Synchronised 4 000 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.
1HYB800001-37 Rev. A
Page 16

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.

7
 1HYB800001-37 Rev. A
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See Maintenance of the operating

mechanism
1HYB800001-37 Rev. A
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7
1HYB800001-37 Rev. A
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4
 1HYB800001-37 Rev. A
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7.6 Table of parts to be serviced

Inspection / Maintenance
Part Part which see Activity after*)
No. must be section number of
Inspected/ switching
replaced operations
Breaker pole type EDF
10036 Lockwasher 7.6.1 replace
10038/1 Sealing ring 7.6.1 replace
10038/2 Sealing ring 7.6.1 replace
10038/3 Sealing ring 7.6.1 replace
10038/4 Sealing ring 7.6.1 replace
10045 Alumina container 7.6.1 replace
10047 Lockwasher 7.6.3 replace
10056 Fixed contact pin 7.7.1 replace
10059 Finger, complete 7.7.1 replace
10060✪ Piston 7.6.3 inspect
10061✪ Flow direction tube 7.6.3 inspect
10064✪ Lockwasher 7.6.1 replace
10065✪ Contract ring 7.7.2 replace
10066✪ Insulating nozzle 7.7.2 replace
10067✪ Auxiliary nozzle 7.7.2 replace
10068✪ Erosion finger 7.7.2 replace
10072 Compression spring 7.7.2 replace
10073✪ Piston guide ring 7.7.2 replace
10074 Multi-contact ring 7.7.2 replace
10076 Cylinder 7.6.3 inspect
10077 Cylinder guide ring 7.7.2 replace
10082 Sealing ring 7.7.3 replace
10090 Sealing ring 7.7.3 replace
10091 Sealing washer 7.7.3 replace
10182 Sealing ring 7.7.3 replace
Spring stored-energy actuator FSA-1(F)
10006 Coil “OPEN” inspect
10166 Motor brushes inspect
10167 Switching element inspect
10168 Switching element inspect

*) Number of switching operations according to Fig. 7/1 of these instructions.

✪ Parts marked as ✪ can be replaced by piston assembly 1HYN400069R1,
which is the part of moving contact (part no. 10013, fig. 7/4)
- Replace means :
As a general rule replace the part when the permissible number of switching
operations according to fig7/1 of these instructions has been reached.
- Inspect means :
Inspect the part thoroughly for wear and replace if necessary. It is not
necessary to replace the part if at the endangered points it exhibits no or only
slight wear and if silver plating is not damaged.
1HYB800001-37 Rev. A
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7.2 Tools, jigs and fixtures and additional parts

Tools according to section 4.1
Special tools, jigs and fixtures as per (Fig. 7/2b).

7.2.1 Following additional tools are needed.

Circlip pliers C8 (straight)

Wrenches 10-43 mm
Set of sockets for socket screws 5-10 mm (Connection 3/8”)

7.3 Procedures
7.3.1 General

Maintenance includes inspection and overhaul work as described in the maintenance

concept, section 7.1 of these instructions. Overhaul work in general, and contact
overhauls in particular, should only be done in closed rooms which are as dust-free
as possible.

As a general rule, in overhaul work, all uncovered sealing elements and

disassembled spring washers and retaining rings are to be replaced.

7.4 Preparation for maintenance

7.4.1 Taking the circuit breaker out of service

- Switch circuit breaker to position “b1” (untensioned and OPEN) (Fig. 2/1)
- Open associated high-voltage disconnectors.
- Turn off control, signal, motor and heating voltages
- Earth high-voltage lines on both ends according to local regulations and isolate
from the installation.
- Remove control, signaling and heating lines (disconnect).
- Reduce SF 6 gas pressure for the transport to the servicing room to pabs= 150
kPa (= 1.5 bar=21.8 lbf. in2). Discharge throught dust filter.
7.5 Removal of breaker poles
7.5.1 Dismantling of the SF 6 connecting pipes

- After loosening the fastening bolts of the SF 6 gas supply system the whole
system can be moved longitudinal. The clamp nuts of the check valve are
screwed out so that the groove in the check valve’s thread is visible . Move the
pipe-system side-ways so the stop is in the clamp nut. In this position all the
three check valves are closed and the clamp nuts can be totally loosened at
the same time as the pipe-system is moved further sideways.

7.5.2 Removal of breaker poles 10171 with crank mechanism 10185

Remove outer breaker poles

- Fasten crane rope beneath upper flange of the breaking chamber insulator and
lightly tension crane rope. Remove fasteners 49621, 49063, 89026. (Fig. 4/1a)
 1HYB800001-37 Rev. A
Page 27

- Move breaker poles away to the side. The coupling shaft 10005 (Fig. 4/1a) will
slide out of the coupling bush 10180. Transport to the service room and place
on a mounting block (provided by the customer).

Dismantling of middle breaker pole.

- Withdraw coupling shafts 10005
- Remove connecting rod “f” (Fig 4/1a)
- Fasten crane rope beneath upper flange and tension crane rope lightly.
Remove fasteners 49621, 49063 and 89026.
- Withdraw breaker pole upwards and transport to the service room.

7.6 Disassembly of breaker pole 10171 (Fig. 7/2a)

- Clean outside surfaces of the breaker poles.
- Release SF6 gas through dust filter.
- In all subsequent work observe cleanliness.
- Parts of different poles may not be interchanged with one another.

7.6.1 Breaker pole disassembly

- Place breaker pole on mounting table, Fastening points are the upper flanges
of the post and breaking chamber insulator and the adapter plate 10098.
- Remove fasteners 49756/2 and washer 89026/2 and and take off the cover
10056/1
- Remove fasteners 49756, 49621/2, 89026/2 and carefully lift the flange 10099/
2 with the fixed contact.
- Place the flange on a safe surface and be careful with the O-ring slot.
- Support link gear 10185 on suitable wood base, screw off and pull out as far as
possible.
- Hold operating insulator socket 10042 from turning with open-end wrench WS
28 mm, release locknuts 49695/ 49586 and turn adjusting screw 10041 until it
releases the operating insulator socket 10042 and the linkage joint 10043.
Completely remove link gear 10185. Remove sealing ring 10038/3 and 10038/4.
- Remove fasteners that keep breaking chamber insulator, terminal flange and
post insulator together. Take off the break chamber insulator remove the
moving contact and place on a good surface.
- Withdraw pin 10050 and operating insulator socket 10042 out of operating
insulator 10049.
- Screw set screw 10051 with locknut 49505 out of adjusting ring 10053.
- Drive out flow direction tube base 10054 with disassembly rod and adapter
00104 (Fig. 7/2b). Remove pin 10029.
- Remove screw 49726/1 and washer 89026/1 and dismantle the post insulator
from adapter plate.
- Release screw 49017 and remove desiccant container. Dispose off desiccant
containers according to local regulations.
- Ensure that the sealing surfaces of the insulator, and crank mechanism
housing and O-ring slots in the flanges are not damaged.
1HYB800001-37 Rev. A
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7.6.2 Disassembly of fixed contact 10030 (Fig. 7/3)

- Screw off screw 49756 with washer 89006/2 and disassemble the flange and
contact holder.
- Remove hex screws 10057 out of finger cage 10058. Pull off finger cage. The
fingers 10059 will fall out.
- Remove fixed contact pin 10056 with socket srench 00103.
- As general rule, the fixed contact pin 10056 the countersunk screws 10057 and
all fingers 10059 are to be replaced.

7.6.3 Disassembly of moving contact 10013 (Fig. 7/4)

- Remove screw 49332 and then remove flange.

- Carefully withdraw moving middle section.
- Clamp piston 10060 in wood jaws or prism, push flow direction tube base
10054 out of flow direction tube 10061 and screw off piston base 10062 with
special torque wrench 00106 (Fig. 7/2b)
- Remove fasteners 49318 and 10064.
- Take off contact ring 10065 with insulating nozzle 10066 and separate.
- Screw off auxiliary nozzle 10067.
- Screw off erosion finger 10068 with torque wrench socket 00102 (fig. 7/2b)
- Remove long screws 10069 our of cylinder base 10070 and pressure relief flap
10071 with compression springs 10072.
- Inspect piston 10060, flow direction tube 10061 and cylinder 10076 concerning
damage.
- Replace all piston guide rings 10073, cylinder guide ring 10077, multi-contact
rings 10074, compression springs 10072 insulating nozzle 10066, auxiliary
nozzle 10067, erosion finger 10068, contact ring 10065 and lock washers 10064.

7.6.4 Cleaning

Clean all parts according to pertaining treatment instructions.

7.7 Maintenance of the assemblies

7.7.1 Maintenance of fixed contact 10030(Fig. 7/3)
- Treat contact surfaces for fixed contact pin with polish cloth and grease ‘P’, &
contact fingers with grease ‘P’ (No polish cloth), 2*) fig 7/3
- Screw fixed contact pin 10056 in with socket wrench 00103 (Fig. 7/2b) and
secure with locking agent “B”. (Observe MD ).
Attention !
Only apply to the last two turns of the thread of the fixed contact holder 10097.
Locking agent must not get onto contact surfaces, fig 7/3 2*).
- Replace contact fingers as follows :
- Slide finger cage 10058 over fixed contact holder 10097 up to about 15
mm (=0.59in) before the limit stop, insert fingers compl. 10059 with
hooked-in springs and snap in. Then push finger cage up to limit stop.
Screw in countersunk screws 10057 and secure with locking agent “B”
observe! Only on the last 4 turns of the thread. Observe MD.
 1HYB800001-37 Rev. A
Page 29

- Assemble the reassembled contact 10030 and the terminal flange and
don’t forget to grease the contact surface, marked 3*), fig 7/3 with grease
“P”.

7.7.2 Maintenance of moving contact 10013 (Fig. 7/4)

Attention !

- Clamp piston 10060 in wood jaws or prisms.

- Treat contact surfaces of erosion finger and of piston with polish cloth and
grease “P”, 2*)
- Screw in erosion finger 10068 with special wrench 00102 (Fig. 7/2b) and
secure with locking agent “B”. (Observe MD).
- Treat the thread of socket 10067 with liquid “E”.
- Assemble by hand and secure with locking agent “B”.
Attention !
Only apply locking agent to last turn of thread, Fig. 7/4* and do not forget to
remove inside catch of special wrench 00102.
- Clean contact surfaces between contact ring 10065 and piston 10060 and
greae ‘P’. Fit contact ring with insulating nozzle 10066 and fasteners 49318,
10064 to piston (Observe MD) and how to secure.
- Screw piston base 10062 in with torque wrench 00106 (Fig. 7/2b) and secure
with locking agent ‘B’.
Attention !
Only apply locking agent to last two turns of inside thread.
- Replace cylinder guide ring 10077 in cylinder base ring 10070, piston guide
rings 10073 and multi-contact ring 10074 in piston 10060, making sure that the
lamella of the multi-contact ring are facing in the right direction.
- Clean and grease cylinder bore 10076 and piston in the area of the multi-
contact ring with grease ‘N’, Fomblin, see 2*) Fig. 7/4.
- Carefully insert assembled middle section into cylinder 10076 and flow
direction tube 10061 into cylinder base 10070, adhering to the 900 position
between the window of the flow direction tube and the cylinder base. Do not
turn middle section, or only turn it in the direction of the arrow.
- Screw in long screws 10069 with pressure relief flap 10071 and compression
springs 10072 and secure with locking agent ‘B’. Observe MD.

7.7.3 Maintenance of crank mechanism 10185 (Fig. 4/1a, 7/5)

- Remove fasteners 49705, 89025 or 49701 and 89154 with shaft guard 10179
or cover 10183 and disassemble completely.
- Push out shaft 10083 and lever 10084 with linkage joint 10085.
- Remove socket head screw 10086 with washers 10088, 89004 and pull out
joint pin 10087.
- Replace following parts :
- O ring 10090
- X ring 10081
- Sealing ring 10182
1HYB800001-37 Rev. A
Page 30

Clean metal parts which are not replaced.

- Assembly in reverse sequence to above disassembly.
Grease X-ring 10081, simmerring 10182 and fill with grease ‘G’ (Mobile Grease
28).
Do not injure sealing rings on the splining.
Treat joint pin 10087 with grease ‘G’.
(Observe MD).
Attention !
Make sure that the puch marks are aligned with one another “e” (Fig. 7/5).
- Treat outer diameter “c” with grease ‘G’ and mounting surfaces “a” of the cover
10183, mm grease ‘S’. (Fluorsilicon grease)

7.8 Assembly of breaker pole (Fig. 7/2a)

- Mounting of operating insulator 10049 on moving contact

- Install snap ring 10055 in groove of flow direction tube base 10054.
- Install flow direction tube base 10054 with snap ring 10055 into flow direction
tube 10061 of such a depth that the pin 10029 can be inserted.
- Slide adjusting ring 10053 over flow direction tube 10061.
- Slide operating insulator 10049 with screen 10095 over flow direction tube.
Insert pin 10029. The pin bore must be in line with the actuating rod axis, and
insert flow direction tube base 10054 in pin 10029 all the way through the
window in the direction flow tube 10061.
Check : The actuating tube base must completely clear the window.
- Bring the adjusting ring 10053 into position such that set-screw 10051 can be
screwed into the bore in the flow direction tube 10061, tighten setscrew 10051
and locknut 49505 and secure with locking agent ‘B’ (Observe MD).
- Install operating insulator socket 10042 and pin 10050 in operating insulator.
The pin bore must align with the operating insulator axis.
- Installation of moving contact 10013 on the terminal flange 10108 :
- Clean contact surfaces on terminal flange, and treat contact surfaces on
cylinder base with a polish cloth. Cleaned surfaces are greased with
grease “P”, Assemble with screw and washers 49332, 10047, 89006/1
and secure with locking agent B. Observe “M D”.
- Treat both outer diameters of the contact ring 10065 (marked in fig. 7/4)
with grease “N”, Fomblin.
- Grease O-ring 10038/1, 10038/2 and O-ring slot on the terminal flange
10108 with greae “S”, fluoro-silicon grease. Place the O-rings in the slot.
- Assemble the breaking chamber insulator and the flange and try to
centre the moving contact in the insulator.
- Pass the post insulator on the operating insulator and mount the two
insulators against the flange with fasteners 49333, 49621 and 89026/3
(fig. 7/2a).
- Treat the O-rings and the slot in the adapter plate with grease “S” and
place the ‘O’-rings in the slot.
 1HYB800001-37 Rev. A
Page 31

- Attach a new desiccant container to the adapter plate 10098 (Fig. 7/2a)
with screws 49017 (6Nm) and secure with locking agent “B”.
- Determine adjusting dimension “A” between operating insulator socket
10042 and linkage joint 10043 (Fig. 7/2c).
- Attach depth gauge 00109 to upper break chamber insulator flange
10016. Push operating insulator 10049 all the way up. Place straight
edge 00114 against lower flange of insulator and link gear 10185 and
measure dimensions “X” and “Y”.
- Calculation formula for dimension “A”
A = X + Y - 50. (= 1.97 in)
- Adjust compass 00115 to dimension “A”.
Remove depth gauge 00109 and straight edge 00114.
- Installation of fixed contact compl. 10030., See fig. 7/2a.
- Treat the O-ring slot on the upper terminal flange 10099/2 and the two O-
ring with grease “S” before placing the O-ring in the slot.
- Assemble the flange with the reassambled contact, 10030, and centre
the contact in the insulator.
- Use fasteners 49756/2, 89026/2, 49621/2 observe MD = 79 Nm.
- Finally treat the O-ring and the slot on the upper terminal flange with
grease “S” and mount the cover10056/1 screw the washer 49756/2 and
89026/2 (MD 45 Nm)
- Mounting of crank mechanism 10185 (Fig. 7/2a)
- Pull operating insulator 10049 into position “OPEN”
- Treat the O-ring slot in the adaptor plate and O-ring with grease “S” place
the O-ring in the slot.
- Place crank mechanism 10185 at a distance of approx. 50 mm (= 1.97
in) in front of lower flange of post insulator.
- Screw adjusting screw 10041 with hex nuts 49586 and 49695 screwed all
the way back simultaneously into thread of operating insulator socket
10042 and of linkage joint 10043 (only one rotation).
- Screw adjusting screw 10041 into dimension “A” with adjusted compass
00115 and secure on both ends according to (Fig 7/2c) with locking
agent ‘B’ (Observe MD).
- Treat sealing surfaces with grease “S” (fluoro-silicon grease)
- Attach crank mechanism 10185 with fasteners 49621/2, 89026/2 and
secure with locking agent ‘B’. (Observe MD)
- Gas filling
- After that the breaker has been reerected, after revision or repair, it
should be filled with SF6-gas before trail operation.
- Evacuate till a pressure of 1 mbar and continue with pumping at least 1
hour from the moment the pressure of 1 mbar is reached.
- Break off the evacuation and fill the breaker with dry, clean nitrogen up
till atmospheric pressure. Leave the breaker alone for a few hours.
- Evacuate again till a pressure of 1 mbar and fill the breaker with clean SF6
gas up till 0.150 MPa abs. Observe the security precautions for gas filling.
Note: Keep the position of the terminals as it was before the breaker was
opened.
1HYB800001-37 Rev. A
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7.9 Erection of breaker pole (Fig. 4/1a, b)

- Bring middle breaking pole all the way into the OPEN position, place actuating
lever 10154 in correct position according to punch marks “a” (Fig. 4/1b). Lower
pole onto support frame 10161 and insert connecting rod joint head in
actuating lever fork. Operating mechanism must be in OPEN position. Insert
hex screws 49063. Apply hex nut 49621 with washers 89026 and tighten only
lightly so that the breaker pole can still be turned easily in the screw clearance.
Treat joint pin 10158 with grease ‘G’ (mobil grease 28) and secure with
fasteners 10064, 89224 and 49215 (Observe MD). Insert coupling shafts 10005
into coupling sleeve and actuating lever. Treat the splines with grease ‘G’.
- Bring outer breaker pole 10171 all the way in to the OPEN position, and from
outside with coupling sleeve mounted slide over coupling shafts as far as
possible. Apply remaining fasteners 49063, 49621 and 89026 and tighten after
final alignment of the breaker poles. The joint heads of the connecting rod must
remain movable, and the coupling shafts axially movable (Observe MD).

- The gas nipple are greased with grease G, Mobil Grease 28, See *), fig. 4/1c.

- Connect the gas system to the breaker poles and screw an all cap nuts up to
the groove. Now the connection is dense, but the check valve is closed. When
all breaker poles are connected in that way. The gas tubes are vacuum-
pumped by the gas filling equipment before connecting to the breaker.

Then the cap nuts are tightened fully while moving the complete tube system to
the side. Tightening torque is 10 Nm.

If the connecting of the gas system to the header block have been dismantled.
They shall be secured with locking agent ‘B’ when reinstalled. Observe the
tightening torque 45 Nm. Fill with SF 6-gas to normal working pressure 0.7 MPa
abs. After conclusion of gas treatment fill the nut and O-ring 10112/c.

7.10 Maintenance of spring operated mechanism 10173 (Fig. 7/6)

- Clean transmission roller “A” worm gear “G” and worm “H” and treat machined
surfaces,*) without disassembly.
- Clean and lightly grease transmission cam wheel “B” locking pawls “C” and “D”,
levers “E” and “F”,*)
After 5,000 switching cycles the operating mechanism is to be overhauled, for
which the manufacturer or his representative is to be consulted.
 1HYB800001-37 Rev. A
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8. Spare parts
8.1 General

8.1.1 Important notes

- Replace all uncovered sealing rings of the insulating gas space.
- Unpacking : shortly before use.
8.1.2 Ordering of spare parts
For ordering, the following data are essential :
- Order no 1......... See order documentation
- Type designation See nameplate
- Serial number See nameplate
- Publication number See end paper
- Part number See spare parts list
- Part designation See spare parts list

8.2 Spare parts

8.2.1 Set of contacts for 1 breaking unit
Comp. No. Art No. Name of Item Fig. Number
10056 HATH408148R1 Fixed contact pin 7.3 1
10059 HATH401095R1 Finger Compl. 7/3 27
10065 HATH306969P3 Contact Ring 7/4 1
10066 HATH307413P1 Insulating Nozzle 7/4 1
10067 HATH407749P1 Auxiliary Nozzle 7/4 1
10068 HATH307654R1 Erosion finger 7/4 1
10074 HAGS301276P24 Multi-contact Ring 7/4 1
10073 HATH408678P1 Piston guide Ring 7/4 2
10077 HATH408677P1 Cylinder guide Ring 7/4 1
10045 HAMT401304R1 Desiccant Cont. 7/2a 1
8.2.2 Gaskets, springs, fasteners for 1 breaker pole.
Comp. No. Art No. Name of Item Fig. Number
10038/2 1HML400410P170 O-ring 7/2a 5
10038/3 1HML400063P145 O-ring 7/2a 1
10038/1 1HML400410P610 O-ring 7/2a 6
10047 MT430575P14 Disc Spring 7/2a 16
10057 STD430017P2205 Countersunk screw 7/3 2
10064 1HYN400575P1 Disc Spring 7/4 12
10072 HATH407739P2 Compression Spring 7/4 3
8.2.3 Complete set of gaskets for gas supervision
Comp. No. Art No. Name of Item Fig. Number
L 00110/a 1HML400063P20 O-ring 4/1c 10
1HYB800001-37 Rev. A
Page 34

L 10112/c 1HML400063P28 O-ring 4/1c 3

L 10118 1HML400063P40 O-ring 4/1c 12
L 00110/b 1HML400063P16 O-ring 4/1c 6
L 10112/b SWT431154P1 Gasket 4/1c 1
8.2.4 Set of gaskets for 1 crank mechanism
Comp. No. Art No. Name of Item Fig. Number
10081 1HYN400061P1 X-ring 7/5 4
10090 AG434301P52 O-ring 7/5 4
10091 1HML400063P25 O-ring 7/5 1
10182 HAMT400593P6 Sealing ring 7/5 2
8.2.5 Spare parts for spring operated mechanism FSA -11
Comp. No. Art No. Name of Item Fig. Number
10166 -- Motor brushes motor 7/6 2
10168 HAGT444559P2 Limit switch 7/6 1
10168 HAGT444559P5 Limit switchT 7/6 1
10066 Close / Tripping as per table given below
10020 Motor as per table given below

Quantity
1
1
1
1
1
 1HYB800001-37 Rev. A
Page 35

8.2.6 Tools for EDF SK

8.2.7 Gas Equipment

Gas filling equipment 1HYN300349R3
Gas filling and evacuation equipment 1HYN300189R1
Gas leak detector LS790A
1HYB800001-37 Rev. A
Page 36

8.2.8 Safety Disc Unit

1 2 3

Item No. Qty. Name of Item Article No.

1 1 Safety Disk Unit 1HYN4005781

2 1 O-ring 1HML400063P75
3 1 O-ring 1HML400063P90
 1HYB800001-37 Rev. A
Page 37

11. Appendix
11.1 Figures
Fig. Designation
1/1 Nameplate
1/2 Tabulated masses
2/1 Circuit breaker
3/1a Breaker Pole (“OPEN” Position)
3/1b Breaker Pole (“CLOSED” position)
3/2 Schematic control diagram
4/1a Circuit breaker, complete
4/1b Connecting rod securement
4/1c SF6 gas line
4/1d Gas filling with SF6
4/2 Transport instructions
5/1 SF6 filling pressure diagram
5/2a Measurement layout for function tests
5/2b Simultaneity monitoring
7/1 Admissible switching cycles for contact overhaul
7/2a Breaker pole, complete
7/2b Tools and overhaul tools
7/2c Length adjustment of moving contact
7/3 Fixed contact
7/4 Moving contact
7/5 Crank mechanism
7/6 Spring stored-energy actuator
1HYB800001-37 Rev. A
Page 38

Fig. 1/1
 1HYB800001-37 Rev. A
Page 39

Type EDF
Mass per citruit breaker (net)

Designation kg (approx.) lb (approx.)

Operating mechanism incl. control 160 396

Breaker poles, pole supports 475 1045

with actuator transmission

Total mass including 815 1793

Supports

Supports 180 352

Mass per pole

kg lb

Breaker pole, complete 125 275

Fig. 1/2
1HYB800001-37 Rev. A
Page 40

Legend to Fig. 2/1

10112 Density monitor

10126 Density monitor cable, compl.

10170 Circuit breaker, type EDF

10171 Breaker pole

10172 Support frame

10173 Control cubicle with stored-energy spring operating mechanism and connecting rod

10174 Support

b Position indicator “CLOSED-OPEN”

b1 Breaker position “OPEN” and springs untensioned (not ready for swithcing)

b2 Breaker position “OPEN” and springs tensioned (ready for CO swithcing)

b3 Breaker position “CLOSED” and springs tensioned (ready for O-CO Swithcing)

C Earthing connection
Fig. 2/1
1HYB800001-37 Rev. A
Page 42

Legend to Fig. 3/1a,b

10013 Moving contact

10017 Cover

10030 Fixed contact

10041 Adjusting screw

10049 Operating insulator

10098 Adapter plate

10099 Upper terminal flange

10106 Insulator for breaking chamber

10108 Lower terminal flange

10171 Breaker pole

10185 Link gear

g-h Arcing contact

k-l Main current contact

O Circuit breaker in “OPEN” position

C Circuit breaker in “CLOSED” position

 10099

10106

10157

10098

Fig. 3/1a,b
1HYB800001-37 Rev. A
Page 44

Legend to Fig. 3/2

10006 Opening coil “OPEN”

10007 Closing coil “CLOSE”

10008 Auxiliary switch (S1)

10009 Auxiliary switch (K1 or K2)

10018 Motor limit switch (S3)

10019 Motor operated spring closing mech.

10020 Spring tensioning motor

10112 Densiy monitor (F2)

10171 Breaker pole

F3 Miniature circuit breaker

F12 Selector switch

S13 Control switch “CLOSE-OPEN”

1) Remote control
 10171 10171
10171

S13

Fig. 3/2
1HYB800001-37 Rev. A
Page 46

Legend to Fig. 4/1a

10005 Coupling Shaft
10112 Density monitor
10118 Heade block
10126 Density monitor cable compl.
10154 Actuating Lever
10161 Support frame
10173 Operating mechanism
10174 Support
10176 Coupling Shaft
L10177 SF6 gas pipe
L10178 SF6 gas pipe
10179 Shaft guard
10180 Coupling Sleeve
10182 Sealing ring
10183 Cover
49063 Hex screw M12x45 mm
49069 Hex screw M16x50 mm
49621 Hex nut M12x0.8D
49622 Hex nut M16x0.8D
49701 Socket head screw M10x20 mm
49705 Socket head screw M10x40 mm
89025 Washer
89026 Washer
89027 Washer
89154 Washer
D High-Voltage terminal:
Per screw fasterner at least
1 washer13/28x3 and
1 Lock washer 13.5/28x1.6
on each side of the fastener
E Coupling, coupling sleeves
F Coupling shaft and guard
f Connecting rod (component of sping
operated mechanism)
g Fasteners
h Fasteners
MD Torque

Nm ft. lbf

13 10
45 33
79 58
190 141
 10183
10005

➤
*) Rotation by 1800

Fig. 4/1a
1HYB800001-37 Rev. A
Page 48

Legend to Fig. 4/1b

10064 Lockwasher

10083 Crankshaft

10154 Actuating lever compl.

10158 Joint pin

49215 Hex screw M 6 x 10 mm

89224 Washer

a Location of punch marks

c Installation location

d Rubber collar *)

e Clamp *)

f Connecting rod, compl. *)

g Punch mark unimportant for type EDF

h,k Locknuts

* Operating mechanism component

MD Torque

Nm ft. lbf

6 4
c=360

Fig. 4/1b
1HYB800001-37 Rev. A
Page 50

Legend to Fig. 4/1c

L 00110/a O-ring 15.3 x 2.4

L 00110/b O-ring 12.3x2.4

L 10177/a SF6 gas pipe

L 10177/b SF6 gas pipe

L 10178 SF6 gas pipe

L 10164 Non-return valve

L 00111 Washer

L 10118 Header block

L 10112/a Density monitor

L 10112/b Manometer *)

L 10112/c Hex. nut and sealing ring

*) At request of customer

1 *) To be greased with greases G,

Mobil Grease 28
Fig. 4/1c
1HYB800001-37 Rev. A
Page 52

Legend to Fig. 4/1d

1 SF6 Gas cylinder

2 Coupling

3 Regulator

4 Coupling

5 Gas Valve

7 Density Switch

8 Gas Valve

9 Pressure Gauge
Fig. 4/1d
1HYB800001-37 Rev. A
Page 54

Legend to Fig. 4/2

10186 Pole support with poles

a Supporting timber
Fig. 4/2
1HYB800001-37 Rev. A
Page 56

Legend to Fig. 5/1

1 Nominal filling pressure curve

2 Replenishment pressure curve (signal “Replenish SF6 gas”)

3 Blocking pressure curve (Signal “OPEN operation blocked”)

4 Filling of SF6 gas at mixed gas filling

Conversion of pressure units

100 kPa = 14.5 lbf/in2 = 1 bar

Conversion of :
Pabs (kPa) to Pe (gauge) lbf/in2
Pabs - 100 x 0.145 (kPa) = Pe (gauge) lbf/in2

Example : Rated filling pressure 1 at 20 0C (=680F) according to

table = 700 kPa (700-100) x 0.145 = 87 (gauge) lbf / in2
 bar ibf/in2 kPa

➤
Pabs Pabs

1000

9 130.5 900 1
8 116 800
2
7 101.5 700 3

6 87 600

5 72.5 500

4 58 400 4

3 43.5 300

2 29.0 200

100

0
-30 -20 -5 0 10 20 30 40 50 60 70 80

Pabs t 0C
kPa -30 -20 -5 0 10 20 30 40 50 60 70 80
1 500 580 625 640 670 700 730 760 790 820 850 880

2 490 520 555 570 590 620 650 670 700 730 750 770

3 470 500 540 550 580 600 630 650 680 700 720 750

4 290 300 330 340 350 360 370 380 400 420 430 440

t 0C
Pabs
bar -30 -20 -5 0 10 20 30 40 50 60 70 80
1 5.0 5.8 6.2 6.4 6.7 7.0 7.3 7.6 7.9 8.2 8.5 8.8

2 4.9 5.2 5.6 5.7 5.9 6.2 6.5 6.7 7.0 7.3 7.5 7.7

3 4.7 5.0 5.4 5.5 5.8 6.0 6.3 6.5 6.8 7.0 7.2 7.5

4 2.9 3.0 3.3 3.4 3.5 3.6 3.7 3.8 4.0 4.2 4.3 4.4

Pabs t0 C / F
lbf/in 2 -30/-22 -20/-4 -5/23 0/32 10/50 20/68 30/86 40/104 50/122 60/140 70/158 80/176
1 72.5 84.1 90.7 92.3 97.2 101.5 105.9 110.2 114.5 118.9 123.3 127.6

2 71.1 75.4 80.5 82.7 85.6 89.9 94.3 97.2 101.5 105.9 108.8 111.2

3 68.2 72.5 78.4 79.3 84.1 87.0 91.4 94.3 98.6 101.5 104.4 108.8

4 42.1 43.5 47.9 49.3 50.8 52.2 53.7 55.1 58.0 60.9 62.4 63.8

Fig. 5/1
1HYB800001-37 Rev. A
Page 58

Legend to Fig. 5/2a,b

Fig. 5/2a Measurement layout for function tests

10171 Breaker pole

Y2, Y3 Coils OPEN

Y1 Coil CLOSE

Q Auxiliary switch

1 Terminal 1 in control cubicle

2 Terminal 2 in control cubicle

3 Terminal 3 in control cubicle

4 Terminal 4 in control cubicle

5 Terminal 5 in control cubicle

6 Terminal 6 in control cubicle

A,B,C Pole coluomn

M1 Time recorder

M2 Main switch of test gear

M3 Control switch of test gear

K1 Terminal 1 on M3

K2 Terminal 2 on M3

UM Measurement voltage

US Control Voltage

C CLOSED

O OPEN

Fig. 5/2b Time diagram of CLOSE-OPEN operation

A,B,C Pole column

I Coil current

t1 Closing time

Dt 1 Closing tolerance of the pole column

t2 Opening time

Dt 2 Opening tolerance of the pole column

t3 Close-open time
Fig. 5/2b

Fig. 5/2a,b
1HYB800001-37 Rev. A
Page 60

Legend to Fig. 7/1

I Breaking current

n Number of switching operations

Fig. 7/1
1HYB800001-37 Rev. A
Page 62

Legend to Fig. 7/2a

10056/1 Cover
10013 Moving contact
10099/2 Upper terminla flange
10029 Pin
10030 Fixed contact, compl.
10038/1 O-ring
10038/2 O-ring
10038/3 O-ring
10041 Adjusting screw
10042 Operating socket insulator
10043 Linkage joint
10045 Desiccant container
10047 Lock washer
10049 Operating insulator
10050 Pin
10051 Set screw
10053 Adjusting ring
10054 Flow direction tube base
10055 Retaining ring
10061 Flow direction tube
10095 Screen
10106 Insulator for breaking chamber
10108 Lower terminal flange
10171 Breaking pole
10172 Support frames
10098 Adapter plate
10185 Link gear
49017 Socket screw M 6 x 20 mm
49332 Socket screw M 10 x 50 mm
49333 Hex screw M 12 x 70 mm
49505 Hex nut M 8x0.5D
49586 Hex nut M 16x0.5D
49621/2 Hex nut M 12 x 0.8 D
49695/1 Hex nut M 16 x 0.8 D
89006/1 Washer M 12 x 40 mm
49726/2 Hex screw M 12 x 25 mm
49756/2 Hex head bolt M 10 x 30 mm
89026/2 Washer
49756/1 Hex Head bolt M 12x60
49333 Hex Head bolt M 12x70
49726/1 Hex Head bolt M 12x45
89006/2 Washer 10.5x20x2
MD Torque

Nm ft. lbf
6 4
20 15
45 33
79 58
MD=45Nm

Fig. 7/2a
1HYB800001-37 Rev. A
Page 64

Legend to Fig. 7/2b

00100 Guide pin

00102 Special Wrench

00103 Socket Wrench

00104 Disassembly Rod with adapter

00105 Set of Wrenches

00106 Sepcial torque Wrench

00107 Measuring kit

6869738-E Depth Gauge

00114 Straight edge

00115 Compass

00116 Cleaning device

00117 Torque wrench

Fig. 7/2b
1HYB800001-37 Rev. A
Page 66

Legend to Fig. 7/2c

00109 Depth gauge

00114 Straightedge

10016 Upper flange

10045 Desiccant container

10049 Actuating rod

10185 Link gear

49621 Hex nut M12x0.8D

49756 Socket head screw M12x70 mm

89026/2 Washer

89026/3 Washer

A Setting dimension x+y-50 mm=A for compass 00115 (Fig. 7/2b)

b Installation of desiccant container according to section 7.8

d Upper Limit stop

x Actual dimension from actuating rod to outer edge of straightedge

Y Actual dimension from linkage joint in Link ger to outer edge of straightedge (in open position)

mm in
50 1.97
 b
10042

10045

Fig. 7/2c
1HYB800001-37 Rev. A
Page 68

Legend to Fig. 7/3

10099/2 Upper terminal flange

49756/2 Hex head bolt

89006/2 Washer

10030 Fixed contact

10056 Fixed contact pin

10057 Countersunk screw M 6 x 16 mm

10058 Finger cage

10059 Finger complete

10097 Fixed contact support

10188 Finger spacing

a Check dimension = 5 mm = 0.197 in

MD Torque

*) Thread turns (2 turns) to be treated with locking agent

2*) Contact sufrace which must remian free of locking agent

3*) Contact surfaces, greased with grease “P”

Nm ft. lbf
6 4
26 19
49 36
10099

10097

10059

Fig. 7/3
1HYB800001-37 Rev. A
Page 70

Legend to Fig. 7/4

10108 Lower terminal flange
49332 Socket screw, M10x40
10047 Disk spring
89006/1 Washer
10013 Moving contact
10060 Piston
10061 Flow direction tube
10062 Piston base
10064 Lock washer
10065 Contact ring
10066 Insulating nozzle
10067 Auxiliary nozzle
10068 Erosion finger
10069 Long screw
10070 Cylinder base
10071 Pressure relief flap
10072 Compression spring
10073 Piston guide ring
10074 Multi-contact ring
10076 Cylinder
10077 Cylinder guide ring
49318 Socket head screw M6x25 mm
MD Torque
* Inside thread (2 turns) to be treated with locking agent
2 *) Contact surface which must remain free of locking agent
3 *) Contact surface, greased with grease “P”
A Note ! Observe carefully that the direction of rotation given in the figure is kept. If it is not
followed the lamella of the multi-contact will be destroyed.

Nm ft. lbf
6 4
11 8
79 58
Fig. 7/4
1HYB800001-37 Rev. A
Page 72

Legend to Fig. 7/5

00112 Non-return valve
10080 Ball bearing
10081 X-ring
10083 Crankshaft
10084 Lever
10085 Linkage joint
10086 Socket head screw
10087 Joint pin
10088 Washer
10090 Sealing ring
10091 Sealing ring
10092 Gas connection
10182 Sealing ring
10183 Cover
10185 Link gear
49701 Socket head screw M10x20 mm
49705 Socket head screw M10x40 mm
89004 Washer
89025 Washer
89154 Washer
MD Torque
a....e See section 7.7.3

Nm ft. lbf
6 4
45 33
110 81
Fig. 7/5
1HYB800001-37 Rev. A
Page 74

Legend to Fig. 7/6

10006 Coil “CLOSE”, “OPEN” (Y1,2,3)

10020 Spring tensionsing motor

10144 Hand crank

10166 Motor brushes

10167 Switching element (S1)

10168 Switching element (S3)

A Transmission roller

B Transmission cam

C Locking pawl

D Locking pawl

E Level

F Lever

G Worm wheel

H Worm

Possible breaker positions according to Fig. 2/1a...c

a Lubricating points of spring retaining pin

10144

Fig. 7/6
 1HYB800001-38 Rev. A

Operating mechanism type FSA 1

Instructions for Operation

and Maintenance

Contents :

1. General
2. Construction
3. Function
4. Erection
5. Commissioning
6. Maintenance
7. Spare Parts
8. Appendix
1HYB800001-38 Rev. A
Page 1

Contents Page
1. GENERAL 1
1.1 Validity 1
1.2 Specification 1
1.3 Masses 1

2. CONSTRUCTION 1
2.1 Operating mechanism cubicle 1
2.2 Drive mechanics 1
2.3 Driving units 2
2.4 Electrical components 3

3. FUNCTION 3
3.1 Functions of the basic mechanism 3
3.2 Charging the closing spring 3
3.3 Closing - operation 4
3.4 Opening - operation 5

4. ERECTION 5
4.1 Delivery 5
4.2 Installation 5

5. COMMISSIONING 5
5.1 Function tests 5
5.1.1 Manual operation 5
5.1.2 Motor operation 5

6 MAINTENANCE (Overhaul) 6
6.1 Duty-related overhaul 6

7 SPARE PARTS 7
7.1 Storage instructions 7
7.2 Spare parts list 7

8 APPENDIX 8
8.1 Figures 8
 1HYB800001-38 Rev. A
Page 2

1. General
1.1 Validity

This operating instruction applies for stored-energy spring operating mechanisms to

SF 6 circuit-breakers of type EDF
- Operating mechanism type FSA 1 (outdoor)

1.2 Specifications

Specifications are contained in the order documentation and on the rating plate.

1.3 Masses
The masses (kg/lb) can be obtained from the order documentation and the shipping
documents. For internal transport and assembly see the instructions for erection and
operation of the circuit breaker, Fig. 1/2

2. Construction
The stored-energy spring operating mechanism comprises the following main parts :

- Operating mechanism cubicle compl.

- Basic mechanism
- Driving unit
- Electrical components

2.1 Operating mechanism cubicle (Fig. 2/1)

In the operating mechanism FSA 1 (outdoor) the electrical components and the
basic mechanism are placed in the operating mechanism cubicle EV 11851.

There is a door with an inspection window for reading the position indicator
EV11825 and the spring charge indicator EV11824 on the operating mechanism
front. The door can be locked with a padlock. When the door is opened the electrical
panel with its electrical components becomes accessible and the hand crank can be
inserted.

The operating mechanism cubicle is designed so that the basic mechanism and the
electrical components are hermetically protected against the effects of the weather.

The outdoor circuit breaker type EDF has the cubicle mounted below the pole
beams of the breaker. Connecting rod projects upwards.
1HYB800001-38 Rev. A
Page 3

2.2 Drive mechanics (Fig. 2/1, 7/1)

The basic mechanism EV 11852 is assembled in a chassis EV 11855 in which the

shaft bearings, the spring suspension points and the switchgear panel are fastened.

Their major parts are :

- Main shaft EV 11815
- Output shaft EV 11816
- Motor EV 11843 with reducer gear EV 11842
- Worm gear EV 11819
- Closing spring EV 11813
- Opening spring EV 11814
- Opening unit EV 11810
- Closing unit EV 11811
- Auxiliary switch EV 11838
- Hydraulic shock absorber EV 11840

2.3 Driving units (Fig. 2/1, 7/1)

Stored-energy spring operating mechanism type FSA 1 (outdoor)

- Lever EV 11848 is located on the output shaft and when its rotates it transmits
the rotary movement to the connecting rod.

- Connecting rod compl EV 11822 (FSA 1) constitutes the connection between

the operating mechanism and the circuit breaker. Bellows EV 11781 seals the
operating mechanism cubicle at the connecting rod.

2.4 Electrical components

In the operating mechanism the auxiliary switches EV 11838, microswitches EV

11826 (motor limit switches), counters EV 11860 and CLOSE and OPEN magnet
coils are integrated in the basic mechanism.

In the mechanism type FSA 1 the electrical control and monitoring elements
necessary for the control of the circuit breaker are additionally arranged on the
switchgear panel.

These are essentially :

- LOCAL-REMOTE selector switch
- ON-OFF-switch
- Motor protection switch
- Auxiliary contacts
- Miniature circuit breakers

The operating mechanism is equipped with a permanently turned-on heating resistor

to avoid the condensation inside the operating mechanism.

If the operating mechanism is to be stored outdoors for periods of longer than four
weeks, the heater should be connected.
 1HYB800001-38 Rev. A
Page 4

3. Function
3.1 Function of the basic mechanism (Fig. 7/1)
- The main shaft EV 11815 serves as the drive shaft for charging the closing spring.

- By means of lever EV 11848 the output shaft EV 11816 transmits the closing
or opening movement to the connecting rod, and hence to the circuit breaker.

- The motor EV 11843 with reducer gear EV 11842 charges the operating
mechanism mechanically (tensions the closing spring). The motor limit switch,
EV 11826, opens when the closing spring is tensioned.

- Hand crank EV 11812 (FSA 1) is used to charge the closing springs by hand
(e.g. on power failure).

- On discharging, closing spring EV 11813 release uses the energy to charge

the opening spring via the output shaft, at the same time closing the breaker.

- On discharging, opening spring EV 11814 release uses the energy to open the
breaker.

- Closing unit EV 11811 holds the closing spring in the charged condition or it
releases it on command electrically via the CLOSE magnet coil or
mechanically (by hand).

- Opening unit EV 11810 holds the opening spring in the charged condition or
releases it on command electrically via the OPEN magnet coil or mechanically
(by hand).

- Hydraulic shock absorber EV 11840 is double acting. It assures a dampened

opening and closing operation.

- Auxiliary switch EV 11838 is controlled by the position of the circuit breaker.

CLOSE and OPEN magnets coils are controlled by its contacts, i.e. the
commands for charging or discharging of the springs are tripped. They also
prevent the CLOSE magnet coils from being excited when the circuit breaker
is closed or the closing spring is not fully charged, or they prevent the OPEN
magnet coils from being energized when the circuit breaker is opened.

- Heater EV 11854 (Fig.2/1) is provided in operating mechanism. The heating

resistor prevents condensation in the operating mechanism cubicle. The
heating resistor prevents condensation in the operating mechanism cubicle.
The heating resistor remains permanently turned on.

3.2 Charging the closing spring (Fig. 7/1)

In Fig. 7/1 the basic mechanism is shown with the circuit breaker in the position
OPEN (“O”) and with the springs in the discharged condition.

The closing spring EV 11813 is charged electrically by motor EV 11843 with

flanged-on reducing gear EV 11842, leading via coupling shaft EV 11841 to worm
gear EV 11819. The hand crank coupling EV 11817 prevents the hand crank from
turning during the electrical charging of the spring. The motor EV 11843 is also
decoupled (by coupling shaft EV 11841) when the spring is charged by hand.
1HYB800001-38 Rev. A
Page 5

As an emergency charging feature the closing spring EV 11813 is charged with

hand crank EV 11812 via bevel gear EV 11818 and worm gear EV 11819 by turning
the main shaft EV 11815. The main shaft EV 11815 is turned via worm wheel and
pull hook EV 11830 which engages the coupling ring EV 11829.
For charging the closing spring approx. 30 rotations of the hand crank are
necessary. On a 1800 rotation the crank EV 11828 runs through top dead center.
The pawl on the control disk EV 11820 is held by lever EV 11832, and the blocking
hook EV 11834 of the closing unit.
The switching cam of crank EV 11828 simultaneously reaches the motor limit switch
EV 11826 and cam follower lever EV 11827 is lifted.
The following functions are thereby initiated :
- Turning off the power supply to the motor by the motor limit switch.
- Preparation of the closing operation by the motor limit switch.
- Spring charge indicator indicates “Spring charged”.
Time necessary for charging the spring at nominal tension : < 15 seconds.

3.3 Closing-operation (the circuit breaker is closed)

When the engagement lever EV 11837 or the closing coil EV 11839 are actuated by
hand or electrically, the lever 11832 and the blocking hook EV 11834 of the closing
unit release the control disk pawl EV 11820.

By releasing the closing spring EV 11813 the main shaft EV 11815 rotates in the
direction shown on fig. 7/1 and in turn the control disk EV 11820 transmits the
rotational movement to the cam follower EV 11836 and operating lever EV 11835.
The output shaft EV 11816 is thereby rotated and the circuit breaker is closed via
operating lever EV 11848 and connecting rod compl. EV 11780/EV 11822.
Simultaneously, opening spring EV 11814 is charged.

When the output shaft has rotated by 60o, the control disk pawl passes over the cam
follower EV 11836 and then the output shaft is released and can rotate in the
opposite direction.

However, this is not possible as long as holding cam EV 11847 is held by lever EV
11832 and blocking hook EV 11834 of the opening unit. The closing spring EV
11813 is automatically recharged again.

At power failure the closing spring can be recharged by hand with had crank EV
11812 (FSA 1).
In this position the following indications are visible :
- Position indicator : “I” (circuit breaker in closed position)
- Spring charge indicator : “Spring charged”
 1HYB800001-38 Rev. A
Page 6

The operating mechanism is ready for another rapid closing operation but the
interlock hook EV 11833 prevents the execution of a closing operation, while the
circuit breaker is closed. Both springs (EV 11813 and EV 11814) remain charged
and both shafts are blocked by the two blocking units (EV 111810 and EV 11811).

3.4 Opening-operation (the circuit breaker is open)

The holding cam EV 11847 is released from lever EV 11832 and the opening unit
blocking hook EV 11834, when disengagement lever EV 11845 and opening coil EV
11846 and/or EV 11839 are actuated manually or electrically.
By discharging the opening spring EV 11814 the output shaft EV 11816 rotates 600 ,
thereby opening the circuit breaker via the connecting rod.
The interlock hook EV 11833 of the closing block is released at the end of the
opening operation and a new closing operation can be executed.

4. Erection
4.1 Delivery
Each circuit breaker is delivered with its corrosponding operating mechanism which
is packed separate or already mounted on the circuit breaker pole beams. At
delivery both springs are uncharged and the circuit breaker is in open position.

4.2 Installation (Fig. 2/1)

If the operating mechanism is delivered separately, the following must be noted :

Mount the operating mechanism or operating mechanisms (which 1-pole operating

mechanism type) on the circuit-breaker pole beams. Make sure that the number of the
circuit breaker corresponds with the number on the operating mechanism rating plate.

The operating mechanism must be mounted on the circuit breaker according to the
instruction for erection and operation of the circuit breaker.

Connect electrical connections according to valid circuit diagram.

Never operate the operating mechanism if it is not connected to the circuit breaker (filled
with SF6-gas to 0.7 MPa) and the electrical connecting lines are not connected.

5. Commissioning
5.1 Function tests
Function tests are performed after the commissioning work and immediately before
the circuit breaker is taken into service, as well as after overhaul work.
Function tests may only be performed with the circuit breaker disconnected from the
high-voltage system and filled with SF6-gas to 0.7 MPa (abs).
5.1.1 Manual operation
For this purpose hand crank EV 11812 is used for charging the closing spring. When
the closing spring has reached the desired tension, it automatically uncouples the
pull hook (EV 11830) of the main shaft, thereby releasing the hand crank.
During these trial switching operations the position indicators (EV 11824 and EV
11825) and the counter must be tested for proper functioning.
1HYB800001-38 Rev. A
Page 7

5.1.2 Motor operation

The motor should be turned on only after the hand crank has been removed, even
though it is uncoupled automatically when the motor is started.

The charging of the closing springs starts as soon as the motor supply is switched
on. The supply of power to the motor is turned off automatically (by microswitch EV
11826) when the closing spring is adequately charged.
- Proper functioning of the operation mechanism should be tested by several
CLOSE and OPEN switching operations.
- Also a test for correct functioning of the selector switch LOCAL-REMOTE
should be performed.
- Motor running time for charging springs at rated voltage : < 15 seconds.

6. Maintenance
6.1 Duty-related overhaul (Fig. 7/1)
After 2000 CO Switching operations the following parts must be cleaned and
lubricated without being disassembled :
- Cam follower EV 11836 with roller shaft, greased with grease G, (Mobile
Grease 28*)
- Worm gearing EV 11819 (worm and worm wheel), grease G (Mobile Grease 28)
- Rollers of levers EV 11832 of closing and opening units, grease L (Aseol
Sylitea 4-018)
Clean and lubricate the machined surfaces of the following cams :
- Control disk with pawl EV 11820, grease L (Aseol Sylitea 4-108)
- Holding cam EV 11847, grease L (Aseol sylitea 4-108)
Treat the worm surfaces of the following pins or cranks with :
- Crank pin EV 11853, grease L (Aseol sylitea 4-108)
- Spring fixation pin EV 11856, grease L(Aseol sylitea 4-108)
- Spring fixation pin EV 11857, grease L(Aseol sylitea 4-108)
- Crank with switching cams EV 11828, grease L(Aseol sylitea 4-108)
Change the following details of the connection rod if required (Fig. 2/2):
- Rod end joint EV 11858 or EV 11782 (in case of obvious wear)
- Bellows EV11781 when there are cracks in material, leaks.

Treat rod end joint with grease G (Mobile Grease 28)

Disassembly and assembly as described in the instructions for erection and

operation of the circuit breaker.

No work is allowed to be carried out until the closing and opening springs are
discharged, and the circuit breaker is in the OPEN “O” position. The power to the
motor must be disconnected.

After 5000 CO switching operations a general overhaul must be performed by

specialized staff. Please, contact the manufacturer or his representative.

*As an alternate to Mobile Grease 28, Molykote Long term 2 plus or Aseol Sylitea 4-
108 may be used.
 1HYB800001-38 Rev. A
Page 8

7. Spare parts
For ordering, the following data are essential :
- Order number See order documentation
- Type designation See rating plate
- Serial number See rating plate
- Publication number See spare parts list
- Part number See spare parts list
- Design Outdoor
- Part designation See spare parts list

7.1 Storage instruction

Before the erection, the operating mechanisms shall be stored indoors or under a
roof as long as possible. If the units are stored outdoor, they must be prevented from
standing in water pools. With outdoor storage under long time, the units shall be
covered with tarpaulin and the heating elements of the operating mechanism shall
be connected.

7.2 Spare parts list

Overhaul parts :
Part No. Part designation Number/Type of operating mechanism Figure
FSA 1 (1) FSA 1 (F)

EV 11781 Bellows - 1 2/1,2/2a,b

EV 11782 Rod end joint - - 2/1,2/2b
EV 11858 Rod end joint 1 1 2/1,2/2a
EV 11859 Motor brush 2 2 7/1

Reserve parts :

Part Number Part designation Number/type of operating mechanism Figure/section

FSA 1 (1) FSA 1 (F)

EV 11810 Opening unit 1 1 7/1 (legend)/3.1

EV 11811 Closing unit 1 1 7/1 (legend)/3.1
EV 11813 Closing spring 1 1 7/1
EV 11814 Opening spring 1 1 7/1
EV 11823 Pin 1 1 7/1
EV 11826 Motor limit switch 2 2 7/1
EV 11836 Cam follower 1 1 7/1
EV 11838 Auxiliary switch 1 1 7/1
EV 11839 Coil “CLOSE”, “OPEN 1” 1 1 7/1
EV 11840 Hydraulic shock absorber 1 1 7/1
EV 11842 Reducer gear 1 1 7/1
EV 11843 Motor 1 1 7/1
EV 11844 Switching element (yellow) 2 2 7/1
EV 11846 Coil “OPEN 2” 1 1 7/1
EV 11854 Heater 1 1 2/1
1HYB800001-38 Rev. A
Page 9

8 Appendix
8.1 Figures
Fig. Title

2/1 Stored-energy spring operating mechanism compl. FSA 1

2/2a Connecting rod compl. FSA (outdoor)

7/1 Drive mechanics (schematic representation)

1HYB800001-38 Rev. A
Page 10
1HYB800001-38 Rev. A
Page 11

Legend to Fig. 2/1

EV 11781 Bellows
EV 11812 Hand crank (FSA 1)
EV 11822 Connecting rod compl. (FSA 1)
EV 11824 Spring charge indicator
EV 11825 Breaker position indicator
EV 11849 Rotational movement lever
EV 11851 Drive assembly cubicle compl.
EV 11854 Heater
EV 11855 Chassis
EV 11858 Rod end joint (FSA 1)
b Breaker position indicators
b1 Breaker position OPEN “O”, springs
“discharged” (not ready for switching)
b2 Breaker position OPEN “O”, springs
“charged” (ready for CO Switching operation)
b3 Breaker position CLOSED “I”, springs
“charged” (ready for O-CO switching operation)
11812

Fig. 2/1
1HYB800001-38 Rev. A
Page 13

Legend to fig. 2/2a

EV11781 Bellow
EV11822 Connection rod compl. (FSA 1)
EV11858 Rod end joint (FSA 1)
84638 Hex nut M20 x 1.5 mm/0.5d
MD Torque
Fig. 2/2a
1HYB800001-38 Rev. A
Page 15

Legend to fig. 7/1

EV11812 Hand crank (FSA 1)
EV11813 Closing spring
EV11814 Opening spring
EV11815 Main shaft
EV11816 Output shaft
EV11817 Handcrank coupling
EV11818 Bevel gearing
EV11819 Worm gearing
EV11820 Control disk with pawl
EV11822 Connecting rod compl. (FSA 1)
EV11823 Pin
EV11824 Spring charge indicator
EV11825 Position indicator
EV11826 Microswitch (motor limit switch)
EV11827 Cam follower lever
EV11828 Crank with switching cams
EV11829 Coupling ring
EV11830 Pull hook
EV11831 Adjusting screw
EV11832 Lever (closing/opening block)*),2*)
EV11833 Interlock hook*)
EV11834 Blocking hook*),2*)
EV11835 cam follower lever
EV11836 Cam follower
EV11837 Engagement lever (closing lever)*)
EV11838 Auxiliary switch
EV11839 Coil “CLOSE”, “OPEN 1”*),2*)
EV11840 Hydraulic shock absorber
EV11841 Coupling shaft
EV11842 Reducer gear
EV11843 Motor
EV11844 Switching element (yellow)
EV11845 Disengagement lever (opening lever)2*)
EV11846 Coil “OPEN 2”, 2*)
EV11847 Holding cam
EV11848 Rotational movement lever (FSA 1, outdoor)
EV11850 Auxiliary switch lever
EV11852 Drive mechanism
EV11853 Crank pin
EV11856 Spring fixation pin
EV11857 Spring fixation pin
EV11859 Motor brush
EV11860 Switching operation counting meter

*) Part of closing block EV11811

2*) Part of opening block EV11810
Fig. 7/1
 1HYB800001-25 Rev.A

ABB Ltd.
Maneja, Vadodara
Gujarat, (INDIA)
Tel. : +91 265 2642141
Fax : +91 265 2638918, 2638911
visit us at : www.abb.com