SF6 Circuit Breakers

Type PMR with Tank Mounted Density Monitor

Publication No. 526P132-006

242 PMR with Tank Mounted Density Monitor Installation & Maintenance

NOTE: For Installation and Maintenance information regarding the 242 PMR Power Circuit Breaker equipped with Cabinet-Mounted Density Monitor, please refer to Publication No. 526P121.

ABB

526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Contents

Contents
1. 1.1 1.2 1.3 1.4 1.5 1.5.1 1.6 1.6.1 1.6.2 1.6.3 1.7 2. 2.1 2.1.1 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 3. 3.1 3.2 3.2.1 3.2.2 3.2.2.1 Breaker Description Bushings and Current Transformers Interrupters, Bellcranks, and Interphase Linkage Mechanism SF6 Gas System and Safety Features Control Cabinet Optional Electrical Control Packages Circuits and Components AC Circuits (Charging Motor & Heaters) DC Circuits Operations Counter Breaker Operation Installation Receiving and Handling the Breaker Moving the Breaker Storing the Circuit Breaker and Spare Parts Long-term Storage Instructions Parts Storage Instructions Installing the 242 PMR Circuit Breaker Installing the Bushing Top Terminal Slow Close Operation 6 7 7 8 8 8 8 9 9 9 9 9 10 10 11 11 12 12 13 14 14 15 16 17 17 19 19 20 21 21 21 22 22 22 22 22 22 22 23 23 23 24

5.2.2 5.2.3 5.2.4 5.2.5 5.2.5.1 5.2.5.2 5.2.5.3 5.2.5.4 5.2.6 5.2.6.1 5.2.6.2 5.2.7 5.2.8 6. 6.1 6.1.1 6.2 6.3 6.4 6.4.1

Replacing the Rupture Disk Replacing the Desiccant Bag Re-installing the Rear Tank Cover Assembly Isolating a Pole Unit De-Coupling the Interphase Linkages (Removing the Interphase Shafts) Synchronizing the Interrupter Contacts Setting the Guide Piston Length Re-Coupling the Interphase Linkages (Re-installing the Interphase Shafts) Rebuilding the Bellcrank Assembly Rebuilding the Left or Right Bellcrank Assembly Rebuilding the Center Bellcrank Assembly Removing/Installing Current Transformers SF6 Gas Density Monitor and Calibration Safe Handling of SF6 Equipment Used to Handle SF6 Decomposition Products Protective Gear SF6 Gas Handling Safety and Purging Practices Removing SF6 Decomposition Products Disposing of Decomposition Products Removing SF6 Gas Residue from Tools and Equipment

30 31 32 32 32 33 33 33 34 34 35 35 37 39 39 39 39 40 40 41

SF6 Gas Reclaiming and Filling Reclaiming SF6 Gas from a Pole Unit Filling the Circuit Breaker with SF6 Gas Filling a Pole Units from a Gas Cylinder Filling Pole Units Using a Gas Service Unit Filling Unopened Pole Units - Initial Filling on Installation (Typically for Domestic Breakers) 3.2.2.2 Evacuating and Refilling Pole Units 3.3 Installing the Portable In-Line Filter 3.4 Replacing Desiccant in the Portable In-Line Filter 3.5 Isolating a Pole Unit from the Gas System 4. 4.1 4.2 4.2.1 4.3 4.4 4.4.1 4.5 4.6 4.6.1 4.6.2 5. 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.2 5.2.1 Testing Pole Resistance Measurement Moisture Measurement of the SF6 Gas Measuring the Moisture Leak Checking Operational and Timing Tests Operational Tests Check the Oil Level in the Mechanism Density Monitor Set Point Tests Tests Using Pole Unit Gas Tests Using a Separate Gas Source

Figures
Figure 1 Lifting the Breaker Figure 2 Control Cabinet 60000 Figure 3 SF6 Gas Density Monitor Calibration Curve for Pressure vs. Temperature Figure 4 SF6 Gas Filling and Density Monitor Calibration Chart Figure 5 Gas Charging Arrangement Figure 6 SF6 Gas Schematic Figure 7 Tank Mounted SF6 Gas Density Monitor 60441 Figure 8 Terminal Pad 20311 Figure 9 Pole Unit Assembly (Left, Center, or Right) Figure 10 Rupture Disk Cover Assembly Figure 11 SF6 Gas System Disconnect Gas Valve Figure 12 Linkage (Front View) Figure 13 Side View of Crank, Linkage, and Pullrod 42 43

44 45 46 47 48 49 50/51 52 53 54 55

Maintenance 25 Maintenance Tips 25 Applying Loctite 25 Seals 27 Flange Corrosion Protection 27 US Standard Torque Table 2a 27 Metric Torque Table 2b 28 Treatment of Silverplating 28 Pole Unit Maintenance Procedures 29 Removing the Rear Tank Cover and Cleaning the Pole Tank 29

526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Contents Figure 14 Manual Open/Close Tool T13451 Figure 15 242 PMR Bellcrank Assemblies (without Valves) Figure 16 Shaft Seal Assembly 10153 Figure 17 Bellcrank Linkage to Interrupter Unit Figure 18 Current Transformer 70000 Figure 19 Tank Heater Assembly 10055

56 57 58 59 60 61

Figure 20 Guide Piston Dimension for HMB Hydraulic Mechanisms 62 Figure 21 Density Monitor Installation to each Tank 63

526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Notes Notice 1 Based on our own experience, you will obtain the best possible operational reliability by following the recommendations given in these instructions. The data contained herein purports solely to describe the product, and it is not a warranty of performance or characteristics. It is with the best interests of our customers in mind that we constantly strive to improve our products and keep them abreast of advances in technology. This may lead to discrepancies between a product and these instructions. Notice 2 Within the scope of these instructions, it is impossible to take into account every eventuality which may arise with technical equipment in service. Please consult our local salesman in the event of any irregularities, especially if not referred to herein. Notice 3 We expressly decline liability for damages resulting from any incorrect operation or wrong handling of our equipment, even if these instructions contain no specific indication in this respect. We stress the fact that only genuine spare parts should be used for replacements. Notice 4 This publication is a copyrighted work. Therefore, it is not permissible to disclose, reprint, copy, or reproduce any part of these instructions without express written permission from ABB. These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchasers purposes, the matter should be referred to ABB Inc.

Copyright 2003, 2005, ABB All rights reserved.

526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 6

Installation & Maintenance

Instructions in this module pertain to receiving, handling, storing, installing, commissioning, and maintaining the 242 PMR circuit breaker. Important: As a convenience and to prevent any oversights, tabular checklists which include all of the tests and items to check during installation, commissioning, and maintenance are provided in the modules listed below. To ensure proper operation, ABB recommends completing the respective checklists when installing, commissioning and maintaining the 242 PMR. Installation and Commissioning Checklist in the Checklists module 5-Year Maintenance Checklists in the Checklists module Checklist in the Mechanism module Timing Checklist in the Customer Data module.

1.

Breaker Description

The 242 PMR circuit breaker is a multiple-tank, sulfur hexafluoride (SF6) puffer-type circuit breaker manufactured by ABB. This high speed, state-of-the-art circuit breaker ensures reliable switching performance and fault interrupting capability. The 242 PMR circuit breaker (Illustration 1) consists of several major components: Three pole units; Six entrance bushings; Bushing-type current transformers; Three interrupter units; Interphase linkages; Mechanism; Control cabinet.

Interphase Linkage

Entrance Bushings Current Transformers

Pole Unit

Control Cabinet Front View Side View

Illustration 1 242 PMR Circuit Breaker

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 7 The three pole units are coupled to a single operating mechanism through an interphase linkage assembly. The pole tank ("U-stamped" ASME pressure vessel) is made up of two halves bolted together in the center and sealed via an O-ring in the center and on each tank end. A nickel reverse buckling rupture disk is fitted to the bottom of each tank to protect against excess pressure build-up which could otherwise lead to catastrophic failure of pressurized components. Two bushings are situated at obtuse angles on each pole tank. The bushings are equipped with top terminals for connecting to the high voltage line or bus. 1.1 Bushings and Current Transformers 1.2 Interrupters, Bellcranks, and Interphase Linkage

The type SD interrupter is a single pressure, single break, sulfur hexafluoride (SF6) gas puffer-type unit capable of interrupting terminal faults and 90 percent short-line faults up to ratings listed on the front cover of this manual. Each interrupter consists of a moving contact assembly and a main contact finger assembly. Both assemblies contain a main contact and an arcing contact. Under normal conditions, the main contacts carry continuous current through the breaker. During interruption, the main contacts part first. Shortly afterward, the arcing contacts part, an arc propagates between them and the current eventually is interrupted. Because the arc is interrupted at the arcing contacts, the integrity of the main current carrying contacts is preserved. The interrupting components are mounted by an insulating support tube situated within the grounded cylindrical tank of each pole unit. In the OPEN position, the moving and main contact finger assemblies are isolated from each other by an insulating interrupter tube. The moving contacts are driven by the bellcrank assembly, which converts the vertical motion of the operating mechanism to the horizontal motion of the interrupter contacts. An insulating pullrod connects the bellcrank assembly to the moving contacts. Three bellcrank assemblies (one for each pole unit) are tied together by the two interphase shafts (left and right 10204 (Fig. 12)). The interphase shafts are coupled to the mechanism pullrod 10207 through a crank at the center pole unit. Working with the mechanism, the bellcrank assemblies open and close the interrupters in the respective pole units. The crank at the center pole converts the vertical motion of the mechanism pullrod to the rotational motion of the interphase shafts. The bellcrank assemblies then convert this rotational motion to the horizontal motion of the interrupters. The three pole units are interconnected by an interphase linkage assembly. The interphase linkage includes the bellcranks and all components that join the individual pole units into a single breaker unit.

The bushings are an integral part of the breaker and are specifically designed to connect to the high voltage line or bus and carry high voltage power to the interrupter while providing line-to-ground insulation. Two plug-in type, entrance bushings are installed at slight angles on top of each pole tank. Top and bottom aluminum flanges are permanently cemented onto the insulators. The bottom flange of the bushing has an adapter plate which keeps the throat shield fixed in position within the bushing insulator. The bushings are hollow, high strength vessels filled with SF6 gas which acts as the insulating medium. A conductor assembly (thru rod) fits to the top flange of the bushing and extends through the hollow center of the bushing and attaches to the interrupter. Bushing-type current transformers (CTs), mounted in weatherproof aluminum protective covers, surround the pockets below the bushings. Each phase of the 242 PMR circuit breaker can be equipped with many combinations of CTs or linear couplers as per customer specifications. CT secondary leads are installed in conduits extending from each CT housing and terminating onto shorting type terminal blocks in the control cabinet. A nameplate on the inside of the cabinet door indicates the location, accuracy, and ratio of the current transformers.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 8 1.3 Mechanism 1.5 Control Cabinet

The HMB-1.8 hydraulic operating mechanism for the 242 PMR circuit breaker is housed within the control cabinet. The HMB mechanism is driven completely hydraulically. A stack of disc springs serves as an energy storage system. During both opening and closing operations, hydraulic oil drives the piston/pullrod of the mechanism, consuming energy from the stack of disc springs. There is no direct mechanical link between the spring stack and the piston/ pullrod. The storage springs are charged using a hydraulic pump; this stored energy provides the driving force for hydraulic oil as the breaker is opened and closed. 1.4 SF6 Gas System and Safety Features

The control cabinet is mounted to the steel structural frame of the circuit breaker. Field wiring enters the control cabinet through a panel at the base of the cabinet and is terminated on the appropriate terminal blocks. The breaker control circuitry is wired and tested at the factory. If required, the circuit breaker also can be fitted with a second control cabinet mounted to the rear of the structural frame. Components housed in the cabinet include: Operating mechanism; CT shorting terminal blocks; Anti-condensation heaters; Control relays; Terminals for field connections; Auxiliary switches; A mechanical operations counter which keeps track of the number of trip operations; Circuit breaker control panel and/or special optional control packages, e.g. Synchronous Control Unit (SCU), Condition Monitoring Unit (CMU), or Breaker Control Unit (BCU). (Refer to section 1.5.1.) 1.5.1 Optional Electrical Control Packages

Pressurized sulfur hexafluoride (SF6) gas surrounds the interrupter and fills the pole tanks and hollow entrance bushings. Sulfur hexafluoride gas is chemically inert and non-flammable. This gas has a high dielectric strength and thermal properties conducive for insulating high voltage and quenching electrical arcs which is why it is used in these types of circuit breakers. Maintaining a proper gas density in the pole units is essential for optimum breaker operation. The pole unit gas pressure and ambient temperature are monitored to derive the gas density. Some breaker models have an SF6 gas density monitor 60441 (Figs. 6 and 21) mounted onto each pole. A quick disconnect valve 10154 (Fig. 11a/b) mounted at each bellcrank conveniently allows for gas filling and reclaiming. The temperature-compensated density gauge mounted off of the gas valve is removed for gas servicing. Other breaker models use a gas manifold 10213 (Figs. 6 and 11) which links the three pole units into a single gas density monitoring system. The gas density monitor 60441 is mounted onto the left pole. A quick disconnect fitting 10154 at each bellcrank assembly conveniently allows the individual pole units to be isolated from the gas manifold. The SF6 gas can be reclaimed from one, two, or all three pole units as desired by loosening the nut on the quick disconnect fitting where the gas is not to be reclaimed without losing any SF6 gas and then opening the sample valve 60007 (Fig. 5) in the control cabinet. This design provision is a great advantage when performing pole unit maintenance. The SF6 gas density monitoring system compensates for pressure changes due to temperature variations and provides alarm and lock-out functions only if low gas density problems exist. Maintaining a proper gas density is critical to ensure the dielectric integrity of the pole unit. A reverse buckling rupture disk is fitted to the bottom of each pole tank. This disk protects against excess pressure build-up which could otherwise lead to catastrophic failure of pressurized components. If the tank pressure exceeds the burst pressure listed on its nameplate (well below the hydrostatic test pressures of all other pressurized components), the disk will rupture directing the exhausting gas downward, under the tank and away from personnel. In compliance with the ASME Pressure Vessel Code, the pole tanks are "U-stamped."

If the breaker is equipped with a Synchronous Control Unit (SCU), this microprocessor controls the breaker for synchronous switching functions in independent pole operating applications. The SCU allows for either synchronous closing or opening of contacts. Synchronous closing improves power quality by reducing transients. This reduction occurs when each phase of the breaker closes on or near voltage zero for capacitive switching or at peak voltage for inductive switching applications. Through synchronous opening, the SCU can optimize arcing times of the interrupters, thereby improving interrupter performance and extending contact life. The SCU monitors system voltage and current through potential transformers and current transformers. If the breaker is equipped with an SCU, a separate instruction booklet for this device will be provided. (The SCU is automatically incorporated on 242 PMRI-type circuit breakers. These breakers are independent poleoperated breakers.) If the breaker is equipped with a condition monitoring unit (CMU) such as the PowerIT Circuit Breaker Sentinel, this unit monitors interrupter nozzle and contact wear, and travel characteristics of breaker timing. The unit will indicate any problems with the interrupter and timing. The advantage of this electrical control/monitoring device is that it precludes routine unnecessary maintenance and indicates when maintenance is required as well as the condition of the interrupter nozzles and contacts. If your breaker is equipped with a CMU, a software interface and an instruction manual will be provided.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 9 1.6 1.6.1 Circuits and Components AC Circuits (Charging Motor & Heaters) 1.7 Breaker Operation

AC circuits include: Charging motor Control cabinet heaters Tank heaters (optional). The charging motor controls are designed to automatically maintain the stored spring energy of the mechanism. A spring limit switch closes to pick up a contactor supplying the charging motor. When the operating energy is restored to its normal level, the limit switch contact opens to turn the charging motor off. Notice: The charging motors can, if specified, be operated on DC power or AC power with DC backup as options.

Under normal conditions, pressurized SF6 gas surrounds the interrupter units and fills the hollow entrance bushings within each pole unit. The gas is both an insulating and arc quenching medium. Current from the bushing conductors flows to the main and moving contact assemblies in the interrupters. During interruption, the mechanism opens, providing the mechanical force required to initiate interruption. This motion is transferred to rotational motion at the interphase linkage. The bellcrank assembly, attached to the interrupter by an insulated pullrod, converts the rotational motion from the interphase linkage to the required horizontal force to open (and close) the interrupter contacts. Consequently, the main contacts within the interrupter part first, then the moving contacts part. An arc propagates between the contacts and is eventually extinguished by the cooling, puffer effect of the SF6 gas circulating through the interrupter to attain successful interruption. All ABB circuit breakers are in compliance with the latest applicable IEC, NEMA, and ANSI C37 standards for outdoor high voltage circuit breakers. Notice: The breaker should not be subjected to duties in excess of nameplate ratings. The nameplate is located on the inside of the control cabinet door and indicates the location, accuracy, and ratio of the current transformers.

Anti-condensation heaters are located in the control cabinet. The normal heater circuit provides for 150 Watts of heat energized continuously (H1 and H2), with another 150 Watts thermostatically controlled (H3 and H4). Notice: The anti-condensation heater circuit is to be energized at all times, regardless of the ambient temperature.

These heaters are series connected for half voltage (1/4 wattage) operation on each heating element to ensure trouble-free service for many years. In operating conditions where ambient temperatures below -22F (-30C) can occur, the breaker pole tanks must be equipped with thermostatically-controlled tank heaters 10055 (Fig. 19) to prevent the SF6 gas from liquefying. The thermostat operates at -10F (-23C). Refer to Figure 19 to view tank heater assemblies installed on a pole tank. The thermostat for the tank heaters can be either located outside of the control cabinet or mounted on the inside wall of the control cabinet, covered with insulation. In either case, the thermostat must be situated in a place at ambient temperature. 1.6.2 DC Circuits

The DC control system converts remote operating signals into breaker operations. This control system also monitors the operational status of the breaker (SF6 pressure, mechanism energy, breaker position, etc.) and automatically performs TRIP BLOCK (or AUTO TRIP) and CLOSE BLOCK functions when necessary. 1.6.3 Operations Counter

The breaker is furnished with a mechanical operations counter which is located in the control cabinet, and visible through a view port. This counter keeps track of the number of trip operations. (Optional electric operations counters can be furnished upon request and, likewise, would be located in the main control cabinet.)

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 10

2.

Installation

Notice:

The 242 PMR breaker is factory-tested and shipped ready for easy and quick installation. After the breaker is installed, a quick verification of a few parameters is all that is required before placing the breaker into service. The Customer Data module serves as a customized reference guide unique for your applications. The nameplate on the inside of the control cabinet door of the breaker indicates the location, accuracy, and ratio of the current transformers. Notice: The 242 PMR circuit breaker should not be subjected to duties in excess of nameplate ratings unless agreed upon at the time of purchase.

If the bushings are shipped separately, such as for overseas shipment, refer to the shipping assembly drawing for special instructions on receiving, handling, and lifting the shipping units.

The breaker either can be installed (section 2.3) or stored (section 2.2). To transport a fully assembled breaker, refer to section 2.1.1.

DANGER
Do not energize, test, or operate the breaker until it is filled with SF6 gas.
x

To prevent any oversights, follow the procedures in this section and complete the appropriate checklists in the Checklists module, Mechanism module, and Customer Data module to ensure proper installation and operation. All personnel designated to install this breaker must review section 6 in this module. DO NOT WEAR POLYESTER, ACETATE, NYLON, OR RAYON CLOTHING (SUCH AS SHINY-TYPE SKI JACKETS AND WIND BREAKERS WHICH USUALLY CONTAIN NYLON) AROUND LIVE ELECTRICAL EQUIPMENT. 2.1 Receiving and Handling the Breaker

NOTICE TO OUR VALUED CUSTOMERS:

x

Please return any YELLOW shipping material (including yellow-painted shipping covers, brackets, braces, etc.) used to protect your breaker to the shipping address listed below.
x

For your convenience, ABB has provided these at no cost.

x

No return authorization is required. Customers outside the domestic United States may disregard this notice.
x

Unless shipping regulations or customers specify otherwise, domestic breakers shipped within the continental United States are completely assembled and contain a partial charge (5 psig (0.03 MPa)) of pure SF6 gas. These breakers just are topped off with more SF6 gas during installation. Whereas, breakers shipped overseas are charged to 5 psig (0.03 MPa) with dry nitrogen gas and the bushings usually are not installed. When the overseas breaker is installed, the bushings will need to be installed (as per the Bushings module), a new desiccant bag 10008 (Fig. 9) will need to be installed in each pole tank and the pole units will need to be closed and evacuated before filling the breaker with SF6 gas as per sections 5.2.3, 5.2.4, and 3.2.2.2 respectively. When the shipped unit(s) arrive(s) at the destination, check the material received against the packing list immediately. A service kit and any special tools required for this breaker should also be included with the breaker shipment. Refer to the Customer Data module for a list of required and optional special tools, materials, and vendors. Inspect the pole tank and flanges for damage. Inspect the bushing insulators for cracks, nicks, or damage. If the pole units are de-pressurized, check for leaks (section 4.3). Contact ABB if there are any problems with the shipment. Be certain that all parts have been received to avoid delays in installation. If the breaker is found to be damaged or is suspected of being damaged, file a claim immediately with the transportation company. Next, notify the local ABB representative of shortages or damaged equipment.

Return Address: Versa-Fab, Inc. Beatty Industrial Park 614 Beatty Road Monroeville, PA 15146
x

Phone: (412) 856-7871; Fax: (412) 856-1638

x

Please send all materials COLLECT using the following carriers: CARRIER USF Holland Yellow Freight (No Account #) Conway (CCX) ABF Estes Roadway ACCOUNT # 55485 Freight collect to ABB Inc. AFBRNXPN008 017886 2538815 206-0024

Contact information is accurate as of time of publication. Please contact your sales representative at ABB Inc. should the above information be incorrect. Customers outside the domestic United States may disregard this notice.
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AB B B

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 11 2.1.1 Moving the Breaker 2.2 Storing the Circuit Breaker and Spare Parts

The breaker should be transported on an air-ride suspension trailer to minimize the effects of shipping stresses. ABB recommends that the pole tanks be outfitted with 5 g rated, MAG 2000 impact monitors and the frame legs be securely strapped to the trailer bed as a precaution against shipping stresses. Check the MAG impact monitor once the breaker arrives at its destination to determine if the breaker experienced intense shipping stresses. If the breaker experiences heavy stress, contact ABB on how to proceed. The lifting arrangement for the fully assembled breaker (with bushings installed) is shown in Figure 1. To move the breaker: 1. 2. Be sure that the breaker is in the OPEN position and that the mechanism springs are completely discharged. The SF6 gas pressure in the pole units should be approximately 5 psig (0.03 MPa) before moving the breaker. (If a fully assembled breaker that has been in service is to be moved, gas needs to be reclaimed to reduce the pressure. Refer to section 3.1.)

The breaker can be stored indoors or outdoors. When a breaker is to be stored, maintain a slight positive pressure of dry SF6 gas (5 psig (0.03 MPa)) to prevent corrosion of the internal components and absorption of moisture. Notice: Breakers shipped with bushings installed (primarily in North America) contain a partial charge 5 psig (0.03 MPa) of pure SF6 gas and just are topped off with more SF6 gas during installation. Whereas, breakers shipped without bushings are charged to 5 psig (0.03 MPa) with dry nitrogen gas. The dry nitrogen gas is also acceptable for storage. A note should be placed on the breaker indicating that it is partially charged with dry nitrogen gas. When this breaker is installed, the pole units will need to be evacuated before filling the breaker with SF6 gas as per section 3.2.2.2. If the fully assembled breaker is to be stored longer than 1 month, refer to section 2.2.1 and protect the operating mechanism and control cabinet from moisture and corrosion by closing the housing and energizing the anti-condensation heaters. A desiccant bag 10008 (Fig. 9) should already be installed in each pole tank. If the pole units have been opened on a breaker which is to be stored, the opened pole units must be closed, evacuated, and filled to a positive pressure with dry, SF6 gas to approximately 5 psig (0.03 MPa). Refer to section 3.2.2.2 in this module for instructions on evacuating and refilling a pole unit which has been opened.

Important:

DANGER
Never move or install a breaker that is fully pressurized with SF6 gas.
3. Lift the breaker as shown in Figure 1. ALWAYS LIFT THE DEPRESSURIZED BREAKER BY THE LIFTING LUGS ON THE FRAME FOLLOWING THE RIGGING ARRANGEMENT IN FIGURE 1 AND USING A CRANE WITH A LIFTING CAPACITY OF AT LEAST 7 TONS. Notice:

Notice:

4.

Remove the leg bolts and retract the extension legs into the breaker frame and fasten the legs into the retracted position using the leg bolts. Mount the breaker to wooden skids at the foot pads to keep the breaker from tipping over during transport. Secure the breaker with straps during transport. Be careful not to damage the entrance bushings.

5. 6.

Sufficient recommended spare parts and renewal parts should be carried in stock to enable prompt replacement of worn or damaged parts and minimize down-time. Renewal parts are consumable parts such as desiccant bags, motor brushes, etc. that most likely will need to be replaced. Spare parts are items which may or may not wear out over time. Refer to the Spare Parts module for a listing of parts to keep in stock. Refer to section 2.2.2 in this module for instructions on storing parts. In cases where product improvement designs may cause a new part to not be identical to the original part, rest assured that the new part will definitely be interchangeable with the original part. As for standard hardware items, it is suggested that these items be purchased locally to save time and expense. ABB will provide spare part hardware when it is of a special nature or where standard hardware is specifically requested.

If possible, transport the breaker on an air ride cushion truck to reduce shipping stresses placed on the breaker.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 12 When ordering spare parts, refer to the breaker nameplate and this manual to properly identify the parts: Order number Code number of type Serial number Publication number Part number see ordering documentation see identification plate see identification plate see cover page see spare parts list 2.2.2 Notice: If the pole units have been opened on a breaker which is to be stored, the opened pole units must be evacuated and filled to a positive pressure with dry, SF6 gas to approximately 5 psig (0.03 MPa). Refer to section 3.2.2.2 in this module for instructions on evacuating and refilling a pole unit which has been opened. Parts Storage Instructions

Five-digit index part numbers in this manual refer to breaker components. ABB Parts and Service will correlate the index part number in this manual to a unique, nine-digit part number specific to your breaker. (The index part number in this manual is merely a reference aid.) Hardware items such as nuts and washers have a ninedigit actual part number prefixed with the letter "H." Index part numbers for special tools used to handle and maintain these circuit breakers are prefixed with the letter T followed by a five-digit number. For example, the index part number for the travel recorder kit is 13435. 2.2.1 Long-term Storage Instructions

Keep spare parts in a clean, dry room to minimize the possibility of moisture and corrosion damage. Preserve spare parts as follows while they are in storage: 1. Carefully handle parts sealed in plastic bags; avoid ripping the bag; (plastic bags must be intact); only remove the bag when you are ready to install the part. Store rubber parts in a cool, dry place; protect them from moisture, light, sun, and rain. Store rupture disks 10017 (Fig. 10) in individual boxes as received from the supplier. Avoid touching or bumping the domed center. Never set the disk down on the domed center side and never install a rupture disk that is dented or scratched. Unsuitable storage causes accelerated aging of seals. The following rules permit spare seals to be stored for several years without deterioration: Maintain a storage temperature between 40F and 70F (4C and 21C). Protect the storage area from water condensation or high humidity, Maintain a closed atmosphere in a suitable packing to reduce the oxidizing effects of air. Store the seals away from effects of ozone or equipment or machines which produce sparks or arcs. Avoid contamination with fluids, oils, and fats. Avoid contact with metals (copper, iron, manganese and their alloys), rubber of other grades, and plastics. Store seals (O-rings) flat with no stress, pressure, deformation, or bending.

2. 3.

Long-term storage means 1-month or longer. Although the breaker can be stored indoors or outdoors, indoors under cover is preferred. If the pole units are to be stored outdoors, follow the precautions listed below. If a breaker is not to be put in service after it is received, continue to maintain the slight positive pressure of dry, SF6 gas (5 psig (0.03 MPa)) (or dry nitrogen gas if it is an overseas shipment). For breakers with dry nitrogen gas, place a note on the pole units indicating that the units are partially charged with dry nitrogen gas. Dry gas (SF6 or nitrogen) prevents corrosion of the internal components and absorption of moisture. Important: Protect the operating mechanism and control cabinet from moisture and corrosion by closing the housing and energizing the anti-condensation heaters in the control cabinet. Wearing gloves, remove the special foamtype Hoffman Rust Inhibitor from the wrapper and install it under the cabinet roof directly over the operating mechanism to prevent rusting. Avoid prolonged breathing of the inhibitor vapors and avoid contact with your skin or eyes. Change this rust inhibitor every 12 months while the pole unit is in storage. The rust inhibitor can be purchased from: Hoffman Engineering Co. Type A-HCI-10E or similar (612)-421-2240 FAX (612)-421-1556

4.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 13 2.3 Installing the 242 PMR Circuit Breaker 8. If the top terminal is not already part of the bushing conductor, install the top terminals on all of the bushings as per section 2.3.1. If the breaker comes with top terminals other than that shown in section 2.3.1 and Figure 8, follow the instructions on the field assembly drawings.

Proceed with extreme caution because installation often involves working near energized lines. After ensuring that all has arrived at the installation site safely: 1. Lift the circuit breaker by its lifting lugs using a crane and lifting slings following the rigging arrangement shown in Figure 1. While the breaker is suspended, extend and fasten the leg extensions but do not yet tighten the bolts on the structural frame to allow fitting and manipulation onto the foundation anchor bolts. Set the breaker on its foundation pad. Place shims to level the breaker frame. Secure the anchor bolts and torque the leg extensions, braces, and breaker frame hardware as per directions in the field assembly drawings. Torque the leg hardware to 100 ft-lbs (135 Nm). Check that the breaker is level. Grout or place shims where needed to level the breaker. Be sure that the breaker frame is well anchored and secure on the foundation. Remove the slings and lifting equipment. Permanently ground the circuit breaker structure. Two NEMA grounding pads, welded to the front and rear structural legs at opposite corners, are provided for this purpose (Fig. 1). The ground cable should be able to carry the available fault current at the breaker location for the maximum duration of the protection scheme.

Notice:

9.

Clean the entrance bushings to remove any dirt or debris as per cleaning procedures in the Bushings module.

2.

10. Touch up any areas of damaged or chipped paint using the provided touch-up paint. 11. Terminate conduit for external control wiring at the removable plate located in the bottom of the control housing. All conduit should be sealed at the cabinet to keep out dirt and moisture. Use control and power wiring of adequate size to maintain voltages at the breaker terminals within ANSI Standard ranges. Refer to the wiring diagram for external connections and to the mechanism nameplate for control voltages and operating pressures. 12. Each current transformer secondary must be connected to a relaying or metering burden or be short circuited at all times. Notice: Before filling the pole units with gas, if the pole units had been opened or if bushings have just been installed, remove the rear tank cover assembly 10032 (Fig. 9) and replace the old desiccant bag 10008 with a new desiccant bag 10008 in each pole tank as per sections 5.2.1 and 5.2.3. Re-install the rear tank cover assembly promptly (section 5.2.4) and then proceed to evacuate and fill the breaker with SF6 gas as per section 3.2.2.2.

3.

4. 5.

DANGER A permanent low resistance ground is essential to adequately protect equipment and personnel.
6. Ground the control cabinet ground terminal 60011 (Fig. 2) located on the inside rear wall of the cabinet. A grounding stud extends through the rear wall and can be accessed from outside of the cabinet. If the bushings were shipped separately, remove the shipping covers from the pocket flange on the pole tank and install the bushing as per instructions in the Bushings module. (Usually separate hardware is shipped to mount the bushings to the pocket flange on the pole tank.)

13. Fill the breaker pole units with SF6 gas. Notice: For pole units either which had been opened or filled with dry nitrogen gas, after the breaker is assembled and new desiccant bags installed, evacuate and fill pole units with SF6 gas as per section 3.2.2.2. Typically domestically shipped breakers are charged with SF6 gas and are fully assembled and therefore, the pole units are topped off with SF6 gas as per section 3.2 (if there were no leaks) without requiring evacuation.

7.

DANGER Do not energize, test, or operate the breaker until it is installed and completely filled with SF6 gas.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 14 14. Test the breaker as per section 4. 15. Complete the following checklists: Installation and Commissioning Checklist in the Checklists module Mechanism Commissioning Checklist in the Mechanism module Timing Checklist in the Customer Data module. (The Timing module defines timing tests to be done and provides instructions for installing the travel recorder kit.) 2. 3. 4. dirt and oxides. Completely wipe off the electrical joint compound with a clean, lint-free wiper and immediately apply a new coat of the compound to the surface to prevent oxidation. Position the terminal pad on the top cap of the bushing. Place a clamping ring 20317 over the terminal with the drip slots at the bottom of the clamping ring. Place four V-clamps 20318 between the clamping ring 20317 and terminal pad and over the holes in the top cap of the bushing. Place a belleville washer H967800 (Fig. 8) on each of the four terminal pad bolts 20019. Place a bolt through each V-clamp, and screw the bolts into the four holes of the top cap of the bushing. Turn the terminal pad to the desired orientation (the terminal can be turned 360 degrees) and torque the bolts to 50 ft-lbs (70 Nm). Slow Close Operation

These checklists include all of the tests and items to check when installing and commissioning the breaker. The checklists specify allowable tolerances along with blank spaces for recording measured values for future reference and comparison. 2.3.1 Installing the Bushing Top Terminal

5.

6.

The standard 242 PMR circuit breaker is provided with six four-hole NEMA terminal pads 20311 (Fig. 8) as part of the field assembly materials. Refer to Plate 1. Bolt 20019 Belleville Washer H967800

2.3.2

V-Clamps 20318

Clamping Ring 20317

The circuit breaker is shipped as a complete ready-toinstall unit and contact inspection or alignment is not required during installation. A slow close or manual operation is not required for inspection or timing. With the 242 PMR circuit breaker, the mechanism cannot be jacked closed. Important: If the breaker is supplied with hex-shaped couplings, slow closing/opening can be done using a 1-3/4" open-end wrench or a large crescent wrench.

Four-Hole NEMA Terminal Pad 20311 Plate 1: Installing the bushing top terminal To install the terminal pad 20311 (Fig. 8) to the top cap of the bushing conductor: 1. Coat the top cap mating surfaces to the terminal pad 20311 with oxygen-inhibiting-type electrical joint compound (found in the service kit). Abrade the bare aluminum contact surface with a wire brush to remove

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 15

3.

SF6 Gas Reclaiming and Filling

The gas service unit is an all-in-one, contained system which allows the SF6 gas to be cost-efficiently and effectively reclaimed and recycled. The features on the gas service unit provide the following distinct advantages: The unit is cost-efficient because it saves money by reclaiming and storing the expensive SF6 gas. The in-line filter on the unit removes moisture and arc by-product impurities from the recycled gas as it is being reclaimed. The unit is environmentally preferred because it eliminates the need to release the SF6 gas into the atmosphere. The built-in vacuum pump on the unit removes air and moisture from the breaker and eliminates the need to have a separate vacuum pump. After the necessary vacuum is attained, the breaker can be refilled with gas directly from the gas service unit. When using a gas service unit, make sure that an in-line portable filter with a molecular sieve medium (desiccant) is installed on the gas service unit. The filter removes moisture and decomposition products from the gas. Refer to section 3.3 to install the filter. Place the filter vertically in the line between the quick disconnect fill valve 10154 (Fig. 5) and the SF6 gas service unit. Gas will be forced to flow through the desiccant in the filter/drier. Care must be taken to ensure that liquid SF6 does not enter the portable filter or breaker. Important: The 13x molecular sieve (desiccant) must be replaced after passing approximately 3500 pounds of gas through the filter. Refer to section 3.4.

During normal operation, the pole tank and entrance bushings are pressurized to 87 psig (0.60 MPa), when using a temperature compensated pressure gauge, with sulfur hexafluoride (SF6) gas. Maintaining a proper gas density is critical to ensure the dielectric integrity of the pole units. The SF6 gas density monitoring system compensates for pressure changes due to temperature variations and provides alarm and lock-out functions if low gas density problems exist. Depending on design, the breaker is equipped with either a single gas density monitor or three. The single density monitor design has a gas manifold (Figs. 6 and 11) that links the 3 pole units into a single gas density monitor system. The monitor is attached to the right pole unit (Figs. 6 and 11). If the breaker uses three monitors, a monitor is attached to each pole unit. A quick disconnect valve 10154 (Fig. 11a/b) at each bellcrank assembly conveniently allows the individual pole units to be filled. The SF6 gas can be reclaimed from one, two, or all three pole units as desired by removing the pressure gauge(s) and/or manifolds from the pole unit(s) and attaching in place of each a hose from a gas service cart.

Warning
Under normal operating conditions, the quick disconnect valve(s) 10154 at the pressure gauge(s) must be tightened to properly monitor the SF6 gas density. Important: For procedures that require the isolation of a pole unit from the breaker's other pole units, follow the instructions in Section 3.5 on Isolating a Pole Unit from the Gas System, paying careful heed to ALL warnings and cautionary statements.

Should the pole unit need to be opened, the SF6 gas needs to be reclaimed. The gas service unit (Plate 2) is the environmentally preferred and recommended equipment to be used when reclaiming SF6 gas as per the procedure in section 3.1. This unit also can be used to evacuate air from pole units and to fill pole units with gas.

Plate 2: Gas service unit

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 16 3.1 Reclaiming SF6 Gas from a Pole Unit Gas in individual pole units can be reclaimed via the quick disconnect gas valves at the bellcranks, after all the gas manifolds and/or bellcrank-mounted density gauges have been removed. Follow the instructions in Section 3.5 if it is necessary to isolate the pole unit from the gas system Notice: If the breaker uses a single density monitor, gas can also be reclaimed from all three pole units simultaneously, via the left pole's quick disconnect valve.

SF6 gas must be reclaimed before opening a pole unit. Gas can be reclaimed from one, two, or all three pole units.

DANGER Remove the SF6 gas before attempting to open the pole unit. Break the vacuum if the tank pressure is below atmospheric pressure.
Use a gas service unit (Plate 2) to reclaim SF6 gas from the pole unit. When using a gas service unit, make sure that an in-line portable filter with a molecular sieve medium (desiccant) is installed. The filter removes moisture and decomposition products from the gas. Refer to section 3.3 to install the filter. Place the filter vertically in the line between the quick disconnect fill valve 10154 (Fig. 5) and the SF6 gas service unit. Important: The 13x molecular sieve (desiccant) must be replaced after passing approximately 3500 pounds of gas through the filter. Refer to section 3.4. It is not economical or environmentally wise to exhaust the SF6 gas to the atmosphere. The gas service unit should be used to reclaim SF6 gas only. Therefore, no air or other gases should ever be in the tank of the gas service unit. Check that air is purged from the unit and that the SF6 gas already contained in the unit is of good quality (particularly in regards to gas moisture content). Use a moisture analyzer to check the moisture content of the gas in the gas service unit. The moisture content ideally should be less than 200 ppmV Review instructions for the gas service unit if you are not already familiar with the unit.

To reclaim SF6 gas from one or more pole units: 1. Loosen the nut on the quick disconnect valve of the density gauge or gas manifold on each pole unit to be reclaimed. Remove the gauge(s) or manifold(s). Attach the flexible hose from the gas service unit to each pole unit to be reclaimed, screwing on the connecting nuts up to the groove in the threads of the disconnect (Malmquist) valve. Evacuate the hose from the gas service unit to drive out air and moisture using the vacuum pump. Screw the nuts fully onto each valve. Follow the gas service unit procedures step-by-step to reclaim the SF6 gas until a vacuum of about 2 mm Hg is achieved. Then close all valves on the gas service unit. Break the vacuum by inserting a quick disconnect valve adapter without a closure on the outside end into the valve. Air will suck into the tank. Since breaking the vacuum fills a pole unit with moist atmospheric air, it is strongly recommended to open the pole unit and clean the internal components of the pole tank promptly after breaking vacuum. Refer to section 5.2.1.

2.

3. 4. 5.

6.

Warning
If powdery decomposition products are present (when the pole unit is opened) they must be removed and disposed of as soon as possible as described in section 6. Clean the breaker parts promptly after opening the pole unit to prevent damage caused by corrosive compounds formed when decomposition products are exposed to moisture in the air.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 17 3.2 Filling the Circuit Breaker with SF6 Gas 3.2.1 Filling a Pole Unit from a Gas Cylinder

The properties of the sulfur hexafluoride (SF6) gas used in the breaker must meet the specifications for sulfur hexafluoride according to ASTM D2472. The circuit breaker should be filled with SF6 gas to a pressure of 87 psig (0.60 MPa) when using a standard temperature compensated pressure gauge. Refer to Figures 3 and 4 when using a non-temperature compensated pressure gauge. Although the pole units can be filled using either a gas cylinder (bottle) (section 3.2.1) or a gas service unit (section 3.2.2), it is recommended to use the gas service unit. The gas cylinder can be used to top off or fill the pole units as long as the pole units have not been opened and contain a definite positive pressure of SF6 gas. Notice: If breakers were shipped with a partial charge of dry nitrogen gas or if the pole units had been opened, a new desiccant bag needs to be installed in the open pole units (section 5.2.3), the rear tank cover re-installed (section 5.2.4), and the pole units will need to be evacuated before being filled with SF6 gas as per section 3.2.2.2. Evacuation must be done within 30 minutes after desiccant replacement.

Filling the breaker pole units with SF6 gas from a gas cylinder should only be done if the pole tanks have not been opened and a positive pressure of at least 5 psig (0.03 MPa) at 68F (20C) remains in the pole tank. Using a portable in-line filter/drier is optional if filling from a gas cylinder. SF6 gas is available in standard industrial type cylinders. The adapter needed for connecting to the cylinder is a CGA #590 male left-hand thread connector. Cylinders containing a charge of either 25 lbs or 115 lbs of gas are available. The pressure in the cylinder is 300 psi at 75F (24C). Important: The gas cylinder should be vertical at all times to prevent introducing liquefied gas into the circuit breaker. Particulate matter within the gas cylinder can be carried with the liquefied gas into the breaker.

Typically when a domestic breaker is shipped from the factory, it already is positively charged with SF6 gas to approximately 5 psig (0.03 MPa). As long as this initial charge of gas is present, the breaker can be simply topped off to the proper level on installation. However, before filling the breaker with SF6 gas, make sure that this positive pressure has not been lost due to leakage or damage during shipping, etc. If the positive charge of gas is gone, determine the cause and correct the problem. Refer to section 4.3 for leak checking procedures. When the leak has been corrected or if you are filling an overseas breaker where the bushings had to be installed, refer to section 5.2.3 for instructions on replacing the desiccant bag. Then, follow the procedure for evacuating and refilling a pole unit which has been opened as per section 3.2.2.2. (Gas filling procedures vary in cases where the breaker pole units have been opened and unopened.) Gas can be filled at an individual pole unit via the quick disconnect valve at the bellcrank, after the gas manifold or bellcrank-mounted density gauge has been reinstalled. Follow the instructions in Section 3.5 if it is necessary to isolate the pole unit from the gas system If the breaker uses a single density monitor, gas can also be filled at all three poles simultaneously via the left pole's quick disconnect valve 10154. To fill the unopened pole unit(s) with gas from a gas cylinder: 1. Purge a hose and filter (if used) by allowing SF6 gas from the cylinder to pass through the hose driving out air and moisture. (A quick blast purge through the hose is not sufficient to adequately eliminate air and moisture especially if using a long hose with a large diameter.) Decrease the gas flow and immediately begin connecting a hose to each necessary pole unit valve. Refer to Plate 3.

2.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 18 3. Attach a hose from the cylinder (with pressure gauge and regulator somewhere in the hose line) to each pole to be filled. Connecting nuts at the valves should only be screwed onto the valves up to the thread gaps until all hoses are connected. Then screw the nuts on fully. Notice: Perform tests as described in section 4 to ensure that the breaker is operating properly before placing the breaker into service. Initially the moisture content tends to be erroneously high when the breaker is just filled with SF6 gas. That is why ABB recommends, if possible, allowing three days to pass after filling the breaker with gas before taking the moisture reading as per section 4.2. At that time, the moisture reading should more accurately reflect the true moisture content of the gas. One cylinder of gas will be sufficient to fill one breaker. Usable gas may remain in the cylinder after the breaker is filled. When filling during cold ambient temperatures, the cylinder may be heated using any of the following methods to convert the liquid SF6 in the cylinder to a gaseous state: An electric blanket heater; Immersing the gas cylinder upright in a drum partially filled with warm water so that approximately half of the cylinder is immersed. Heat the water with a portable gas or electric heater. Plate 3: Disconnect valve for connecting the fill hose 4. Fill the pole unit(s) to 87 psig (0.60 MPa) when using the standard temperature compensated pressure gauge. Refer to Figures 3 and 4 when using a nontemperature compensated pressure gauge. When using a non-temperature compensated pressure gauge, compensate for temperature variation as shown in the pressure vs. temperature characteristics of Figure 3. The SF6 Gas Filling and Density Monitor Calibration Chart in Figure 4 is a quick reference, tabular version of the characteristics in Figure 3. For example, at 30F (-1C) the correct fill pressure would be 78.2 psig (0.54 MPa). At higher altitudes the fill pressure at 68F (20C) is slightly different and increases incrementally almost linearly by approximately 1.4 psig per 3000 ft for fill pressures at 68F (20C). 5.

Warning
Never heat a gas cylinder with an open flame. Energize heaters only when transferring the gas. When heating the cylinder, be sure that the temperature in the cylinder does not exceed 100F (38C). For single hose filling, unscrew the disconnect valve nut. Then remove the hoses. Pressurized gas in the hoses will escape to the atmosphere. If an octopus hose is used, then unscrew each disconnect valve nut until the thread gap is visible. Then remove the hoses. Pressurized gas in the hoses will escape to the atmosphere. 6. After filling and removing the fill hose, reattach the pressure gauge or gas manifold on the pole unit and check that the nut on the quick disconnecting valve 10154 (Fig. 11a/b) is tight. Allow the gas pressure and temperature to stabilize for 15 minutes and re-check the pressure in the pole unit before removing the gas filling equipment. Perform tests as described in section 4 to ensure that the breaker is operating properly before placing the breaker into service. Initially the moisture content tends to be erroneously high when the breaker is just filled with SF6 gas. That is why ABB recommends, if possible, allowing three days to pass after filling the breaker with gas before taking the moisture reading as per section 4.2. At that time, the moisture reading should more accurately reflect the true moisture content of the gas.

Important:

Notice:

Warning
The gas regulator must be adjusted approximately to the final fill pressure of the breaker (87 psig (0.60 MPa)) at 68F (20C) such that the SF6 plumbing, density monitor, and gauge are not over-pressurized. Compensate for temperature variations as needed. Do not over-pressurize the circuit breaker when filling the breaker with SF6 gas. Over-pressurization may cause the rupture disk to burst. Notice: Allow the gas pressure and temperature to stabilize for 15 minutes and re-check the pressure in the pole unit before removing the gas filling equipment.

Notice:

Notice:

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 19 3.2.2 Filling Pole Units Using a Gas Service Unit Gas can be filled at an individual pole unit via the quick disconnect valve at the bellcrank, after the gas manifold or bellcrank-mounted density gauge has been reinstalled Follow the instructions in Section 3.5 if it is necessary to isolate the pole unit from the gas system If the breaker uses a single density monitor, gas can also be filled at all three poles simultaneously via the left pole's quick disconnect valve 10154. To fill an unopened pole unit: 1. 2. Remove the pressure gauge or manifold from the pole unit disconnect valve on the bellcrank housing. Purge the hose from the gas service unit with a quantity of SF6 gas equal to approximately 10 times the volume of the hose to eliminate air and moisture. (A quick blast purge through the hose is not sufficient to adequately eliminate air and moisture - especially if using a long hose with a large diameter.) Decrease the gas flow from the gas service unit and immediately connect the hose to the disconnect valve, first up to each valve thread gap and then fully tightened. Open the appropriate valve on the gas service unit.

The gas service unit (Plate 2 in section 3) can be used to fill pole units which have never been opened, e.g. on initial installation of the breaker (section 3.2.2.1) or when evacuating and refilling pole units which have been opened (section 3.2.2.2). When using a gas service unit, make sure that an in-line portable filter with a molecular sieve medium (desiccant) is installed on the gas service unit. The filter removes moisture and decomposition products from the gas. Refer to section 3.3 to install the filter. Place the filter vertically in the line between the quick disconnect fill valve 10154 (Fig. 5) and the SF6 gas service unit. Gas will be forced to flow through the desiccant in the filter/drier. Care must be taken to ensure that liquid SF6 does not enter the portable filter or breaker. Important: The 13x molecular sieve (desiccant) must be replaced after passing approximately 3500 pounds of gas through the filter. Refer to section 3.4.

3.

No air or gas other than SF6 should ever be in the tank of the gas service unit. Check that air is purged from the unit and that the SF6 gas already contained in the unit is of good quality (particularly in regards to gas moisture content). Before refilling, use a moisture analyzer to check the moisture content of the gas in the gas service unit. Review instructions for the gas service unit if you are not already familiar with the unit. 3.2.2.1 Filling Unopened Pole Units - Initial Filling on Installation (Typically for Domestic Breakers) When the breaker is shipped from the factory, it already is positively charged with SF6 gas to approximately 5 psig (0.03 MPa). As long as this initial charge of gas is present, the breaker can be simply topped off to the proper level on installation. However, before filling the breaker with SF6 gas, make sure that this positive pressure has not been lost due to leakage or damage during shipping, etc. If the positive charge of gas is gone, determine the cause and correct the problem. Refer to section 4.3 for leak checking procedures. When the leak has been corrected, refer to section 5.2.3 for instructions on replacing the desiccant bag. Then, follow the procedures for closing, evacuating, and refilling a pole unit which has been opened as per sections 5.2.4 and 3.2.2.2.

4.

Plate 4: Disconnect valve for connecting the fill hose

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 20 5. Fill the pole unit to 87 psig (0.60 MPa) when using the standard temperature compensated pressure gauge. Refer to Figures 3 and 4 when using a non-temperature compensated pressure gauge. When using a non-temperature compensated pressure gauge, compensate for temperature variation as shown in the pressure vs. temperature characteristics of Figure 3. The SF6 Gas Filling and Density Monitor Calibration Chart in Figure 4 is a quick reference, tabular version of the characteristics in Figure 3. For example, at 30F (-1C) the correct fill pressure would be 78.2 psig (0.54 MPa). At higher altitudes the fill pressure at 68F (20C) is slightly different and increases incrementally almost linearly by approximately 1.4 psig per 3000 ft for fill pressures at 68F (20C). 2. Attach the flexible hose from the gas service unit to the disconnect valves on each pole to be evacuated.

Important:

Notice:

Warning
Do not over-pressurize the circuit breaker when filling the breaker with SF6 gas. Over-pressurization may cause the rupture disk to burst. 6. After filling and removing the fill hose, reattach the pressure gauge or gas manifold on the pole unit and check that the nut on the quick disconnecting valve 10154 (Fig. 11a/b) is tight. Allow the gas pressure and temperature to stabilize for 15 minutes and re-check the pressure in the pole unit before removing the gas filling equipment. Perform tests as described in section 4 to ensure that the breaker is operating properly before placing the breaker into service. Initially the moisture content tends to be erroneously high when the breaker is just filled with SF6 gas. That is why ABB recommends, if possible, allowing three days to pass after filling the breaker with gas before taking the moisture reading as per section 4.2. At that time, the moisture reading should more accurately reflect the true moisture content of the gas. 3.2.2.2 Evacuating and Refilling Pole Units Use this procedure for pole units which have been opened to evacuate pole units of air and refill with SF6 gas. Notice: Since the pole units had been opened, a new desiccant bag 10008 (Fig. 9) on the rear tank cover assembly must be installed just before re-installing the rear tank cover assembly 10032 and proceeding with the evacuation/ refill procedure. (Refer to sections 5.2.3 and 5.2.4 for specific instructions.) 5. 6.

Plate 5: Disconnect valve for connecting the fill hose 3. 4. Start the vacuum pump and/or follow the gas service unit procedures step-by-step to evacuate the pole unit(s). Follow the gas service unit procedures step-by-step to evacuate the pole tank(s). Pull a vacuum to below 1.0 mm Hg absolute. (Use an accurate electronic vacuum gauge to verify the vacuum reading.) Once vacuum has reached less than 1.0 mm Hg, hold the vacuum for a minimum of 1 hour. After vacuum is complete, turn off the vacuum pump. Fill the pole unit to 87 psig (0.60 MPa) when using the standard temperature compensated pressure gauge. Refer to Figures 3 and 4 when using a non-temperature compensated pressure gauge. Whenusing a non-temperature compensated pressure gauge, compensate for temperature variation as shown in the pressure vs. temperature characteristics of Figures 3 and 4. At higher altitudes the fill pressure at 68F (20C) is slightly different and increases incrementally almost linearly by approximately 1.4 psig per 3000 ft for fill pressures at 68F (20C).

Notice:

Notice:

Important:

Notice:

Warning
Do not over-pressurize the circuit breaker when filling the breaker with SF6 gas. Over-pressurization may cause the rupture disk to fail. Notice: Allow the gas pressure and temperature to stabilize for 15 minutes and re-check the pressure in the pole unit before removing the gas filling equipment.

To evacuate and refill one, two, or all three pole units: 1. Remove the pressure gauges or gas manifolds from the pole unit bellcrank housings.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 21 7. When all pole units have been filled with SF6 gas, remove the filling hose and then reattach the density gauge or gas manifold on each pole unit's disconnect valve, and tighten the large nut. 4. Pour the desiccant from the shipping container directly into the filter on the gas service unit using a funnel; fill to about 1 inch from the top of the unit. Fill the unit with desiccant as quickly as possible to reduce the time which the molecular sieve and the interior of the column are exposed to atmospheric moisture. Install the top pipe plug as soon as the filter is filled. Isolating the Pole Unit from the Gas System

Warning
Ensure that the nut on each quick disconnect valve 10154 is tight for proper operation. 8. Perform tests as described in section 4 to ensure that the breaker is operating properly before placing the breaker into service. Initially the moisture content tends to be erroneously high when the breaker is just filled with SF6 gas. That is why ABB recommends, if possible, allowing three days to pass after filling the breaker with gas before taking the moisture reading as per section 4.2. At that time, the moisture reading should more accurately reflect the true moisture content of the gas. Installing the Portable In-Line Filter 5. 3.5

If a breaker uses three gas density monitors, then each pole unit is automatically isolated and there is no need to further follow the instructions in this section. If a breaker uses only one monitor, a gas manifold (Figs. 6 and 11) links the three pole units into a single gas density monitoring system. A Quick Disconnect Gas Valve 10154 (Figs. 5 and 9) is at each bellcrank or tank belly which allows pole units to be isolated from the gas manifold as needed. This fitting has a groove in its barrel which serves as an indicator showing that the pole unit is either open to the gas system or isolated. The groove is not visible when the pole unit is open to the gas manifold and the nut is tight.

Notice:

3.3

A filter utilizing the 13x molecular sieve (desiccant) can be used on either the gas cylinder or on the gas service unit. To install the portable in-line filter, place the filter vertically in the line between the pole unit quick disconnect valve and the SF6 gas service unit or gas cylinder. The gas will be forced to flow through the desiccant. Use care to ensure that liquefied SF6 does not enter the portable filter or breaker. Replace the desiccant (13x molecular sieve) after passing approximately 3500 pounds of gas through the filter. Refer to section 3.4. 3.4 Replacing Desiccant in the Portable In-Line Filter

DANGER Before proceeding, isolate, ground, and de-energize the circuit breaker.
To isolate the pole unit from the gas system: 1. Turn or loosen the nut on the fitting until a large groove (Figs. 9-View A, 11) in the threads of the fitting is visible. When the groove is visible, stop turning the nut. Do not remove the nut completely. As long as the nut is just loosened and not removed, the tubing side of the fitting remains sealed in this intermediate position by Orings and the pole unit is isolated. At this point, the fitting is self-sealed by a spring-loaded valve. The tubing side to the fitting does not self-seal when the nut is removed completely and the tubing is pulled from the fitting. This is why the nut should not be completely removed.

The portable in-line filter for the gas service unit incorporates a 13x molecular sieve (desiccant) to remove moisture from the SF6 gas. When the desiccant is spent, it needs to be replaced. (This desiccant is not to be confused with the desiccant bag in the rear tank cover of the pole unit.) The key rule of thumb when replacing the desiccant is to avoid exposing the desiccant to atmospheric moisture. Therefore, it is best to perform this replacement procedure indoors if possible. If hoses are not connected to the gas service unit, always keep the flared cap in place to protect the threads and sealed from the atmosphere. (Perform this procedure indoors if possible.) To replace the desiccant in the portable in-line filter: 1. Stand the gas service unit upright and remove the pipe plug at the bottom end of the unit, releasing the old desiccant. Discard the used desiccant. Check the plug and clean the threads thoroughly. Apply Teflon tape and Rector Seal #2 to the pipe plug and replace the plug.

Notice:

If a pole unit needs to be opened, the SF6 gas must be reclaimed as per instructions in Section 3.2

Warning
Remove the SF6 gas before attempting to open the pole unit. Break the vacuum if the tank pressure is below atmospheric pressure. After evacuating and/or refilling the pole unit, reconnect it to the gas manifold by fully tightening the Quick Disconnect Gas Valves 10154. Important: Ensure that the nut on each Quick Disconnect Gas Valve 10154 is tight for proper operation.

2. 3.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 22

4.

Testing

4.2.1

Measuring the Moisture

The following should be performed when installing the breaker: Pole resistance measurement (section 4.1); Moisture measurement of the SF6 gas (section 4.2); Leak checking (section 4.3); Operational and timing tests (section 4.4 and the Customer Data module); Checking the oil level in the mechanism (Mechanism module). 4.1 Pole Resistance Measurement

To ensure reliable moisture measurements, pay particular attention to cleanliness and prescribed procedure, particularly as it applies to preventing moisture from contaminating the moisture analyzer (hygrometer) and its connections. It is important that the recommendations of the analyzer supplier be followed carefully. The gas can be sampled through a 1/4-inch NPT male fitting that is part of the sample valve tool T13480. To use this tool, attach it to the malmquist adapter tool T13481 (Figure 5). Both tools are available in the general maintenance tool kit assembly (available for order through ABB). Use only dry stainless steel tubing to connect the moisture analyzer to the disconnect gas valve on the bellcrank. 4.3 Leak Checking

Using a 100 A micro-ohmmeter (or millivolt drop meter), perform a contact resistance (or milliVolt drop) measurement on each pole of the breaker. Refer to the Customer Data module for the contact resistance value. 4.2 Moisture Measurement of the SF6 Gas

After the breaker has been opened or if an SF6 leak is suspected, check the following threaded, O-ring and gasket connections with a hand-held halogen leak detector: 4.4 Tube connections and fittings to the density gauge; SF6 gas density monitors; SF6 gas plumbing and gas manifolds; Rupture disk; Bushing flanges; Rear tank cover assembly; Bellcrank housing; Interphase shaft seals with the breaker opened and closed. Operational and Timing Tests

The maximum moisture level permitted in the SF6 gas when measured at 1 atmosphere of pressure is: 500 ppmV (by volume) at 68F (20C) for up to 3 days after filling 200 ppmV (by volume) at 68F (20C) after the pole unit has been allowed to stabilize for at least 3 or more days after gas filling Caution Should the moisture content of the SF6 gas exceed 200 ppmV 3 or more days after gas filling, the SF6 gas must be reclaimed and recycled through a drying filter. Before refilling, the circuit breaker must be evacuated to eliminate moisture using the procedure in section 3.2.2.2 for evacuating and refilling a pole unit that has been opened. Because there is always a higher partial pressure of moisture vapor external to the pole unit, moisture will slowly migrate into the pole units over time. This is why it's important to have a moisture content of no more than 200 ppmV three days after filling the breaker with gas. The desiccant bags 10008 (Fig. 9) in each pole tank will sufficiently remove moisture from the gas. The desiccant bags are replaced whenever the interrupter is opened for inspection or replaced. However, the moisture content can go as high as 500 ppmV before requiring a dry-out procedure (using a drying filter) for the SF6 gas. The maximum moisture content to be expected from an SF6 gas cylinder is: SF6 Dew Point of -50F (-45C) or 63 PPM by volume Use a moisture analyzer (hygrometer) to measure the moisture content of the SF6 gas in each pole unit. Refer to section 4.2.1. 3. 4.

Before placing the breaker into service, perform operational and timing tests. Section 4.4.1 defines operational tests; the Timing module details procedures for timing tests. 4.4.1 Operational Tests

The control relays, protection devices, and schemes must be fully checked by operational tests to ensure that the breaker is ready for service. Because the control schemes are usually designed as per customer specifications, operational tests vary depending upon the particular control scheme. Refer to the breaker control schematic to determine the necessary operational tests to be performed. Generally, operational tests include the following steps: 1. Assure that the circuit breaker will open and close electrically at both the local control switches and at the remote control switches. If a local/remote or maintenance test switch is used, verify that it is functioning properly. Check the alarm and operation lock-out functions for proper actuation. One parameter is monitored: the operating energy of the mechanism. To verify the operating energy of the mechanism, refer to the "Commissioning" section of the Mechanism module. Verify that the anti-pumping circuitry is operating properly as per your particular control scheme. Test any optional devices i.e., undervoltage relays, reclose time delay relays, etc.

2.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 23

Tank Existing Quick Disconnect Valve

Tank Boss

Pressurizing Valve (Valve #1)

Pressure Gauge (Density)

Gas Release Valve (Valve #2) Disconnect Valve Manifold Block

Density Monitor

Flexible Conduit

Cover hanging from Conduit

Illustration 2 Density Monitor Calibration Tool (T993DMM) Using Pole Unit Gas

4.5

Check the Oil Level in the Mechanism

Check the oil level in the mechanism every year. Refer to the Mechanism module for instructions on checking the oil level. 4.6 4.6.1 Density Monitor Set Point Tests Tests Using Pole Unit Gas 6

Use valve # 1 to pressurize the density monitor. Slowly bleed off pressure with valve # 2, monitoring the alarm contacts of the density monitor. Replace monitor if set points are more than 2 psi out of the specified range. When testing is complete, close all valves, remove the density monitor from the test device, remove the test device, reattach density monitor to the tank mounted disconnect valve, apply Dow 1292 grease to the tank boss surface, and attach the cover assembly. Make sure that the wires are not trapped and the wire terminations at the monitor are in good condition. Tighten the cover retaining nut (use Loctite 242 on threaded stud) until there is a sudden increase in torque . The cover will be flat against the tank boss at this point. Inspect the cover gasket and make sure it is sealed against the tank boss. Reattach the plastic caplug over the stud end, turning while pushing to engage the stud threads into the caplug end shape.

Test Procedure: 1 2 3 4 Remove cover assembly (one nut at bottom of cover) and push down and out of the way. Remove density monitor from existing disconnect valve. Attach test device at existing disconnect valve. Valves # 1 and # 2 must be closed. Attach density monitor to disconnect valve on test device.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 24

Tank

Tank Boss

Existing Quick Disconnect Valve

Illustration 3 Density Monitor Calibration Tool (T994DMM) Using Separate Gas Source

Flexible Conduit Existing Density Monitor

Disconnect Valve

Pressure Gauge

Fill/Release Valve

Test Gas Source

Cover, hanging from Conduit

Manifold Block Provide Support Here

4.6.2

Tests Using a Separate Gas Source

Test Procedure: 1 2 3 4 5 Remove cover assembly (one nut at bottom of cover) and push down and out of the way. Remove density monitor from existing disconnect valve. Attach density monitor to test device disconnect valve. Attach hose from a gas bottle (N2 suggested) to valve on test device. Use valve to pressurize the density monitor. Remove hose and slowly bleed off pressure with valve, monitoring the alarm contacts of the density monitor. Replace monitor if set points are more than 2 psi out of the specified range.

When testing is complete, remove the density monitor from the test device, reattach density monitor to the tank mounted disconnect valve, apply Dow 1292 grease to the tank boss surface, and attach the cover assembly. Make sure that the wires are not trapped and the wire terminations at the monitor are in good condition. Tighten the cover retaining nut (use Loctite 242 on threaded stud) until there is a sudden increase in torque . The cover will be flat against the tank boss at this point. Inspect the cover gasket and make sure it is sealed against the tank boss. Reattach the plastic caplug over the stud end, turning while pushing to engage the stud threads into the caplug end shape.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 25

5.

Maintenance

DANGER
Failure to observe the requirements of OSHA Standard 1910.269 can cause death or severe burns and disfigurement. That standard specifically prohibits the wearing of polyester, acetate, nylon, or rayon clothing by employees working with exposure to electric arcs or flames.
5.1 Maintenance Tips During maintenance, especially if the pole units are open to the atmosphere, avoid introducing loose dirt, especially metallic particles, into an open pole unit. This material can cause dielectric failure. Protect insulating surfaces from physical, damage (nicks and scratches) and keep surfaces clean and dry at all times. In silverplated joints, place the Loctite in the bolt holes and not on the bolt threads. Wear snug-fitting cloth gloves when handling insulating parts and surfaces. Wipe insulating surfaces with new, clean lint-free wipers dampened with denatured ethyl alcohol. Important: Never clean an insulating component with the same wiper used to clean aluminum or metal parts.

Procedures, materials, and equipment required for routine maintenance and testing of the 242 PMR circuit breakers are described in this portion of the module. By following the maintenance procedures in this manual, the 242 PMR circuit breaker will provide years of reliable, dependable service. Routine minimal maintenance checks are recommended yearly and every 5-years (see Table 1). Important: 5-Year Maintenance Checklists are included in the Checklists module. A Timing Checklist is in the Customer Data module. These checklists include the necessary items to check when performing routine maintenance on the breaker. The checklists specify allowable tolerances along with blank spaces for recording measured values for future reference and comparison.

Interrupter maintenance is based on the current load on the interrupter contacts. If the breaker is equipped with a Condition Monitoring Unit (CMU), the CMU indicates when interrupter maintenance (replacing nozzles and contacts in the interrupter) is required. Refer to the Interrupters module for details and the checklist for interrupter maintenance. In the absence of a CMU, interrupter maintenance is scheduled according to guidelines suggested in the Interrupters module. Table 1 on the next page provides a list of maintenance checkpoints and suggested inspection frequency for general breaker maintenance. Specific maintenance procedures for components such as the mechanism and interrupters are found in their respective modules. A service kit and any special tools required for this breaker should have been included with the original breaker shipment. Refer to the Customer Data module for a list of required and optional special tools and materials. All personnel designated to inspect and maintain this breaker must review section 6 in this module.

5.1.1

Applying Loctite

Apply Loctite Threadlocker to all critical bolted joints. Four types of Loctite are used for specific applications: 222, 242, 262, and 271. The Torque Tables 2a and 2b specify the recommended torque and type of Loctite to be applied to all fasteners (U.S. Standard and metric) in the breaker except where specified otherwise. Remove all old Loctite from bolt threads and in blind holes. Allow adequate time for all threads to dry prior to re-assembling parts. Caution In silverplated joints, place the Loctite in the bolt holes and not on the bolt threads. For all other joints, unless otherwise indicated, apply one to two drops of Loctite sparingly to the threads at the end of the bolt. If used improperly, especially in current carrying joints, Loctite can squeeze between contact areas and may cause a high resistance joint. Ensure that excess Loctite does not squeeze into contact areas.

DANGER
To prevent injury or equipment damage, the breaker must be removed from service, isolated, and grounded before performing any maintenance.
DO NOT WEAR POLYESTER, ACETATE, NYLON, OR RAYON CLOTHING (SUCH AS SHINY-TYPE SKI JACKETS AND WIND BREAKERS WHICH USUALLY CONTAIN NYLON) AROUND LIVE ELECTRICAL EQUIPMENT.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 26

Table 1 Suggested Maintenance Table Inspection Intervals Item/Condition Yearly (Breaker in-service) V V V V Test the circuit 5-7 Years (Remove from service) V V V V Test the circuit T T T T T T T T T Refer to the Checklists module

Record Number of Operations Check SF6 Gas Pressure/Density Check Anti-Condensation Heaters for Proper Operation Check Insulators for Cracks Check Tank Heaters for Proper Operation Check SF6 Gas Density Monitor Settings Check Moisture Content of the SF6 Gas Leak Test all Flanges, Fittings, and Gas Sealing Connections Perform Circuit Breaker Timing Perform Contact Resistance (Micro-Ohms) Measurements Check Bushing Hardware for Tightness Check Tank Hardware for Tightness (including tank heads, tank half flanges, etc.) Check Rupture Disk Hardware for Tightness Check Breaker Operating Linkage (including Auxiliary Switch Linkage) for tightness of connections Complete Maintenance Checklist Mechanism Maintenance Check Hydraulic Oil Level in the Mechanism Check Mechanism Anti-Condensation Heaters for Proper Operation Check Pump Motor Start Counter (for indication of excessive hydraulic pump starts-refer to the Mechanism module for details) Verify Mechanism Limit Switch Settings Check the Charging Motor Brushes for Excessive Wear Check Auxiliary Switch for Proper Adjustment Check That Mechanism Mounting Hardware and Wiring Terminals Are Tight

V V V -

V V V T T T T

Interrupter Maintenance

If your breaker is equipped with a Condition Monitoring Unit (CMU), this unit will indicate when it is necessary to replace the interrupter nozzles and contacts. In the absence of a CMU, refer to the Interrupters module, Table 1.

V - Visual Inspection, may require opening cabinets to read gauges and counters T - Physical Inspection - requires removing breaker from service and hands-on procedures "-" indicates no inspection needed

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 27 5.1.2 Seals 5. Always check seals for cracks, deformities, and brittleness before they are installed. Acceptable seals are free of cracks. Do not install seals that are cracked, brittle, or deformed. Flange Corrosion Protection

Sealing rings which have been in service will be deformed from being compressed into their sealing grooves. Therefore, when disassembling components with sealing rings, replace them. Replacements are available from ABB. Maintenance tips pertaining to seals include: 1. 2. 3. 4. Do not grease or lubricate O-rings or any other seals unless specified otherwise. Never clean seals with abrasives even if they are very fine. Use only lukewarm, soapy water to clean the seals. Use a soft, dry cloth to dry the seals.

5.1.3

Dow Corning FS-1292 Grease is recommended to be applied to sealing joints as a flange corrosion protectant. This grease is to be applied to all flange surfaces outside of the O-ring seals or areas where water can become entrapped between metal-to-metal joints. This grease should also be applied to bolt threads where water or moisture can become entrapped.

Table 2a
Torque Values for USA Standard Fasteners Material of Nut that Fastener screw s into Siz e Units Cast Aluminum or C o p p er Fastener Grade
S A E 2, 5, 8, B8 #10 ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm 3 4 6 8 12 16 20 30 50 70 70 100 100 135 SS-A2 2 3 6 8 11 15 19 25 45 60 65 85 85 115 S A E 2, B 8 3 4 6 8 12 16 20 30 50 70 70 100 100 135

Steel, Wrought Aluminum or Helicoils Fastener Grade

S A E 5, B 8 4 6 10 13 19 25 33 45 80 105 110 150 150 200 SAE 8 6 8 14 19 27 37 45 60 110 150 150 200 150 200 SS-A2 2 3 6 8 11 15 19 25 45 60 65 85 85 115

1/4-inch

5/16-inch

3/8-inch

1/2-inch

9/16-inch

5/8-inch

3/4-inch

ft-lbs

150

7/8-inch Nm 200

1-inch

Note: Use Loctite 222 for #10 to 1/4-inch screws and Loctite 242 for bolts larger than 1/4-inch. Keep Loctite off silverplated surfaces. Apply Loctite into bolt holes of silverplated joints and not on bolt threads.
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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 28 5.1.4 Treatment of Silverplating with Shell Alvania No. 2 Grease. Thoroughly rub the grease into the microscopic pores of the silverplated surface; remove all excess grease so that only a light film remains. Refer to the special ABB procedures (Supplements 1 and 2 addended to this module) for special applications pertaining to sliding surfaces and silverplated (static) surfaces and Shell Alvania No. 2 Grease.

Polish silverplated contact areas lightly with Scotch-Brite to remove surface oxide. Do not heavily abrade the silverplated surfaces to avoid rubbing off the plating. In situations where sliding contact joints are used, such as in the case of the plug-in type bushing conductors or main breaker contacts, the silverplated areas must be lubricated

Table 2b
Torque Values for Metric Fasteners Material of Nut that Fastener screw s into Cast Aluminum or C o p p er Siz e Units Fastener Grade
Grade 5.8, 8.8, 10.9 & Above M5 ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm 3 4 5 7 13 18 25 35 45 60 70 90 100 140 145 195 SS-A2 & Button Head 3 4 5 7 11 15 20 28 35 50 55 75 85 115 120 165 Grade 5.8 3 4 5 7 13 18 25 35 45 60 70 90 100 140 145 195 150 200

Steel, Wrought Aluminum or Helicoils Fastener Grade

Grade 8.8, 10.9 & Above 5 7 8 11 20 27 38 50 65 90 105 140 150 200 150 200 SS-A2 & Button Head 3 4 5 7 11 15 20 28 35 50 55 75 85 115 120 165

M6

M8

M10

M12

M14

M16

M18

M20

Note: Use Loctite 222 for M 5 to M 6 screws and Loctite 242 for bolts larger than M 6. Keep Loctite off silverplated surfaces. Apply Loctite into bolt holes of silverplated joints and not on bolt threads.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 29 5.2 Pole Unit Maintenance Procedures Observe all safety precautions pertaining to handling SF6 gas and its by-products as per section 6. Open the pole tank by removing the tank end bolts 10071 (Fig. 9) and washers holding the rear tank cover assembly 10032 in place.

Special pole unit maintenance procedures include: Removing the rear tank cover and cleaning the pole tank (section 5.2.1); Replacing the rupture disk (section 5.2.2); Replacing the desiccant bag (section 5.2.3); Re-installing the rear tank cover assembly (section 5.2.4); Isolating a pole unit (section 5.2.5); Rebuilding the bellcrank (section 5.2.6); Removing/installing current transformers (section 5.2.7); SF6 gas density monitor calibration (section 5.2.8).

Warning
If powdery decomposition products are present accompanied by an odor of rotten eggs (when the pole unit is opened) they must be removed and disposed of as soon as possible as described in section 6. Give the most priority to removing and cleaning the interrupter (as per instructions in the Interrupters module). You will need to work fast to minimize exposing the decomposition products to atmospheric air moisture. Clean the powder off the interrupter first, then clean the internal surface of the bushing insulators as per instructions in the Bushings module. Then remove any lingering decomposition products from the pole tank internal surface. Work on one pole unit at a time. If decomposition products are present on parts, do not allow these parts to sit overnight with this powder on them. Clean the parts off promptly otherwise the parts will corrode. Collect all powdered decomposition products with an approved vacuum cleaner. Wipe all internal tank surfaces, the bushing conductor 20001 (Fig. 9), and interrupter, especially insulating surfaces, with lint-free wipers dampened with denatured ethyl alcohol. Important: As an extra precaution, do not leave even a clean pole tank open overnight. Re-install the rear tank cover with a few bolts to keep out debris and moisture.

DANGER
To prevent injury or equipment damage, the breaker must be removed from service, isolated, and grounded before performing any maintenance procedures.
5.2.1 Removing the Rear Tank Cover and Cleaning the Pole Tank

Prior to removing the rear tank cover assembly 10032 (Fig. 9), reclaim the SF6 gas from the pole unit as described in section 3.1. Work on one pole unit at a time. Do not open all three pole units at once if the units have been in service for a while. When opening a pole unit which has been in service for a while, a significant amount of SF6 decomposition products (in the form of a powder) can accumulate in the pole unit and on the interrupter and within the bushing internal walls. (These decomposition products are formed by heat produced during current interruption.) As long as the pole unit is sealed and the internal atmosphere is dry, these decomposition products pose no inherent threat to the breaker. However, when exposed to ambient air moisture, such as when the pole unit is opened, these SF6 decomposition products can quickly form corrosive and conductive compounds which are aggressive toward materials within the circuit breaker, especially insulating surfaces, if subjected to prolonged exposure to atmospheric air. Refer to section 6 for more details.

To re-install the rear tank cover assembly with a new desiccant bag, refer to sections 5.2.3 and 5.2.4.

Warning
Solid SF6 decomposition products could be harmful if swallowed by humans or animals. Do not inhale or allow decomposition products to come in contact with the skin, eyes, and respiratory system. Severe irritation or burning may result. As a precaution, wear gloves, protective clothing, and a respirator before removing the rear tank cover assembly.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 30 5.2.2 Replacing the Rupture Disk

The bottom of each pole tank is equipped with a nickel reverse buckling rupture disk 10017 (Figs. 9 and 10). If the disk ruptures (for example from over-pressurization due to over-filling or as the result of a defective disk, etc.) it needs to be replaced. The burst pressure of the ruputre disk is given on the first sheet of the wiring diagram shipped with the breaker. The following procedure assumes that the pole unit is empty of SF6 gas. To replace the rupture disk: 1. Remove the four bolts 10072 (Fig. 10) which fasten the rupture disk holding ring 10036, O-ring 90035, and rupture disk 10017 in place. Refer to Illustration 4. Replace the old rupture disk and rupture disk O-ring with a new rupture disk 10017 and new rupture disk Oring 90035. Caution Store rupture disks 10017 in individual boxes as received from the supplier. Avoid touching or bumping the domed center. Never set the disk down on the domed center side and never install a rupture disk that is dented or scratched. 3. Clean all metal parts of the rupture disk assembly with lint-free wipers dampened with denatured ethyl alcohol. Apply FS-1292 to the threads of the four bolts 10072. Clean out the O-ring groove with lint-free wipers dampened with denatured ethyl alcohol. Install a new rupture disk O-ring 90035. Make sure that the rupture disk is centered over the 60 mm hole (Illustration 4) before proceeding. Grease the recessed surface outside the O-ring with Dow Corning FS-1292 Grease. Re-install the rupture disk holding ring 10036 by installing the bolts 10072 (with FS-1292 Grease on the bolts) and washers H420A64012 using the appropriate torquing pattern to ensure even tightening and sealing. Torque the bolts to 50 ft-lbs.

FS-1292 Grease

FS-1292

10017 10036 Rupture Disk Rupture Holding Ring Disk

60 mm Hole 90035 O-Ring Bolts 10072 Washer FS-1292 to bolt threads Torque to 50 ft-lbs

2.

Cross Sectional View

Illustration 4 Rupture Disk Cover Assembly

4. 5.

6. 7.

Replace the desiccant bag with a new desiccant bag as described in section 5.2.3 and then re-install the rear tank cover assembly as described in section 5.2.4.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 31 5.2.3 Replacing the Desiccant Bag

"Desiccant" refers to a molecular sieve which removes moisture as well as SF6 decomposition products from the gas. A desiccant bag 10008 (Fig. 9) is installed in every pole unit at the rear tank cover assembly 10032. Important: Any time that a pole unit has been opened or otherwise exposed to the atmosphere, replace the desiccant bag . The desiccant bag should be installed immediately before the pole unit is closed with the evacuation process following soon thereafter to prevent prolonged exposure to moist atmospheric air.

Screws 10095

Before replacing the desiccant bag, perform the following maintenance procedures: Reclaim all SF6 gas from the tank as per section 3.1. Remove the rear tank cover assembly as described in section 5.2.1. To replace the desiccant bag: 1. Obtain a new desiccant bag 10008 (Fig. 9 and Illustration 5). These bags are shipped in a hermetically sealed reinforced aluminum foil bag to prevent contamination due to atmospheric moisture. The date of manufacture is marked on the outer bag. Do not use any desiccant bags marked with a date that is over two years old. Cover 10037

Desiccant Bag 10008

Important: 2.

Carefully open the outer aluminum bag at one end. If using a knife or scissors, be careful not to tear the inner bag when opening the outer bag. Immediately check that the dot on the moisture indicator tag included in the bag is blue. If it is not blue, the outer bag may have been damaged. In this case, do not use the new desiccant bag; discard it and get a new one. The protective outer bag is sealed under vacuum as indicated by the tight-fit. However, in very warm ambient temperatures, the molecular sieve gives off air it has absorbed which may cause the outer bag to expand and look like a pillow. This does not necessarily indicate that the desiccant is ineffective; the desiccant bag still is usable.

Illustration 5 Desiccant Bag and Rear Tank Cover Assembly

3.

Install the desiccant bag by removing the screws 10095 (Fig. 9 and Illustration 5), which fasten the cover 10037 to the rear tank cover assembly 10032. Place the new desiccant bag between the cover and rear tank cover. Re-install the screws 10095. Torque the hardware as specified in Tables 2a/b. Discard used desiccant bags with other decomposition products. Regenerating the desiccant for reuse, although possible, is not recommended. Use precautions described in section 6.4 when removing the desiccant bags.

4.

Re-install the rear tank cover assembly and apply vacuum as soon as possible to avoid over-exposing the desiccant to moist atmospheric air. Refer to section 5.2.4.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 32 5.2.4 Re-installing the Rear Tank Cover Assembly 5.2.5 Isolating a Pole Unit

Prior to re-installing the rear tank cover assembly 10032 (Fig. 9), be sure to install a fresh desiccant bag 10008 (if it has not already been done as per section 5.2.3). To install the rear tank cover assembly 10032 (Fig. 9): 1. Grease the rear tank cover flange from the outer circumference of the O-ring groove to the outside edge of the flange with Dow Corning FS-1292 Grease. Install a new O-ring 90002 (Fig. 9) by pressing it firmly into the groove. This O-ring does not require lubrication. (Refer to section 5.1.2 for guidelines about O-ring seals). Apply FS-1292 Grease to the threads of the tank end bolts 10071 and re-install the rear tank cover assembly 10032 using these bolts with washers H420A64012. Torque the bolts as specified in Tables 2a/b. Evacuate and refill the breaker with SF6 gas; refer to section 3.2.2.2.

Certain maintenance tasks require isolating a pole unit which entails de-coupling the interphase linkages. Eventually, the more critical tasks of synchronizing the interrupter contacts and re-coupling the interphase linkages arise.

DANGER Before beginning this procedure, isolate the breaker from high voltage and properly ground the breaker.
5.2.5.1 De-Coupling the Interphase Linkages (Removing the Interphase Shafts)

2.

3.

Warning
Before proceeding, verify that the operating mechanism is discharged in the OPEN position and that all control power is disabled. To remove the right side interphase shaft 10204 (Fig. 12): 1. 2. Punch out the roll pins 10209 from the couplings 10205. Slide the couplings 10205 onto the interphase shaft 10204 and lift off the shaft.

4.

To remove the left side interphase shaft 10204 (Fig. 12): 1. 2. Remove cover 10208 (Fig. 12) and linkage access cover 10212. Remove the retaining bolt 10188 (Fig. 13) and washer H973A06504 which holds the crank wrist pin 10210 in place. Slide out the crank wrist pin 10210 and move the mechanism pullrod assembly 10207 out of the way. Remove the crank bolt 10233 and nut H420A58008 from the center of the crank 10206. Slide the crank 10206 onto the interphase shaft 10204 (Fig. 12). Punch out the roll pin 10209 from the coupling 10205. Slide the coupling onto the interphase shaft and lift the crank and shaft away.

3. 4. 5. 6.

Proceed to section 5.2.5.2.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 33 5.2.5.2 Synchronizing the Interrupter Contacts If the interrupter units have been de-coupled, they must be properly synchronized with each other before re-installing the interphase linkages. To do this, all three interrupter units must be pulled into the fully OPEN position as described in the steps below. Only after all three interrupters are pulled into the fully open position can the interphase linkages be re-installed. 5.2.5.4 Re-Coupling the Interphase Linkages (Re-installing the Interphase Shafts)

Warning
Before proceeding, verify that the interrupter contacts have been synchronized as described in section 5.2.5.2 and that the operating mechanism is discharged in the OPEN position and that all control power is disabled. Open the disconnects in the control cabinet to all AC and DC power sources. Notice: Apply FS-1292 Grease to splined linkages.

Warning
It is absolutely essential that the interrupter contacts be properly synchronized with each other as well as with the operating mechanism. To synchronize the interrupter contacts: 1. Slide the manual open/close tool T13451 (Fig. 14) onto the splines of the bellcrank shaft 10156 (left) (Fig. 15), 10157 (center), or 10156 (right). Facing the control cabinet (bellcrank end of the interrupter), with the ratchet handle on the manual open/ close tool T13451 (Fig. 14), rotate the bellcrank shaft to the fully OPEN position by rotating the ratchet handle toward the rear of the breaker until you feel the interrupter bottom out. Caution You must feel the interrupter bottom out when rotating the bellcrank shaft to ensure that the interrupter is in the fully OPEN position. 3. 4. 5. Repeat steps 1 and 2 for each bellcrank shaft. Check the guide piston setting as per section 5.2.5.3. Re-couple the interphase linkages as per section 5.2.5.4. 2.

To re-install the right side interphase shaft 10204 (Fig. 12): 1. Slide the couplings 10205 onto the right side interphase shaft 10204 and re-install the shaft. Make sure that the flatter side of the shaft is closest to the center pole unit, facing down and horizontal. Tap the roll pins 10209 into the couplings 10205.

2.

To re-install the left side interphase shaft 10204 (Fig. 12): 1. Slide the linkage access cover 10212 (Fig. 12) over the left side interphase shaft 10204 before re-installing the shaft. Slide the crank 10206 (Fig. 13) and coupling 10205 (Fig. 12) onto the left side interphase shaft. Re-install the left side interphase shaft aligning the line-up dot on the crank 10206 (Fig. 13) with the lineup dot located on one of the splines of the center bellcrank shaft 10157. Caution The line-up dot on the crank and the line-up dot on the center bellcrank shaft must be aligned to ensure proper synchronization of the interrupters with respect to the mechanism. 4. Apply Loctite 242 to the crank bolt 10233 and re-install this bolt with nut H420A58008 into the crank 10206. Torque the bolt as per Tables 2a/b in this module. Tap the roll pin 10209 (Fig. 12) into the coupling 10205. Make sure that the interrupters are in the fully open position. Fully open the mechanism by pushing down on the pullrod assembly to bottom the mechanism into its opened position. Move the mechanism pullrod assembly 10207 into position and slide the crank wrist pin 10210 (Fig. 13) into place. The mechanism must be fully open. The crank wrist pin usually can be re-installed without requiring any adjustment of the pullrod length. However, because this pin is finely machined for precision fitting, it is sometimes difficult to insert the pin. Therefore a very slight adjustment of the turnbuckling pullrod may be required to align the pin. To adjust the

2. 3.

5.2.5.3 Setting the Guide Piston Length For breakers equipped with an HMB hydraulic mechanism, a guide piston screws 54040 (Fig. 20) screws on top of the mechanism pullrod. A very important length 114 mm, between the center of the piston pin 54045 and the mechanism top plate must be attained to ensure proper operation. This length is attained by removing cotter pin A and turning the screw-on guide piston up or down as needed. Re-install the cotter pin after attaining the dimension.

5. 6.

Notice:

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 34 pullrod, loosen the jam nuts 10230 (Fig. 13) and 10229 and then turn the pullrod slightly (on the order of a half turn) until the pin fits. Apply Loctite 242 to the jam nuts and torque as per Tables 2a/b in this module. If the pin alignment is off significantly, (more than 1 mm) the interrupters may not be fully opened or properly synchronized. 7. Apply Loctite 222 to the retaining bolt 10188 and reinstall this bolt with washer H973A06504 to hold the crank wrist pin 10210 in place. Torque as per Tables 2 a/b in this module. Re-install the covers 10208 (Fig. 12) and 10212. 5.2.6.1 Rebuilding the Left or Right Bellcrank Assembly To rebuild the left or right bellcrank assembly 10159 or 10160 (Fig. 15): 1. Install the buffer 10166 (Fig. 15) in the bellcrank housing 10172 (left) or 10173 (right); secure the buffer with retaining ring 10179. Install bearing 10164 in the bellcrank. Apply a light coat of ProAA2 Grease to the shaft seal assembly 10153 where shown in Figure 16. Reinstall the shaft 10156 (Fig. 15) on the bellcrank. Ensure that connector arm bolt 30150 (Fig. 17) and washer H973A03004 are installed in the back side of the internal crank prior to installing the internal crank 10162 (Fig. 15) on the shaft 10156. Install the internal crank 10162. Align the point center punch marks of the bellcrank shaft 10156 with the internal crank 10162 (Illustration 6). Make sure that the "hooked" curved end of the internal crank is facing the top of the bellcrank. Apply a light coat of FS-1292-Grease to the shaft seal assembly 10153 where shown in Figure 16. The grease eases assembly of the O-rings and prevents twisting. Wipe off excess grease. Install the shaft seal assembly on the bellcrank using bolts 10182 (Fig. 15) and M8 flat washers; apply Loctite 242 and torque as per Tables 2a/b. Refer to Plate 6. Align the hole in the internal crank 10162 with the bellcrank access hole as shown in Illustration 6.

2. 3.

8.

4.

After re-installing the interphase linkages, inspect the following: If the pole unit was opened, a new desiccant bag 10008 (Fig. 9) will need to be installed in the rear tank cover, the pole tank closed and an evacuation/refill procedure must be performed as described in the respective sections 5.2.3, 5.2.4, and 3.2.2.2. 5.2.6 Rebuilding the Bellcrank Assembly 7. 5. 6.

Each pole unit has a bellcrank assembly, 10151 (center pole), (Fig. 15) 10159 (left pole) and 10160 (right pole). The left and right bellcrank assemblies are rebuilt the same way (as per section 5.2.6.1); the center bellcrank assembly is rebuilt slightly differently (as per section 5.2.6.2).

8.

9.

10162 Internal Crank

Align the point center punch marks when assembling the bellcrank.

Plate 6: Shaft seal assembly

Illustration 6 Side View of Bellcrank

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 35 10. Remove the old O-ring 90002 (Fig. 15) at the bellcrank flange and clean the O-ring groove and flange with wipers dampened with denatured ethyl alcohol. 11. Install a new tank end O-ring 90002 on the bellcrank end of the pole tank flange. 12. Apply FS-1292 Grease to the mating flange of the bellcrank and pole tank and to the quick disconnect valve 10154 shown in Figure 11a/b and install this fitting on the bellcrank. 5.2.6.2 Rebuilding the Center Bellcrank Assembly Rebuilding the center bellcrank assembly 10151 (Fig. 15), requires procuring two new shaft seal assemblies 10153 (Fig. 16). Proceed as follows: 1. Install the buffer 10166 (Fig. 15) in the bellcrank housing 10152 (center); secure the buffer with retaining ring 10179. Clean and degrease the metal parts on the shaft seal assembly 10153 (Fig. 15). Apply FS-1292 Grease. Apply a light coat of ProAA2 Grease to the two shaft seal assemblies 10153 where shown in Figure 16. Apply a light and even coat of ProAA2 Grease to the bellcrank shafts 10157 (Fig. 15), sealing to edge of the lip seals while rotating the shaft. Re-install the shafts on the center bellcrank. Ensure that the connector arm bolt 30150 (Fig. 17) and washer H973A03004 are installed in the back side of the internal crank 10162 (Fig. 15) prior to installing the internal crank on the shaft 10157. Install the internal crank 10162. Align the point center punch marks of the bellcrank shaft 10157 with the internal crank 10162 (Illustration 6 from the previous section). Make sure that the "hooked" curved end of the internal crank is facing the top of the bellcrank. Apply a light coat of FS-1292-Grease to both shaft seal assemblies 10153 (Fig. 16). Install a shaft seal assembly on either side of the bellcrank 10151 (Fig. 15) using bolts 10182 and M8 flat washers; apply Loctite 242 and torque as per Tables 2a/b. Refer to Plate 6 from the previous section. Align the hole in the internal crank 10162 with the bellcrank access hole as shown in Illustration 6. 1. 5.2.7 Removing/Installing Current Transformers

Refer to the last sheet on the wiring diagram for current transformer (CT) wiring, CT ratios, accuracies, relative position to breaker contacts, and any special connections for test switches or plugs that may have been installed on the breaker for testing and monitoring of the CTs. The current transformer location nameplate is located inside the door of the main control cabinet and lists the ABB part numbers for the CTs, the CT curve number, the ratio, and the accuracy class. Notice: Each current transformer secondary must be connected to a relaying or metering burden or be short circuited at all times.

Prior to removing/installing a CT or a protective cover 70001 (Fig. 18), reclaim almost all of the SF6 gas (as per section 3.1) to lower the system pressure to approximately 5 psig (0.03 MPa). Caution Do not stand on the CT protective cover, otherwise you could crush the cover or damage the seal around the lip of the bottom support. To remove the CTs: Start by removing the CT protective cover 70001 (Fig. 18) as follows: remove the bolts 70009, nuts H673A09102, and flat washers H420A64008 at the bottom of the CT protective cover. Carefully lift the protective cover over the top of the bushing; avoid damaging the porcelain glaze or sheds. Caution Bumping a pressurized bushing could result in cracking the insulator and causing it to rupture. 3. 4. Disconnect the CT leads either at the CTs or at the control cabinet. Using a light crane, carefully note the number of pressboard spacers (70005, 70006, and 70007) installed and lift the CT over the top of the bushing; avoid bumping or damaging the bushing insulator. Save the pressboard spacers for re-use on installation.

2. 3. 4.

5.

2.

6. 5.

7. 8.

9.

10. Remove the old O-ring 90002 (Fig. 15) at the bellcrank flange and clean the O-ring groove and flange with wipers dampened with denatured ethyl alcohol. 11. Install a new tank end O-ring 90002 on the bellcrank end of the pole tank flange. 12. Apply FS-1292 Grease to the mating flange of the bellcrank and pole tank and to the quick disconnect valve 10154 shown in Figure 11a/b and install this fitting on the bellcrank.
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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 36 To install a CT: 1. 2. Using a light crane, carefully lower the CT over the top of the bushing; avoid damaging the bushing insulator. While lowering the CT in place, install the appropriate number of pressboard spacers 70005, 70006, and 70007 (Fig. 18). Caution Pressboard spacers must be installed to ensure that the CTs are isolated from the CT protective cover 70001 and bottom support 70003. 3. Connect the secondary leads to the shorting terminal blocks. Refer to Plate 7. Caution When re-installing the CT protective cover 70001 (Fig. 18), be careful not to damage the insulating seal 70002. This seal serves both as a weather seal and an insulating barrier. Without this insulating barrier, the CT protective cover would form a continuous conducting loop around the CTS, thereby shorting the CTs and jeopardizing CT accuracy. 4. Carefully place the CT protective cover over the top of the de-pressurized bushing; avoid bumping the bushing. The CT protective cover should seat itself evenly on the insulating seal without excessive force. Re-install the bolts 70009 (Fig. 18), nuts H673A09102, and two flat washers H420A64008 at the bottom of the CT protective cover to fasten the cover to the support. Plate 7: Shorting terminal blocks

5.

Warning
Evacuate and fill the breaker with SF6 gas if the gas had been reclaimed as recommended. Refer to the section 3.2.2.2.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 37 5.2.8 SF6 Gas Density Monitor and Calibration Breakers either have 1.) a single SF6 gas density monitor mounted onto the left pole tank, a gas density gauge mounted onto the right pole tank's bellcrank housing, and a gas manifold connecting all three pole tanks; or 2.) three SF6 gas density monitors, each mounted to a pole tank, with a gas density gauge mounted onto each pole tank's bellcrank housing. In either design, each monitor has pressure switches. The pressure gauges are visible when facing the breaker cabinet front. The density monitor can compensate for outdoor temperature variations ranging from -55F to 150F (-40C to 66C). The monitor automatically adjusts the operating points of the pressure switch to higher or lower pressures based on temperature changes. If the SF6 gas pressure drops below 76 psig (0.52 MPa) at 68F (20C), the monitor actuates an alarm. If the SF6 gas pressure drops below 72 psig (0.50 MPa) at 68F (20C), the monitor will lock out circuit breaker operation (or AUTO TRIP and BLOCK CLOSE) and provide the appropriate alarm. Once the density monitor is isolated, low density alarm simulations can be performed using test manifolds available from ABB.

Since SF6 gas serves as the insulating and arc quenching medium within the pole tanks, it is essential that the proper SF6 gas density be maintained. The SF6 gas density is checked indirectly by monitoring pressure as a function of temperature, i.e., a given temperature X and pressure Y correspond to a certain density (assuming a constant volume). Based on the correlation between temperature and pressure, the SF6 gas density monitor 60441 (Fig. 7) operates as a temperature-compensated pressure switch to indirectly monitor the density of the SF6 gas. The SF6 gas density monitor is calibrated at the factory as follows: The temperature probe is set at 68F (20C); Switch C (Fig. 7) is set to close at 76 psig (0.52 MPa) at 68F (20C) (low gas density alarm point) with decreasing pressure; Switches B1 and B2 (Fig. 7) provide alarm indication and are set to close at 72 psig (0.50 MPa) CLOSE BLOCK and TRIP BLOCK (or AUTO TRIP) if the SF6 gas density is at or below 72 psig (0.50 MPa) at 68F (20C) (which is the minimum pressure necessary to maintain the full interrupting rating). These contacts (63B1 & 63B2) generally close on loss of gas density and energize the appropriate relay(s) to execute lock-out functions (or AUTO TRIP) with decreasing pressure (unless alternate values are listed in the wiring diagrams). Note that at higher altitudes the alarm and lock-out pressures at 68F (20C) are slightly different and increase incrementally almost linearly by approximately 1.4 psig per 3000 ft for alarm and lock-out pressures at 68F (20C).

DANGER To prevent personal injury and damage to the equipment, before beginning any calibration or adjustment, de-energize the breaker and remove it from service.

Warning
Never change the factory-set alarm and lockout switch settings shown in the wiring diagrams - otherwise breaker failure could result.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 38 It is not recommended to recalibrate the density monitors in the field. However, to calibrate the SF6 gas density monitor and adjust the pressure switches: 1. Refer to the SF6 Gas Density Monitor Calibration Curve and Chart (Figs. 3 and 4) to correlate the proper alarm and lock-out pressure settings for the current ambient temperature. At higher altitudes the alarm and lock-out pressures at 68F (20C) are slightly different and increase incrementally almost linearly by approximately 1.4 psig per 3000 ft. 5. After adjustments are complete, perform a final verification of all pressure switches. Reapply external thread locking material to hold nuts in place.

Warning
The isolation valve must remain open for proper operation of the low density SF6 alarm and lockout controls. A closed isolation valve could result in low gas density operation and cause breaker failure or damage. 6. Complete the density monitor calibration section in the Checklists module.

Notice:

2.

Determine the actual alarm and lock-out settings by performing the following procedure: a. Remove the monitor cover. Remove the monitor from the disconnect valve on the pole unit, turning the large nut to remove. Attach a test manifold, using either gas from the pole unit or a separate gas source to test pressure settings. Pressurize the monitor to slightly above the alarm settings. Bleed gas through the manifold relief valve until the alarm occurs. Read the setting on the supplied gas density gauge 60023.

a. c. 3.

If the pressure spread (differential) between pressure switches is correct, with all settings either high or low by the same amount, use the main pressure adjustment nut (Fig. 7) to make the necessary changes. Use the main pressure adjustment nut to adjust all of the pressure switches at one time. Turning this nut clockwise increases the settings of all of the pressure switches by the same increment, while turning it counter-clockwise decreases all of the settings. To change the pressure setting of an individual pressure switch, use the individual pressure switch adjustment nut (Fig. 7). Turning the nut clockwise increases the alarm pressure setting, while turning it counterclockwise decreases the alarm pressure setting. Adjusting one of the individual switches will often affect the settings of the other pressure switches. Adjustments should be made in small increments and a final verification of all pressure switch settings should be performed.

4.

Important:

Always adjust in the order from high pressure switches to low pressure switches, i.e. start with switch C and then adjust switches B1 and B2.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 39

6.

Safe Handling of SF6

Full-face Comfo II respirator or equivalent with twin cartridges for organic vapors and acid gases, i.e., GMC or equivalent; Supplied air-line respirator - MSA pressure demand type with Ultravue face piece and web belt-mounted demand regulator, 50 ft. of air supply hose, manifold with quick-disconnect and automatic shut-off outlets, cylinder pressure regulator; must have NIOSH/ MESA Approval No. TC-19C-93, or equivalent from other manufacturer; Respirable, compressed air supply - 300 lb, approved portable tank with air meeting Grade D, ANSI Standard Z86.1-1974 with supply hose inlet pressure between 80 to 100 psig; Industrial wet or dry type vacuum cleaner with nonmetallic attachments, micro staphicidal filter elements (particles to 0.3 microns), two 15-inch lengths of plastic hose and coupler; Cleaning solvent: denatured ethyl alcohol. 6.1.1 Protective Gear

In its pure, natural state, sulfur hexafluoride (SF6) gas is colorless, odorless, tasteless, possesses a low order of toxicity, and is approximately five times heavier than air. SF6 gas is chemically inert and non-flammable. The gas has a high dielectric strength and thermal properties conducive for insulating high voltage and quenching electrical arcs. When SF6 gas is subjected to an electric arc within the interrupter, heat causes the gas to decompose into potentially toxic by-products both in gaseous and white/tan/gray powder form. The amount of decomposition by-products is a function of the intensity and duration of the arc. When SF6 decomposition products are exposed to moisture, they tend to form corrosive and conductive compounds which can be both harmful to human beings and aggressive towards materials within the circuit breaker, especially insulating surfaces if subjected to prolonged exposure. (In the presence of moist air, noxious decomposition products have a characteristic odor of rotten eggs.) SF6 gas and its decomposition products present no injury or illness problems if dealt with properly. As with other chemicals, health hazards may exist under particular conditions, if exposure or handling is careless or improper. The only danger in breathing too much pure SF6 gas in a non-ventilated area is that it displaces oxygen and can cause suffocation if the oxygen content of the air is reduced from the normal 20 percent to less than 13 percent.

Minimum required protective gear to be worn when handling SF6 gas-insulated apparatus are: Gloves; Full-face Comfo II respirator or equivalent with twin cartridges for organic vapors and acid gases, i.e., GMC or equivalent. Full protective gear includes: Gloves; Hooded disposable coveralls; Non-Disposable Neoprene Gloves - 14-inch size; Non-Disposable Rubber Boots - 17-inch size, overthe-shoe style; Supplied air-line respirator. 6.2 SF6 Gas Handling Safety and Purging Practices

DANGER Avoid inhaling large amounts of SF6 gas and decomposition by-products. Avoid skin or eye contact with the decomposition products because they can cause skin rashes, eye irritation, and chemical burns. Wear the prescribed protective gear indicated in section 6.1.
6.1 Equipment Used to Handle SF6 Decomposition Products

Use the following equipment to perform maintenance on the breaker if decomposition products may be present: Hooded disposable coveralls - Tyvec, Durafab, or equivalent - made of paper with nylon reinforcement material; Non-Disposable Neoprene Gloves - 14-inch size; Non-Disposable Rubber Boots - 17-inch size, overthe-shoe style; Clean, oil-free dry air supply with a capability to provide sufficient purging and ventilating capacity;

Safety practices when handling SF6 gas-insulated apparatus are: Perform SF6 gas handling, filling or reclaiming outdoors; If procedures involving SF6 gas insulated equipment must be done indoors, work in a well-ventilated room; make sure the ventilating equipment is operating; No smoking; No exposed heaters, flames, or arc-producing equipment should be used in the area while the gas is being handled; If, when handling used SF6 gas, the odor of rotten eggs is detected, personnel not wearing respiratory equipment should promptly evacuate the area; Correct any gas leaks at hose or fitting connections at the breaker, on the service cart, or at the cylinder. If a tent-like enclosure is used around the work area, use a dry air ventilation system while performing maintenance work.

August 2005

526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 40 If decomposition products are found, remove them as per section 6.3. If no decomposition products are found: 1. Purge the apparatus thoroughly with dry air from a suitable source. Do not purge with damp or wet air as it can endanger the integrity of insulation materials and prolong dry-out and reconditioning time. It is only safe to assume that there may be hazardous gaseous products present. All personnel should stand clear of the apparatus during purging. 2. Allow purging to continue long enough to assure a minimum of at least 10 complete air changes through the total apparatus before working on the equipment. If the SF6 gas has not been fully evacuated from the apparatus prior to purging, perform a minimum of 100 air changes. Reduce the purging air supply to a low level (approximately 10 air changes per hour) to provide continuous ventilation of the apparatus while personnel are working internally in the apparatus. Removing SF6 Decomposition Products 5. 6.4 Disposing of Decomposition Products

Important:

Dispose the decomposition products outdoors since corrosive or toxic gases may evolve from the solid arc products or from the molecular sieve (desiccant). Disposal of the SF6 residue involves neutralizing the decomposition products. Notice: Wear full protective gear during disposal.

To properly dispose of decomposition product residue: 1. Place materials used and retrieved in clean-up operations in large plastic or metal containers. These containers serve as refuse containers. Empty the vacuum cleaner housing and the absorption filter material into the container. Note or measure the volume of material in the container. In a separate container (plastic pail), measure a volume of water 1.5 times that of the above refuse material. Empty the water into the refuse container pouring the water quickly at first then slowly. The water mixing with the SF6 refuse will produce some heat and foam. Measure a quantity of soda ash (sodium carbonate) or lime (calcium oxide) equal to at least one-quarter the volume of the refuse and add this neutralizing agent to the water-refuse material. Add the cleaning rags, protective clothing (even though it is disposable), along with the filters from the vacuum cleaner and respirator to the neutralizing mixture in the refuse container. Allow the refuse container to stand uncovered for 24 hours. Afterwards test the pH of the refuse mixture. The mixture should be at least slightly alkaline (greater than 7). If the pH is between 7 and 10, the refuse is now rendered harmless and may be disposed of in a normal manner as per local ordinances. If the solution pH is less than 7, it is still acidic and harmful; add additional soda ash or lime to neutralize the refuse mixture to a pH greater than 7 but less than 10. Then dispose of the material as per local ordinances.

2. 3. 4.

3.

6.3

If significant arc powders or noxious odors are detected upon opening a pole unit or any other apparatus: 1. 2. Wear full protective clothing and a supplied air full-face respirator. Establish a restricted safety zone around the equipment. Personnel cannot enter this zone without wearing full protective gear. If performing this work outdoors, the zone may need to be extended downwind of the work site. Use a vacuum cleaner equipped with filters. This vacuum cleaner should be used exclusively for removing SF6 decomposition products. Wipe up any remaining powdered decomposition products with rags using denatured ethyl alcohol. Remove and dispose the molecular sieve (desiccant) within the apparatus as per section 6.4; keep the full protective gear on. Place materials used and retrieved in clean-up operations in large plastic or metal containers. These containers serve as refuse containers. Proceed with purging as per section 6.2 after removing all decomposition products.

6.

7. 8.

3.

4. 5.

6.

7.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 41 6.4.1 Removing SF6 Gas Residue from Tools and Equipment

To clean tools and equipment which have been exposed to SF6 decomposition products: 1. 2. 3. Prepare a mild (10%) lime or soda ash solution and use this as the neutralizing solution. Wash any hand tools, non-disposable protective gear, and equipment employed in the clean-up operation. Vacuum some of this neutralizing solution through the hose and into the vacuum cleaner to neutralize particles adhering to this equipment. Rinse all washed tools and equipment thoroughly with water. Wash the rubber boots and Neoprene gloves in water.

4. 5.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 42

T13442

Center of Gravity 10044 60010 NEMA Grounding Pad 10017

10043

10092 Loctite 242

Figure 1 Lifting the Breaker 10017 10043 10044 10092 60010 T13442 Rupture Disk Leg Extension Support Structure Lifting Lug View Port Windows Sling

August 2005

60011

60010

60001 Figure 2 Control Cabinet 60000 60001 60009 60010 60011 Anti-Condensation Heater Removable Plate View Port Window Control Cabinet Ground Terminal

60009

526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 43

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 44

Pressure psig MPa 1 2 90 80 70 3 60 50 40 30 20 10 Temperature F -30 -20 -10 C 0 -18 10 20 -7 30 40 4 50 60 16 70 80 27 90 100 110 38 49 0.62 0.55 0.48 0.42 0.35 0.28 0.21 0.14 0.07

Saturation Curve

1 2 3

Normal Filling Pressure psig or MPa Low Pressure Alarm (Contact 63-2C Closes) Low Pressure Lock-Out (Contact 63-2B1 & 63-2B2 Close) If the breaker has tank heaters, the gas pressure will most likely be higher than the values listed for temperatures below -10F (-23C). However, at sustained temperatures below -20F (-29C) the gas is likely to liquefy. Note that at higher altitudes the fill pressure at 68F (20C) is slightly different and increases incrementally almost linearly by approximately 1.4 psig per 3000 ft for fill, alarm and lock-out pressures at 68F (20C). For example: Add an additional Add an additional Add an additional Add an additional 1.4 psig 2.8 psig 4.2 psig 5.3 psig at 3000 feet at 6000 feet at 9000 feet at 12000 feet

Notice:

Figure 3 SF6 Gas Density Monitor Calibration Curve for Pressure vs. Temperature Important: Refer to Figure 4 for a tabular version of the characteristics above.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 45

Tabular Version of the Pressure vs. Temperature Characteristics shown in Figure 3

Temp. F -40 -30 -20 -10 0 10 20 30 40 50 60 68 70 80 90 100 110 Temp. C -40 -34 -29 -23 -18 -12 -7 -1 4 10 16 20 21 27 32 38 43 *Fill psig Saturated Saturated Saturated 68.8 71.1 73.4 75.8 78.2 80.5 82.8 85.2 87.0 87.6 90.0 92.3 94.7 97.1 **Fill MPa Saturated Saturated Saturated 0.47 0.49 0.51 0.52 0.54 0.56 0.57 0.59 0.60 0.60 0.62 0.64 0.65 0.67 *Alarm psig Saturated Saturated 58.0 60.0 62.1 64.0 66.2 68.1 70.2 72.3 74.3 76.0 76.4 78.5 80.5 82.7 84.8 **Alarm MPa Saturated Saturated 0.40 0.41 0.43 0.44 0.46 0.47 0.48 0.50 0.51 0.52 0.53 0.54 0.56 0.57 0.58 *Lock-Out psig Saturated Saturated 54.9 56.9 58.8 60.8 62.7 64.7 66.6 68.5 70.4 72.0 72.3 74.2 76.2 78.2 80.1 **Lock-Out MPa Saturated Saturated 0.38 0.39 0.41 0.42 0.43 0.45 0.46 0.47 0.49 0.50 0.50 0.51 0.53 0.54 0.55

* +/- 2 psig (Fill to 87 psig when using the standard temperature compensated pressure gauge) ** +/- 0.01 MPa

IMPORTANT:

The shaded row indicates pressure readings 2 psi for circuit breakers equipped with temperature compensated pressure gauges used on the pole units.

Notice:

If the breaker has tank heaters, the gas pressure will most likely be higher than the values listed for ambient temperatures below -10F (-23C). However, at sustained temperatures below 20F (-29C) the gas is likely to partially liquefy. Note that at higher altitudes the fill pressure at 68F (20C) is slightly different and increases incrementally almost linearly by approximately 1.4 psig per 3000 ft for fill, alarm and lock-out pressures at 68F (20C). For example: Add an additional Add an additional Add an additional Add an additional 1.4 psig 2.8 psig 4.2 psig 5.3 psig at 3000 feet at 6000 feet at 9000 feet at 12000 feet

Figure 4 SF6 Gas Filling and Density Monitor Calibration Chart

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 46

View A Breaker during Normal Operating Conditions

(or during shipping)

60023 Note: Remove during Gas Charging (View B) or Gas Sampling (View C) 10154

10154 T13446

View B Breaker during Filling Procedure

View C Arrangement for Gas Sampling

T13480 T13481

NPT Male Fitting

Figure 5 Gas Charging Arrangement 10154 60023 T13446 T13480 T13481 Quick Disconnect Gas Valve (Malmquist) SF6 Gas Density Gauge SF6 Gas Regulator, Hose and Adapter Assembly Gas Sample Valve Malmquist Adapter (for Malmquist fitting)

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 47 SF6 Gas Density Monitor 60441

Left Pole Unit 10047

Left Pole Unit 10047 SF6 Gas Density Monitor 60441

Gas Manifold for Bellcrank 10237

SF6 Gas Density Gauge 60023

Center Pole Unit 10048 Quick Disconnect Gas Valves 10154 Rupture Disk 10017

Center Pole Unit 10048

SF6 Gas Density Monitor 60441 Rupture Disk 10017

Quick Disconnect Gas Valve 10154

Gas Manifold for Tanks 10238

Right Pole Unit 10049

Right Pole Unit 10049 SF6 Gas Density Monitor 60441

SF6 Gas Density Gauge 60023

Schematic A 242 PMR with single tank-mounted gas density monitor

Schematic B 242 PMR with three tank-mounted gas density monitors

Figure 6 SF6 Gas Schematic for 242 PMR with Tank-Mounted Mini-Monitor Pressure Switch(es)
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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 48

Disconnect Gas Valve

Individual Pressure Switch Adjustment Nut

Main Pressure Adjustment Nut

Wiring Terminal Block

Set to close at 76 psig (0.52 MPa) at 68F (20C) Set to close at 72 psig (0.50 MPa) at 68F (20C) Set to close at 72 psig (0.50 MPa) at 68F (20C)

Set each switch to the pressure indicated in Figures 3 and 4.

If the pressure spread (differential) between pressure switches is correct, with all settings either high or low by the same amount, use the main pressure adjustment nut to make the necessary changes. Use the main pressure adjustment nut to adjust all of the pressure switches at one time. Turning this nut clockwise increases the settings of all of the pressure switches by the same increment, while turning it counter-clockwise decreases all of the settings. To change the pressure setting of an individual pressure switch, use the individual pressure switch adjustment nut. Turning the nut clockwise increases the alarm pressure setting, while turning it counter-clockwise decreases the alarm pressure setting. Important: Adjusting one of the individual switches will often affect the settings of the other pressure switches. Adjustments should be made in small increments and a final verification of all pressure switch settings should be performed.

Always adjust in the order from high pressure switches to low pressure switches, i.e. start with switch C and then adjust switches B1 and B2.

Figure 7 Tank Mounted SF6 Gas Density Monitor 60441

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 49

20311**

20019 H967800 Torque 50 ft-lbs (70 Nm)

20318 Oxygen Inhibiting Type Electrical Joint Compound* 20317

Figure 8 Terminal Pad 20311

20019 20311 20317 20318 H967800

Terminal Pad Bolts Terminal Pad Clamping Ring V-Clamps Belleville Washer, M12

*Requires surface preparation with Electrical Joint Compound as described in step 1 in section 2.3.1. **Rotate to the desired orientation. Refer to Plate 1 for more details.

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 50

10069*** H420A64012***

FS-1292* 20009 20010

H420A64012 10070*** FS-1292* to flange and bolt threads**

90003 FS-1292* FS-1292*

10096

20001 10095*** 10032 10008 90002

90002 10151 or 10159 or 10160

H420A64012 10071*** FS-1292* to flange and bolt threads**

10052 10015 30000 or 30121 or 30122 10154 View A For Tank Mounted Density Monitor

30052****

10017

10037 10071*** 20018 H420A64012 H420A60016 FS-1292* to flange Loctite 242 and bolt threads**

10072*** Tighten this bolt enough to 10091 center the interrupter. Do not overtighten this bolt.

* **

Apply Dow Corning FS-1292 Grease to all flange surfaces outside of the O-ring groove to prevent corrosion. Apply Dow Corning FS-1292 Grease to bolt threads

*** Unless otherwise indicated, torque as per Tables 2a/b **** Prepare sliding surfaces as per Supplement 1 sheet at the end of this module. ***** Apply Dow Corning FS-1292 Grease on O-Rings prior to insertion. Figure 9 Pole Unit Assembly (Left, Center, or Right) 10047 or 10048 or 10049

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 51

H420A64008 90022***** 10196*** 10154 View A For Tank Mounted Density Monitor

Groove (indicates that this fitting is self-sealed when visible)

Figure 9 Pole Unit Assembly (Left, Center, or Right) 10047 or 10048 or 10049 10008 10015 10017 10032 10037 10047 10048 10049 10052 10069 10070 10071 10072 10091 10095 10096 10151 10154 10159 10160 10196 20001 20009 20010 20018 30000 30052 30121 30122 90002 90003 90022 H420A60016 H420A64008 H420A64012 Desiccant Bag Pole Tank Rupture Disk Rear Tank Cover Assembly Cover Left Pole Unit Assembly Center Pole Unit Assembly Right Pole Unit Assembly Tank Half Bushing Top Flange Bolts Bushing Bottom Flange Bolts Tank End Bolts Rupture Disk Bolts Tank Half (with Rupture Disk) Desiccant Bag Cover Screws Tank End Alignment Pin Bellcrank Assembly (Center) Quick Gas Disconnect Valve (Malmquist) Bellcrank Assembly (Left) Bellcrank Assembly (Right) Malmquist Mounting Bolt Bushing Conductor Front Bushing Assembly Rear Bushing Assembly Bushing Conductor Bolt Interrupter Unit (Center) Plug-in Connection Interrupter Unit (Left) Interrupter Unit (Right) O-Ring, Tank End O-Ring, Bottom Flange Vacuum/Fill Valve O-Ring Flat Washer, M16 Flat Washer, M8 Flat Washer, M12

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FS-1292 Grease

10017*

60 mm Hole 90035

10036 10072 H420A64012 FS-1292 to bolt threads Torque to 50 ft-lbs

Cross Sectional View

*Make sure that the rupture disk is centered over the 60 mm hole before tightening the bolts 10072.

Figure 10 Rupture Disk Cover Assembly 10017 10036 10072 90035 H420A64012 Rupture Disk Rupture Disk Holding Ring Rupture Disk Bolts Rupture Disk O-Ring Flat Washer, M12

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 53 Quick Disconnect Gas Valve 10154

242 PMR with three tank-mounted gas density monitors

Quick Disconnect Gas Valve 10154 Gas Manifold for Tanks 10238 (located behind cabinet)

Quick Disconnect Gas Valve 10154

242 PMR with single tank-mounted gas density monitor

Gas Manifold for Bellcrank 10237

Quick Disconnect Gas Valve 10154

Figure 11a SF6 Gas System with Disconnect Gas Valve (see Figure 11b for closeup details)

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FS-1292 Grease 60023 SF6 Gas Density Gauge Note: Remove during Gas Charging

Bellcrank Assembly
(detail)

10154 Quick Disconnect Gas Valve

FS-1292 Grease

10154 Quick Disconnect Gas Valve

(detail)

Groove (indicates that this fitting is self-sealed when visible)

For pole units not to be removed or isolated, loosen this nut until the groove is visible (Detail B). The gas will remain sealed within the pole unit at normal pressure. When this nut is tightened, the gas will flow through the gas manifold. This nut must be tight during normal operation. Quick Disconnect Gas Valve 10154 T13481 FS-1292 Grease

Detail A

Groove (indicates that this fitting is self-sealed when visible)

Detail C

Detail B
Manifold Tubing

Completely loosening the nut and removing the Malmquist adapter T13481 will break the seal of the manifold or gauge, and allow access to the valve for reclaiming or refilling purposes (See Section 3).

Figure 11b SF6 Gas System with Disconnect Gas Valve (Details of the valve and its operation)

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 55

H973A06504 H800A12904 10204 FS-1292 Grease

10208

10209 & 10205

FS-1292 Grease

10204 When installing the interphase shaft, the flatter side should be closest to the center pole unit, facing down and horizontal.

10151

10157 10212

10214 10221

H699A41801 H973A03010 H699A06034 FS-1292 Grease to pin

10207 Set the length of the mechanism pullrod with the interrupter and mechanism in the fully open position.

Figure 12 Linkage (Front View) Unless otherwise indicated, torque all hardware as per Tables 2a/b in this module. 10151 10156 10157 10204 10205 10207 10208 10209 10212 10214 10221 H699A06034 H699A41801 H800A12904 H973A03010 H973A06504 Center Bellcrank Assembly Bellcrank Shaft (Left/Right) - not shown Bellcrank Shaft (Center) Interphase Shaft (Left/Right) Coupling Mechanism Pullrod Assembly Cover Roll Pin Linkage Access Cover Rubber Boot Cable Tie Clamp Cotter Pin Pin Screw, 1/4-20 x 3/4-inch Washer Flat Washer, 1/4-inch

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10188* H973A06504 Loctite 222 10206

10233* H420A58008 Loctite 242

10210 FS-1292 Grease

10174

10229* H420A64016 Loctite 242

10207 Set the length of the mechanism pullrod with the interrupter and mechanism in the fully open position. Double nuts for mounting the mechanism

10230* H420A64020 Loctite 242 10175

*Unless otherwise indicated, torque all hardware as per Tables 2a/b in this module.

Figure 13 Side View of Crank, Linkage, and Pullrod 10174 10175 10188 10206 10207 10210 10229 10230 10233 H420A58008 H420A64016 H420A64020 H973A06504 Rod End, Upper Rod End, Lower Retaining Bolt Crank Mechanism Pullrod Assembly Crank Wrist Pin Upper Jam Nut Lower Jam Nut Crank Bolt Nut, M8 Flat Washer, M16 Flat Washer, M20 Flat Washer

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 57

Socket

T13451

1/2-inch drive ratchet

Figure 14 Manual Open/Close Tool T13451

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10164 10172

10153

10182 H420A64008 Loctite 242 Torque as per Tables 2a/b

Clean the seal area; degrease metal parts; apply FS-1292 Grease 10153 10157

10182 H420A64008 Loctite 242 Torque as per Tables 2a/b 10153 10164 10156 10173 10152

10153

10156

Lubricate lightly and evenly with ProAA2 Grease, sealing the edge of lip seals while rotating the shaft

Left Bellcrank Assembly 10159

Center Bellcrank Assembly 10151

Right Bellcrank Assembly 10160

90002 Figure 15 242 PMR Bellcrank Assemblies (without Valves) 10179

10151 10152 10153 10156 10157 10159 10160 10162 10164 10166 10172 10173 10179 10182 90002 H420A64008

Bellcrank Assembly (Center) Bellcrank Housing (Center) Shaft Seal Assembly Bellcrank Shaft (Left/Right) Bellcrank Shaft (Center) Bellcrank Assembly (Left) Bellcrank Assembly (Right) Internal Crank Bearing Buffer Bellcrank Housing (Left) Bellcrank Housing (Right) Retaining Ring Shaft Seal Bolts Tank End O-ring Flat Washer, M8

10166

10162 Align the point center punch marks when assembling the bellcrank.

Side View of a Bellcrank Assembly

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526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 59

10164 10169 10170 10168

FS-1292 Grease to ease assembly of O-rings and prevent twisting; wipe off excess grease. 10180

10167

Pro AA2 Grease prior to assembly

Pro AA2 Grease prior to assembly

90005

FS-1292 Grease

Figure 16 Shaft Seal Assembly 10153 10164 10167 10168 10169 10170 10180 90005 Bearing Bushing Gas/Vacuum Lip Seal Weather Seal Aluminum Spacer Seal Assembly Snap Ring O-Ring (Shaft Seal Assembly)

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30150 H973A03004 10151 10159 10160 30051 30106

10161 10163

30195

30210

30032

Figure 17 Bellcrank Linkage to Interrupter Unit

10151 10159 10160 10161 10163 30032 30051 30106 30150 30195 30210 H973A03004

Bellcrank Assembly (Center) Bellcrank Assembly (Left) Bellcrank Assembly (Right) Connecting Pin Connector Arm Operating Pullrod Support Tube Pullrod Coupling Connector Arm Bolt Jam Nut Operating Pullrod Jam Nut Flat Washer, 1/4-inch

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Notice:

Be sure to install the CTs with the polarity marks and white dot facing upward. 10070 H420A64012 Apply FS-1292 Grease to bolt threads

Apply FS-1292 Grease to flange 70000 70006 70002 70001

70010* H673A05907 H973A04503 HNB335050P609 (two) Loctite 242

70007 70005 70003 70004 70009 H673A09102 H420A64008 70011* H673A05909 H973A04501 H420A64012 Loctite 242

*Torque and apply Loctite as per Tables 2a/b in this module Figure 18 Current Transformer 70000 10070 70000 70001 70002 70003 70004 70005 70006 70007 70009 Bushing Bottom Flange Bolts Current Transformer CT Protective Cover Insulating Seal Bottom Support Mounting Bracket Bottom Pressboard Spacer Vertical Pressboard Spacers Inter CT Pressboard Spacers CT Cover Bolts 70010 70011 H420A64008 H420A64012 H673A05907 H673A05909 H673A09102 H973A04501 H973A04503 HNB335050P609 Upper Bracket Mounting Bolts Lower Bracket Mounting Bolts Flat Washer, M8 (Two) Flat Washer, M12 Nut, 3/8-16 Nut, 1/2-13-inch Nut, 5/16-18 Lock Washer, 1/2-inch Lock Washer, 3/8-inch Flat Washer, M10

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10056

A
10090

10056 8-1/2" Strap 6-5/16"

1-1/4"

10056

10089 Approximately 200 square inches of heated surface H973A09108 (seven) 10055

10016

View A-A Pre 2002 version

10056 8-1/2"

10056 10090

10016

Figure 19 Tank Heater Assembly 10055 10016 10055 10056 10089 10090 H973A09108
August 2005

View A-A 2002 or later version

Tank Heater Tank Heater Assembly Tank Heater Insulation Tank Heater Retainer Assembly Tank Heater Strap Compression Washer

526P132-006 242 PMR with Tank Mounted Density Monitor - Installation & Maintenance Page 63

54045 Cotter Pin A

54040

Figure 20 Guide Piston Dimension for HMB Hydraulic Mechanisms 54040 54045 Guide Piston Piston Pin

For breakers equipped with an HMB hydraulic mechanism, a guide piston screws 54040 (Fig. 14) screws on top of the mechanism pullrod. A very important length 114 mm, between the center of the piston pin 54045 and the mechanism top plate must be attained to ensure proper operation. This length is attained by removing coter pin A and turning the screw-on guide piston up or down as needed. Re-install the cotter pin after attaining the dimension.

Guide Piston Dimension 114 mm attained by turning guide piston up or down

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10154 Quick Disconnect Gas Valve

Supplied on Frame Mounted to Cabinet

60441 SF6 Gas Density Monitor

Caplug

Figure 21 Density Monitor Installation to Tank

August 2005