132kV CB - TSG

INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
145kV GAS CIRCUIT BREAKER

TYPE LW9-145
TENAGA SWITCHGEAR SDN. BHD.

(A Subsidiary of Tenaga Nasional Berhad) (321326-M)
CONTENTS LIST
1.0 GENERAL
1.1 Type and Designation 03
1.2 Main Application and Scope 03
1.3 Service Condition 03
1.4 Technical Ratings 03
2.0 STRUCTURE AND PRINCIPLE

2.1 General Construction and Principle 06
2.1.1 Single Pole Circuit Breaker 09
2.1.2 Support Porcelain Unit 10
2.1.3 Absorbent 10
2.1.4 Hermetically Sealing 10
2.1.5 Interrupter Unit 10
2.1.6 Driving Mechanism 11
2.2 Spring Operating Mechanism 12
2.2.1 Opening Operation 13
2.2.2 Closing Operation 13
2.2.3 Manual Operation of Circuit Breaker 13
2.2.3.1 Manual Charging of Closing Spring 13
2.2.3.2 Manual Opening of Circuit Breaker 14
2.2.3.3 Manual Closing of Circuit Breaker 14
2.2.4 Prevention of Closing and Tripping Operations 14
2.2.5 Control of the Circuit Breaker 15
2.2.5.1 Local Control 15
2.2.5.2 Remote Control 15
2.2.5.3 Condition of Electrical Operation 15
2.3 SF6 Gas System 15
2.3.1 System Construction 15
2.3.2 Gas Control Valve 16
2.3.3 Density Meter 16
3.0 INSTALLATION AND COMMISSIONING

3.1 Basic Flow Chart for Installation and Commissioning 17
3.2 Inspection, Unpacking and Storage 18
3.2.1 Inspection 22
3.2.2 Precaution During Loading, Unloading and Unpacking 22
3.2.3 Storing 22
3.3 Preparation for Basic Installation 18
3.3.1 Foundation Installation 19
3.4 Special Tool for Installation 19
3.5 Material and Parts Used in Installation 20
3.6 Installation Procedure 21
3.7 Tightening Torque Values 25
3.8 Inspection and Adjustment 25
3.8.1 Inspection of Slow Closing/Slow Opening Device 25
3.8.2 Manual Closing 26
3.8.3 Stroke Measurement 27
3.8.4 Inspection on Tripping and Closing Coils Clearance 28
3.8.5 Adjustment on Tripping and Closing Coils Clearance 29
3.9 SF6 Gas Evacuation and Filling Procedures 30
3.9.1 Evacuation of SF6 Gas 30
3.9.2 Filling of SF6 Gas 30
3.9.3 Detection of SF6 Gas Leakage 32
OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009
Page 1 of 42
3.10 SF6 Gas Moist Test 33
3.11 Testing 33
3.11.1 Main Circuit Resistance Test 33
3.11.2 Insulation Resistance Test 33
3.11.3 Operating Value Inspection of Gas Pressure Switch 34
3.12 Installation, Adjustment, Testing and Final Inspection 34
3.13 Application of Water-Proof Gum 34
4.0 MAINTENANCE AND INSPECTION

4.1 Inspection Item 35
4.2 Safety 36
4.3 Procedures 37
4.4 Note 37
5.0 OVERHAUL METHOD

5.1 Inspection of Main Contact and Nozzle Inspection 38
5.2 Fixed Contact Inspection 38
5.3 Moving Arc Contact Inspection 39
5.4 Assembly of Fix Contact Seat and Gas Sealing Components 39
6.0 TROUBLESHOOTING GUIDE 41
7.0 ORDERING GUIDE 42
8.0 CONCLUSION 42

Page 2 of 42
1.0 GENERAL
1.1 Type and Designation

LW9-145, 145kV High Voltage SF6 Gas Circuit Breaker.
1.2 Main Application and Scope

LW9-145 high Voltage SF6 gas circuit breaker is a 3-phase a.c, 50 Hz outdoors electrical
equipment mainly for control and protection of transmission lines, transformer and an
interconnected circuit breaker.
It has been designed for a system voltage of 145kV. The product introduces self-blast
interrupter. Each pole has one breaking chamber and all three poles are installed on one
frame, this along three-pole mechanical inter-operation by a single spring operating
mechanism to achieve local and remote electrical control or local manual control.
1.3 Service Condition

Table 1. Service condition
No Description Unit Technical ratings
1 Altitude above sea level m ≤1000
2 Ambient temperature °C -30 ~ +40
3 Maximum daily temperature difference °C 30
Not more than 700 Pa (34
4 Maximum wind pressure m/s
m/s)
5 Ice coating thickness mm 10
Seismic level (sine resonance beat wave) Horizontal: 0.30
6 g
Ground acceleration Vertical: 0.15
7 Nominal creepage distance mm/kV 20, 25
1.4 Technical Ratings

Table 2. Main technical rating
1 Rated voltage kV 145
2 Rated frequency Hz 50
3 Rated current A 3150
4 Rated short circuit breaking current Ie kA 31.5
Percentage of DC component of rated short
5 kA 45%
circuit breaking current
6 Rated short time withstand current kA 31.5
7 Rated peak withstand current kA 80
8 Rated short circuit making current kA 80
9 Rated peak withstand current kA Ie x 90%, le x 75%
10 Rated out-of-phase breaking current kA Ie x 25%
11 Rated line charging breaking current A 50
12 Rated operating sequence - O-0.3s-CO-180s-CO
13 First pole to clear factor - 1.5
14 Breaking time ms 60
15 Opening time ms ≤30
16 Closing time ms ≤150
17 O-C time ms ≥300
18 C-O time ms ≥40
19 Synchronous opening operation ms 2
20 Synchronous closing time ms 4

Page 3 of 42
Rated insulation level
Across breaks kV 315
1 min power frequency
Between phases 275
withstand voltage
kV
(R.M.S) (dry and wet) Phase to earth 275
21 Lightning impulse Across breaks kV 750
withstand voltage Between phases 650
kV
(Peak) Phase to earth 650
5 min withstand voltage Across breaks kV
test at zero gauge 109
pressure (R.M.S) Between phases kV
22 Rated pressure of SF6 gas (at 20°C) Bar 6.0
23 Annual gas leakage - ≤1%
24 Mechanical endurance Time 2000
25 Gas filled in each set of breaker kg 7
26 Total weight per set kg 160
Horizontal
N 1250
longitudinal
Static pulling force
27 Horizontal
of terminal N 750
transverse
Vertical direction N 1000
28 Resistance of main circuit per pole µΩ 45
Table 3. Mechanical ratings

No Items Unit Ratings Remarks
1 Travel mm 150 ± 2-3
2 Contracting travel mm 27 ± 2
Travel of piston rod of spring
3 mm 100 ± 0-3
mechanism
Gap between roller of lever and
4 mm 1.4 ± 0.3 Circuit breaker in
cam of mech.
opening state and
Clearance between positioning
spring has been
5 nut of closed spring and mm 12 ~ 47
charged
positioning rod
Travel of closed electromagnet C mm 5.0 ~5.5
Gap between trigger and tripper
mm 2.0 ~ 2.5
D Circuit breaker in
6 C-D mm 3.0 ~ 3.5 opening state.
Gap between trigger and anti- Refer Fig.13
pumping rod E mm 1.0 ~ 2.0
Travel of closed electromagnet F mm 2.8 ~ 3.2

Circuit breaker in
Gap between trigger and tripper
7 mm 0.8 ~ 1.2 opening state.
G
Refer Fig.12
F-G mm 1.6 ~ 2.4

Page 4 of 42
Table 4. Control and auxiliary circuits ratings
No Items Unit Ratings Remarks
Control voltage of tripping and See ordering contract
1 V 125 DC
closed coils for 220 DC
2 Current of tripping coil A 5.5
No Description Unit Ratings Remarks
3 Current of closed coil A 3.2
4 Power supply voltage of motor V 125 DC See ordering contract
5 Power of motor W 300
6 Revolution of motor r.p.m 750
7 Current of motor A 5.5/ 2.7
Voltage V AC240
8 Heater
Power W 100
Table 5. Ratings of SF6 gas pressure (relative) at 20°C

No Item Unit Ratings
1. Rated Filling Pressure Bar 6.0
2. Refilling Gas Alarm Pressure Bar 5.5 ± 0.03
3. Circuit Breaker Lockout Pressure Bar 5.0 ± 0.03

Page 5 of 42
2.0 STRUCTURE AND PRINCIPLE
2.1 General Construction and Principle

The LW9-145 HV SF6 circuit breaker incorporates the self-blast interrupter. Each pole of the
breaker is of a single column and one breaking chamber.
The breaker consists of three single poles, which are mounted on the same frame, for 3
phase mechanical interoperation by one spring operating mechanism.
The interrupter is in the uppermost of the product while the support porcelain and frame
(driving system and SF6 gas pipe are installed inside) are installed on the circuit breaker
support structure. The spring operating mechanism is installed on the front of the frame.
The general layout and installation foundation of the circuit breaker is shown in Figure 1. For
detail dimension and parts descriptions, please refer to approved general arrangement
drawings.
1900 1900
INTERRUPTER
CHAMBER
1280
INSULATOR
TERMINAL
PAD
SUPPORT
INSULATOR
5725
OPERATING LINK OPERATING

MECHANISM/HORIZONTAL MECHANISM BOX
FRAME
439
4005
(190 MAX)
1400
2050
2200
GROUND LEVEL GROUND LEVEL
Figure 1. LW9-145 gas circuit breaker general arrangement

Page 6 of 42
2-1
2-7
2-14
2-2
2-4
2-8
2-3
2-13
2-5
2-9
2-12
2-6 2-10
2-11
2-15 2-16
2-17
2-1 Auxiliary contacts 2-9 SF6 gas density meter

2-2 Circuit breaker Close indicator 2-10 Tripping Coil
2-3 Circuit breaker Open indicator 2-11 Manual trip button
2-4 Operation counter (Trip) 2-12 Closing Coil
2-5 Local/Off/Remote selector switch 2-13 Manual close button
2-6 Trip/Neutral/Close selector switch
2-14 Closing spring (covered)
2-7 Spring charge/discharge indicator2-15 “D” Valve
2-8 Spring charging motor 2-16 “E” Valve
2-17 SF6 gas inlet
Figure 2. General arrangement of components inside the mechanism box (left side)

Page 7 of 42
3-2
3-3
3-1
3-4
3-5
3-6
3-7
3-1 Terminal blocks 3-5 Thermostat

3-2 Panel lighting limit switch 3-6 Heater switch
3-3 Miniature circuit breaker 3-7 Contactors
3-4 Heater light
Figure 3. General arrangement of components inside the mechanism box (left side)

Page 8 of 42
2.1.1 Single Pole Circuit Breaker
4-1 4-10
4-2 4-11
4-12
4-3 4-13
4-4 4-14
4-15
4-5 4-16
4-6
4-17
4-7
4-8
4-9 4-18
4-19

Page 9 of 42
4-1 Absorbent 4-8 Support Porcelain 4-15 Moving Arc Contact
4-2 Interrupter Porcelain 4-9 Insulating rod 4-16 Piston Rod
4-3 Moving contact 4-10 Upper Terminal 4-17 Lower Flange
4-4 Cylinder 4-11 Contact Seat Rod 4-18 Operating Rod
4-5 Piston 4-12 Fixed Arc Contact 4-19 Linear Sealing Device
4-6 Intermediate Contact 4-13 Fixed Contact
4-7 Lower Terminal 4-14 Nozzle
Figure 4. The structure of the single pole circuit breaker
2.1.2 Support Porcelain Unit

The interrupter porcelain is mounted on top of the support porcelain. Apart from supporting
the interrupter assembly, the support porcelain undertakes to insulate the current carrying
path (and other associated assemblies) from earth.
Insulation rod (4-9) is used to connect the operating rod (4-18) and the piston rod (4-16). Its
other main function includes the insulation of live internal parts from earth. The SF6 gas
within the lower porcelain is common with that inside the interrupter porcelain.
2.1.3 Absorbent
Absorbent (4-1) is placed inside the interrupter cover and is used for keeping the SF6 gas
dry. It also absorbs deteriorate gas resulting from arc decomposition. The absorbent must be
replaced when the interrupter cover is removed for service, maintenance, etc.
2.1.4 Hermetically Sealing

Two hermetically sealing methods, linear sealing and static sealing are adopted for use in
this breaker. For the latter, the common ”O” ring and sealant are used. But for the former,
which is only employed at the lower opening of the support porcelain, the hermetically
sealing device (4-19) is adopted.
It is mounted at the bottom of the support porcelain to achieve a dynamic (movable) seal by
compressing sealing discs with spring. The dismantling of the linear hermetically sealing
device at site is generally NOT RECOMMENDED. This is to safeguard the proper
functioning of the device at all times. Extra care and caution must be practiced during
assembly and inspection.
2.1.5 Interrupter Unit

The interrupter of the circuit breaker is of the self-blast structure. When the breaker open,
the high-pressure heat-expansible gas flowing inside the puffer cylinder is used to extinguish
the arc. Its simple interrupting principle illustrated in Figure 5.

Page 10 of 42
FIXED MAIN CONTACT
ARC
FIXED ARC CONTACT
MOVING ARC
NOZZLE
CONTACT
CYLINDER MOVING CONTACT

INTERMEDIATE
PISTON
CONTACT
Figure 5. Interrupter unit
2.1.6 Driving Mechanism
6-9 6-10 6-1
6-2
6-3
6-4
6-8 6-7 6-6 6-5
6-1 Single Phase CB 6-6 SF6 Gas Pipe

6-2 Operating rod 6-7 Opening Spring
6-3 Connecting Plate 6-8 Shock Absorber
6-4 Lever 6-9 Joint Bearing
6-5 Connecting Rod 6-10 Clamp
Figure 6. The structure of driving mechanism
The driving mechanism of the breaker connects the individual interrupter poles with the
operating mechanism, which in turn transfers the operating force to the moving contact
system of the breaker

Page 11 of 42
2.2 Spring Operating Mechanism
A spring-operated mechanism is used to drive the interrupters. It is mounted on the base
frame. The force from the mechanism is transferred to the three single-phase columns by
non-adjustable inter-phase links. The mechanism uses separate springs for opening and
closing operations.
The closing spring is charged by a ratchet and pawl arrangement, which is driven by an
electric motor, while the opening spring is charged by the closing action of the mechanism;
through a set of bevel gears. A system of latches is used to maintain the circuit breaker in its
intended position, i.e. open or closed position.
The moving contacts of the puffer interrupters in each phase column are operated via a
system of inter-phase drive links by a mechanism which utilizes separate springs for opening
and closing operations.
The construction and the working principle of the spring operating mechanism are illustrated
in Figure 7.
CAM (i)
CIRCUIT BREAKER (a) OPENING SPRING (b)
LEVER (l) SHOCK ABSORBER (v)
RATCHET SHAFT (s) CLOSING SPRING (c)
A
PAWL (j) CAM SHAFT (r)
MAIN DRIVE SHAFT (t) B RATCHET WHEEL (d)
PIN (q) CLOSING HOLDING LATCH (e)
LEVER (k) ANTI-CLOSING PIN (w)
PIN (o) CLOSING TRIGGER (f)
TRIP HOLDING LATCHED (m) CLOSING COIL (g)
ROLLET (u) ANTI-PIMPING LEVER (p)
TRIP TRIGGER (n) ANTI-TRIPPING PIN (x)
Figure 7A
CLOSED POSITION TRIP COIL (h)
(CLOSING SPRING CHARGED)
Figure 7B Figure 7C
OPEN POSITION CLOSED POSITION
(CLOSING SPRING CHARGED) (CLOSING SPRING DISHARGED)
Figure 7. Working principle of spring operating mechanism

Page 12 of 42
2.2.1 Opening Operation
Refer to Figure 7A
Opening spring (b) exerts a thrust upon arm ‘A’ of lever (l) to produce an anti clockwise
torque on lever (k) via main drive shaft (t) to which both levers are secured. This torque is
resisted by the engagement of pin (o) with trip holding latch (m) which the movement is
blocked by the trip trigger (n).
The sequence of events when an OPENING operation is initiated is as bellow:

1) Trip coil (h) is energized by the OPENING signal, causing its plunger to kick trip trigger
(n) rotating it clockwise.
2) Trip holding latch (m) is free to turn clockwise and disengages from pin (o) which is
secured to lever (k).
3) The torque exerted by opening spring (b) upon levers (l) and (k) is now unopposed and
they rotate anti-clockwise.
4) Circuit breaker (a) is OPENED through a drive link connected to arm ‘B’ of lever (l). The
mechanism configuration of OPENING operation is shown in Figure 7B.
2.2.2 Closing Operation

Refer to Figure 7B
Closing spring (c) exerts an anti-clockwise torque upon ratchet wheel (d), which is secured
to camshaft (r) along with cam (i). This torque is resisted by the engagement of pin (q) with
closing holding latch (e) which the movement is blocked by closing trigger (f).
The CLOSING operation is described as below:

1) Closing coil (g) is energized by the closing signal, causing anti-pumping lever (p) to kick
the closing trigger (f). It will rotate it clockwise.
2) Closing holding latch (e) is now free to turn anti-clockwise and disengages from pin (q),
which is secured to ratchet wheel.
3) The torque exerted by closing spring (c) is now unrestrained and cam (i) is driven anti-
clockwise against roller (u) thus give impact of clockwise rotation to levers (k) and (l)
4) Opening spring (b) is charged by the motion of arm ‘A’ of lever (l) whilst at the same time
the interrupter is CLOSED by the motion of arm ‘B’ of lever (l).
5) Pin (o) engages automatically with trip holding latch (m), which is locked by trip trigger
(n) so providing a restraint against charged opening spring (b).
The mechanism configuration on CLOSING operation is shown in Figure 7C but before the
re-charging of the closing spring begins.
2.2.3 Manual Operation of Circuit Breaker
2.2.3.1 Manual Charging of Closing Spring

In the event of the power supply to the spring charging motor is failed the spring can be
charged manually. This is done by fixing a ratchet spanner (17mm A/F) on the hexagonal
end of the camshaft and turning it in an anti-clockwise direction.

Page 13 of 42
WARNING
Before attempting a manual spring charge, please check the relevant safety precautions and
procedure before attempting.
2.2.3.2 Manual Opening of Circuit Breaker

Since use of the manual opening overrides the electrical gas lockouts, it is imperative that
the SF6 gas density is confirmed before this facility is used. Push the spring-loaded push
button to trip.
2.2.3.3 Manual Closing of Circuit Breaker

Possible only when the closing spring is fully charger. Please also ensure that SF6 gas
density is sufficient before this facility is used. Push the spring-loaded push button to close.
2.2.4 Prevention of Closing and Tripping Operations

Provision is made to mechanically prevent the mechanism performing a closing or tripping
operation. This is achieved by inserting anti-closing or anti- tripping pin (w) and (x) which
prevent the closing or opening triggers (f) and (n) rotating on their axis pins. (Refer to Figure
7A and 8). Fully inserted the anti closing/tripping pin into the pin opening as shown in figure
8A and 8B below.
WARNING
a) This pin should be used only to prevent unintentional and unsafe operations during
maintenance or inspection of the circuit breaker. The anti tripping/closing pin is removed
prior to breaker put into service.
b) Do not use the above torque value for covers with flexible gaskets, but tighten to
compress gasket thickness by 1/3 only; this ensures weather tightness.
Figure 8A. Anti-tripping pin Figure 8B. Anti-closing pin

Page 14 of 42
2.2.5 Control of the Circuit Breaker
2.2.5.1 Local Control

The electrical controls and SF6 gas filling facilities are situated within the mechanism housing
which forms an integral part of the circuit breaker assembly.
2.2.5.2 Remote Control

The electrical control of circuit breaker is possible by put the Local/Off/Remote selectors
switch to remote position and cabling to remote control panel.
2.2.5.3 Conditions for Electrical Operation

Electrical control of the circuit breaker, whether remote or local is depend on their conditions:
a) The appropriate electrical supplies must be available for the opening coils, closing coil
and closing spring charging motor.
b) The local/Off/Remote selector switch located in the mechanism housing must be set to
the correct position.
2.3 SF6 Gas System
2.3.1 System Construction

The switchgear equipped with a common temperature compensated pressure switch with
gauge (density meter) to automatically monitor the status of the SF6 gas in all the pole units.
This density meter is located inside the mechanism housing, and has two sets of contacts.
One set of contacts provides an alarm indication when the gas pressure falls to a level of 5.5
bar.
The other set prevents operation if gas pressure falls to a level of 5.0 bar. However, we are
pleased to inform that the circuit breaker is able to interrupt short circuit current at 5.0 bar
and were proven during the type test.

Page 15 of 42
A B C
A VALVE B VALVE C VALVE
SF6 GAS DENSITY D VALVE
E VALVE
NORMALLY OPEN VALVE NORMALLY CLOSED VALVE
Figure 9. SF6 gas system
The temperature-compensating feature of the switch avoids alarms and lockouts due to
normal pressure variations associated with ambient temperature changes. The pressure
gauge has a color-coded face for ease of reading from a distance
The SF6 gas system consists of SF6 gas density meter, inlet valve E and valves A, B, C, D
and SF6 gas piping. The SF6 gas system is illustrated in Figure 9.
2.3.2 Gas Control Valve

Under normal condition valves A, B and C are in open position to maintain an equivalent SF6
gas pressure in the 3-phase interrupters, piping system and SF6 gas density meter. Valve A,
B and C physically located at the bottom of bushing assembly, inside the horizontal frame.
Valve E is in closed position under normal condition. When SF6 gas density drops, an alarm
is activated. SF6 gas refilled can be carried out through the supply inlet even when the circuit
breaker is in operation (energized). Valve D and E physically located inside the mechanism
box assembly.
2.3.3 Density Meter

The SF6 gas density meter consists of a temperature compensated pressure switch with
pressure gauge. The pressure reading shown is a relative pressure.

Page 16 of 42
3.0 INSTALLATION AND COMMISSIONING
3.1 Basic Flow Chart for Installation and Commissioning
INSPECTION & RECEIVE.

OPEN BOX, STORING
PREPARATION OF
FOUNDATION INSTALLATION
ANCHOR BOLT INSTALLATION
SUPPORT, FRAME &

MECHANISM BOX ASSEMBLY
SINGLE PHASE
INTERRUPTER
SF6 GAS PIPE CONNECTION
TERMINAL ASSEMBLY
SECONDARY WIRING
STROKE MEASUREMENT
SF6 GAS LEAKAGE

TEST SF6 GAS MICRO MOISTURE
INSPECTION
APPLY WATERPROOF
COMMISSIONING

Page 17 of 42
3.2 Inspection, Unpacking and Storage
3.2.1 Inspection
When the switchgear is delivered to the site, the customer must inspect all the received
components thoroughly according to the packing list. If any abnormalities are observed,
kindly contact Tenaga Switchgear Sdn. Bhd. (Business Development Dept.) at the soonest
possible.
3.2.2 Precaution during Loading, Unloading and Unpacking

a) Prevent extreme humidity when loading and unloading of switchgear components.
b) Avoid vigorous shock (stress) on switchgear components during loading and unloading.
c) DO NOT open any valve on the switchgear.
d) When lifting porcelain bushing from the crate, extra caution must be practiced, as the
porcelain is susceptible to damage when handle carelessly.
e) Inspect all components to ensure that they are free from damage.
3.2.3 Storing
If the switchgear does not intend for immediate installation, it must be kept in an elevated,
dry; clean area and strictly shielded from water and moisture.
It is advisable to leave the heater in the operating mechanism Switched On and the
thermostat set to 5oC above the ambient temperature (in Malaysia, set the thermostat at
±35oC, other places outside Malaysia, check the local ambient temperature) at all time.
3.3 Preparation for Basic Installation

During assembly, attention must be paid to the following:
a) Avoid working under rain.
b) Avoid knocking against SF6 gas piping and SF6 valve.
c) Do not damage SF6 system sealing surface or “O” ring.
d) Do not re-use “O” ring.
e) Circuit breaker is evacuated and filled with 0.5bar of SF6 gas before delivery. At site, if
inspection reveals nothing peculiar, SF6 gas can be filled instantly.
f) Before filling of SF6 gas, the bottle and the SF6 gas filling piping and associated
accessories must be completely dry and clean from dust and any foreign particles,
before any filling take place.
g) As the circuit breaker is only filled with 0.5bar of SF6 gas when it leaves the factory, care
must be taken not to open the SF6 gas valve at site.
h) After completing installation, strictly avoid fast closing and opening operation before SF6
gas is filled at rated pressure. The manual operating device may be used to perform the
slow opening and closing operations.
Page 18 of 42
a) Before operating the circuit breaker manually, the closing and opening preventive pin
must be removed, and electric supply must be turned off.
b) Once the circuit breaker is delivered to site, ensure that appropriate care is taken when
handling the components. This will guarantee that the circuit breaker will perform as
intended without any problem.
3.3.1 Foundation Installation

LW9-145 foundation load and anchor bolt dimension arrangement must comply with the
requirements as specified in the customer specifications. The foundation design must be
strong and rigid enough to withstand vibration from circuit breaker during operation. Anchor
bolts of M24 are recommended.
3.4 Special Tools for Installation

Refer to table 6 for installation special tools. Remember to store the tools in order, as they
are essential in case that the circuit breaker needs to be maintained/ serviced/ overhauled/
tested.
Table 6. Special tools

No Name Drawing Remark
Slow closing/opening
operation
5KA.487.024
1
Tool
operation
Ratchet spanner
2
3 Bearing
operation
Filling of SF6 gas

4 Pipe and valve
Retaining ring plier Elasticity retaining

5
ring for shaft

Page 19 of 42
3.5 Material and Parts Used in Installation
Refer to table 7 for the necessary material and preparation prior to installation.
Table 7. Parts and accessories for installation works

No Name and specification Qty Application Remark
Terminal pad
1 Z type conductive grease 30g Supplied
assembly
SF6 gas pipe
2 Sealing gum 1 Supplied
connecting seal
Sealing gum Mechanism box frame
3 1 Supplied
(water proof) proof rain
To Polish conductive
4 Cleaning cloth 2 pieces Not Supplied
surface
Shaft pin, manual
Low temperature No. 2
5 0.5 kg operating tool Supplied
lubricating grease
lubrication
6 Alcohol 1 bottle Clean parts, proof dry Not Supplied
7 Dust free tissue paper 2 packs Clean parts, proof dry Not Supplied
Polish conductive
8 Sand paper No. 400 3 pieces Not Supplied
surface
9 Terminal pad 6 Connect busbar Supplied
Stainless steel bolt To assemble terminal
10 18 Supplied
M12X14 pad
11 Anchor bolt M24 8 Supplied
Fixed the product on
12 Nut M24 8 Supplied
the base
13 Washer 24 8 Supplied
14 Tight gum 1 Supplied
15 “O” ring 22 x 2.4 2 Filling the SF6 gas Supplied
SF6 gas pipe seal and
16 “O” ring 10 x 1.9 4 Supplied
connection
17 Retaining ring for shaft 30 4 Supplied
Shaft pin assembly

Page 20 of 42
3.6 Installation Procedures
Table 8 outlines the major installation procedure involved in the erection and installation of
the circuit breaker.
Table 8. Major installation procedures

No item Application Tool & Material
Foundation Preparation, constructions of plinth and
plinth and installations of anchor bolt by other.
1
anchor bolts.
a) The H-Frame and the Mechanism Box

has already been installed together at the
factory.
b) Lift the frame and mechanism box

assembly slowly and carefully.
c) Firmly install the frame and mechanism

box onto the support structures.
d) Tighten evenly the frame onto the support

structures using 8 pieces of M20 x 40 bolt
and washer. Lifting machine
Horizontal e) Check the leveling at several points on Spanner

frame and top of the frame using the spirit level to
2
mechanism get the level of 1/1000. Spirit level
box assembly
M20 x 40 bolt &
washer
a) Use the sandpaper to polish the contact Spanner/torque

surface of the terminal pad as well as the wrench
circuit breaker column’s terminal flange.
Sand paper
b) Use alcohol to clean the contact surface (No. 400)
of terminal pad and terminal flange and
Terminal pad
3 apply grease. Alcohol
assembly
c) Use bolt M12 x 50 to tighten the terminal Electrical
pad to the terminal flange. contact grease
d) Repeat the above process for other poles. Dust free tissue
paper
Page 21 of 42
a) Please note that each bushing engraved
with phase identification followed by a
serial number at the bottom part of each
support bushing as follow, A XXXXXX, B
XXXXXX and C XXXXXX, e.g. A 123456.
b) Single-phase circuit breaker pole and

mechanism must be assembled
according to the factory delivery and
serial number. The bushing serial number
must correspond to serial number at the
flange of horizontal frame. Do not
interchange or swap the sequence or
serial number.
c) Remove all protection cover and rubber

gasket, which covered the flange on the
horizontal frame.
d) Remove back cover of the horizontal

frame.
e) Prior to installation, ensure the correct

phase. Phase ‘A’ circuit breaker pole is Lifting rope
located at the extreme left of the
horizontal frame (see from front view, Spanner
Circuit
facing the mechanism box. Refer figure
4 breaker pole C). Retaining plier
assembly
f) Use the circuit breaker pole’s bottom Low
protection bracket for lifting up the circuit temperature no.
breaker to vertical position, as shown in 2 lubricating
figure A. grease
g) After vertically lifting the circuit breaker, Dust free tissue

remove the protection bracket and plastic paper
film on the valve.
h) At lifting position, pull down the piston rod

slowly until it reaches a complete stop.
i) Slowly place the bushing on the

horizontal frame.
j) Care must be taken from on the SF6

valve direction on the circuit breaker
when moving downward to the frame.
k) Connect the connecting plate (4-3) as

shown in Fig. 4, to the connecting rod (4-
2) using ∅13 pin. These link plates must
not be interchanged or modified from its
original fixed position Apply grease on the
∅13 pin and do the connection. Install the

Page 22 of 42
retaining clip as well.
l) After completed the above assembly, let

the circuit breaker firmly seat on the
flange surface, pre-tighten the nut,
remove the lifting rope, finally tighten all
the nuts.
m) Repeat the above procedure until all the

3-pole circuit breaker completely
assembled.
n) If the operating rod (6-2) can not install

with the connecting plate (6-3), use slow
closing/opening devise.
TO CRANE
PROTECTION
BRACKET
Figure A.
TO CRANE
Figure B.

Page 23 of 42
SERIAL NO.
"A" "B" "C"
Figure C.
a) Remove nut from the valve, see figure E

below.
b) Use alcohol to clean the SF6 gas valve.
c) Place the “O” ring into the valve’s groove.
d) Screw in Nut (3) into Adapter (2) and

tighten.
Spanner
Alcohol
SF6 gas pipe
connection to
5 Dust free tissue
circuit breaker
paper
pole
Sealing gum
Figure D.

Page 24 of 42
1 3
Figure E
Before filling of SF6 gas, ensure the gas in

the cylinder comply with IEC396 standard.
Filling of SF6 Slowly fill the SF6 gas to avoid icing on

6 Filling adapter
gas valve or in gas cylinder.
Filling of SF6 gas procedures refer 3.9.2.
3.7 Tightening Torque Values

Table 9. Tightening torque for metric fixings
TIGHTENING TORQUES FOR METRIC FIXINGS
FIXING SIZE Torque (Nm)
M4 1.89 (1.6 - 1.9)
M5 3.5 (3.2 - 3.8)
M6 6 (15.3 - 6.4)
M8 14 (12.8 - 14.7) (24.5 - 30.3) (43 - 51)
M10 27 (108 -127)
M12 47 (196 - 245) (343 - 421)
M16 118 (677 - 833)
M20 216
M24 294
M30 755
3.8 Inspection and Adjustment
3.8.1 Inspection of Slow Closing/Slow Opening Operating Device

a) Open bottom plates of the frame (10-6) and cover plate. Apply lubricating oil to the
thread of the lifting rod (10-8) and terminal part bearing (10-10). Put bearing (10-10) and
nut (10-9) on the lifting rod (10-8).
b) Fix lifting rod (10-8) on lever 11 through bottom hole of housing mechanism and put
sleeve plate (10-4) around nut (10-9).
c) Rotate nut (10-9) clockwise to open the circuit breaker or rotate anti-clockwise to close
the circuit breaker.
d) For manual opening operation, press the tripping magnet to release the interlock pin and
closing control latch.

Page 25 of 42
3.8.2 Manual Closing
a) In the absent of power supply, closing spring can be charged manually as illustrate in
Figure 10.
b) Insert sleeve rod (10-1) and sleeve spanner (10-3) into the hexagon hole of the ratchet
wheel.
c) Rotate sleeve spanner (10-3) clockwise to charge the spring.
10-1
10-11
CHARGING 10-2
10-10 10-3
10-9
10-8 10-12
10-7
10-6
CLOSE
10-5 OPEN
10-4
10-1 Rod
10-2 Ratchet shaft
10-3 Spanner
10-4 Sleeve spanner
10-5 Bushing
10-6 Cover plate
10-7 Mechanism box
10-8 Lifting rod
10-9 Nut
10-10 Bearing
10-11 Bending lever
10-12 Closing spring charge
Figure 10. Manual operating device assembly

Page 26 of 42
3.8.3 Stroke Measurement
a) Before measurement, cut off all control and auxiliary supply. Stroke reference must
comply with the requirement in Table 10. Please refer to Figure 11 for the operation
sequence.
b) Connect test lamp (or buzzer) between the top and bottom terminal of the interrupter.
Manually operate to open the circuit breaker and measure the distance of A1 and B1.
c) Manually close the circuit breaker, when the test lamp just begin to light (or buzzer just
begin to buzz), this is the position at instant of contact touching, measure the distance of
A2.
d) Continue close operation until the manual operating mechanism become loose. This is
the close position, measure the distance of A3 and B2.
e) Carry out calculation according to Table 10 and compare it with the technical
requirement whether it is satisfactory.
f) Circuit breaker is at open position, closing spring in charging condition, measure gap G3
between roller and charging position cam.
Table 10. Stroke measurement

Measured
Items Code Requirement Unit
device
Stroke of contact
A1 - A3 150 mm
Straight edge/
Interrupter Overstroke of
steel ruler/ lamp
contact A2 - A3 27 ± 2 mm
Travel of piston
Operating
of mech. B2 - B1 100 mm Straight edge
mechanism

Page 27 of 42
A2
A1
A3
A) OPEN POSITION B) JUST TO CLOSE POSITION C) CLOSE POSITION
B1 B2
G
B
=
1.
4±
0.
3
A) OPEN POSITION B) CLOSED POSITION
Figure 11. Travel measurement of circuit breaker
3.8.4 Inspection on Tripping and Closing Coils Clearance

Clearance adjustment of the tripping and closing coils are generally not performed at site.
However, for final verification purposes the following inspection methods can be used.
The checking must ensure that all requirements (as per Table 3) are satisfied. When
measuring the tripping magnet clearance, product must be in closed position.
Insert tripping preventive pin (12-6) into operating mechanism for measurement. When
measuring the closing magnet clearance, product must be in open position. Insert closing
preventive pin into operating mechanism for measurement.

Page 28 of 42
3.8.5 Adjustment on Tripping and Closing Coils Clearance
Clearance of the magnet has been adjusted in the factory, thus adjustment can be made
using the following methodology (Refer to Figure 12 and Figure 13):
Adjustment of dimensions F: Loosen nut (12-3), symmetrically tighten screw (12-2) to

adjust the limit dimension.
Adjustment of dimensions G: Loosen nut (12-1), turn plunger bar to move the knocking
position of the plunger.
Adjustment of dimensions C: Loosen nut (13-4), symmetrically tighten screw (13-3) to

adjust the limit dimension.
Adjustment of dimension D & E: Loosen nut (13-2), turn plunger bar to move the knocking
position of the plunger.
Note: It is to be noticed that the magnet clearances are interrelated. When any adjustment
is made, check to confirm that all dimensions complies with the requirement, before
tightening the screws into place.
NUT (12-1)
BOLT (12-2)
OPENING COIL (12-5) NUT (12-3)
PLUNGER (12-4)
F = 2.8~3.2mm
STROKE
ANTI OPEN PIN (12-6) PLUNGER (12-8)
G = 0.8~1.2mm
OPENING LATCH (12-7)

GAP
Figure 12. Tripping coil clearance

Page 29 of 42
NUT (13-2)
CLOSING PLUNGER (13-1) BOLT (13-3)
NUT (13-4)
CLOSING COIL (13-5)
C = 5.0~5.5mm
SUPPORT (13-7)
STROKE
COIL (13-6)
CLOSE LATCH (13-8)

D = 2.0~2.5
LATCH (13-9)
E = 1.0~2.0
ANTI-JUMP PIN (13-10)
Figure 13. Closing coil clearance
3.9 SF6 Gas Evacuation and Filling Procedures

The single-phase circuit breaker has been evacuated at the factory prior to delivery and filled
with 0.5 bar of SF6 gas.
Evacuation at site is not necessary. However, remember to first inspect the SF6 gas
pressure gauge before filling the gas to the rated operating pressure.
The gauge reading should be equivalent to the factory-filled pressure. If not, the circuit
breaker has to be evacuated until it reaches at least -1.0 bar. Only then the SF6 gas be filled.
Refer figure 14 for evacuation and filling of SF6 gas.
3.9.1 Evacuation of SF6 Gas

1. Connect hose between inlet valve (14-9) and vacuum pump. Inspect the rotation
direction of the vacuum pump. Start the pump and confirm that there is no leakage.
2. Open the valve on the product (valve A to E). After vacuum reaches -1.0 bar, continue
evacuation for another 30 minutes.
3. Before stopping the vacuum pump, close valve “E” (14-1) first, followed by all other
valves on the equipment. This is to avoid the loss of vacuum in the equipment.
3.9.2 Filling of SF6 Gas

1. Removes cover plates (14-9) from valve E and clean the sealing surface. Placing “O”
ring properly into the inlet valve groove. Do not apply sealant on the “O” ring
2. Open valve A, then at the same time open valve D and valve E (Refer to Fig 6). Use
small amount of SF6 gas inside the interrupters to blow out the air in the pipe, then close
valve D and valve E.

Page 30 of 42
3. Remove the SF6 gas sealing cover (14-8), connect gas pipe and then tighten nut (14-5)
properly.
4. When connecting gas pipe adapter (14-2) and valve E, first leave a gap. Open the bottle
valve and the regulator valve at the SF6 bottle slowly.
5. Use small amount of SF6 gas from the bottle to blow out the air in the pipe, then close
regulator valve. Quickly tighten adapter (14-2).
6. After completing the above-mentioned procedure, inspect valve A, B, C and D to confirm

that they are fully opened.
7. Adjust regulator valve and valve of SF6 bottle, so as to maintain the outlet pressure of the
regulator valve at 2.0 bar - 5.0 bar.
8. Observe the SF6 gas density meter inside the circuit breaker’s operating mechanism box.
When the reading reaches the specified pressure in Table 5, (with a tolerance of +0.3
bar), close valve E first; then close the bottle valve and regulator valve.
9. Remove gas filling hose adapter (14-2) and fix cover plate of valve (14-9). The filling of
gas has now been completed.
14-4
14-1 14-2 14-3 14-5 14-6
14-9 14-8 14-7
14.1 “E” Valve 14.6 SF6 gas bottle valve

14.2 Adapter 14.7 SF6 gas
14.3 Gas pipe 14.8 Cover
14.4 Reduce pressure valve 14.9 Cover plate
14.5 Nut
Figure 14. Filling of SF6 gas

Page 31 of 42
Figure 15. Valve and gas inlet
3.9.3 Detection of SF6 Gas Leakage
Use the SF6 gas leakage detector to inspect all sealing surfaces of the interrupter and the
SF6 gas piping. If there is no leakage, the product is considered to be in good order.
If any leakage is found, wrap with plastic film and leave it for 24 hours. Check the density of
the SF6 gas inside the plastic film as shown in Fig. 16. If the SF6 gas density is
unacceptable, the sealing is deemed to be damaged. As such, the necessary corrective
action needs to be performed.

Page 32 of 42
FLANGE
SF6 LEAK DETECTOR

O RING SEALING GUM
Figure 16. Gas leakage inspection
3.10 SF6 Gas Moisture Test

SF6 gas sample is obtained by slowly releasing a very small quantity of SF6 gas into the
measuring instrument. The moisture content in the SF6 gas prior to operation MUST NOT
exceed 150 ppm (parts per million).
3.11 Testing
Precaution
When SF6 gas pressure is lower than 4.0 bar, NO OPERATION IS ALLOWED.
3.11.1 Main Circuit Resistance Test

With the circuit breaker in closed position, the resistance (using a micro-ohm meter) between
the upper terminal of the interrupter and the lower terminal MUST NOT exceed 45 µΩ.
3.11.2 Insulation Resistance Test

Use a 1000V insulation resistance tester to test the insulation resistance between the main
circuit terminals and the main circuit to earth. Insulation resistance measured must not be
less than 1000MΩ.
Use a 500V insulation resistance tester to test the insulation resistance of the auxiliary circuit
to earth. Insulation resistance measured MUST NOT be less than 1000MΩ.
3.11.3 Operating Value Inspection of Gas Pressure Switch

Close valve D of interrupter (Refer to Fig 6). Use a multimeter to test the contact points of
the SF6 gas pressure switch, to determine whether it is in close or open position. Open valve
E slowly to allow the SF6 gas pressure in the pipe to drop gradually.

Page 33 of 42
Detect the pressures at which the SF6 pressure alarm and the interlock operates. Close
valve E and slowly open valve D to allow the SF6 gas from the interrupter to flow into the gas
piping.
The SF6 gas pressure in the piping will slowly increase. Detect the pressures at which the
SF6 gas filling and the SF6 gas interlock reset functions operate. The test results must
comply with the requirement specified in Table 4.
3.12 Installation, Adjustment, Testing And Final Inspection

a) Check all bolts, nuts and screws to ascertain tightness.
b) Check to confirm that the shaft pin and the retaining ring are correctly installed.
c) SF6 gas must be at rated pressure and all valves should be in correct positions.
d) Leave local-remote switch in the required position. Confirm that the Auto-Manual switch
is positioned at the Auto contact.
e) Remove any foreign material in the mechanism box and frame.
f) Check if that all cover plates have been tightened. Remember to remove any foreign
object on the mechanism box and the frame.
g) Confirm that the trip and close preventive pins have been released.
3.13 Application of Water-Proof Gum

To avoid water from seeping into the mechanism box and frame; clean external surface of
the product then apply water-proof gum to all flanges which are connected to the cover plate.
This must only be done after the final inspection. For all bolts and nuts of the positioning
cover plate, also apply waterproof gum on them. Upon completion of the above work, the
product is ready for operation.

Page 34 of 42
4.0 MAINTENANCE AND INSPECTION
4.1 Inspection Item

To guarantee that the product performs reliably at all times, a routine maintenance schedule
is necessary. In Table 11, 12 and 13, we propose a comprehensive maintenance schedule
to ensure that the product performs satisfactorily at the highest level.
Since the SF6 gas is hermetically sealed, the losses are negligible. As such, the proposed
inspection and maintenance schedules are tailored to focus on the operating mechanism
and other moving parts and assemblies.
Table 11. Recommended maintenance program

Inspection Frequency Description
Patrol inspection Every week Check if there are any
abnormalities of circuit breaker.
Annual inspection Every 5 years Short out of operation for

maintenance.
Overhaul inspection Every 12 years shown in table Long out of operation, overhaul
12 each part.
Table 12. Recommended overhaul period of main contact

Condition Times
Rated current breaking 2000
Rated short circuit current breaking 20
Notes: Circuit breaker should be overhaul when it operates up to 3000 times of

mechanical operation.
Table 13. Inspection items in overhaul

Overhaul
No Items Inspection Contents Class
P R M
1 Appearance Damage and pollution of porcelain. 0 0
Colour variation of wiring terminal. 0
Loose of earth terminal. 0 0 0
Position indicator. 0 0
Operation number of circuit breaker. 0 0
2 Body Stroke of circuit breaker and contacting 0 0

stroke. 0
Contacts nozzle replace with new ones. 0
Replace absorbent. 0 0
Measurement of resistance of main circuit. 0
Replace “O” ring.

Page 35 of 42
3 Operating Measure dimension of mechanism. 0 0
Lubrication of mechanism. 0 0 0
Tighten bolt and replace retainer. 0
Inspect leakage of oil from buffer. 0 0 0
4 SF6 gas system Measure SF6 pressure and ambient 0 0

temperature.
Measure moisture of SF6 gas. 0 0
Check leakage for disassembled position. 0 0
5 Control System Inspect reset of SF6 pressure switch. 0 0

Inspect the contact of auxiliary switch. 0 0
Inspect loose of control circuit. 0 0
Measure insulation resistance of control 0 0
circuit.
Inspect heater. 0 0
6 Operation Measure the time and speed of opening and 0 0

closing.
Note: P : Patrol Inspection

R : Annual maintenance (Regular Maintenance)
M : Overhaul Maintenance (Major Maintenance)
Measurement on moisture of SF6 should be done periodically (once in a year is

suggested), moisture content is no more than 300ppm (V/V) during servicing.
4.2 Safety
WARNING
Before attempting examination and/or overhaul of any item of equipment, it is essential that
the concerned maintenance staff and the operational staff shall be made aware of and
complies with the following:
a) The station safety regulation or its equivalent legislative safety documentation relevant to
the site, the general plant area and the particular equipment involved.
b) The Station Safety Regulations, or its equivalent, relating to the handling of SF6 gas and
SF6 gas insulated equipment.
c) Any station or board ‘Code of Practice’ relating to the handling of components which
have been subjected to arced SF6 gas.
d) The safety recommendations described thought this manual.
e) The necessary authorization to perform service must be obtained, which should be in the
form of a ‘permit to work’ license, or its equivalent, in accordance with the station
operating procedures.

Page 36 of 42
4.3 Procedures
Warning
Prior to maintenance of the circuit breaker, ensure that the following conditions have been
met. It is also recommended that, whenever possible, the energy stores in both the opening
spring and closing spring are released.
1) OPEN the circuit breaker from Local or Remote control.

2) Isolated and earth the circuit breaker in accordance with the supply authority’s
Regulations.
3) Switch off the MCB of spring charging motor.
4) CLOSE the circuit breaker. This operation discharges the energy stored in the closing
spring, but causes the opening spring to become charged.
5) OPEN the circuit breaker. This operation discharges the energy stored in the opening
spring.
6) Switch off the MCB of the closing and tripping control circuits.
7) Lock the LOCAL/OFF/REMOTE selector switch located inside the mechanism housing in
the OFF position.
8) If access is required to component within the phase columns, then first evacuate the SF6
gas.
4.4 Note
Certain aspects of maintenance may require the circuit breaker to remain in the CLOSED
position, with both the closing spring and opening spring in the charged condition. In these
circumstances, the recommended procedure prior to commencing maintenance is as
follows:-
1) Lock the LOCAL/OFF/REMOTE selector switch in the LOCAL position and padlocked.
2) Insert the anti-closing and anti-tripping pins into position inside the operating mechanism.
3) Switch off the MCBs of the closing and tripping control circuits and also the closing
spring charging motor circuit.

Page 37 of 42
5.0 OVERHAUL METHOD
5.1 Inspection of Main Contact and Nozzle
(A) 17-1 17-5 17-7

17-6
APPLY
SEALING 17-2 18
GUM
17-3 18
17-4
17-8
(B) (C) 17-10
APPLY
SEALING
GUM
17-11
TOP
TERMINAL
17-9 FLANGE
(DO NOT DAMAGE
(D) PORCELAIN) (E)
17-12 17-14
17-13
17-15
Figure 17. Contact inspections
5.2 Fixed Contact Inspection

As shown in Figure 17, remove 6 pieces of M12 bolt (17-1) and use two M12 bolts to jack-up
the fix contact seat (17-4).
Do not remove the two positioning pins (17-1) because this is for position guiding after
completed the overhaul of circuit breaker.
Carefully remove the fix arc contact seat. Inspect the fix arc contact (17-11), if there is any
damage. If necessary to replace, use spanner (17-10) as shown in Figure 16 to remove it.

Page 38 of 42
5.3 Moving Arc Contact Inspection
Inspect nozzle (17-13) and moving arc contact (17-15) if there is any damage. Use assembly
tool (17-12) as shown in Figure 17 and insert into the nozzle (17-13) slot.
Remove and inspect the moving arc contact (17-15) and replace it with new one if required.
Use spanner (17-14) as shown in figure 17 to loosen or to tighten the moving arc contact.
5.4 Assembly of Fix Contact Seat and Gas Sealing Components

Using of hack saw blade and hard material is not permissible for scrapping the scrapping the
sealant on the sealing surface. This is to avoid scratches on the sealing surface. Use alcohol
to remove the sealant on the sealing surface.
Use alcohol to clean “O” ring groove. The sealing surface must not have any scratches and
must be free from dirt to avoid leakage. Strictly follow the application of sealant gum as
describe in Table 15.
When assembly of fix arc contact seat (17-4) and interrupter bushing (17-3), use positioning
pin (17-5) for positioning. Use sandpaper no. 400 or greater to polish the terminal pad (17-6).
Table 15. Sealant application procedure

Schematic diagram Description
1 For the application on a narrow section, cut off
the attached nozzle sealant at a proper position
TUBE and fit the nozzle to the top of the tube.
NOZZLE
2 Clean out the grooves. Wipe off or dry out the

FLANGE FACE GROOVE solvent completely
3 Apply the gas sealer with the nozzle over (a)

section at external airside.
EXTERNAL GAS SIDE
AIR SIDE
(a) SECTION

Page 39 of 42
4 Smooth out the uneven surface of the gas
sealer applied over (a) section, with fingers
softly.
5 Attached O” ring.
"O" RING
6 Apply the gas sealer over (b) section with the

nozzle.
(b) SECTION
7 Smooth out the uneven surface of the gas

sealer applied over (b) section with fingers
softly.
8 Spread out the gas sealant over the whole area

of the flange face from (b) section to the external
APPLY GAS DO NOT APPLY airside thinly with fingers.
SEALANT HERE GAS SEALANT HERE
(For water-proof and rust prevention)

Page 40 of 42
6.0 TROUBLESHOOTING GUIDE
Table 16. Troubleshooting guidelines
INSPECTION / CORRECTIVE
NATURE OF FAULT POSSIBLE CAUSES
MEASURES
1. Electrical closing 1.1 Failure of control Check the voltage of control
is not possible. circuit. circuit and incoming supply
voltage.
1.2 Fault in electrical Check wiring for loose terminals,

control system. or disconnection. Check function
of closing coil, gas density,
auxiliary switches, relay, etc.
1.3 Gas pressure too low. Increase gas pressure to the

rated value, and check gas
density meter for correct
operation. Check for gas
leakage from flange joints and
piping.
1.4 Other. Check if closing is possible by

manual operating of closing coil.
2. Manual closing is 2.1 Incorrect adjustment Check and adjust gaps ‘D’, and
not possible. of, or mechanical fault ‘E’ and stroke ‘C’ before replace
in closing coil moving closing coil in faulty. (Refer
elements. Table 2 and Figure 12)
2.2 Anti-closing pin still Remove anti-closing pin.

fitted to mechanism.
3. Electrical opening 3.1 Check on power Check that control voltage is

is not possible. supply. greater that minimum operating
voltage.
3.2 Fault in electrical Check wiring for loose terminals,

control system. or disconnection. Check function
of closing coil, gas density,
auxiliary switches, etc.
3.3 Gas pressure too low. Increase gas pressure to the

rated value, and check gas
density switch for correct
operation. Check
for gas leakage from flange
joints and piping.
3.4 Other. Check if tripping is possible by

manual operating of trip coil.

Page 41 of 42
4. Manual opening is 4.1 Incorrect adjustment Check and adjust gaps ‘G’ and
not possible. or mechanical fault in stroke ‘F’ in accordance with
trip coil moving Table 2 and Figure 13. Replace
element. closing coil in faulty.
4.2 Anti-trip pin still fitted Remove anti-tripping pin.

to mechanism.
5. Gas pressure is 5.1 Gas leakage caused Carry out gas leakage test to
too low. by incorrect sealing of identify source of leakage, and
components. take remedial action. Increase
gas pressure to rated value.
5.2 Malfunction of gas Check the operation of gas

monitoring pressure monitoring pressure gauge and
gauge. replace if fault.
7.0 ORDERING GUIDE

The following must be specified clearly when ordering a circuit breaker:
a) Rated system voltage.
b) Rated system current and fault level current.
c) Rated voltage of trip coil, close coil and control scheme.
d) Rated voltage of motor for spring charging mechanism.
e) Number of spare contacts for auxiliary switch.
f) Other technical specifications/requirements.
8.0 CONCLUSION
The data furnished in this manual are for the guidance of qualified installation and operating
personnel. In case of doubts in the meaning or interpretation of the information given, kindly
contact Sales And Marketing Department, Tenaga Switchgear Sdn. Bhd.
The circuit breaker would provide satisfactory service upon adhering to the
recommendations provided herein. Due to continuous improvement, the equipment may
differ in details from that described in this manual.

Page 42 of 42

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INSTALLATION, OPERATION AND

145kV GAS CIRCUIT BREAKER

TENAGA SWITCHGEAR SDN. BHD.

2.0 STRUCTURE AND PRINCIPLE

3.0 INSTALLATION AND COMMISSIONING

4.0 MAINTENANCE AND INSPECTION

5.0 OVERHAUL METHOD

6.0 TROUBLESHOOTING GUIDE 41

7.0 ORDERING GUIDE 42

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

1.1 Type and Designation

1.2 Main Application and Scope

1.3 Service Condition

1.4 Technical Ratings

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

Table 3. Mechanical ratings

Travel of closed electromagnet F mm 2.8 ~ 3.2

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

Table 5. Ratings of SF6 gas pressure (relative) at 20°C

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

2.1 General Construction and Principle

OPERATING LINK OPERATING

GROUND LEVEL GROUND LEVEL

Figure 1. LW9-145 gas circuit breaker general arrangement

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

2-1 Auxiliary contacts 2-9 SF6 gas density meter

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

3-1 Terminal blocks 3-5 Thermostat

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

2.1.2 Support Porcelain Unit

2.1.4 Hermetically Sealing

2.1.5 Interrupter Unit

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

CYLINDER MOVING CONTACT

Figure 5. Interrupter unit

2.1.6 Driving Mechanism

6-9 6-10 6-1

6-8 6-7 6-6 6-5

6-1 Single Phase CB 6-6 SF6 Gas Pipe

Figure 6. The structure of driving mechanism

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

Figure 7. Working principle of spring operating mechanism

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

The sequence of events when an OPENING operation is initiated is as bellow:

2.2.2 Closing Operation

The CLOSING operation is described as below:

2.2.3 Manual Operation of Circuit Breaker

2.2.3.1 Manual Charging of Closing Spring

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

2.2.3.2 Manual Opening of Circuit Breaker

2.2.3.3 Manual Closing of Circuit Breaker

2.2.4 Prevention of Closing and Tripping Operations

Figure 8A. Anti-tripping pin Figure 8B. Anti-closing pin

OPERATION & MAINTENANCE MANUAL LW9-145 GCB REV. 01 - JAN 2009

2.2.5.1 Local Control

2.2.5.2 Remote Control

2.2.5.3 Conditions for Electrical Operation