ABB 5HK Series Installation and operating instructions

IB
6.2
.
1.7
D
Installation
/
Maintenance
Instructions
Medium
-
Voltage
Power
Circuit
Breakers
Type
5
HK
1200
thru
3000
Amperes
5000
Volts
JL
llll
Mllll
ABB
Power
Distribution
,
Inc
.
Circuit
Breaker Division
ASEA
BROWN
BOVERI
Courtesy of NationalSwitchgear.com

IB
6.2
.
1.7
D
Page
2
Ann
MIPIP
ASEA
BROWN
BOVERI
J
CONTENTS
PAGE
INTRODUCTION
RECEIVING
AND
STORAGE
CIRCUIT
BREAKER
INSTALLATION
INFORMATION
General
Installation
Inspection
Removing
Interphase
Barrier
Removing
Arc
Chutes
Insulation
Structure
Manual
Slow
-
close
to
Check
Contact
Pressure
Installing
Arc
Chutes
Installing
Interphase
Barriers
Installing
Circuit
Breaker
into
Compartment
CIRCUIT
BREAKER
REMOVAL
Removal
From
Connected
Position
Disconnect
Position
Removal
from
Switchboard
Safe
Operation
Recommendations
MAINTENANCE
AND
ADJUSTMENTS
General
Information
Contact
Pressure
Contact
and
Insulation
Cleaning
Millivolt
Drop
Test
Puffers
Bridge
Pivot
Opening
Times
Closing
and
Opening
Times
Arc
Chutes
Operating
Mechanism
Control
Relay
Adjustment
Racking
Mechanism
Lubrication
Dielectric
Tests
Electrical
Characteristics
of
Control
Devices
.
.
..
ELECTRICAL
OPERATING
SEQUENCE
GROUND
AND
TEST
DEVICES
RENEWAL
PARTS
3
3
3
3
3
3
4
4
4
5
5
5
6
6
6
J
r
'
6
6
6
6
7
8
8
8
9
9
9
9
10
10
10
11
11
11
12
13
)
Courtesy of NationalSwitchgear.com

IB
6.2
.
1.7
D
Page
3
AII
It
MIPIP
ASEA
BROWN
BOVERI
Section
3
.
CIRCUIT
BREAKER
INSTALLATION
3.1
GENERAL
Priorto
installation
of
thecircuit breaker into
a
switchboard
,
certain
preliminary
inspections
are
made
to
ensure
proper
operation
.
Section
1
.
INTRODUCTION
These
instructions
for
installation
,
operation
and
mainte
-
nance
of
HK
circuit
breakers should
be read
carefully
and
used
as a
guide
during
installation
and
initial
operation
.
The
specific
ratings
of
each model circuit breaker
are
listed
on
the individual
nameplates
.
File these instructions
in
a
readily
accessible
place
to
-
gether
with
drawing
and
descriptive
data
of
the
switchgear
.
These instructions
are
guides
to
proper
maintenance
of
the
equipment
to
prolong
its
life
and
usefulness
.
CAUTION CAUTION
CAUTION
CAUTION
PRIOR
TO
ANY
DISASSEMBLY
OR
INSPECTION
OF
THE
CIRCUIT
BREAKER
THE
CLOSING
SPRINGS
SHOULD
BE
DISCHARGED
AND
THE BREAKER
SHOULD
BE
OPEN
.
IF IT
IS NECESSARY
TO
RAISE
OR
MOVE
THE BREAKER
ATTACH
THE
LIFTING
YOKE
AT
POINTS
4
(
FIGURE
1
)
,
OR
A FIFTH
WHEEL AT
POINT
7
(
FIGURE
2
)
TO TRANSPORT
THE
BREAKER
AS
RE
-
QUIRED
.
Section
2
.
RECEIVING
AND
STORAGE
Immediately
upon
receipt
of
the circuit breakers
,
examine
the
cartons to
determine
if
any
damage
or
loss
was sus
-
tained
during
transit
.
If
injury
or
rough handling
is evident
,
file
a
damage
claim
at
once
with
the
carrier
and
promptly
notify
the
nearest
district
office
.
Asea Brown Boveri
,
Inc
.
is
not
responsible
for
damage
of
goods
after
delivery
to
the
carrier
.
However
,
the
company
will
lend assistance
if
noti
-
fied of
claims
.
Unpack
the circuit breakers
as
soon as
possible
after
receipt
.
If
unpacking
is
delayed
,
difficulty
may
be
experi
-
enced
in
making
a
claim
for
damages
not
evident
upon
receipt
.
Use
care
in
unpacking
in
order
to
avoid
damaging
any
of
the
circuit breaker
parts
.
Check
the
contents
of
each
carton
against
the
packing
list
before
discarding
any
pack
-
ing
material
.
If
any
shortage
of
material is discovered
,
promptly
notify
the
nearest
district
office
.
Information
speci
-
fying
the
purchase
order number
,
sales order
number
,
carton
number and
part
numbers
of
the
damaged
or
miss
-
ing
part
should
accompany
the claim
.
Circuit
breakers
should be
installed
in
their
permanent
location
as soon as
possible
.
If
the breakers
are
not to
be
placed
in
service
for
some
time
,
it
is
requ
ired
that
adequate
means
of
protection
be
provided
.
This
may
be done
by
keeping
the
breaker
in
its
original
shipping
carton
and
storing
in
a warm
(
approximately
15
°
C
)
dry
(
50
%
max
humidity
)
and uncontaminated
atmosphere
.
If
the circuit
breaker
cannot
be stored
properly
due
to
abnormal
circum
-
stances
,
it
must
be
thoroughly
checked
before
going
into
service
to
ensure
that
it
is without
damage
and
it
has
not
become
generally
contaminated
.
3.2
INSTALLATION INSPECTION
Inspect
condition
of
circuit breaker
arc
chutes
,
contact
and
electrical
connections
priorto
installing
the circuit
breaker
into the
switchboard
.
Even
though
each circuit
breaker is
completely adjusted
and tested
at
the
factory
,
shipping
and
handling
conditions could
cause
defects
.
3.3
REMOVING
INTERPHASE
BARRIER
For
5
HK
75
,
150
and
250
,
remove
two
lower
front
sheet
screws
,
lift
straight
up
above
arc
chutes
by
grasping
front
handle and
top
sheet
at
rear
,
then draw
barrierforward
and
away
from
circuit breaker
.
For
5
HK
350
,
remove
two
lower
front
sheet
screws
,
and
lift
front
sheet
up
and
away
from
the breaker
.
Remove
arc
chute tie
bar
at
upper
front of
arc
chutes
.
Pivot
rear
brace
at
rear
of
each barrier
upward
and
slide the
separate
barriers
forward
and
away
from
the circuit
breaker
.
CAUTION CAUTION
CAUTION CAUTION
THE
5
HK
350
BARRIERS
WILL
NOT
STAND
UNSUP
-
PORTED
AND
MUST
BE
BRACED
.
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
purchaser
'
s
purposes
the
matter
should be
referred
to
the
nearest
District
Office
.
Courtesy of NationalSwitchgear.com

IB
6.2
.
1.7
D
Page
4
A
»
11
MIPIP
ASEA
BROWN
BOVERI
3.4
REMOVING ARC
CHUTES
(
See
Figure
1
)
For
5
FIK
75
,
150
and
250
,
remove
nut
(
6
)
and
gently
disconnect
return
connection
(
5
)
.
Grasp
the
arc
chute
(
I
)
at
the
front
and
top
and
gently
tilt
on
its
pivot
towards the
rear
until
it
rests
on
the lead
support
molding
(
2
)
.
If
other than
visual
inspection
is
to
be done
,
the
arc
chute
,
in
the tilted
position
,
should be
lifted
straight
out
of
the
pivot
guide
slots
and
fingers
and removed
from
the circuit breaker
.
For
5
HK
350
,
remove
nut
(
6
)
and
gently
disconnect
return
connection
(
5
)
.
Remove bolt
connecting
the
front
leg
of
the
arc
chute
to
the block
on
the base sheet
of
the
circuit
breaker
.
Attach the
accessory
lifting
bracket
to
the tie bar
bushing
at
the
top
front
of
the
arc
chute
and
slowly
raise
the
arc
chute
as
required
by
means
of
a
hoist
.
It
will
pivot
at
its
terminal connection and then should be
guided straight
out
of
the
pivot
guide
slot and
fingers
and removed
away
from
the circuit breaker
.
If
only
a
visual
examination
is
to
be
made
,
each
arc
chute
may
be
tilted back
gently
,
hand held
and
then
slowly
lowered
.
3.5
ARC CHUTE EXAMINATION
Examine
arc
chutes
carefully
before
placing
into
service
.
Look
for
any
breakage
to
liner
plates
and
arc
chute
plates
.
Check
for
presence
of
any
foreign
particles
such
as
chips
of
ceramic and metal
.
Inspect
exterior
for
any
damage
or
deformation
.
The
polyester glass moldings
occasionally
have
some
small cracks
develop
in
resin
-
rich
areas
,
but
these cracks do
not
indicate
defective
material
and
should
not
cause
concern
.
3.6
INSULATION STRUCTURE
All
insulated
parts
should be checked
for
damage
.
Any
dust
or
dirt should
be removed
by
compressed
air
or
wiped
with
a
clean
,
lint
-
free
cloth
saturated
with
an
oil
-
free
solvent
.
This is
important
because the
soot
or
dirt
can
accumulate
and
,
with
moisture
,
place
the circuit
breaker
in
jeopardy
,
dielectrically
.
The
lead
support
moldings
are
polyester
glass
and
occasionally
have
some
resin
-
rich cracks
or
crazing
develop
,
but
these
do
not
indicate
defective
mate
-
rial
and should
not
cause concern
.
CAUTION CAUTION CAUTION
CAUTION
3.7
MANUAL
SLOW
-
CLOSE
TO CHECK CONTACT
PRESSURE
(
Figure
2
)
NOTE
:
Ensure that accessories that
affect
electrical
/
me
-
chanical
operation
are
set
in
their
operating
positions
:
i
.
e
.
,
undervoltage
devices should be
energized
or
mechanically
closed
;
mechanical interlocks
,
key
or
other
,
should be
properly
set
,
etc
.
1
.
Turn
racking
screw
clockwise
approximately
two
to
three
turns
until the
racking
-
unlocking
lever
snaps
into
the
first
position
corresponding
to
the
“
DISCONNECT
”
position
.
2
.
Engage
manual
charge
handle
(
8
)
with
charging
lever
(
3
)
.
Pump
charging
lever
until
breakerclosing
springs
snap
into
charge
position
,
then
remove
handle
.
3
.
Insert
BOTH
tangs
of
spring
retainer bracket
(
7
)
into
holes
of
closing spring guides
(
2
)
.
4
Pull manual close lever
(
4
)
to
discharge
closing
springs
onto
tangs
of
spring
retainer bracket
(
7
)
.
At
this time
the
contacts
will
partially
close
.
5
.
Re
-
engage
manual
charge
handle
(
8
)
with
charging
lever
(
3
)
,
then
slowly
pump
to
slow
-
close breaker
contacts
.
Check
contact
pressure
as
listed
in
paragraph
5.2
.
Use the
manual
trip
button
(
6
)
to
open
the breaker
.
6
.
To
remove
spring
retainer
bracket
(
7
)
from
circuit
breaker
,
continue
pumping
until
closing springs
are
again
heard
to
snap
into
fully
-
charged
position
.
Spring
retainer bracket
can now
be
removed
.
7
.
Discharge
closing springs
by
pulling
manual close lever
(
4
)
and
pushing
manual
trip
button
(
6
)
at
the
same
time
to
effect
trip
-
free
operation
.
(
The breaker
can
also be
closed
first
and then
tripped
.
)
BE
SURE
RETURN
CONNECTION
IS CLEAR
AND
DOES
NOT
CATCH
ON
THE
ARC
CHUTE
.
ALSO
BLOCK
WHEELS
TO
PREVENT BREAKER
FROM
ROLLING
.
)
Fig
.
1
-
View
Showing
Chute
and
Contact Structure
Courtesy of NationalSwitchgear.com

IB
6.2
.
1.7
D
Page
5
Aim
MIPIP
ASEA
BROWN BOVERI
8
.
Lift
front
sheet
in
place
so
that
it
looks
over
the
arc
tie bar
.
9
.
Secure
the
barrier
front
sheet
in
place
with
the
two
lower
front
sheet
screws
.
CAUTION
CAUTION CAUTION
CAUTION
ON
5
HK
350
,
FOR
OLDER
UNMARKED
BARRIERS
,
INSURE
THAT
THE
FLUX
SHUNT
PAD
IS
INSTALLED
BETWEEN
POLES
.
3.10
INSTALLING
CIRCUIT
BREAKER
INTO COM
-
PARTMENT
(
See
Figures
2
and
3
)
NOTE
:
CLOCKWISE
ROTATION
of
racking
crank
for
inserting
breaker
.
COUNTERCLOCKWISE
rotation
of
racking
crank
for
removal
of
the breaker
1
.
Turn
motor
disconnect
switch
(
if
supplied
) (
1
,
Figure
2
)
to
“
OFF
”
position
.
2
.
Engage
racking
crank
(
4
,
Figure
3
)
and
push
racking
unlocking
lever
(
3
)
to
left
,
then
rotate
racking
crankcounter
-
clockwise
only
until
resistance
to
motion is
felt
.
(
DO NOT
FORCE
.
)
3
.
Engage
f
ifth
wheel
with
hole
guide
(
5
,
Figure
2
)
and
push
circuit breaker
into
compartment
until
stopped
.
(
If
closing
springs
were
left
in
charged
condition
,
they
will
automati
-
cally discharge
.
)
4
.
Engage
racking
crank
and
rotate
clockwise
until
racking
mechanism
automatically
stops
at
“
DISCONNECT
”
posi
-
tion
.
(
Breaker is
now
held
captive
in
compartment
.
)
5
.
To
rack
circuit
breaker
to
‘
TEST
”
position
,
push
racking
unlocking
lever
(
3
,
Figure
3
)
to
left
,
rotate
racking
crank
approximately
1
/
4
turn
clockwise
,
then release
unlocking
lever
.
Continue
cranking
until
racking
mechanism
auto
-
matically
stops
at
“
TEST
’
position
.
6
.
With
the circuit
breaker racked
to
“
TEST
”
position
,
check
for
proper
operation
by
operating
all
possible
means
of
Fig
.
2
—
Front View
of
Control
Panel
3.8
INSTALLING
ARC
CHUTES
(
See
Figure
I
)
Position
arc
chute
(
I
)
in
tilted
position
,
squarely
down into its
rear
pivot
guide
slots and
fingers (
avoid
bumping
and
chipping
of
all
moldings
)
,
then
lower
slowly
into
position
.
CAUTION
CAUTION CAUTION
CAUTION
BE
SURE
RETURN
CONNECTION
IS CLEAR
AND
NOT
CATCH
ON
THE
ARC CHUTE
.
Securely
fasten
return
connection
(
5
)
by
its
nut
(
6
)
Also
,
on
5
HK
350
breakers
the
front
arc
chute
support
leg
must
be
secured
to
its hold
down
block
.
3.9
INSTALLING
INTERPHASE
BARRIER
1
.
For
5
HK
75
,
150
and
250
,
lift
barrier and
slide
it
approxi
-
mately
halfway
on
the breaker
.
2
.
After
aligning
the
vertical
sheets
of
the barrier
properly
between the lead
support
moldings
and inside
the
clips
on
the outside
moldings
,
slide the barrier
as
far
to
the
rear as
possible
.
3
.
Lift
the
barrier
slightly by
its handle
at
the
lower
front
(
Figure
2
)
to
permit
the
rear
brace
of
the barrier
to
drop
down
behind
the
arc
chutes
.
4
.
Push
firmly
down
and back
on
the
barrier handle
to
properly
position
the
interphase
barrier
in
place
.
5
.
Secure
the barrier
in
place
with
the
two
lower
front
sheet
screws
.
6
.
For the
5
HK
350
,
slide
the
right
and
left
interphase
barriers
,
as
marked
,
in
place
between
the
lead
support
moldings
and inside
of
the
clips
on
the
outside
moldings
,
and
pivot
the
rear
brace
downward
hehind the
arc
chutes
.
7
.
Install the
arc
chute
tie bar
at
the
upper
front
on
the
arc
chutes
.
Fig
.
3
-
Method
of
Racking
Circuit
Breaker
Courtesy of NationalSwitchgear.com

IB
6.2
.
1.7
D
Page
6
ABB
ASEA
BROWN
BOVERI
opening
and
closing
.
This
includes
control
switches
,
relays
,
etc
.
Turn
motor
disconnect
switch
(
1
,
Figure
2
)
to
“
ON
”
position
to
charge
the
closing
springs
,
and
operate
the
breaker
as
required
.
If
motor
disconnect
switch
(
1
,
Figure
2
)
is
not
provided
,
springs
will
automatically
charge
when
approaching
‘
TEST
portion
.
FOR
SAFETY
:
When
racking
circuit
breaker
to
“
CON
-
NECTED
”
position
,
close
compartment
door
(
1
,
Figure
3
)
and
insert
racking
crank
(
4
,
Fiqure
3
)
through
sliding
panel
(
2
,
Figure
3
)
.
7
.
Push
unlocking
lever
(
3
)
to
left
and
turn
racking
crank
(
4
)
approximately
1
/
4
turn
clockwise
,
then
release
unlocking
lever
.
Continue
cranking
until
racking
mecha
-
nism
automatically
stops
at
“
CON
NECTED
”
position
.
4.4
SAFE
OPERATION
RECOMMENDATIONS
1
.
It
is
recommended
that
any
circuit
breaker
be
withdrawn
and
stored
in
the
test
position
whenever
it
is
to
be
main
-
tained
in
the
open
position
with
no
planned
switching
.
2
.
It
is
recommended
that
a
ground
test
device
be
con
-
nected
to
the
proper
compartment
when
any
work
is
to
be
done
on
any
bus
or
feeder
circuit
.
Section
5
.
MAINTENANCE
AND
ADJUSTMENTS
5.1
GENERAL
INFORMATION
HK
circuit
breakers
are
designed
for
minimum
mainte
-
nance
and
tested
to
ensure
that
minimum
maintenance
will
be
required
.
Only
one
basic
adjustment
is
normally
re
-
quired
and
that
is
contact
adjustment
.
This
should
be
checked
to
the
dimensional
values
required
as
described
in
paragraph
5.2
.
Other
adjustments
are
required
only
when
operational
check
indicates
a
need
.
During
maintenance
checks
,
all
accessible
bolts
,
nuts
and
screws
should
be
routinely
checked
to
ensure
that
they
are
tight
.
It
is
recom
-
mended
that
the
5
HK
75
,
5
HK
150
and
5
HK
250
circuit
breakers
be
normally
inspected
after
2000
operations
and
that
the
5
HK
350
circuit
breakers
be
normally
inspected
after
1000
operations
.
These
operations
can
be
either
no
-
load
mechanical
or
load
current
switching
where
the
power
factor
is
relatively
high
.
When
the
circuit
breakers
are
used
for
direct
bulk
capacitor
or
reactor
switching
operations
or
for
motor
starting
applications
,
it
is
recommended
the
5
HK
75
,
5
HK
150
and
5
HK
250
circuit
breakers
be
inspected
after
1000
operations
and
that
the
5
HK
350
circuit
breakers
be
inspected
after
500
operations
because
of
the
switching
severity
If
however
,
after
the
first
inspection
period
,
there
is
no
indication
of
any
problem
,
actual
operating
experience
can
dictate
the
inspection
cycle
.
Regarding
maintenance
recommendations
following
fault
duty
,
reference
is
made
to
ANSI
Standard
C
37.04
to
which
the
circuit
breakers
have
been
tested
.
In
accordance
with
this
standard
,
a
total
of
400
%
asymmetrical
fault
duty
can
be
accumulated
.
This
is
to
be
ten
or
less
close
-
open
operations
at
less
than
85
%
of
full
duty
;
but
it
can
be
an
accumulation
over
a
long
time
period
of
lower
currents
.
The
condition
of
the
breaker
should
be
such
that
after
this
duty
it
is
capable
of
one
more
close
-
open
operation
at
full
fault
current
.
Inspection
is
to
be
made
at
this
time
to
ensure
compliance
with
this
requirement
.
Final
operation
can
be
made
if
everything
is
satisfactory
.
At
this
time
,
maintenance
should
be
performed
,
reconditioning
done
and
replace
-
ment
made
as
indicated
.
In
accordance
with
the
same
standard
it
is
recommended
that
after
a
major
fault
duty
cycle
(
CO
-
15
SEC
CO
)
Which
is
known
to
be
between
85
and
100
%
of
the
circuit
breaker
CAUTION
CAUTION
CAUTION
CAUTION
DO
NOT
ATTEMPT
TO
RACK
ANY
FURTHER
The
circuit
breaker
may
now
be
put
in
service
and
be
operated
as
required
Section
4
.
CIRCUIT
BREAKER
REMOVAL
(
See
Figure
3
)
4.1
REMOVAL
FROM
“
CONNECTED
”
POSITION
To
remove
circuit
breaker
from
“
CONNECTED
”
position
,
open
the
breaker
as
required
.
1
.
Open
sliding
door
(
2
)
in
front
compartment
door
(
1
)
.
2
.
Engage
racking
crank
(
4
)
and
push
racking
unlocking
lever
(
3
)
to
left
.
3
.
Rotate
racking
crank
(
4
)
counterclockwise
approxi
-
mately
1
/
4
turn
,
then
release
unlocking
lever
.
4
.
Continue
cranking
counterclockwise
until
racking
mechanism
automatically
stops
at
“
TEST
”
position
.
4.2
“
DISCONNECT
”
POSITION
Repeat
same
operation
for
"
DISCONNECT
”
position
.
4.3
REMOVAL
FROM
SWITCHBOARD
To
position
the
racking
mechanism
for
withdrawal
of
the
circuit
breaker
from
the
switchboard
,
again
push
racking
unlocking
lever
to
the
left
and
turn
racking
crank
counter
-
clockwise
only
until
resistance
to
motion
is
felt
.
(
Approxi
-
mately
2
-
3
turns
-
DO
NOT
FORCE
.
)
The
circuit
breaker
can
now
be
removed
from
the
compart
-
ment
by
pulling
on
the
handle
located
at
the
bottom
of
the
front
barrier
,
or
by
pulling
at
the
lower
edge
of
the
front
barrier
on
the
1200
and
2000
ampere
,
5
HK
350
breaker
.
NOTE
:
The
closing
springs
,
if
charged
,
will
automatically
discharge
when
the
circuit
breaker
is
withdrawn
from
the
switchboard
.
)
Courtesy of NationalSwitchgear.com

Aim
MIPIP
IB
6.2
.
1.7
D
Page
7
ASEA
BROWN
BOVERI
rated
asymmetrical
short
circuit
current
,
the
circuit
breaker
be
inspected
regardless
of
any
time
period
or
number
of
operations
.
Also
,
when the
circuit
breaker is
applied
on
reclosing duty
,
it
should be
inspected
immediately
afterthe
series
of fault
operations
in
the
same
range
of
currents
.
The condition
of
the circuit
breaker
after
interruption
de
-
pends
on
circuit conditions
regarding
such
things
as
power
factor
,
X
/
R
ratio
and
relay delay
times
.
Experience
with
specific
circuits
will
indicate the
future
amount
of
mainte
-
nance
that
will
be
required
for
the various breakers and
then
procedural
modification
can
follow
.
Where unusual service conditions exist
,
as
covered
by
ANSI Standard
C
37.04
,
it
must
be assumed that these
conditions
were
considered
at
the time
of
order
;
that the
equipment
supplied
was
designed
for
the
special applica
-
tion
;
and that
an
appropriate supplemental
maintenance
program
has been
developed
.
These maintenance instruc
-
tions
cover
only
circuit breakers used under standard usual
service
conditions
.
After
normal
service without
major
fault
interruption
,
the
following
tests
and
adjustments
should be made
.
NOTE
:
The
following
tabulated
tests
and
adjustments
are
all that
are
normally
necessary
for
proper
maintenance
and
operation
of
the
HK
circuit breaker
.
The
remaining
portions
of
the
breaker
-
close coil
assembly
,
shunt
trip
device
,
control
relay
,
auxiliary
switch
and
motor
—
require
no
main
-
tenance
during
the standard
life
of
the circuit breaker
regardless
of
the
operatinq
duty
.
5.2
CONTACT
PRESSURE
(
See
Figure
4
)
(
A
)
With
the circuit
breaker withdrawn
from
the switch
-
board
,
the
following
step
-
by
-
step
procedure
should be
followed for
properly checking
and
/
or
adjusting
the
contact
pressure
on an
“
HK
”
type
circuit breaker
.
1
.
Remove
interphase
barrier
assembly
and
remove arc
chutes
as
described
previously
.
2
Turn
racking
screw
clockwise
approximately
two to
three
turns
until the
racking
-
unlocking
lever
snaps
into
the
first
position
corresponding
to
the
‘
’
DISCONNECT
’
position
.
3
.
Manually
slow
-
close the
circuit
breaker
as
described
in
parag
raph
3.7
,
but
only
to
the
point
that the
arc
contacts
just
touch
.
All
arcing
contacts
shouldtouch
within
1
/
32
"
,
after
all
free
play
has been
removed
by pulling
the
bridge
arm
toward the
open
position
.
4
.
Continue
the
slow
-
close
operation
to
fully
close the
breaker
.
Each
pole
should have
approximately
7
/
64
”
to
3
/
16
”
main
contact
compression
measured
at
"
A
”
between
the
edge
of
the
metal
stop
plate
and the main
contact
stop
.
(
This dimension
measured
on
either side is
sufficient
)
.
A
rod
or
drill
of
these sizes
can
be used
for
measuring
.
Complete
charging
the
sprinqs
and
remove
the slow
close
bracket
.
Fig
.
4
—
Contact
Pressure
and
Bridge
Pivot
Pressure
5
.
Open
the
breaker
.
Fast close the breaker
.
Each
pole
should have between
7
/
64
"
to
3
/
16
"
main
contact
pressure
.
At
this
point
,
if
the
adjustments
are
correct
,
complete
steps
B
6
,
B
7
,
B
8
and
B
9
following
.
(
B
)
If
any
adjustment
is incorrect
,
use
the
following
proce
-
dure
to
readjust
contact
pressure
or
to
initially adjust
when
changes
are
made
.
1
Completely
slow
-
close the circuit breaker and
set
each
pole
for
7
/
64
"
main
contact
compression
at
"
A
”
(
A
7
/
64
”
rod
ordrill should
fit
tightly
between the
EDGE
of
the metal
stop
plate
and the
main
contact
stop
.
)
2
.
Open
thecircuit
breaker
,
manually
recharge
the
closing
springs
,
and
partially
slow
-
close the circuit breaker
until
the
arcing
contacts
of
any
pole
or
poles
just
touch
.
3
.
Advance the
adjustment
of
the
lagging
pole
or
poles
so
that the three
arcing
contacts
touch
simultaneously
within
1
/
32
"
.
This
adjustment
is made
by loosening locking
bolt
or
set
screw
(
depending
on
model
) (
2
)
and
rotating adjusting
stud
(
3
)
.
4
Complete
slow
-
close
operation
to
fully
closed
position
and check that the main
contact
compression
of
the
pole
or
poles
that
were
advanced
does
not
exceed
3
/
16
"
.
Also
,
the
arcing
contact
springs
on
these
poles
should
not
be
fully
compressed
.
If
the
3
/
16
"
dimension is exceeded
,
the entire
procedure
should
be
repeated
to
obtain the
correct
gap
at
“
A
”
.
NOTE
:
Occasionally
,
the
centerpole
contact
pressure
may
slightly
exceed
3
/
16
"
However
,
if
the
outer
poles
are
within
3
/
16
"
dimension
and the
arcing
contact
springs
of
the
Courtesy of NationalSwitchgear.com

IB
6.2
.
1.7
D
Page
8
ASEA
BROWN BOVERI
center
pole
are
not
fully
compressed
no
readjustments
need be
made
.
When
this condition
exists
,
the
center
pole
parts
before
the
outer
poles
on
opening
.
5
.
Open
breaker
,
recharge closing springs
,
remove
slow
-
close bracket
,
fast
close
the
breaker
,
recheck
adjustments
for
7
/
64
"
to
3
/
16
”
,
“
A
”
dimension
.
NOTE
:
Fast
-
closing
the
circuit
breaker
may
result
in
a
slight
increase
in
contact
pressure
over
slow
-
closing
.
6
.
Tighten
the
locking
bolt
(
2
)
on
each
adjusting
stud
(
3
)
to
lock
the
contact
pressure
adjustment
stud
in
place
.
7
.
The
arc
chutes
can
now
be
replaced
,
and the
interphase
barrier
assembly
can
now
be reinstalled
.
8
.
Return the
racking
screwto
its
original
position
by
turning
it
counterclockwise
approximately
two to
three
turns
until
it
stops
.
9
.
The circuit breaker
can
now
be
replaced
in
its
compart
-
ment
and
returned
to
service
.
The
following
table lists the millivolt
drop
and
resistance
values
for
the
circuit
breakers
,
when
manufactured
,
cov
-
ered
by
this instruction book
,
from
terminal
,
exclusive
of
the
primary
disconnects
.
Maximum
Micro
-
Ohms
Maximum
MV
Drop
*
Circuit
Breaker
5
HK
75
,
5
HK
150
,
5
HK
250
5
HK
350
,
1200
Ampere
8
40
5
HK
150
,
5
HK
250
,
5
HK
350
2000
Ampere
7
35
5
HK
350
,
3000
Ampere
4
20
5.3
CONTACT
AND
INSULATION
CLEANING
All
dirt
,
soot
or
grease
should be removed
from
circuit
breaker
contacts
and
surface of
entire
current
-
carrying
structure
,
as
well
as
ail
insulation
surfaces
,
with
a
cloth
saturated
with
an
oil
-
free
OSHA
-
approved
solvent
.
Clean
-
ing
of
insulation is
important
because
soot
and dirt
can
accumulate
and
,
with
moisture
,
place
the circuit breaker
in
jeopardy
,
dielectrically
.
A
degree
of
burning
and
pitting
of
circuit breaker
arcing
contacts
is
to
be
expected
from
normal
operation
;
also
,
on
highly
inductive
or
capacitative
circuits and
after
major
interruptions
,
some
pitting
may
occur on
main
contacts
.
A
moderate
amount
of
pitting
will
not
interfere
with
operation
of
the
contacts
.
When
necessary
to
dress the
contacts
,
cover
the
puffer
nozzle
(
5
,
Figure
1
)
with
a
cloth
,
then
follow
the
contour
of
the
contacts
with
a
fine file
.
Do
not
attempt
to
eliminate
pitting
entirely
.
Afterthis
maintenance
,
contact
pressure
(
paragraph
5.2
)
;
and
millivolt
drop
(
paraqraph
5.4
)
should
be
checked
.
NOTE
:
Replacement
of
contacts
is
required
when
:
after
repeated
dressing
of
any
contacts
,
less than
50
%
of
the
original
contact
material thickness is
left
;
*
the
tips
of
the
stationary
arcing
contacts
have been eroded
away
;
any
contact
has been
broken
or
cracked
.
*
On
5
HK
350
,
3000
the
arcing
contct
can
be inverted
when
working
surface
is reduced
to
less
than
50
%
.
*
Millivolt
drop
with
200
amperes
flowing
.
Breakers
operating
with
normal
loading
will
require
no
maintenance
if
the millivolt
drop
does
not
exceed
150
%
of
the
listed
values
.
If
the
millivolt
drop
does
exceed
150
%
of
the
above
values
,
the
main and
arcing
contacts
should be
dressed
with
a
fine
file
,
cleaned
and
adjusted
for
proper
contact
pressure
and
then
rechecked
.
If
the values
are
still
in
excess
of
the
150
%
value
,
the
bridge
pivot
pressure
should
be
readjusted
as
outlined
in
Paragraph
5.6
.
NOTE
:
For
optimum
performance
of
the
circuit
breakers
during
periods
of
increased
loading
,
it
is
recommended
that
the
listed
values be
met
.
After
all
above
steps
have been
taken and the millivolt
drop
is
still
excessive
,
contact
the
nearest
district
office for
recommendations
.
)
5.5
PUFFERS
(
3
,
Figure
1
)
CAUTION CAUTION
CAUTION CAUTION
FOR
SAFETY
KEEP
CLEAR
OF
ALL
MOVING
PARTS
.
The
performance
of
the
puffers
should be
checked
during
a
normal maintenance interval
.
Each
puffer
should
provide
a
moderate
blast
of
air
at
breaker
contacts
,
on
opening
of
thecircuit
breaker
.
This
can
be detected
by holding
a
piece
of
paper
approximately
8
-
1
/
2
"
x
11
"
over
the
top
of
the
contacts
and
opening
the circuit breaker
.
All
three
poles
must
have
puffing
action
or
the circuit breaker
must not
be
placed
in
service
.
5.4
DC
MILLIVOLT DROP
TEST
During
normal
maintenance
periods
the condition
of
the
circuit breaker
can
easily
be
determined
by
performing
a
millivolt
drop
test
.
This
test
shou Id
be
performed
regardless
of
whether the
circuit
breaker had
interrupted
low
or
high
currents
or
has
minimum
operations
.
Courtesy of NationalSwitchgear.com

A
IK I
!
MINK
IB
6.2
.
1.7
D
Page
9
ASEA
BROWN
BOVERI
5.8
ARC
CHUTES
The
arc
chutes
should be
inspected
internally
to
ensure
that
no
breakaqe
occurred
to
liner
plates
or
arc
plates
.
Further
,
there
may
be
a
crust
formed
on
the
liner
plates
if
load
current
interruptions
were
close
to
the
continuous
current
rating
of
the breaker
,
or
moderate
faults
were
interrupted
.
This
crust
should be removed
by
carefully
using
a
carbo
-
rundum
stone
or
scraper
.
The
arc
chute should then be
blown
out
with
compressed
air
to
remove
the resultant
dust
and
particles
.
After
400
%
accumulated
current
or
major
interruptions
occur
,
the
circuit
breaker
should be
inspected
immediately
.
All
maintenance
checks
or
tests
noted above should be
carried
out
,
plus
close examination
of
the
arc
chute
.
Arc
plate
and liner
plate
breakage
should be
carefully
looked
for
,
along
with
excessive
erosion
of
the
arc
plates
.
Arc
plates
are
made
of
ceramic material
and
perform
the
function of
extracting
heat
from
the
arc
as
it
is
beinq
forced
into
and
elongated
by
them
.
The
leading edges
become
coated
with
glass
that
comes
to
the
surface from
the
extreme
heat
.
Direct
measure
of
use
is the
amount
of
glass
beads evident
.
When
the entire
leading edge
and
portions
of
the
flat
arc
plate
are
heavily
encrusted
with
glass
beads
,
the
arc
chute
should be
replaced
.
It
should be noted
that this condition
will
vary
between
arc
chutes
on
the
same
breaker because
of
single
-
phase
fault
and
asymmetrical
current
incidences
.
5.6
BRIDGE PIVOT
PRESSURE
(
See
Figure
4
)
Bridge
pivot
pressure
should be
adjusted
only
when
the
millivolt
drop
test
indicates
a
problem
.
When
adjustment
is
necessary
,
adjust
as
follows
:
1
.
Locking
bolt
(
2
)
should be loosened
on
solid
pushrod
models
.
Springloaded
pushrod
models do
not
require
dis
-
connecting
.
2
.
Bridge
(
I
)
should be
disconnected
from
adjusting
stud
(
3
)
on
solid
pushrod
models
.
3
.
Loosen
one
set
screw
(
6
)
in
one
pivot
nut
-
either side
.
4
.
Tighten
bridge
pivot
nut
(
5
or
7
)
securely
(
approximately
75
ft
.
lbs
.
)
.
Then
gradually
backup
pivot
nut
(
approximately
1
/
2
to
1
-
1
/
2
flats
until
bridge
motion is
just
free
when
bridge
is
moved
by
hand
.
On
spring
-
loaded
pushrod
models
,
lift
bridge
against spring
and then
slowly
release
,
ensuring
that
it
resets
freely
.
5
.
Tighten
set
screw
(
6
)
in
nut
that
was
loosened
,
reconnect
adjusting
stud
,
if
disconnected
,
and
readjust
contact
pres
-
sure as
described
in
Paragraph
5.2
.
5.7
CLOSING
AND
OPENING
TIMES
After
operation
intervals
noted
previously
or
a
chanqe
in
bridge
pivot
adjustment
,
it
is
recommended
that
opening
and
closing
times
be checked
by
use
of
a
cycle
counter
,
time
-
travel
analyzer
,
'
oscillograph
,
etc
.
,
to
monitorthe time
from
energizing
to
arcing
contact
touch
or
part
.
*
For
measuring
circuit breaker
speeds
,
analyzer
mounting
support
and
instructions
are
available
on
special
order
.
Circuit
breaker
closing
and
opening
times should be
within
the
following
time
ranges
for
normal
operation
.
5.9
OPERATING
MECHANISM
(
See
Figure
5
)
The
operating
mechanism is
adjusted
at
the
factory
for
proper
operation
and
should
not
be disturbed
unless the
circuit
breaker does
not
close
electrically
on
reclosing duty
.
This condition is
caused
when the
latch check
switch
(
2
)
at
right
side
of
breaker
(
when used
)
is
not
actuated
.
Circuit
breaker should
not
close
before
trip
latch
(
4
)
has
reset
.
Latch
-
check switch
adjustments
made
with
latch
(
4
)
against
stop
pin
(
3
)
:
1
.
Turn
in
adjusting
screw
(
1
)
until
contacts
of
switch
(
2
)
“
break
”
as
indicated
by
an
audible click
or
check
with
bell
ringer
.
2
.
Retract
adjusting
screw
until
switch
contacts
“
make
’
'
.
3
Rotate
adjusting
screw
one
turn
more
.
(
Adjustment
screw
is
self
-
locking
.
)
Opening
Time
Range
-
MS
**
Closing
Time
Range
-
MS
* *
5
HK
75
,
5
HK
150
,
5
HK
250
1200
Ampere
5
HK
150
and
5
HK
250
2000
Ampere
5
HK
350
,
1200
and
2000
3000
Ampere
50
-
90
23
-
35
60
-
95
23
-
35
50
-
90
65
-
95
23
-
35
23
-
35
* *
At
125
Vdc
-
times
at
other
voltages
may vary
slightly
.
NOTE
:
5
HK
250
,
80
/
kA
/
hiqh
momentary
,
same as
5
HK
350
,
1200
and
2000
Ampere
,
in
table
above
.
NOTE
:
Below
0
°
C
,
the
closing
times
will
increase
(
but
with
no
reduction
in
closing
force
)
;
and
opening
times
will
be
within
the limits
.
Adjustments
to correct
speeds
,
if
found
to
be
outside limits
,
are
critical and the
nearest
district
office
should be contacted
for
recommendations
.
Courtesy of NationalSwitchgear.com

IB
6.2
.
1.7
D
Page
10
ASEA
BROWN
BOVERI
©
@
\
A
"
O
IKVCR
iQ
)
'
OPENING
THE
R
.
H
.
HOUSING
PADLOCK
LOCKOUT
PLATT
-
4
Fig
.
7
—
Racking
Mechanism
Fig
.
5
—
Latch
Check
Switch
Adjustment
5.10
CONTROL
RELAY
ADJUSTMENT
(
See
Figure
6
)
The
control
relay
does
not
normally
require
any
adjustment
in
the
field
.
The
gap
between
the
control
device
lever
and
the
limit
switch
crank
should
be
between
0.06
"
and
0.09
"
with
the
closing
springs
charged
.
If
the
gap
measurement
is
incorrect
adjust
all
5
HK
circuit
breakers
except
5
HK
350
,
3000
by
shimming
either
at
the
lever
bracket
or
the
control
device
mounting
screws
as
illustrated
in
Figure
6
.
Before
changing
shims
at
the
two
control
device
screws
,
loosen
all
three
screws
,
replace
shims
and
then
tighten
all
three
screws
.
The
5
HK
350
,
3000
is
adjusted
by
means
of
an
adjusting
head
screw
fastened
to
the
lever
.
tioned
properly
,
which
should
be
corrected
as
follows
1
.
Remove
the
front
mechanism
coverplate
.
2
.
With
circuit
breaker
closed
,
make
adjustments
by
regu
-
lating
length
of
connecting
rod
(
1
)
for
1
/
8
"
minimum
to
3
/
16
"
maximum
clearance
at
“
A
”
between
trip
link
(
3
)
and
block
-
ing
lever
(
2
)
.
)
5.12
LUBRICATION
The
HK
circuit
breakers
are
lubricated
during
factory
assembly
:
1
.
All
mating
surfaces
of
moving
current
-
carrying
joints
have
been
lubricated
with
NO
-
OX
-
ID
special
grade
"
A
"
grease
manufactured
by
Sanchen
Company
.
2
.
All
other
mechanism
parts
,
bearings
,
pins
,
etc
.
,
have
been
lubricated
with
ANDEROL
757
manufactured
by
Huls
America
Inc
.
(
formerly
Nuodex
,
Inc
.
)
(
ABB
No
.
71299
A
,
4
oz
.
tube
)
.
If
the
grease
should
become
contaminated
or
parts
are
replaced
,
lubrication
should
be
done
with
NO
-
OX
-
ID
or
ANDEROLgrease
as
applicable
.
Use
of
othergreases
have
not
been
proven
by
test
and
are
not
recommended
.
NOTES
:
1
.
Do
not
use
NO
-
OX
-
ID
grease
on
any
main
and
moving
contact
surfaces
.
2
.
It
is
recommended
that
the
primary
disconnects
be
maintained
by
renewing
with
the
NO
-
OX
-
ID
grease
during
maintenance
periods
.
3
.
Do
not
use
light
oil
to
lubricate
any
mechanism
parts
.
In
emergency
situations
,
Anderol
732
may
be
used
as
a
temporary
lubricant
.
In
these
cases
,
allow
time
for
the
solvents
to
evaporate
prior
to
any
mechanical
operations
.
It
is
mandatory
that
the
breaker
undergo
thorough
lubrication
with
Anderol
757
at
the
next
maintenance
interval
.
Use
of
solvents
to
free
contaminated
lubricant
is
strictly
forbidden
without
immediate
relubrication
using
Anderol
757
.
Note
that
bearing
surfaces
must
be
repacked
and
this
will
require
disassembly
of
the
mechanism
.
Do
not
operate
the
circuit
breaker
without
completing
this
procedure
.
4
.
The
charging
motor
is
sealed
and
no
lubrication
is
required
.
SHIM
IF
REQUIRED
CONTROL
PAN
I
fff
"
~
~
Lli
I
'
LEVER LEVER
PIVOT
BRACKET
CONTROL
DEVICE
LIMIT
SWITCH
CRANK
Fig
.
6
—
Control
Relay
5.11
RACKING
MECHANISM
(
See
Figure
7
)
The
circuit
breaker
racking
mechanism
is
adjusted
at
the
factory
and
should
not
be
disturbed
unless
it
becomes
possible
to
close
the
breaker
during
a
racking
operation
.
If
it
is
possible
to
close
breaker
during
a
racking
operation
,
it
may
be
that
interlocked
blocking
members
are
not
posi
-
Courtesy of NationalSwitchgear.com