Indoor Vacuum Circuit Breaker - Type VD4 / VD4E

Instruction for Installation, Operation & Maintenance

Instruction for Installation, Operation & Maintenance of Vacuum Circuit Breaker Type VD4 / VD4E

Contents

Pg. No.

A.

General

5

B.

Design

9

C.

Installation & Commissioning

13

D.

Operation & Maintenance

17

E.

Drawings & Spare Parts Reference

33

3

4

A. GENERAL

A. GENERAL Key to type designation

Pg. No. 6

Information on rating plate

7

Weight of circuit breaker

7

Handling & storage Condition on delivery Receipt Unloading Storage rules & regulations

8 8 8 8 8

Normal operating conditions

8

Special operating conditions

8

5

A. GENERAL

The Vacuum Circuit Breaker type VD4E / VD4 are intended for indoor installation in airinsulated switchboards. Vacuum circuit breakers are advantageous to use in distribution networks especially where there is a high switching frequency in the working current range and/or where a certain number of short circuit breaking operations are expected.

Type VD4 / VD4-E vacuum circuit breakers are suitable for auto-reclosing, and have exceptionally high operating reliability and long life. The guaranteed technical particulars have been confirmed by numerous tests in our collaborators own laboratory & other independent laboratories of world repute.

Key to type Designation
As an example the type designation for VD4 12.06.25E is illustrated below VD4 Vacuum as arc quenching medium Rated voltage in kV 12, for 12kV Rated continuous current in Amps. 06 for upto 800 Amps. 12 for 1250 Amps. 16 for 1600 Amps. Rated breaking current in kA 13 for 13.1 KA 20 for 20 KA 25 for 26.3 KA For entry level rated current (up to 800A) 12 06 25 E

6

No. Year of Manufacture IEC : 60056 / 62271-100 12kV 50Hz 28 / 75kVp 800 or 1250 or 1600 Amps 13. 63kA or 80kA O-0.Information on Rating Plate Type Sr. Component 3 Poles (Kgs) Operating mechanism (Kgs) Structure (Kgs) Total(Kgs) VD4E 35 50 15 100 VD4 50 60 15 125 7 . Year Standard Rated voltage Frequency Insulation level Normal current Short circuit breaking current Duration of short circuit Short circuit making current Operating sequence Weight Auxiliary voltage: Closing coil Opening coil Motor Instruction Manual Circuit Breaker VD4 or VD4-E Breaker Production Serial No.1 or 20 or 26.3 kA 3sec.3S-CO-3min-CO 100Kgs for VD4E or 125Kgs for Vd4 Rated voltage for closing coil Rated voltage for opening coil Rated voltage for spring charging motor 1VDU09001-YN Break-up of the weight of the circuit breaker Weight in Kgs.

8 . . . . Increased ambient temperature : . . corrosive or combustible gases. Receipt Each delivery is to be checked on receipt for : . The manufacturers must be consulted in advance about each special operating condition. . Normal Operating Conditions The vacuum circuit breakers of type VD4 are basically suitable for normal operating conditions for indoor Switchgear and switchboard in accordance with IEC publication 694.Allow for the reduction in the dielectric strength of the air. GENERAL Handling & Storage General The Medium Voltage circuit breakers are delivered firmly screwed to the floor of their containers or crates and must always be transported or stored in an upright position. -The responsible claims inspector according to the insurance certificate for the purpose of making out a damage or loss Certificate. .A. . The original packing can be used for storage. The circuit breaker is transhipped in packing in the open (OFF) position and with the closing spring discharged. smoke.Any possible damage in transit and material losses.Major rapid temperature fluctuations..g.Provide additional ventilation for heat dissipation. .5°C (according to "minus 5 indoor " class) Humidity : Maximum average relative humidity measured over 24 hours: 95% Maximum average relative humidity measured over 1 month: 90% Maximum site altitude : <1000m (above MSL) Note: The ambient air should not be excessively contaminated by dust.With high humidity . Unloading Unloading of the package units must only be carried out with a crane. if any. electric heaters) to preclude condensation. Site altitude over 1000 m : . .Current carrying capacity is reduced.Completeness and correctness (Check against order and delivery documents). Storage Rules and Regulations The material shall be stored in a well ventilated storage room and to be protected against dirt. must be notified immediately to: -The manufacturer -The forwarding agent and the insurance company. fork lift truck and / or transport trolley jack. . without the plastic sheet. . . Climate : . damage and water ingression..Implement preventive measures (e.To minimize risk of corrosion avoid areas with: . vapours or salt. however. Abnormality. Condition on delivery The factory assembled circuit breakers are checked at the works for completeness of the equipment and simultaneously subjected to a routine test in accordance with the IEC publication 56. Special Operating Conditions Special operating conditions are to be agreed on by the manufacturer and user. The following limit values apply : Ambient temperature : Maximum + 40°C Maximum 24 hour average + 35°C Minimum . thus verifying their correct structure and function.

10 Structure & function 10 Constructional details 10 Pole assembly 10 Operating mechanism 10 Truck assembly 10 Working principle of pole assembly . DESIGN General features Pg.Contact operation .Principle of interruption 11 11 11 9 .B. DESIGN B. No.

With the breaker closed. . . The live parts of the breaker poles are located in the insulating material pole tubes 12 and protected from impact and other external influences.B. Pole assembly (Drg. Truck assembly (Drg. 45) Pole assembly consists of a vacuum interrupter (V1002 / V2002) mounted firmly in the Pole housing (V1001/ V2001) made out of epoxy resin. Motor cut-off switch and auxiliary switch. 41) This assembly consists of : Frame assembly Wheel rack assembly Automatic secondary plug & socket assembly.2 in the vacuum interrupter 15. . travel and mass is low. The moving contact of the interrupter is connected to the operating mechanism through a Operating stud (V1003/ 2003). Closing / tripping magnet for performing closing / opening operation of the circuit breaker electrically. are mounted on the bracket shaped rear part of the breaker mechanism housing 1. Structure and Function (Drg. . . Interlocking rod assembly Bottom plate assembly Emergency trip assembly The above assembly provides the following features : The poles. . . subsequently low spring forces are sufficient for operation. Operating Mechanism The operating mechanism consists of : A spring charging unit which can be charged manually or electrically by a geared motor. . 43 & 44) conductor (V1008). A spring charged operating mechanism . . the current path leads from the breaker upper terminal 13 and a chamber holder fixed in the pole tube to the fixed contact 15. the NO contact of the cut-off switch is opened interrupting the motor circuit.3 and the flexible conductor / roller contact 16.1.no. . Mechanical indicator showing spring charged / discharged condition. The interrupter is firmly fixed on the top connection bar and the moving contact of the interrupter is connected to the bottom connection bar with a Flexible . .no. pg. A truck assembly with relevant interlock features. The breaker operating mechanism is thus extremely low in wear. which are constructed in column form. The spring charging mechanism ensures that the breaker can perform O-C-O operation if it is closed and charged. Indicator for open / close position of the circuit breaker. Optional items like under voltage trip additional trip coil and blocking magnet. DESIGN General Features The vacuum interrupter in VD4 / VD4E circuit breakers are designed such that the contact speed. The switching motion is effected by means of the insulated coupling rod 18 with internal contact pressure springs 17. As soon as the energy is removed from the spring charging mechanism.4A & 4B.2 & 3. . The spring charging mechanism can also be recharged manually by means of a charging handle. Switch for annunciation and control of auxiliary circuits. .2 to the breaker lower terminal 14. . then via the moving contact 15.nos. 10 . Operation counter showing total number of operations performed by the breaker. and the maintenance requirement are accordingly negligible. . The breaker can perform C-O operation if it is open and charged. pg. . pg. Constructional details Vacuum circuit breaker type VD4-E / VD4 consists of : Breaker poles of epoxy resin firmly holding and protecting the vacuum interrupter assembly from impacts and other external influences. The disc springs inside the operating studs exerts the required contact pressure on the contacts.

Working Principle of pole assembly Contact operation The closing and opening operations can be carried out by means of the energy stored in the operating mechanism. . due to short arcing time. . Principle of interruption Due to the extremely low static interrupter chamber pressure of 10-4 to 10-8 in mbars. Breaker can not be closed when it is in intermittent position. and additionally. only a relatively small contact gap is required to achieve a high dielectric strength.The movement / stroke of the moving contact of the vacuum interrupter is achieved through the 11 . the associated arc energy. Closed breaker can not be moved from test to service position or vice-versa. The movement of the selector is blocked when the breaker is in the closed condition. . A closed breaker can not be pushed into test position from withdrawn position. are extremely low. operating levers driven by the individual cam discs mounted on the common shaft. Very high contact pressure is maintained through the spring washer assembly housed in a operating stud. Due to small contact gap and high conductivity of the metal vapour plasma. which has advantageous effects on the life of the contacts and thus on that of the vacuum interrupters. the arc drop voltage. The arc is extinguished on one of the first natural current zeros. One common spiral spring is used to carry out the closing and opening operation of the breaker and three individual compression spring assemblies are used to assist the opening operation of the three poles..

12 .

No. INSTALLATION & COMMISSIONING Preparatory work Tools & accessories Technical documents Pg. 14 14 14 Erection 14 Electrical connections High voltage connections Low voltage connections Earthing 14 14 14 14 Commissioning General checks Table 1: Precommissioning checks Functional checks Final Checks Handing over 15 15 15 16 16 16 13 . INSTALLATION & COMMISSIONING C.C.

Flat nose plier with side cutter size . Cleaning and degreasing are to be carried out in the same manner. Put the breaker into the cubicle and check the following : .Torque screw drives Range 0 . . connected to the cubicle main earth busbar.Torque wrenches Range 0 -150Nm . Earthing The permanent earthing is provided by means of earthing busbar in all the switchgear cubicles. Electrical connection High voltage connections Clean and degrease the silver plated contacts with a clean.Cleaning cloth .9 (1set) .Extensions Range 0 .120mm (1no) .Ratchet . Each circuit breaker is provided with earthing finger contacts mounted on. Let dry well.Allen keys size . Proper engagement of secondary plug and socket. Apply a thin film of contact grease / Vaselene to the contact surfaces.Special tools . Free movement of the breaker from withdrawn position to Test and from Test to Service and vice versa.10Nm . Circuit diagram. . Dimensional drawings. .5-32 (1set) . The high voltage connections are provided by means of assembly of connection bars on the breaker side and finger pocket assembly on the cubicle side. Tools and Accessories . Technical documents Assembly drawings. in turn.Open end & ring spanners size . 14 . These finger contacts engage and slide against the wedge type contact provided in the switchgear cubicle. Proper engagement of connection bars with the cubicle contacts. With a linen cloth. . .Screw drivers size .00-5 (1set) . Lubricate the earthing contacts on the breaker truck and cubicle with a thin film of vaselene or contact grease and ensure proper contact engagement. . which is.Extractor plier (1no) . .Main shaft rotation tool. When all the panels are erected correctly. The movement of all the handles should be easy and smooth.250mm .270. There are terminals for connecting external earthings to this busbar. non-linting linen cloth and cleaning agent. The stations earthing terminal is connected only in the end cubicle. Erection For erection of switchgear cubicle.3 .Grease ISOFLEX TOPAS NB 52 .Special socket for M6 nylock nut assembly. . Proper engagement of earthing contacts. . ERECTION & COMMISSIONING Erection Preparatory work The following items should be held in readiness before the circuit breaker is placed in position. refer the relevant instruction manual for the particular cubicle type. check that the cubicle fronts are in line and that the cubicle doors with the interlocking devices work correctly. Low voltage connections The auxiliary circuit connection shall be checked as per the relevant schematic diagram for correctness.C.Circlip plier (1no) . Proper functioning of various interlocks. .Special screw driver for torsion spring. . Customer’s order reference drawings. .Loctite 290. the top of the breaker truck. . .

Ensure that the instruction manual is available to the operator at all the times. . Check that the value of the supply voltage for the auxiliary circuit is with in 85% and 110%. of the electrical devices. of the rated voltage. . . Shunt opening Close the circuit breaker. Connect the release shunt closing release with the relative rated auxiliary supply voltage. discharge the closing springs (by closing & opening the circuit breaker). .Commissioning General procedures Before putting the circuit breaker into service carry out the following checks : Check the tightness of the power connections on the circuit breaker terminals. NOTE: Connect the undervoltage release with the relative rated auxiliary supply voltage (if provided) 2. Manual operating mechanism PROCEDURE POSITIVE CHECK The operations and the Carry out a few closing and opening relevant indications occur operation NOTE : Connect the correctly. Shunt closing Open the circuit breaker. . Motor operated mechanism (if provided) 3. undervoltage release with the relative rated auxiliary supply voltage (if provided) The geared motor Connect the geared motor for spring charging with the relative rated auxiliary recharges the spring after each closing operation. supply voltage. Remove the transport caps from the poles. Disconnect the power supply relevant indication occur from the release. . The circuit breaker closes correctly and the relevant indications occur correctly. 15 . 4. Undertvoltage Connect the undervoltage release with the The circuit breaker closes release relative rated auxiliary supply voltage and and the relevant indications (if provided) occur correctly. Carry out a few closing and opening operations. . . Check that no foreign material has got into the moving parts. correctly. then remove the cover of the operating mechanism. . To gain access to the operating mechanism safely. 1 : Table 1: Precommissioning Checks SUBJECT OF INSPECTION 1. Connect the release shunt opening release with the relative rated auxiliary supply voltage. The circuit breaker opens and the relevant indication occur correctly. 5. Check that air circulation in the circuit breaker installation site is adequate so that there is no danger of overheating. Carry out the checks indicated in table no. The circuit carry out the circuit breaker closing breaker opens and the operation.

Test service position indications occur correctly. Insulation resistance PROCEDURE POSITIVE CHECK Insert the auxiliary contacts into suitable Signals occur correctly signaling circuits. The breaker mounting screws are well tightened. 9. . Final checks Rack in the breaker into the switchgear cubicle. Auxiliary contacts in the operating mechanism 7. Test service position limit switch operation 8. terminals and connecting leads. Check interlock functions Interlock should function correctly. Functions of various interlocks Functional checks . measure insulation The insulation resistance resistance between phases and phase to should be at least 50 Mega Ohm & if the value is less earth. find out the cause. . With 2500V Meggar. . Re-check all electrical connections.C. Carry out a few closing and opening operations of the circuit breaker. . Move the breaker from test to service few times. Handing over After the checks are completed. Functional checks must only be carried out when: The circuit breaker is disconnected from the high voltage network and is correctly earthed. 16 . The functional check is to be performed in accordance with the instructions for operation and maintenance of the Operating mechanism and to be repeated for every remote controlled command point. ERECTION & COMMISSIONING SUBJECT OF INSPECTION 6. . the circuit breaker can be handed over for commissioning. Any foreign material that is likely to disturb operations is removed.

12 Coupling of drive pole 12.11 Operating coil assembly 12. D-shaft assembly 6. Closing spring assembly 3. Instruction for discharging and charging 14. Operating lever assembly 12.13 Motor assembly 12.9 Auxiliary shaft assembly 12.Inspection details & actions Table 4 . Half shaft assembly 8.11A Operating magnet 12. Stop washer assembly 4. OPERATION & MAINTENANCE General Features Table 2 . Cam disc assembly 7.12.7 Assembly of charging ratchet 12. Counter assembly 9. Ratchet assembly 11.8 Lockout lever assembly 12. Truck assembly VD4 / VD4E breaker for Unisafe panel Pg. Instruction for discharging and charging 15. Supporting crank assembly 10.6 Assembly process 12. 18 18 19 20 20 21 21 21 21 21 21 22 22 22 22 22 22 22 23 23 23 23 24 24 24 27 27 27 28 28 29 29 30 30 30 30 31 31 31 17 .13A Motor cut-off switch assembly 13. No. Tripping spring assembly 2.10 Auxiliary switch assembly 12. Operating mechanism assembly 12.D.1 . OPERATION & MAINTENANCE D.Inspection periodicity Lubrication Operation & maintenance of pole assembly General Maintenance Replacement of complete pole assembly Dismantling Assembly Operation & Maintenance of Operating mechanism 1.Maintenance schedule Table 3 .10A Auxiliary switch 12. Latch assembly 5.

dirt or damage of any kind. Clogging may cause a reduction in the closing or opening speed. interrupted current values and relative power factor as well as the ambient conditions. On the basis of the results obtained during the periodic inspections. e. General features During normal service the circuit breakers require only limited maintenance. Various factors must be taken into account. . OPERATION & MAINTENANCE OPERATION & MAINTENANCE Caution : Before carrying out any maintenance work it is essential to follow the procedures given below : Open the circuit breaker and check that the closing springs are discharged . The frequency and the sort of inspections and maintenance basically depend on the service conditions. When the circuit breaker is in service it should be visually inspected from outside to detect any dust.g. frequency of operations. Table 2 Maintenance schedule Maintenance operations Carry out the general inspection Installation in normal ambient One year Installation in dusty (or polluted) ambient Six months Six months Six months Six months Three years or every 5000 operations Five years or every 10000 operations Carry out visual inspection One year from outside and inspect the medium voltage parts Measure the insulation resistance Lubricate the sliding points Three years One year Five years or every 10000 Carry out the operating mechanism maintenance operations Ten years or every 20000 Complete overhaul operations 18 . These rules should also be followed: Any circuit breaker which operates only a few times. 2 gives the maintenance schedule showing the time intervals after which maintenance work is generally required. should be operated from time to time to prevent clogging. . it is possible to set the optimal time limits for carrying out maintenance work. Table no.D. that is remains closed (ON) or open (OFF) for long periods. Work must only be carried out when the circuit breaker is withdrawn from the enclosure.

Tighten the connection nut earthing connection fully and cover it with neutral grease. Operating and Carry out the functional tests Replace the damaged or faulty control elements elements (if necessary ask manufacturer) 19 . Clean the connections and Traces of overheating or loose screws on the connections of the breaker terminals with a rough rag soaked in a suitable solvent. Operating mechanism Abnormalities noticed Presence of dust on the mechanism Distorted or oxidized springs Locking rings out of place. Medium voltage Presence of dust or dirt on the compartment parts insulating parts Locking rings out of place. Earthing Traces of oxidation and/or loose Clean with a rough cloth soaked in suitable solvent. Earthing isolating Traces of oxidation Clean with a rough cloth contact soaked in a suitable solvent and lubricate moderately with neutral grease. Clean with a dry brush or cloth 2. Loose Refix the locking rings in their position and tighten the nuts or nuts or screws screws.General Inspection of the Circuit Breaker Table 3 Inspection details and actions Parts subjected to 1. Ask manufacturer for Distortion or cracking of the replacement of the damaged insulating parts parts Clean with a rough cloth soaked Oxidized isolating contacts in a suitable solvent and lubricate moderately with neutral / contact grease. 6. loose nuts or screws Wires and relative fasteners detached Remedies Clean with a dry brush or cloth Replace the damaged spring Refix the locking rings in their position and tighten the nuts or screw suitably. 4. 3. Replace the wires fasteners and reconnect the detached wire correctly. Check the supply voltage of the The releases and the electrical 5. circuit breaker terminals Cover them with neutral grease and tighten the screws. Auxiliary circuit supply voltage operating mechanism electrical interlocking devices must work correctly for values between 85% accessories and 110% of the relative rated voltage.

Of operations 5.3. 6. The special grease type ISOFLEX TOPAS N852 shall be used for operating mechanism lubrication.D.000 Points to Note Task/Parts tobe maintained INSPECTIONS: Operating mechanism complete Screw connections Cable connections Return springs Circlips and Retaining rings Interlocking rod assly. The sliding parts shall be operated a few times after lubrication so that the lubricant will penetrate properly through out the sliding / rolling surface. Motor cut off switch MAINTENANCE: Lubrication Closing spring assly. Clean brush or soft cloth shall be used to carry out the lubrication. 20 .000 10. The lubrication shall be carried out as per the schedule given in table 2 .000 As reqd. OPERATION & MAINTENANCE Table 4 : Inspection periodicity Based On years Occasionally After Year Based on No. Spring charging motor Return springs Stop washer Auxiliary switch setting Flexible Trip coil Close Coil Undervoltage coil Blocking coil Additional trip coil Major overhaul X X X X X X X X X For proper functioning For tightness 2 2 X X X X X X X 1 1 X X X X X X X X X For Deformation For proper functioning and arcing level For Deformation For Deformation For gap setting X X X X X X 5 5 X 5 5 5 5 X X X X X X X X X 1 1 X XX X X X General inspection /lubrication For tightness For tightness For Deformation For Deformation & Intactness For proper functioning For proper functioning For proper functioning Lubrication All the sliding parts subject to friction must be lubricated at the scheduled time. Microswitch assly. 20. clause no.

Remove the Hex. To fully discharge the closing spring. Is fully withdrawn from the cubicle. The pole assembly (Drg. No. . Also pull the lower end of the operating stud from bottom side and match the hole of operating stud with the holes on the pair of levers. . . .4a & 4b. . . (V2008) Top connection bar / Support (V1004 / V2004) Bottom connection bar/Contact flange assly. Insert the pin in the operating stud and put the special circlip on it. . .Operation & Maintenance of Pole assembly General Weight of each pole assembly is approximately 12 Kg for VD4-E and 17 Kg for V D4. Separate the pole assembly from the operating mechanism assembly (V1000 / V2000). . . Dismantling : Before dismantling the pole. . socket head screw (V6091) from the bottom side of the breaker. . couple all the poles one by one to the mechanism and bring the mechanism to a completely open position by rotating the main shaft in reverse direction. . Is in the open position and the closing spring of the operating mechanism is fully discharged. . Assembly: Hold the pole assembly in a proper position and match the holes on the housing with the holes on the bottom side of the breaker frame. Before commencing the maintenance work. . socket head screw (V6091) and spring washer(V6092) from bottom side. No. . (V1005 / V2006) . the following details should be furnished : Rated voltage Rated normal current Breaker type & serial number Order reference number . and rotate the main shaft in the opposite direction. 30). Insert the special tool in the main shaft. . Tighten the Hex. . . Maintenance The breaker pole with vacuum interrupter is maintenance free upto reaching the permissible number of vacuum interrupter operating cycles. Checking of the vacuum is only necessary when there is a good cause to suspect that force applied externally to a pole tube has caused damage to the vacuum interrupter inside. . Similarly. refer instruction 13(pg. ensure that the breaker is in 'open' condition and closing spring is discharged. Take care to hold the pole assembly properly while dismantling the screw. 21 .pg. . ensure that the circuit breaker : Is disconnected from the high voltage and auxiliary voltage terminals. Replacement of complete pole assembly Note To order the complete pole assembly for circuit breaker type VD4E / VD4. Remove the special circlip (V6089) and the pin (V6090) which connects the operating stud (V1003 / V2003) end to the lever assembly from the bottom side. Tightening torque for these bolts is 45 Nm. 45) consists of the following components : Pole housing (V1001 / V2001) Vacuum interrupter (V1002 / V2002) Operating stud (V1003 / V2003) Flexible conductor (V1008) Roller contact assly. Caution This service work may only be performed by switchgear manufacturer's servicing personnel or adequately trained specialist staff.

6B. refer fig.D. Press the pins completely in the curve washer. hold both the free ends of the links in the fish plate (V4405) and pass a cylindrical pin (V4406) and lock it with the circlip (V4404). Stop washer assembly (V4300) (Drg. Insert the shaft in the crank (V4502) as shown in fig. 51) Take the spring holder (V4101). 2. The position of the crank is very important. Closing spring assembly (V4200) (Drg.no. pg. 6B. 6B. insert link one each (V4403) and put the circlip (V4404) on both the latches. 48) Caution : The hex. 48) Refer to the assembly drawings 6A to 6E.6E. Cam disc Assembly (V4600) (Drg. Mount the roller chain (V4208) and tie it with wire so that it will not come out from the sprocket wheel disc. one inside the other. as shown in drg. place the compression springs (V4103 and V4104) . 6. pg. Hold the plate in a position and tighten it with a hex.no. Now put this assembly of operating disc on the spring drum (V4205) on the close side of the drum and check that it rotates on the drum easily. Apply a light coat of grease on the outer and inner surface of the springs. Take a D-Shaft (V4501 ). 49) Take operating disc (V4201) and insert separating plate (V4202) in the operating disc as shown in figure 6C. apply a light coat of grease on the periphery of the cam disc. 6B. Hammering to be done very carefully so that it will not damage the crank.Once the stop washer is inserted in the pins. socket head screw should be tightened after the complete assembly of the breaker before charging the spring to its required precharge value. pg. Now apply a light layer of grease on the spiral spring surface and fix the spiral spring (V4206) with one end of the spring latched in a groove provided on the drum and cover the open end of the drum with the sprocket wheel disc (4207). assembled one inside the other.no. 6B. Now insert 6 cylindrical pins (V4304 [A/B]) in the curve washer LHS with a light coat of grease. 51) Hold the cam disc (V4601) firmly on the working table and press the spring dowel pin (V4602 and V4603) respectively. on it place the spring guide (V4102) on top of the spring. Now. 6C. Hold the assembly properly and insert the spring dowel pin O5x30 (V4503) / and fix the crank by a dowel pin. pg. also press the right hand curve washer in the pins and press the assembly so that there is no gap between the three cam discs. 5. Now insert the stop washer (V4305 [A/B]) in such a way that stopper nose of curve washer and stop washer are in opposite direction to each other and at 45° apart. OPERATION & MAINTENANCE Operation and Maintenance of Operating Mechanism (Drg. First of all make the sub-assemblies ready for the final assembly as given below: 1. 22 . 6B. Take curve washers LHS & RHS (V4301[A/B] / V4302 [A/B]) and insert 6 nos. dampers (V4303) in each curve washer. After the assembly. 6E. Apply a light coat of grease Isoflex Topas N852 on the moving area of latch for free movement of the latches. The assembly drawing is self explanatory and shows different assemblies in different sheets. 6A to 6E.no. pg. socket head screw (V4203) with spring washer (V4204). pg. On the other end of the latch. Tripping spring assembly (V4100) (Drg. mount them on the common pin.no.no. Check that the springs are in vertical position and tighten the socket head bolt M6x70 to clamp the spring in the compressed position. pg.nos. 4. 48) Take the latches (V4401 and V4402) respectively. 47 to 51) 3. Latch assembly (V4400) (Drg. D-Shaft Assembly (V4500) (Drg.

Now insert the half shaft in the crank (V4702) as shown in drawing. Supporting crank assembly (V4900) (Drg. Insert the torsion springs (V4711 ) and (V4710) in each shaft and lock one end of the spring in between the washer (V4705) and lock the other end with the half shaft itself. Again insert (V4705) and lock it with nylock nut (V4707). The chamfers of both the supporting cranks should be face to face to each other and then . 49) Refer to drg. 6B. check the free movement of the other fish plate and half shaft. 23 . 10. Similarly for the other crank. pg. socket head cap screw M6x45 & M6x30 (V5102 & V5103) insert spacer (V5104). The role pin insertion should be such that it should equally come out of the half shaft from both the sides. pg. After checking for both the half shafts. 68. 7. socket head screw M4x16 (V4701 ) as shown in drg. pg. Hold 2 cranks (V4702) as shown in the drg. plain washer (V4705)and 1 no. apply a light coat of grease on the rolling & moving areas of fish plate. Mount the fish plate (V4703) on tripping side and fish plate (V4704) on the closing side of the crank. pg. Caution While mounting these fish plates.fix the locking roller (V4903 [A/B]) and the cylindrical pin (V4904) a light coat of grease Isoflex Topas N852 . put washer (V4705) and lock it with nylock nut.item no. longer screw. Half shaft assembly (V4700) (Drg. 6C. Now hang the tension spring (V4805) in the hole provided on the arm and crimp its end suitably so that it will not come out of the hole.Caution Outer spring dowel pin slit should be pressed in such a way that the slit is kept towards the center of the cam and the inner spring dowel pin slit should be kept opposite to the outer one. Take the supporting crank ( V4901 [A/B] and V4902[A/B]) and identify it as LH side and RH side on the basis of chamfer provided. Now take that half shaft (V4708).no. Position the arm of the counter suitably and tighten it with a screw driver.no. 9. Now put the spacer (V4905[A/B]) in between the two supporting cranks duly greased on from inside and then insert a grooved pin (V4906[A/B]) through the given hole of the supporting crank as shown in drg. CHECK : Holding one of the fish plates. Ratchet assembly (V5100) (Drg.no. 48) Take a counter assembly . 48) 8.6B from the RH side. Apply a light coat of grease on the rolling area of the supporting crank and the locking roller. Now insert 1 no. 6B. Counter assembly (V4800) (Drg. Apply a light coat of grease on both the ends. (V4801 ).no. First of all take a shaft (V5101 ) and place it in such a way that the groove side of the shaft is up and then put the items in sequence as given below : First take Hex. 6B. 48) Take the hex. Now mount this counter on a mounting angle (V4802) with M3 cheese head screw (V4803) and spring washer (V4804). Insert a roll pin(V4709)on the hole provided on the slit end of the half shaft. plain thick washer (V4706). 6C showing the assembly of the ratchet for charging. ensure that the slots provided on the fish plate are well guided in the boss provided on the crank ( V4702).

pg. pg. 6E.socket head screws fixed earlier. insert V5105 . For R-pole operating lever special pin(V5206). 6B & 6D 12.no. Insert the D-shaft assembly with torsion spring (V6004) and push the bush (V6005) from outside the sheet and hold it in the proper position as shown in fig 6B. 24 . 11. Now take the bolt (V5203) and insert the bolt through LH side lever and pass it through the roller bearing (V5204). Also check the assembly for spring action for the latches.1 Take operating housing (V6001 ) and fix the special bush (V6002) as shown in drg. is After keeping all sub-assemblies ready for main assembly. Also fix the nylock hex. nut (V5117) on hex.no. the assembly of 3 operating levers (V5200) shall be done. 6A-6E. which is to be clamped on both the ends by a special circlip (V6012). 6E.D. The assembled levers are to be inserted in the pivot plates of the operating housing as shown in the drg. Place the bush (V6003) in the hole provided in the side sheet. socket head screw M6 on the longer screw put two plain washers (V5118) and then one big washer (V5119) and tighten it with t he nylock nut (V5117). Socket headed screw (V6007) with spring washer & hexagonal nut (V6008 & V6009). Do not excessively tighten the nylock nuts. (6B & 6D). OPERATION & MAINTENANCE Now in a small hole of the conical plate (V5107). 8) Blocking lever assembly. The charging lever (V5115) shall be located on two hex. With the spacer (V6010) and the duly greased grooved pin (V6011 ). Put the circlip (V5205) and clamp it. the D Shaft assembly (V4500) shall be mounted as shown in drg. Once the positioning is done. hook both the latches to the spring (V5114) properly and fix it in the special slots provided on the support plate and conical plate one each. Operating lever assembly (V5200) (Drg.3 After this assembly. 12. 5) Supporting crank assembly. 6A to 6E for the mechanism assembly. 6) Main shaft assembly. Put another tubular rivet (V5110) and lock the small cheese head screws with a nylock nut (V5116) of size M3. clamp the bush with bracket (V6006). 6A & 6B. Operating mechanism assembly(V5200) (Drg. 9) Auxiliary shaft assembly. Above that insert support plate (V5108) with cheese head screw (V5109) and tubular rivet (V5110)fixed on it. Apply a light coat of grease and mount the half shaft assembly as shown in the drg. insert the cylindrical pin (V5111 ) and locate the sprocket (V5112) with the right direction. 4) Control shaft assembly. Check the assembly for its operation by charging it through the hole provided on the charging lever (V5115) for its movement in the right direction. Apply a light coat of grease on the pin and in between the conical plate and support plate. Locate the tripping spring assembly as shown in the fig. 51) 12. 2) D-shaft assembly. Ensure that the spring guide is well located in the hole provided Take the operating levers (V5201 [A/B] & V5202 [A/B]) and pair it on the basis of LH side 8 RH side.M3x25 cheese head screw M3x25 (V5105) and a tubular rivet (V5106). shall be used instead of (V5203). 10) Coil assembly. 7) Charging ratchet assembly.2 After this assembly.51) The operating mechanism assembly sub-divided into different sub-assemblies : 1 ) Half shaft assembly. and hold the bracket with hex. 6E. latch (V5113). 12. 3) Operating lever assembly. After this. Repeat the assembly of support plate and conical plate duly greased and fix the other end of two latches in the slots. we shall start the main assembly of operating mechanism. Refer drg. 47 . Now take 2 nos.

Refer. 2) Check the action of the torsion spring by applying a force on the lockout lever. 12. align the hook of the spiral spring with the shaft keyway and insert the shaft through the spring drum and the operating disc. Check: 1) Check the movement of the control shaft. Hook the long leg of the torsion spring (V6015) in the groove provided on the pin (V4906 [A/B]) with a special fixing screw driver carefully. Fix the bush / spacer (V6021/ V6063) Refer assembly fig.6 After this assembly. (V6020) is well located in the groove of the lockout lever and on the leg of the torsion spring. Apply a light coat of grease inside the bush.4 Now the assembly of the control shaft shall be carried out in the following steps. The cam disc crest profile shall be kept towards the front side or operator side. before inserting the assembly of closing spring (V4200). Apply a light coat of grease and insert a main shaft (V6023) through it. Position the dowel pin (V6020) well above the leg of the torsion spring and press the dowel pin until it comes out from the other end.on the operating housing as well as the free movement of the lever assembly in the operating mechanism. 3) Check the dowel pin . Now insert the spiral dowel pin (V6017) in the holes to locate the control shaft and to hold the torsion spring in a position.6B. Fix the bush (V6022).6C & 6D). Now.5 As per the sequence of assembly. place one or two washers (V6016). It shall be free in the two end bushes. Apply a light coat of grease from the inner surface of the bush / spacer and take the assembly of supporting crank made. Check : Check for the free movement of the supporting crank inside the grooved pin (V4906 [A/B]). Insert the cam disc (V6024). 12. 12. separate out all the items to be mounted on the main shaft and clean them thoroughly. as shown in drg. in the middle partition of the operating mechanism. 25 .as shown in drg 6D. Mount the compression spring (V6029) and the roller (V6030) on the control shaft (V6014) and hold it with a clip and now insert the closing spring as explained in point no. the assembly of main shaft shall be carried out in the following sequence. 6B in the hole provided on operating housing. 4)Check the other two roll pins (V6017). fix the bush (V6013) duly greased from inside . Remove the grooved pin (V4906 [A/B]) without disturbing the whole assembly and hold it in the proper position and insert the same pin through the middle partition of the operating mechanism and pass it through the supporting cranks and bushes (V6064 & V6065) mounted on the other plate of the mechanism. supporting crank assembly shall be mounted on the operating mechanism at this stage.item no. 2. (6A. depending on the space available next to the bush. Use stepped bush (V6062) for the assembly of R-pole operating lever. as explained in point no. First of all. Also check the projection of dowel pin from the rear side. Now insert the lockout lever (V6018) with the torsion spring (V6019) inside the lockout lever as shown in Fig.9 (V4900). Now insert the control shaft (V6014) as shown and put torsion spring (V6015) in the other end of the control shaft and then fix the bush (V6002) from outside and locate the control shaft in it. 6C. are equally out of the control shaft from both the sides and dowel pins are not rubbing on the bush (V6013). apply a light coat of grease ISOFLEX TOPAZ N852.

Then. fix the bush (V6035). apply a light coat of grease in the groove of rolling surface and hold it on the roller (V6028) and insert the main shaft through the control washer as shown in fig.e. The second nose of the stop washer shall be in the clockwise direction while looking from LH side. As soon as the roller (V6030) rests on a operating disc. supporting crank assembly (V4900). Align the assembly with main shaft and insert the key (V6034) first on the inner cam disc and push the shaft ahead. Ensure the circlip is fixed properly in the groove of the main shaft as shown in the drg 6E. After this insertion. push the main shaft still ahead and repeat the assembly of cam disc (V4600) in the same way as done earlier and put the retainer circlip on the right hand side of the shaft. CAUTION A) As the roller (V6030) is a friction roller. The dowel pin position with respect to the key way of cam disc is very important here. When the cam disc is inserted in the main shaft.D. Once this assembly is completed. The next step is to insert the spacer tube (V6032). OPERATION & MAINTENANCE which is mounted on the spring drum.item no. 6B and insert the spacer (V6025) and then fix the cam disc assembly (V4600) as described Point-3 and one more spacer (V6025) on the other side of the cam disc. This completes the assembly of main shaft. 6C & 6E. duly greased. 6D. grease shall not be applied on the surface of the roller. the spacer tube (V6025) and the special washer (V6026) shall be inserted as shown in fig 6D. in its proper position and lock it with the hex. socket head bolt (V6037) and nylock nut . The next assembly on the main shaft is the assembly of stop washer (V4300) (refer point-3) on the main shaft. Now take the control washer (V6031). Push the shaft still further till it comes to the end of the spacer. Fix the cam disc assembly as per point 6 and as shown in drg. This spacer shall be inserted in such a way that the longer edge from the cutout is inserted in the shaft from left hand side. i. After this. B) While inserting the main shaft from right hand side. the lever assembly (V6027) shall be mounted on the shaft and fix the roller (V6028). Fix the assembly of stop washer in line with the main shaft and position it in such a way that out of two noses of the stop washer the 1st nose is hold against The roller of the above assembly. Then insert the stop (V6033) in the shaft key way and the cutout of the spacer. 26 . on the pin of the lever assembly. the main shaft shall be inserted in such a way that longer distance from the edge of the shaft enters from right hand side. Push the main shaft till it comes out of the cam disc (V6024). Now. locate the other key on the outer cam disc and push the main shaft still ahead. check that all the items on the main shaft are mounted correctly and nothing is missed out. The next component on the main shaft is the cam disc assembly (V4600). Push the main shaft still further and fix the retainer circlip (V6036) with a special circlip plier. CAUTION : Ensure that both the circlips are fixed properly in the groove of the shaft. Let the shaft guide properly in the bush as shown in fig. The next step is to roll the cam disc (V6024). remove the clip and release the roller. the dowel pin shall be on the rear side and it shall be well located in between operating lever assembly (V5200) of the Y-Pole (middle pole). ensure that the hole on the main shaft comes to a right position. (V5117). For this purpose. Now as the main shaft comes out of the position.

insert the bush (V6002) on the plate of operating housing from inside duly greased and then push the auxiliary shaft through the bush. insert pin (V6046). Once this assembly is completed. 4 in a proper position and insert the auxiliary shaft through a spacer (V6058). Take lockout lever (V6045).7 Assembly of charging ratchet : The charging ratchet assembly which is made as per point no. First of all. at the same time. hold the non-return plate. bolt (V6044). After this. Push the shaft till it matches with the hole on crank (V6057) and fix the dowel 27 . CAUTION: While inserting the auxiliary shaft (V6066). the position of the sprocket wheel by locking it with the special circlip (V6012). Now insert another bush (V6040) in the slot of the lever and insert the ratchet shaft in the bush. Let the auxiliary shaft to come out from the next plate and add washer (V6016). 12. 50 & 48) The auxiliary shaft assembly is done on the upper side of the operating mechanism and is used for operating the auxiliary switch as well as the ON-OFF indicator. pg. The ratchet shaft shall be mounted with a sprocket wheel. 6C and fix the other end with Hex. Now. Insert the special pin (V6048) from right hand side. crank (V6054) in the opposite direction. align the latch assembly as made earlier in point no. Then insert 2 nos. Now. check the hole position of the shaft. 10.no. the pin on the lever assembly shall be inserted in the hole of the control shaft (V6014) and lock it with a circlip (V4404). hook one end of the torsion spring (V6042) against this bolt and the other end in between the washers on the charging ratchet assembly as shown in drg 6C. pg. This assembly shall be started from right hand side. shall be mounted in the spring drum compartment of the operating housing. Now. Now. pull the free end of the torsion spring (V6051) and hook it to the LH side sheet with the special tool.no.12. fix the bush (V6038) on both the side plates and mount the indicator lever assembly (V6039) in the bush. Put the thick washer (V6049) after the middle partition and insert the lockout lever with the spring mounted in the pin. insert the lockout lever (V6055) duly hooked with the torsion spring (V6056). (V6043) in a proper position and insert the duly greased pin (V6068) in the hole of charging shaft as shown in drg. push the auxiliary shaft. 6D& 6B. Fix the bush (V6053) on the RH side plate of the operating housing and insert the auxiliary shaft through the bush.8 Lockout Lever Assembly Refer drg. insert the torsion spring (V6051) in such a way that one free end shall be lifting the pin (V4904) of the supporting crank assembly. with chain (V4208) on it and also the torsion spring (V6042).9 Auxiliary Shaft Assembly : (Drg. (V6041 ). Now insert the washer (V6016) again and insert the crank (V6057). Push the pin further to pass it through the other sheet and fix the circlip (V6052). hook one end of the torsion spring (V6004) wound on the D-shaft assembly on a special pin (V6050) and pull the other end of the spring on the special pin(V6048) then push ahead the pin through the lockout lever. Slide the cylindrical pin (V5111) in the hole of the charging shaft and match the sprocket wheel to hold by the pin and fix the sprocket wheel. (6B. Let the shaft pass through the next plate of the operating housing and then pass it through the ON-OFF indicator(V6061 ). 12. Now. 48). Ensure. Now. Now hold the torsion spring (V6047) within the lockout lever.

Also hammer the same dowel pin to fix the ON-OFF indicator (V6061).53) The new arrangement of Auxiliary Switch is recently introduced in these breakers 28 .A . (V6077). which are mounted loosely. V6075) in the fork of the auxiliary switch and lock it with the circlip .10.10 Auxiliary Switch Assembly (Drg.item no. First of all. one is used as a motor cut-off switch and other two are used for closing & tripping circuit and for annunciation.Auxiliary Switch Assembly (Drg. fasten the screws of the auxiliary switch. Note-2 : The other two switches have a combination of 2NO+3NC and 3N0+2NC. Do not forget to fix the earthing strip (V6073) and fix the special pin (V6074). Note-1 : The auxiliary switch used for motor cut-off have a contact combination of 2N0+3NC. After this. (V4207) . Then place the auxiliary switches (V6079 & V6080) as identified earlier and tighten it with the hardware . Setting-1 : For motor cut-off switch : Charge the spring of the circuit breaker. Now place the rubber washer . Take item no. 12. 52) Totally there are three auxiliary switches used in this circuit breaker.item no. as it charges the bracket lifts (V6088) up the auxiliary switch fork. CHECKING : Once the fixing is done. Thus. pg. Close the breaker and set the gap between the forks of the auxiliary switches and the body to 1 to 2 mm approx. OPERATION & MAINTENANCE pin (V6017) through the shaft. (V6081.no. shall be fixed after setting of the stroke. M4 spring washer and M4 plain washer respectively. ensure that the fork of the auxiliary switch is properly guided in the operating crank of the auxiliary shaft and there is no undue stresses on the auxiliary switch fork otherwise it may break. Out of the three auxiliary switches. 12. Socket head screw M4x30.no. The gap shall be set at 1. the total number of contacts are 5NO+5NC.5 mm.7. Now connect the other end of the lever assembly (V6027) to the ON-OFF indicator with a pin (V6060) and a special clip (V6076). CHECK Check that the whole assembly of the auxiliary shaft is correct as per drawing and no part is missing in it. This hardware shall be kept loose and shall be tightened after the setting of the auxiliary switch. insert the cylindrical pin . V6082 & V6083) hex.item no.auxiliary switch plate and on the top side of the plate. This setting shall be done when the breaker is in closed condition.item no. You should measure the gap between moving fork and the fixed body of the auxiliary. CAUTION :While inserting the auxiliary switch plate. pg. Now position the two cranks (V6054) in the appropriate position and fix it with hexagonal socket head bolt (M4x25) (V6059) with the nylock nut (V4707). (V6078) on the tapped holes of the auxiliary switch plate. the auxiliary switches. Setting-2 : Switches for annunciation scheme.0 to 1. 7A.D. and fasten the screws completely. fix two spacers (V6070) with the help of M5x25 hexagonal socket head screw (V6071) and self locking nut (V6072).

Refer drg. Now.no.8 which shows general arrangement of mounting of the operating coils. push the pin in the link and fix the split pin. drg. Once the appropriate coils (as per specified voltages in the order) are identified. hold the magnet support (V6086) such a way that it backs-up the coils. Ensure the bending of the split pin is proper.no. The auxiliary switch (V6122) is mounted in a inverted position on the top sheet of the breaker frame and the movement to operate the auxiliary switch is taken from the main shaft instead of an auxiliary shaft as in earlier version. CAUTION While fixing the closing coil (V6084) & tripping coil (V6085). check the movement of the push button levers is smooth and proper. pg. The fixing plate is provided with a tapped holes to mount these screws. 12. Dismantling of Auxiliary switch: Remove the M6 bolt from top of the breaker frame and remove the pin connecting the Aluminium link with the operating lever. take the wires of the coil out and connect it to the appropriate auxiliary switch position or on the terminals as per order related schematics or typical circuit diagram refer. 53 ) The new operating coil assembly consists of two different operating coils mounted independently and operate the closing & tripping latches independently. After this. This arrangement is simple in construction and it consists of one auxiliary switch containing 6N0+6NC contact configuration having a rotary action and rotates 90° between two end positions.11 Operating Coil Assembly (Drg 8.11. they are fixed in the proper position and shall be located in the holes provided on the fixing plate.Operating magnet assembly (Drg. A simple Aluminium link (V6124) is connected to transfer the motion from shaft to the auxiliary switch shaft through an arm (V6123). There are different coils available for different voltage ratings and one should ensure while ordering/mounting of coils on the circuit breaker for the for the right coils as per specifications. 54): Normally the two coils are mounted on each circuit breaker to facilitate the Electrical closing and electrical tripping of the circuit breaker. The axial movement of plunger of the coil is converted to the rotary movement of the latching 29 . check the following: a) Direction of rotation of coil. pg. 5 12. Vacuum circuit breaker type VD4E & VD4 is mounted with a special type of coil in which electrical energy is converted into a rotary motion to operate the closing and tripping mechanism of the circuit breaker.and the constructional details are shown in the drg: 7A. Assembly of the Auxiliary switch: Mount the auxiliary switch in the inverted position on the breaker frame and fix it with the M6 hardware. Insert the hexagonal socket head screw M4x35 (V6087) along with the plain & spring washers (V6083 & V6082). Now position the arm of the auxiliary switch in the respected position and fix the aluminium link to connect it to the operating lever of the breaker.A . b) Roll pin on the plunger shaft is guided properly in the half shaft slits. 7A. CHECK Once both the coils are mounted on the breaker.

no.13. Assembly of magnets: Ensure the rating of the closing magnet l opening magnet is as specified in the drawing. 9. the roller will drop down 30 . Now tighten the hexagonal socket head screw M6x16 (V6093) along with spring washer (V6094).9. There are normally 3 switches mounted on the micro switch mounting bracket (V6131) consisting of 1 NO + 2 NC contacts used for Motor cut-off spring charge indication and closing interlock purpose. Once the drive assembly is completed. 2) Charge the spring manually and carry out ON-OFF operation. 12. with help of Grooved pin(V6099) and circlip (V6100). One shall ensure that the closing spring is in completely discharged condition. 13. which are precharged for assembly easiness.12 Coupling of drive and pole : Coupling of drive and poles is possible only when the operating mechanism and poles are assembled completely. Once the appropriate motor is identified. (V6097) are assembled with the help of dowel pin (V6098) as shown in drg. OPERATION & MAINTENANCE shafts. fix the motor properly on the motor support plate of the operating mechanism. the opening springs get discharged and spring holder cap seats in a hole provided on the operating housing. thus executing the closing and opening command.55) There are different motors available for different voltage ratings. The crank (V6095) along with cover plate and cylindrical pin. Instruction for discharging and charging: Before starting any maintenance work or replacement of components of operating mechanism. Drg7A shows the arrangement of motor cut-off switch and its function. Now set the setting screw provided on the closing f lap (V6127) and opening flap (V6128) which is connected to the half shaft and lock the same with nut. Mount the closing magnet / opening magnet mounting bracket in the inverted position on the breaker frame and fix it with the M6 hardware. The collar of motor should be properly located in the hole provided on the motor support plate. One end of cover plate is connected to the charging ratchet assly. discharge the tripping springs. 3) Using the screw driver press the roller (V6030) against the compression spring (V6029) which is mounted on the lever assembly (V6014). 12. As you unscrew these three bolts. Then Fix the crank with motor shaft by using Hex socket head cap screw M4x35 (V6101 ) washer (V6083) and self locking nut (V4707). One should be very careful while ordering / mounting motor on the circuit breaker for the specified voltage as per the order specification.D. Without discharging the closing spring to its zero energy level it is very dangerous to work on mechanism. The discharging shall be done by removing the hexagonal socket head bolt from the rear side by unscrewing it.13 Motor Assembly : (Drg. Dismantling of magnets: Remove the M6 bolt from top of the breaker frame and remove the closing coil (V6125) / opening coil (V6126) from the breaker as shown in the Fig No 7A. Ensure the bending of the split pin of the plunger is proper. 12. Follow the steps given below to discharge the spring.A Motor cutoff Switch Assembly : The motor cut-off switch assembly is now an independent assembly where the bracket (V6088) drives the Lever assembly (V6129) and operate a set of snap-action switch (V6130) by a lever-fulcrum mechanism. 1) The spring is normally charged for 4 turns. pg. For coupling the poles with the operating mechanism refer the assembly instruction as described in clause A of the pole assembly.

The panel contacts are mounted in the bushing and the metallic shutters are provided hence. Put the spacer (V6103) in between frame and breaker and tighten hex bolt M12 x45 (V6104). 4) Complete 4 rotations of the spring drum and release the lever assembly. VD4 / VD4E Breaker for Unisafe Panel: The switchgear panel type Unisafe and the vacuum circuit breaker type VD4 / VD4E are of a very compact design. (V6105) on truck frame and interlocking assly (V6106) as shown in drg 10. .and then carry out the ON -OFF operation. Check the parallelity of the connection bars and other dimensions as per assembly drg. 1) Normally 4 complete turns are stored in a closing spring and a last turn to operate the breaker. The Rack-in mechanism is made as a part of the circuit breaker. The contact arrangement adapted for this breaker is Tulip contact system and hence better alignment. Drg. Ensure that greasing is done properly on all the rolling surfaces and then fix the front cover assembly (V6116) by hanging it on the top and fix it with the hex. Complete the Emergency trip assly (V6107). Adjust the length of actuators. 14. Auxiliary switches. 10. 2) Press the lever assembly(V6039) and hold it while charging. . Hence. 7) Check the freeness of the spring drum. The main features of this combination are: . 4) Repeat the same three times. Mount the barrier plate (V6108) from the rear side of the breaker frame and fix the connection pieces (V6109) on each terminal and the connection bars item no (V6110 to V6115) on each phase upper and lower terminals and maintain the center distance of 185 +/.no. 6) Using a special tool rotate the shaft after each ON -OFF command to complete the operation. 15. Truck assembly (ref. Instruction for discharging and charging: Follow the procedure to charge the closing spring. Push rod assembly. Drg 1A shows General Arrangement and basic dimensions of the breaker type VD4 / VD4E suitable for Unisafe panel. Motor assembly. Once again check the breaker for completeness and also paint seal the key assemblies like interlocks. flexibility and contact engagement with cubicle contact can be achieved.(V6102) on the working table and insert the breaker with pole inside the frame. the problems related to interchangeability are eliminated. 56) Place the frame assly.1 . 5) Last one or two operations may not complete on its own as the energy level in the spring gets reduced. 5) For the next charging the roller (V6030) will drop in the pocket and spring charging indicator will show the position "SPRING CHARGED" . Mount 24 plug assly. Also measure the distance between upper and lower terminal and it shall be 367 +/. 10. 3) Mark a line on the spring drum and start charging manually. thus the spring is completely discharged. socket head bolt with the washer. pg. Confirm operation of emergency trip and interlocking rod assembly.no. 31 . Now the circuit breaker is ready for operation.2. better compartmentalization is achieved.

32 .

34 Component Part Numbers 35 33 .E. LIST OF DRAWING & COMPONENT PART NUMBERS List of Drawings Pg.No. LIST OF DRAWINGS & COMPONENT PART Nos. E.

E. LIST OF DRAWINGS & COMPONENT PART Nos. List of Drawings Fig No. 1 1A 2 3 4A 4B 5 6A to 6E 7 7A 8 9 10 Description VD4 / VD4-E Circuit Breaker Drawing VD4 / VD4-E Breakers for Unisafe Cubicle Cross Sectional View Of VD4 Circuit Breaker Cross Sectional View Of VD Interrupter Pole Assembly Of VD4-E Breaker Pole Assembly Of VD4 Breaker Typical Circuit Diagram Operating Mechanism Auxiliary Switch Assembly Coil & Aux. Switch Arrangement (New) Operating Coil Assembly Motor Mounting Assembly Truck Assembly 34 .

SOCKET HD. 4A 4A V1003 V1004 V1005 V1006 V1007 V 1008 V1009 V1010 V1011 V1012 V1013 V1014 V1015 V1016 V1017 V1018 (Unplated) V1019 V 1020 V2001 V2002 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4A 4B 4B V2003 V2004 V2005 V2006 V2007 V2008 V2009 V2010 V2011 V2012 V2013 V2014 V2015 V2016 V2017 35 4B 4B 48 4B 4B 4B 4B 4B 4B 4B 4B 4B 4B 4B 4B .NAME OF ITEM POLE HOUSING VACUUM BOTTLE ASSY.BAR(BOTTOM) BUSH LABEL STICKER FLEXIBLE CONDUCTOR SUPPORTING PLATE SUPPORTING PLATE CONTACT TERMINAL SPECIAL NUT CONTACT NUT SPRING WAVE WASHER SAFETY WASHER HEX. SAFETY WASHER CONICAL SP. GROUP VC2 OPERATING STUD CONNECTION PART CHAMBER SUPPORT CONTACT FLANGE CONTACT PISTON ROLLER CONTACT COMP. V1001 V1002 DRG. WASHER HEX. HD. SOCKET HD. HD. SC. CAP SCREW REFERENCE No. SOCKET HD. CAP SCREW POLE HOUSING VACUUM BOTTLE ASSY. NUT HEX. SOCKET HD. SC. WASHER SPRING WASHER SPECIAL WASHER SPRING WASHER PRESSURE PLATE HEX. CAP SCREW HEX. CAP SCREW HEX. No. GROUP VG2S OPERATING STUD CONN. CAP SCREW CONICAL SP. CAP SCREW HEX. BAR (TOP) CONN.

9 6A.6B 6A.6B . SC.6B 6B 6A.6C 6C 6C 6A 6A. NAME OF ITEM HEX.6C. NUT GREASE SPRING HOLDER SPRING GUIDE COMPRESSION SPRING COMPRESSION SPRING OPERATING DISC SEPARATING PLATE HEX.6B 6A.6B 6A 6B 6A. LATCH LINK CIRCLES FISH PLATE CYLINDRICAL PIN D-SHAFT CRANK SPRING DOWEL PIN CAM DISC SPRING PIN SPRING PIN HEX.6B 6A 6A.7 6C 6A.6C 6C 6A. WASHER HEX.6D. HD. SOCKET HD.6B 6A.6B.6B 6A 6A. CAP SCREW CRANK FISHPLATE-OFF FISHPLATE-ON PLAIN WASHER SPRING WASHER NYLOCK HEX. SOCKET HD. 4B 4B 4B 4B 6A 6A.6B 6A. CAP SCREW SPRING WASHER SPRING DRUM SPRING SPROCKET WHEEL DISC ROLLER CHAIN CURVE WASHER CURVE WASHER DAMPER CYLINDRICAL PIN STOP WASHER LATCH ASSY. V4101 V4102 V4103 V4104 V4201 V4202 V4203 V4204 V4205 V4206 V4207 V4208 V4301A/B V43O2A/B V4303A V4304A/B V43O5A/B V4401 V4402 V4403 V4404 V4405 V4406 V4501 V4502 V4503 V4601 V4602 V4603 V4701 V4702 V4703 V4704 V4705 V4706 V4707 V4708 36 DRG. V2018 V2019 V2020 ISOFLEX TOPAS N852.6E 6E 6E 6A. LIST OF DRAWINGS & COMPONENT PART Nos.6B 6A. CAP SCREW CONICAL SP. No.6B 6A.6B 6B 6B 6A. NUT HALFSHAFT REFERENCE No.6B 6B 6A.E.6E 6E 6E 6A.

6C 6B 6A.6D 7 6A.6C 6C 6C 6A.6B.6C 6A.6B 6A 6A.6B 6A.6C 6A. No. SCREW SPRING WASHER TENSION SPRING BLOCKING CRANK BLOCKING CRANK BLOCKING ROLLER CYLINDRICAL PIN SPACER GROOVED PIN SHAFT HEX.6B 6B.6B. V4709 V4710 V4711 V4801 V4802 V4803 V4804 V4805 V4901A/B V4902A/B V4903A/B V4904 V4905A/B V4906A/B V5101 V5102 V5103 V5104 V5105 V5106 V5107 V5108 V5109 V5110 V5111 V5112 V5113 V5114 V5115 V5116 V5117 V5118 V5119 V5201 V5202 V5203 V5204 V5205 V5206 V6001 V6002 V6003 V6004 37 DRG. HEAD SCREW TUBULAR RIVET CONICAL PLATE SUPPORT PLATE SLOTTED CH.6E 6A 6E 6A.6B.6B .NAME OF ITEM SPRING PIN TORSION SPRING TORSION SPRING COUNTER ANGLE SLOTTED CHEESE HD.6E 6B. SOCKET HEAD SCREW SPACER SLOTTED CH.6C 6A.6C 6A.6C 6C 6C 6A.6B 6A 6A 6A.6B. HEAD SCREW TUBULAR RIVET CYLINDRICAL PIN SPROCKET LATCH TORSION SPRING CHARGING LEVER NYLOCK HEX. SOCKET HEAD SCREW HEX. NUT SPRING WASHER PLAIN WASHER LEVER LEVER BOLT ROLLER BEARING RETAINING CIRCLIP SPECIAL PIN HOUSING BUSH AUXILIARY SWITCH PLATE TORSION SPRING REFERENCE No.6B 6A. 6A.6E 6A.6B 6A.6C 6A.6C 6A 6A.6E 6A 6A.6C 6C 6A.6B 6A.6C 6A.6B.6C 6A. NUT NYLOCK HEX.6C 6C 6A.6C 6C 6A.

6C 6C 6C 6A.6C 6A.6E 6D 6D 6D 6C 6C 6D 6A.6B 6A.6E 6A. 6B 6B 6B 6A. No.6C 6B 6B 6A. V6005 V6006 V6007 V6008 V6009 V6010 V6011 V6012 V6013 V6014 V6015 V6016 V6017 V6018 V6019 V6020 V6021 V6022 V6023 V6024 V6025 V6026 V6027 V6028 V6029 V6030 V6031 V6032 V6033 V6034 V6035 V6036 V6037 V6038 V6039 V6040 V6041 V6042 V6043 V6044 V6045 V6046 V6047 DRG. SOCKET HEADED CAP SCREW HEX.E. LIST OF DRAWINGS & COMPONENT PART Nos.6B 6B 6A.NUT SPRING WASHER TUBE CYLINDRICAL PIN RETAINING WASHER BUSH LEVER ASSEMBLY TORSION SPRING WASHER SPRING PIN LOCKOUTLEVER TORSION SPRING SPRING PIN BUSH BUSH SHAFT CAM DISC SPACER SPECIAL WASHER LEVER ASSEMBLY ROLLER COMPRESSION SPRING ROLLER CONTROL WASHER SPACER TUBE STOP FORK LOCK (KEY) BUSH CIRCLIP MOTOR BUSHING LEVER ASSEMBLY BUSH SPROCKET WHEEL TORSION SPRING NON RETURN PLATE HEX. NAME OF ITEM BUSH BRACKET HEX.6D 6D 6A.6D 6A.6B 6A.6B 6E 6A.6E 6E 6D 6A.6B 6B.6C 6C 6A.6B 6A.6B 6A.6D.6B 6A.6C 6A.6C.6E 6A. BOLT LOCKOUTLEVER PIN SPRING 38 REFERENCE No.6B.6C 6A.6C 6C 6A.6B .6C 6A.6B.

SOCKET HEADED SCREW BRACKET SPECIAL CIRCLIP PIN HEX.CAP SCREW PIN SPACER HEX. No.8.6C 6D 6D 6A 6B.6D 7 7 7 7 7 7 6D.HEADED SCREW CYLINDRICAL PIN ON. 6A. V6048 V6049 V6050 V6051 V6052 V6053 V6054 V6055 V6056 V6057 V6058 V6059 V6060 V6061 V6066 V6068 V6070 V6071 V6072 V6073 V6074 V6075 V6076 V6077 V6078 V6079 V6080 V6081 V6082 V6083 V6084 V6085 V6086 V6087 V6088 V6089 V6090 V6093 V6094 V6095 V6096 V6097 V6098 DRG.6D 6A.NAME OF ITEM SPECIAL PIN PLAIN WASHER PIN TORSION SPRING RETAINING CIRCLIP BUSH CRANK LOCKOUTLEVER ASSEMBLY TORSION SPRING CRANK SPACER HEX.6D 6A.SOCKET HEADED SCREW SELF LOCKING NUT EARTHING STRIP SPECIAL PIN CYLINDRICAL PIN RETAINING CIRCLIP RETAINING CIRCLIP RUBBER WASHER AUXILIARY SWITCH AUXILIARY SWITCH HEX.OFF INDICATOR SOCKET HD.6D 6A. SO.7 7 7 7 7 7 7.8 7.SOCKET HEADED SCREW SPRING WASHER PLAIN WASHER CLOSING COIL TRIPPING COIL MAGNET SUPPORT HEX.6B.9 8 8 8 8 7 7 7 9 9 9 9 9 9 . SOCKET HD SCREW SPRING WASHER CRANK COVER PLATE CYLINDRICAL PIN DOWEL PIN 39 REFERENCE No.6B 6B 6D 6D 6A.6B 6A.6B 6B 6B 6A.

No. 9 9 9 9 9 10 10 10 10 10 10 10 10 10 10 10 10 10 6A 6A. NAME OF ITEM GROOVED PIN RETAINING CIRCLIP HEX.E.SOCKET HEAD SCREW FRAME SPACER HEX.6C 6B 6B 6C 7A 7A 7A 7A 7A 7A 7A 7A 7A 7A 40 . V6099 V6100 V6101 V6102 V6103 V6104 V6105 V6106 V6107 V6108 V6109 V6110 V6111 V6112 V6113 V6114 V6115 V6116 V6117 V6118 V6119 V6120 V6121 V6122 V6123 V6124 V6125 V6126 V6127 V6128 V6129 V6130 V6131 DRG. LIST OF DRAWINGS & COMPONENT PART Nos.BOLT 24 PIN PLUG ASSEMBLY INTERLOCKING ASSEMBLY EMERGENCY TRIP ASSEMBLY BARRIER PLATE CONNECTION PIECE CONNECTION BAR CONNECTION BAR CONNECTION BAR CONNECTION BAR CONNECTION BAR CONNECTION BAR FRONT COVER ASSEMBLY HEX. BOLT HALFSHAFT DOWEL PIN LOCKING LEVER BLOCKING LEVER AUXILIARY SWITCH AUXILIARY SWITCH ARM ALUMINIUM LINK CLOSING MAGNET (NEW) OPENING MAGNET (NEW) CLOSING FLAP OPENING FLAP LEVER ASSEMBLY SET OF MICROSWITCH M/S MTG BRACKET REFERENCE No.

No. 1 .VD4E Breaker 41 VD4 Breaker Drg.

VD4E Breaker for UNISAFE cubicle 42 VD4 Breaker for UNISAFE cubicle Drg. 1A . No.

No.2 Roller contact / Flexible conductor 17 Contact pressure spring 18 Insulated coupling rod 19 Operating spring 20 Shift lever pair Drg.removable Insulating material pole tube Upper breaker terminal Lower breaker terminal 15 Vacuum interrupter 16. 2 .43 Cross sectional view of VD4E CB Cross sectional view of VD4 CB 1 1.1 12 13 14 Breaker mechanism housing Front cover .

3 15.4 15.2 15.6 15.1 15.5 15. No.15.7 Insulator Fixed contact Movable contact Metal bellows Screen Guide cylinder Lid Cross section of vacuum interrupter Drg.3 44 .

No. 4A Pole assembly Drg.45 Drg. 4B Pole assembly for VD4E / VD4 breaker . No.

Drg. 3.5 46 Spring charging motor Closing coil Tripping coil (S3. 4. No. 8. S4) CB Auxiliary switch contacts Microswitch operates in T or S positionm Plug & socket (S1) Motor cut-off switch Breaker . 2. 7.1. 5. Typical circuit diagram 6.

47 Drg. No. 6A Operating Mechanism Assembly for VD4E / VD4 breaker .

48 Drg. 6B Operating Mechanism Assembly for VD4E / VD4 breaker . No.

6C Operating Mechanism Assembly for VD4E / VD4 breaker .49 Drg. No.

No.50 Operating Mechanism Assembly for VD4E / VD4 breaker Drg. 6D .

No.51 Operating Mechanism Assembly for VD4E / VD4 breaker Drg. 6E .

No.Auxiliary Switch assembly Drg. 7 52 .

No.Arrangement drawing with coil and auxiliary switch Drg. 7 53 .

No. 8 .54 Opening coil assembly Drg.

No. 9 55 .Motor mounting assembly Drg.

No.56 Truck assembly Drg.10 .

ABB Limited Plot No. We reserve the right to make amendments in the course of technical progress. Street No. Satpur.No liability is accepted for the accuracy of the information contained in the publication.422 007 Tel: +91 235 2351095 to 8 +91 253 2351261 to 4 Fax: +91 253 2350644 / 2351249 1VDU09001-YN . Nashik . 17 MIDC Estate. 79.