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

Information on Rating Plate

Type Sr. No. 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. Year of Manufacture IEC : 60056 / 62271-100 12kV 50Hz 28 / 75kVp 800 or 1250 or 1600 Amps 13.1 or 20 or 26.3 kA 3sec. 63kA or 80kA O-0.3S-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. Component 3 Poles (Kgs) Operating mechanism (Kgs) Structure (Kgs) Total(Kgs) VD4E 35 50 15 100 VD4 50 60 15 125

7

A. 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 circuit breaker is transhipped in packing in the open (OFF) position and with the closing spring discharged. 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, thus verifying their correct structure and function. Receipt Each delivery is to be checked on receipt for : - Completeness and correctness (Check against order and delivery documents). - Any possible damage in transit and material losses. Abnormality, if any, must be notified immediately to: -The manufacturer -The forwarding agent and the insurance company. -The responsible claims inspector according to the insurance certificate for the purpose of making out a damage or loss Certificate. Unloading Unloading of the package units must only be carried out with a crane, fork lift truck and / or transport trolley jack. Storage Rules and Regulations The material shall be stored in a well ventilated storage room and to be protected against dirt, damage and water ingression. The original packing can be used for storage, however, without the plastic sheet.

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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. The following limit values apply : Ambient temperature : Maximum + 40°C Maximum 24 hour average + 35°C Minimum - 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, smoke, corrosive or combustible gases, vapours or salt. Special Operating Conditions Special operating conditions are to be agreed on by the manufacturer and user. The manufacturers must be consulted in advance about each special operating condition. Site altitude over 1000 m : - Allow for the reduction in the dielectric strength of the air. Increased ambient temperature : - Current carrying capacity is reduced. - Provide additional ventilation for heat dissipation. Climate : - To minimize risk of corrosion avoid areas with: - With high humidity - Major rapid temperature fluctuations. - Implement preventive measures (e.g. electric heaters) to preclude condensation.

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8

B. DESIGN

B.

DESIGN General features

Pg. No. 10

Structure & function

10

Constructional details

10

Pole assembly

10

Operating mechanism

10

Truck assembly

10

Working principle of pole assembly - Contact operation - Principle of interruption

11 11 11

9

B. DESIGN

General Features The vacuum interrupter in VD4 / VD4E circuit breakers are designed such that the contact speed, travel and mass is low, subsequently low spring forces are sufficient for operation. The breaker operating mechanism is thus extremely low in wear, and the maintenance requirement are accordingly negligible. Structure and Function
(Drg.2 & 3, pg.no. 43 & 44)

conductor (V1008). The moving contact of the interrupter is connected to the operating mechanism through a Operating stud (V1003/ 2003). The disc springs inside the operating studs exerts the required contact pressure on the contacts. Operating Mechanism The operating mechanism consists of : A spring charging unit which can be charged manually or electrically by a geared motor. Mechanical indicator showing spring charged / discharged condition. Indicator for open / close position of the circuit breaker. Closing / tripping magnet for performing closing / opening operation of the circuit breaker electrically. Operation counter showing total number of operations performed by the breaker. Motor cut-off switch and auxiliary switch. Switch for annunciation and control of auxiliary circuits. Optional items like under voltage trip additional trip coil and blocking magnet. The spring charging mechanism ensures that the breaker can perform O-C-O operation if it is closed and charged. The breaker can perform C-O operation if it is open and charged. As soon as the energy is removed from the spring charging mechanism, the NO contact of the cut-off switch is opened interrupting the motor circuit. The spring charging mechanism can also be recharged manually by means of a charging handle. Truck assembly (Drg.1, pg.no. 41) This assembly consists of : Frame assembly Wheel rack assembly Automatic secondary plug & socket assembly. Interlocking rod assembly Bottom plate assembly Emergency trip assembly The above assembly provides the following features :

The poles, which are constructed in column form, are mounted on the bracket shaped rear part of the breaker mechanism housing 1. The live parts of the breaker poles are located in the insulating material pole tubes 12 and protected from impact and other external influences. With the breaker closed, the current path leads from the breaker upper terminal 13 and a chamber holder fixed in the pole tube to the fixed contact 15.2 in the vacuum interrupter 15, then via the moving contact 15.3 and the flexible conductor / roller contact 16.2 to the breaker lower terminal 14. The switching motion is effected by means of the insulated coupling rod 18 with internal contact pressure springs 17.

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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. A spring charged operating mechanism . A truck assembly with relevant interlock features.

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Pole assembly (Drg.4A & 4B, pg.nos. 45) Pole assembly consists of a vacuum interrupter (V1002 / V2002) mounted firmly in the Pole housing (V1001/ V2001) made out of epoxy resin. 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

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10

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Closed breaker can not be moved from test to service position or vice-versa. Breaker can not be closed when it is in intermittent position. 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.

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. Principle of interruption Due to the extremely low static interrupter chamber pressure of 10-4 to 10-8 in mbars, only a relatively small contact gap is required to achieve a high dielectric strength. The arc is extinguished on one of the first natural current zeros. Due to small contact gap and high conductivity of the metal vapour plasma, the arc drop voltage, and additionally, due to short arcing time, the associated arc energy, are extremely low, which has advantageous effects on the life of the contacts and thus on that of the vacuum interrupters.

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. 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.The movement / stroke of the moving contact of the vacuum interrupter is achieved through the

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12

C. INSTALLATION & COMMISSIONING

C. INSTALLATION & COMMISSIONING Preparatory work Tools & accessories Technical documents

Pg. No. 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

C. ERECTION & COMMISSIONING

Erection Preparatory work The following items should be held in readiness before the circuit breaker is placed in position. Tools and Accessories - Torque wrenches Range 0 -150Nm - Ratchet - Torque screw drives Range 0 - 10Nm - Extensions Range 0 - 250mm - Allen keys size - 3 - 9 (1set) - Open end & ring spanners size - 5-32 (1set) - Screw drivers size - 00-5 (1set) - Flat nose plier with side cutter size - 120mm (1no) - Circlip plier (1no) - Extractor plier (1no) - Loctite 290,270, - Grease ISOFLEX TOPAS NB 52 - Cleaning cloth - Special tools - Main shaft rotation tool. - Special screw driver for torsion spring. - Special socket for M6 nylock nut assembly. Technical documents Assembly drawings. Customer’s order reference drawings. Circuit diagram. Dimensional drawings. Erection For erection of switchgear cubicle, refer the relevant instruction manual for the particular cubicle type. When all the panels are erected correctly, check that the cubicle fronts are in line and that the cubicle doors with the interlocking devices work correctly. The movement of all the handles should be easy and smooth. Put the breaker into the cubicle and check the following :

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Free movement of the breaker from withdrawn position to Test and from Test to Service and vice versa. Proper engagement of secondary plug and socket. Proper functioning of various interlocks. Proper engagement of earthing contacts. Proper engagement of connection bars with the cubicle contacts.

Electrical connection High voltage connections Clean and degrease the silver plated contacts with a clean, non-linting linen cloth and cleaning agent. Let dry well, With a linen cloth. Apply a thin film of contact grease / Vaselene to the contact surfaces. 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. Cleaning and degreasing are to be carried out in the same manner. Low voltage connections The auxiliary circuit connection shall be checked as per the relevant schematic diagram for correctness. Earthing The permanent earthing is provided by means of earthing busbar in all the switchgear cubicles. There are terminals for connecting external earthings to this busbar. The stations earthing terminal is connected only in the end cubicle. Each circuit breaker is provided with earthing finger contacts mounted on, the top of the breaker truck. These finger contacts engage and slide against the wedge type contact provided in the switchgear cubicle, which is, in turn, connected to the cubicle main earth busbar. Lubricate the earthing contacts on the breaker truck and cubicle with a thin film of vaselene or contact grease and ensure proper contact engagement.

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14

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. Check that the value of the supply voltage for the auxiliary circuit is with in 85% and 110%, of the rated voltage, of the electrical devices. Check that no foreign material has got into the moving parts.

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To gain access to the operating mechanism safely, discharge the closing springs (by closing & opening the circuit breaker), then remove the cover of the operating mechanism. Check that air circulation in the circuit breaker installation site is adequate so that there is no danger of overheating. Remove the transport caps from the poles, Ensure that the instruction manual is available to the operator at all the times. Carry out the checks indicated in table no. 1 :

Table 1: Precommissioning Checks SUBJECT OF INSPECTION 1. 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. 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. Carry out a few closing and opening operations. . NOTE: Connect the undervoltage release with the relative rated auxiliary supply voltage (if provided)

2. Motor operated mechanism (if provided)

3. 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. The circuit carry out the circuit breaker closing breaker opens and the operation. Disconnect the power supply relevant indication occur from the release. correctly. 4. Shunt opening Close the circuit breaker. Connect the release shunt opening release with the relative rated auxiliary supply voltage. 5. Shunt closing Open the circuit breaker. Connect the release shunt closing release with the relative rated auxiliary supply voltage. The circuit breaker opens and the relevant indication occur correctly. The circuit breaker closes correctly and the relevant indications occur correctly.

15

C. ERECTION & COMMISSIONING

SUBJECT OF INSPECTION 6. Auxiliary contacts in the operating mechanism 7. Test service position limit switch operation 8. Insulation resistance

PROCEDURE

POSITIVE CHECK

Insert the auxiliary contacts into suitable Signals occur correctly signaling circuits. Carry out a few closing and opening operations of the circuit breaker. Move the breaker from test to service few times. Test service position indications occur correctly.

With 2500V Meggar, 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. Check interlock functions Interlock should function correctly.

9. Functions of various interlocks

Functional checks

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Functional checks must only be carried out when: The circuit breaker is disconnected from the high voltage network and is correctly earthed. The breaker mounting screws are well tightened. Any foreign material that is likely to disturb operations is removed. 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. Final checks Rack in the breaker into the switchgear cubicle. Re-check all electrical connections, terminals and connecting leads. Handing over After the checks are completed, the circuit breaker can be handed over for commissioning.

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D. OPERATION & MAINTENANCE

D. OPERATION & MAINTENANCE General Features Table 2 - Maintenance schedule Table 3 - Inspection details & actions Table 4 - Inspection periodicity Lubrication Operation & maintenance of pole assembly General Maintenance Replacement of complete pole assembly Dismantling Assembly Operation & Maintenance of Operating mechanism 1. Tripping spring assembly 2. Closing spring assembly 3. Stop washer assembly 4. Latch assembly 5. D-shaft assembly 6. Cam disc assembly 7. Half shaft assembly 8. Counter assembly 9. Supporting crank assembly 10. Ratchet assembly 11. Operating lever assembly 12. Operating mechanism assembly 12.1 - 12.6 Assembly process 12.7 Assembly of charging ratchet 12.8 Lockout lever assembly 12.9 Auxiliary shaft assembly 12.10 Auxiliary switch assembly 12.10A Auxiliary switch 12.11 Operating coil assembly 12.11A Operating magnet 12.12 Coupling of drive pole 12.13 Motor assembly 12.13A Motor cut-off switch assembly 13. Instruction for discharging and charging 14. Instruction for discharging and charging 15. Truck assembly VD4 / VD4E breaker for Unisafe panel

Pg. No. 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

D. 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 . Work must only be carried out when the circuit breaker is withdrawn from the enclosure. General features During normal service the circuit breakers require only limited maintenance. The frequency and the sort of inspections and maintenance basically depend on the service conditions. Various factors must be taken into account. e.g. frequency of operations, interrupted current values and relative power factor as well as the ambient conditions. Table no. 2 gives the maintenance schedule

showing the time intervals after which maintenance work is generally required. On the basis of the results obtained during the periodic inspections, it is possible to set the optimal time limits for carrying out maintenance work. These rules should also be followed: Any circuit breaker which operates only a few times, that is remains closed (ON) or open (OFF) for long periods, should be operated from time to time to prevent clogging. Clogging may cause a reduction in the closing or opening speed. When the circuit breaker is in service it should be visually inspected from outside to detect any dust, dirt or damage of any kind.

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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

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General Inspection of the Circuit Breaker Table 3 Inspection details and actions Parts subjected to 1. Operating mechanism Abnormalities noticed Presence of dust on the mechanism Distorted or oxidized springs Locking rings out of place, 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. Replace the wires fasteners and reconnect the detached wire correctly. Clean with a dry brush or cloth

2. Medium voltage Presence of dust or dirt on the compartment parts insulating parts Locking rings out of place. Loose Refix the locking rings in their position and tighten the nuts or nuts or screws screws. 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. 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. circuit breaker terminals Cover them with neutral grease and tighten the screws. 3. Earthing isolating Traces of oxidation Clean with a rough cloth contact soaked in a suitable solvent and lubricate moderately with neutral grease. 4. Earthing Traces of oxidation and/or loose Clean with a rough cloth soaked in suitable solvent. Tighten the connection nut earthing connection fully and cover it with neutral grease. Check the supply voltage of the The releases and the electrical 5. Auxiliary circuit supply voltage operating mechanism electrical interlocking devices must work correctly for values between 85% accessories and 110% of the relative rated voltage. 6. Operating and Carry out the functional tests Replace the damaged or faulty control elements elements (if necessary ask manufacturer)

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D. OPERATION & MAINTENANCE

Table 4 :

Inspection periodicity
Based On years Occasionally After Year Based on No. Of operations 5,000 10,000 As reqd. 20,000 Points to Note

Task/Parts tobe maintained

INSPECTIONS: Operating mechanism complete Screw connections Cable connections Return springs Circlips and Retaining rings Interlocking rod assly. Microswitch assly. Motor cut off switch MAINTENANCE: Lubrication Closing spring assly. 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. The lubrication shall be carried out as per the schedule given in table 2 , clause no. 6.3. Clean brush or soft cloth shall be used to carry out the lubrication. The special

grease type ISOFLEX TOPAS N852 shall be used for operating mechanism lubrication. The sliding parts shall be operated a few times after lubrication so that the lubricant will penetrate properly through out the sliding / rolling surface.

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Operation & Maintenance of Pole assembly
General Weight of each pole assembly is approximately 12 Kg for VD4-E and 17 Kg for V D4.
The pole assembly (Drg.4a & 4b,pg. No. 45) consists of the following components : Pole housing (V1001 / V2001) Vacuum interrupter (V1002 / V2002) Operating stud (V1003 / V2003) Flexible conductor (V1008) Roller contact assly. (V2008) Top connection bar / Support (V1004 / V2004) Bottom connection bar/Contact flange assly. (V1005 / V2006)

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Replacement of complete pole assembly Note To order the complete pole assembly for circuit breaker type VD4E / VD4, the following details should be furnished : Rated voltage Rated normal current Breaker type & serial number Order reference number

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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. Before commencing the maintenance work, ensure that the circuit breaker : Is disconnected from the high voltage and auxiliary voltage terminals. Is in the open position and the closing spring of the operating mechanism is fully discharged. Is fully withdrawn from the cubicle. Caution This service work may only be performed by switchgear manufacturer's servicing personnel or adequately trained specialist staff.

Dismantling : Before dismantling the pole, ensure that the breaker is in 'open' condition and closing spring is discharged. To fully discharge the closing spring, refer instruction 13(pg. No. 30). 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. Remove the Hex. socket head screw (V6091) from the bottom side of the breaker. Take care to hold the pole assembly properly while dismantling the screw. Separate the pole assembly from the operating mechanism assembly (V1000 / V2000). 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. Tighten the Hex. socket head screw (V6091) and spring washer(V6092) from bottom side. Tightening torque for these bolts is 45 Nm. Insert the special tool in the main shaft, and rotate the main shaft in the opposite direction. 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. Insert the pin in the operating stud and put the special circlip on it. Similarly, 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.

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21

D. OPERATION & MAINTENANCE

Operation and Maintenance of Operating Mechanism
(Drg. 6A to 6E, pg.nos. 47 to 51)

3. Stop washer assembly (V4300)
(Drg. 6B; pg.no. 48)

Refer to the assembly drawings 6A to 6E. The assembly drawing is self explanatory and shows different assemblies in different sheets. First of all make the sub-assemblies ready for the final assembly as given below: 1. Tripping spring assembly (V4100)
(Drg. 6E; pg.no. 51)

Take the spring holder (V4101), place the compression springs (V4103 and V4104) , assembled one inside the other, on it place the spring guide (V4102) on top of the spring. Check that the springs are in vertical position and tighten the socket head bolt M6x70 to clamp the spring in the compressed position. Apply a light coat of grease on the outer and inner surface of the springs. 2. Closing spring assembly (V4200) (Drg. 6C; pg.no. 49) Take operating disc (V4201) and insert separating plate (V4202) in the operating disc as shown in figure 6C. Hold the plate in a position and tighten it with a hex. socket head screw (V4203) with spring washer (V4204). 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.

Take curve washers LHS & RHS (V4301[A/B] / V4302 [A/B]) and insert 6 nos. dampers (V4303) in each curve washer. Now insert 6 cylindrical pins (V4304 [A/B]) in the curve washer LHS with a light coat of grease. Press the pins completely in the curve washer. 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, refer fig. 6B.Once the stop washer is inserted in the pins, 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. After the assembly, apply a light coat of grease on the periphery of the cam disc. 4. Latch assembly (V4400)
(Drg. 6B, pg.no. 48)

Take the latches (V4401 and V4402) respectively, mount them on the common pin. On the other end of the latch, insert link one each (V4403) and put the circlip (V4404) on both the latches. Now, 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). Apply a light coat of grease Isoflex Topas N852 on the moving area of latch for free movement of the latches. 5. D-Shaft Assembly (V4500)
(Drg. 6B, pg.no. 48)

Caution : The hex. socket head screw should be tightened after the complete assembly of the breaker before charging the spring to its required precharge value. 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). Mount the roller chain (V4208) and tie it with wire so that it will not come out from the sprocket wheel disc.

Take a D-Shaft (V4501 ), as shown in drg. 6B. Insert the shaft in the crank (V4502) as shown in fig. 6B. The position of the crank is very important. Hold the assembly properly and insert the spring dowel pin O5x30 (V4503) / and fix the crank by a dowel pin. Hammering to be done very carefully so that it will not damage the crank. 6. Cam disc Assembly (V4600)
(Drg.6E, pg.no. 51)

Hold the cam disc (V4601) firmly on the working table and press the spring dowel pin (V4602 and V4603) respectively, one inside the other.

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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. 7. Half shaft assembly (V4700)
(Drg. 6B, pg.no. 48)

8. Counter assembly (V4800)
(Drg. 6B, pg.no. 48)

Take a counter assembly - item no. (V4801 ). Position the arm of the counter suitably and tighten it with a screw driver. Now mount this counter on a mounting angle (V4802) with M3 cheese head screw (V4803) and spring washer (V4804). 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. 9. Supporting crank assembly (V4900)
(Drg. 6B, pg.no. 48)

Take the hex. socket head screw M4x16 (V4701 ) as shown in drg. 68. Hold 2 cranks (V4702) as shown in the drg. Mount the fish plate (V4703) on tripping side and fish plate (V4704) on the closing side of the crank. Caution While mounting these fish plates, ensure that the slots provided on the fish plate are well guided in the boss provided on the crank ( V4702). Now insert 1 no. plain washer (V4705)and 1 no. plain thick washer (V4706). Again insert (V4705) and lock it with nylock nut (V4707). Similarly for the other crank, put washer (V4705) and lock it with nylock nut. Now take that half shaft (V4708). Apply a light coat of grease on both the ends. Insert a roll pin(V4709)on the hole provided on the slit end of the half shaft. The role pin insertion should be such that it should equally come out of the half shaft from both the sides. Now insert the half shaft in the crank (V4702) as shown in drawing. 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. CHECK : Holding one of the fish plates, check the free movement of the other fish plate and half shaft. After checking for both the half shafts, apply a light coat of grease on the rolling & moving areas of fish plate.

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. The chamfers of both the supporting cranks should be face to face to each other and then - fix the locking roller (V4903 [A/B]) and the cylindrical pin (V4904) a light coat of grease Isoflex Topas N852 . 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.6B from the RH side. Apply a light coat of grease on the rolling area of the supporting crank and the locking roller. 10. Ratchet assembly (V5100)
(Drg. 6C, pg.no. 49)

Refer to drg. 6C showing the assembly of the ratchet for charging. 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. socket head cap screw M6x45 & M6x30 (V5102 & V5103) insert spacer (V5104), longer screw.

23

D. OPERATION & MAINTENANCE

Now in a small hole of the conical plate (V5107), insert V5105 - M3x25 cheese head screw M3x25 (V5105) and a tubular rivet (V5106). Above that insert support plate (V5108) with cheese head screw (V5109) and tubular rivet (V5110)fixed on it. After this, insert the cylindrical pin (V5111 ) and locate the sprocket (V5112) with the right direction. Apply a light coat of grease on the pin and in between the conical plate and support plate. Now take 2 nos. latch (V5113), 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. The charging lever (V5115) shall be located on two hex.socket head screws fixed earlier. Repeat the assembly of support plate and conical plate duly greased and fix the other end of two latches in the slots. Put another tubular rivet (V5110) and lock the small cheese head screws with a nylock nut (V5116) of size M3. Do not excessively tighten the nylock nuts. Also fix the nylock hex. nut (V5117) on hex. 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). 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. Also check the assembly for spring action for the latches. 11. Operating lever assembly (V5200)
(Drg. 6E, pg.no. 51)

12. Operating mechanism assembly(V5200)
(Drg. 6A-6E, pg.no. 47 - 51)

The operating mechanism assembly sub-divided into different sub-assemblies : 1 ) Half shaft assembly. 2) D-shaft assembly. 3) Operating lever assembly. 4) Control shaft assembly. 5) Supporting crank assembly. 6) Main shaft assembly. 7) Charging ratchet assembly. 8) Blocking lever assembly. 9) Auxiliary shaft assembly. 10) Coil assembly.

is

After keeping all sub-assemblies ready for main assembly, we shall start the main assembly of operating mechanism. Refer drg. 6A to 6E for the mechanism assembly. 12.1 Take operating housing (V6001 ) and fix the special bush (V6002) as shown in drg. (6B & 6D). Apply a light coat of grease and mount the half shaft assembly as shown in the drg. 6B & 6D 12.2 After this assembly, the D Shaft assembly (V4500) shall be mounted as shown in drg. 6A & 6B. Place the bush (V6003) in the hole provided in the side sheet. 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. Once the positioning is done, clamp the bush with bracket (V6006), and hold the bracket with hex. Socket headed screw (V6007) with spring washer & hexagonal nut (V6008 & V6009). 12.3 After this assembly, the assembly of 3 operating levers (V5200) shall be done. The assembled levers are to be inserted in the pivot plates of the operating housing as shown in the drg. 6E. With the spacer (V6010) and the duly greased grooved pin (V6011 ), which is to be clamped on both the ends by a special circlip (V6012). 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. Locate the tripping spring assembly as shown in the fig. 6E. Now take the bolt (V5203) and insert the bolt through LH side lever and pass it through the roller bearing (V5204). Put the circlip (V5205) and clamp it. For R-pole operating lever special pin(V5206), shall be used instead of (V5203).

24

on the operating housing as well as the free movement of the lever assembly in the operating mechanism. Use stepped bush (V6062) for the assembly of R-pole operating lever. 12.4 Now the assembly of the control shaft shall be carried out in the following steps. First of all, fix the bush (V6013) duly greased from inside - as shown in drg 6D, in the middle partition of the operating mechanism. 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. Apply a light coat of grease inside the bush, place one or two washers (V6016), depending on the space available next to the bush. Now insert the spiral dowel pin (V6017) in the holes to locate the control shaft and to hold the torsion spring in a position. Now insert the lockout lever (V6018) with the torsion spring (V6019) inside the lockout lever as shown in Fig.6B. 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. Check: 1) Check the movement of the control shaft. It shall be free in the two end bushes. 2) Check the action of the torsion spring by applying a force on the lockout lever. 3) Check the dowel pin - item no. (V6020) is well located in the groove of the lockout lever and on the leg of the torsion spring. Also check the projection of dowel pin from the rear side. 4)Check the other two roll pins (V6017), are equally out of the control shaft from both the sides and dowel pins are not rubbing on the bush (V6013). 12.5 As per the sequence of assembly, supporting crank assembly shall be mounted on the operating mechanism at

this stage. Fix the bush / spacer (V6021/ V6063) Refer assembly fig. 6B in the hole provided on operating housing. Apply a light coat of grease from the inner surface of the bush / spacer and take the assembly of supporting crank made, as explained in point no.9 (V4900). 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. 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. Check : Check for the free movement of the supporting crank inside the grooved pin (V4906 [A/B]). 12.6 After this assembly, the assembly of main shaft shall be carried out in the following sequence. Refer, (6A,6C & 6D), separate out all the items to be mounted on the main shaft and clean them thoroughly, apply a light coat of grease ISOFLEX TOPAZ N852. Fix the bush (V6022). Apply a light coat of grease and insert a main shaft (V6023) through it. Now, before inserting the assembly of closing spring (V4200), Insert the cam disc (V6024), as shown in drg. 6C. The cam disc crest profile shall be kept towards the front side or operator side. 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. 2, align the hook of the spiral spring with the shaft keyway and insert the shaft through the spring drum and the operating disc,

25

D. OPERATION & MAINTENANCE

which is mounted on the spring drum. As soon as the roller (V6030) rests on a operating disc, remove the clip and release the roller. Push the main shaft till it comes out of the cam disc (V6024). The next component on the main shaft is the cam disc assembly (V4600). Fix the cam disc assembly as per point 6 and as shown in drg. 6C & 6E. 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, 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). After this insertion, the spacer tube (V6025) and the special washer (V6026) shall be inserted as shown in fig 6D. Now, the lever assembly (V6027) shall be mounted on the shaft and fix the roller (V6028), duly greased, on the pin of the lever assembly. Now take the control washer (V6031), 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. 6D. The next step is to insert the spacer tube (V6032). 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. Then insert the stop (V6033) in the shaft key way and the cutout of the spacer. Push the shaft still further till it comes to the end of the spacer. The next assembly on the main shaft is the assembly of stop washer (V4300) (refer point-3) on the main shaft. 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, i.e. supporting crank assembly (V4900). The second nose of the stop washer shall be in the clockwise direction while looking

from LH side. Align the assembly with main shaft and insert the key (V6034) first on the inner cam disc and push the shaft ahead. Then, locate the other key on the outer cam disc and push the main shaft still ahead. Now as the main shaft comes out of the position, fix the bush (V6035). Let the shaft guide properly in the bush as shown in fig. 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. Push the main shaft still further and fix the retainer circlip (V6036) with a special circlip plier. Ensure the circlip is fixed properly in the groove of the main shaft as shown in the drg 6E. After this, 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 : Ensure that both the circlips are fixed properly in the groove of the shaft. Once this assembly is completed, check that all the items on the main shaft are mounted correctly and nothing is missed out. The next step is to roll the cam disc (V6024), in its proper position and lock it with the hex. socket head bolt (V6037) and nylock nut - item no. (V5117). This completes the assembly of main shaft. CAUTION A) As the roller (V6030) is a friction roller, grease shall not be applied on the surface of the roller. B) While inserting the main shaft from right hand side, ensure that the hole on the main shaft comes to a right position. For this purpose, the main shaft shall be inserted in such a way that longer distance from the edge of the shaft enters from right hand side.

26

12.7 Assembly of charging ratchet : The charging ratchet assembly which is made as per point no. 10, shall be mounted in the spring drum compartment of the operating housing. First of all, fix the bush (V6038) on both the side plates and mount the indicator lever assembly (V6039) in the bush, at the same time, the pin on the lever assembly shall be inserted in the hole of the control shaft (V6014) and lock it with a circlip (V4404). Now insert another bush (V6040) in the slot of the lever and insert the ratchet shaft in the bush. The ratchet shaft shall be mounted with a sprocket wheel, (V6041 ), with chain (V4208) on it and also the torsion spring (V6042). 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. Ensure, the position of the sprocket wheel by locking it with the special circlip (V6012). Once this assembly is completed, hold the non-return plate, (V6043) in a proper position and insert the duly greased pin (V6068) in the hole of charging shaft as shown in drg. 6C and fix the other end with Hex. bolt (V6044). After this, 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. 12.8 Lockout Lever Assembly Refer drg. (6B, pg.no. 48). Take lockout lever (V6045), insert pin (V6046). Now hold the torsion spring (V6047) within the lockout lever. Insert the special pin (V6048) from right hand side. Put the thick washer (V6049) after the middle partition and insert the lockout lever with the spring mounted in the pin. Now, 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. Now, insert the torsion spring (V6051) in such a way that one free end shall be lifting the pin (V4904) of the supporting crank assembly. Push the pin further to pass it through the other sheet and fix the circlip (V6052). Now, pull the free end of the torsion spring (V6051) and hook it to the LH side sheet with the special tool. 12.9 Auxiliary Shaft Assembly : (Drg. 6D& 6B, pg.no. 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. This assembly shall be started from right hand side. CAUTION: While inserting the auxiliary shaft (V6066), check the hole position of the shaft. Fix the bush (V6053) on the RH side plate of the operating housing and insert the auxiliary shaft through the bush. Then insert 2 nos. crank (V6054) in the opposite direction. Let the shaft pass through the next plate of the operating housing and then pass it through the ON-OFF indicator(V6061 ). Let the auxiliary shaft to come out from the next plate and add washer (V6016). Now, insert the lockout lever (V6055) duly hooked with the torsion spring (V6056). Now insert the washer (V6016) again and insert the crank (V6057). Now, push the auxiliary shaft, align the latch assembly as made earlier in point no. 4 in a proper position and insert the auxiliary shaft through a spacer (V6058). Now, insert the bush (V6002) on the plate of operating housing from inside duly greased and then push the auxiliary shaft through the bush. Push the shaft till it matches with the hole on crank (V6057) and fix the dowel

27

D. OPERATION & MAINTENANCE

pin (V6017) through the shaft. Also hammer the same dowel pin to fix the ON-OFF indicator (V6061). 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). CHECK Check that the whole assembly of the auxiliary shaft is correct as per drawing and no part is missing in it. Now connect the other end of the lever assembly (V6027) to the ON-OFF indicator with a pin (V6060) and a special clip (V6076). 12.10 Auxiliary Switch Assembly (Drg.7; pg.no. 52) Totally there are three auxiliary switches used in this circuit breaker. Out of the three auxiliary switches, one is used as a motor cut-off switch and other two are used for closing & tripping circuit and for annunciation. Take item no. (V4207) - auxiliary switch plate and on the top side of the plate, fix two spacers (V6070) with the help of M5x25 hexagonal socket head screw (V6071) and self locking nut (V6072). 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. Note-2 : The other two switches have a combination of 2NO+3NC and 3N0+2NC. Thus, the total number of contacts are 5NO+5NC. First of all, insert the cylindrical pin - item no. V6075) in the fork of the auxiliary switch and lock it with the circlip - item no. (V6077).

Now place the rubber washer - item no. (V6078) on the tapped holes of the auxiliary switch plate. Then place the auxiliary switches (V6079 & V6080) as identified earlier and tighten it with the hardware - item no. (V6081, V6082 & V6083) hex. Socket head screw M4x30, M4 spring washer and M4 plain washer respectively. This hardware shall be kept loose and shall be tightened after the setting of the auxiliary switch. CAUTION :While inserting the auxiliary switch plate, 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. CHECKING : Once the fixing is done, the auxiliary switches, which are mounted loosely, shall be fixed after setting of the stroke. Setting-1 : For motor cut-off switch : Charge the spring of the circuit breaker, as it charges the bracket lifts (V6088) up the auxiliary switch fork. You should measure the gap between moving fork and the fixed body of the auxiliary. The gap shall be set at 1.0 to 1.5 mm. After this, fasten the screws of the auxiliary switch. Setting-2 : Switches for annunciation scheme. This setting shall be done when the breaker is in closed condition. Close the breaker and set the gap between the forks of the auxiliary switches and the body to 1 to 2 mm approx. and fasten the screws completely. 12.10.A - Auxiliary Switch Assembly (Drg. 7A, pg.no.53) The new arrangement of Auxiliary Switch is recently introduced in these breakers

28

and the constructional details are shown in the drg: 7A. 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. 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. A simple Aluminium link (V6124) is connected to transfer the motion from shaft to the auxiliary switch shaft through an arm (V6123). 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. Assembly of the Auxiliary switch: Mount the auxiliary switch in the inverted position on the breaker frame and fix it with the M6 hardware. 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, push the pin in the link and fix the split pin. Ensure the bending of the split pin is proper. 12.11 Operating Coil Assembly (Drg 8; pg.no. 54): Normally the two coils are mounted on each circuit breaker to facilitate the Electrical closing and electrical tripping of the circuit breaker. 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. Refer drg.8 which shows general arrangement of mounting of the operating coils.

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. Once the appropriate coils (as per specified voltages in the order) are identified, they are fixed in the proper position and shall be located in the holes provided on the fixing plate. Now, hold the magnet support (V6086) such a way that it backs-up the coils. Insert the hexagonal socket head screw M4x35 (V6087) along with the plain & spring washers (V6083 & V6082). The fixing plate is provided with a tapped holes to mount these screws. CAUTION While fixing the closing coil (V6084) & tripping coil (V6085), check the following: a) Direction of rotation of coil. b) Roll pin on the plunger shaft is guided properly in the half shaft slits. CHECK Once both the coils are mounted on the breaker, check the movement of the push button levers is smooth and proper. After this, 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. drg. 5 12.11.A - Operating magnet assembly (Drg. 7A, pg.no. 53 ) The new operating coil assembly consists of two different operating coils mounted independently and operate the closing & tripping latches independently. The axial movement of plunger of the coil is converted to the rotary movement of the latching

29

D. OPERATION & MAINTENANCE

shafts, thus executing the closing and opening command. 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. Assembly of magnets: Ensure the rating of the closing magnet l opening magnet is as specified in the drawing. Mount the closing magnet / opening magnet mounting bracket in the inverted position on the breaker frame and fix it with the M6 hardware. 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. Ensure the bending of the split pin of the plunger is proper. 12.12 Coupling of drive and pole : Coupling of drive and poles is possible only when the operating mechanism and poles are assembled completely. Once the drive assembly is completed, discharge the tripping springs, which are precharged for assembly easiness. The discharging shall be done by removing the hexagonal socket head bolt from the rear side by unscrewing it. As you unscrew these three bolts, the opening springs get discharged and spring holder cap seats in a hole provided on the operating housing. For coupling the poles with the operating mechanism refer the assembly instruction as described in clause A of the pole assembly. 12.13 Motor Assembly : (Drg. 9; pg.no.55) There are different motors available for different voltage ratings. One should be very careful while ordering / mounting motor on the circuit breaker for the specified voltage as per the order specification. Once the appropriate motor is identified, fix the motor properly on the motor support plate of the operating

mechanism. The collar of motor should be properly located in the hole provided on the motor support plate. Now tighten the hexagonal socket head screw M6x16 (V6093) along with spring washer (V6094). The crank (V6095) along with cover plate and cylindrical pin. (V6097) are assembled with the help of dowel pin (V6098) as shown in drg.9. One end of cover plate is connected to the charging ratchet assly. with help of Grooved pin(V6099) and circlip (V6100). Then Fix the crank with motor shaft by using Hex socket head cap screw M4x35 (V6101 ) washer (V6083) and self locking nut (V4707). 12.13.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. Drg7A shows the arrangement of motor cut-off switch and its function. 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. 13. Instruction for discharging and charging: Before starting any maintenance work or replacement of components of operating mechanism. One shall ensure that the closing spring is in completely discharged condition. Without discharging the closing spring to its zero energy level it is very dangerous to work on mechanism. Follow the steps given below to discharge the spring. 1) The spring is normally charged for 4 turns. 2) Charge the spring manually and carry out ON-OFF operation. 3) Using the screw driver press the roller (V6030) against the compression spring (V6029) which is mounted on the lever assembly (V6014), the roller will drop down

30

and then carry out the ON -OFF operation. 4) Repeat the same three times. 5) Last one or two operations may not complete on its own as the energy level in the spring gets reduced. 6) Using a special tool rotate the shaft after each ON -OFF command to complete the operation. 7) Check the freeness of the spring drum, thus the spring is completely discharged. 14. Instruction for discharging and charging: Follow the procedure to charge the closing spring. 1) Normally 4 complete turns are stored in a closing spring and a last turn to operate the breaker. 2) Press the lever assembly(V6039) and hold it while charging. 3) Mark a line on the spring drum and start charging manually. 4) Complete 4 rotations of the spring drum and release the lever assembly. 5) For the next charging the roller (V6030) will drop in the pocket and spring charging indicator will show the position "SPRING CHARGED" . Now the circuit breaker is ready for operation. 15. Truck assembly (ref. Drg.no. 10; pg.no. 56) Place the frame assly.(V6102) on the working table and insert the breaker with pole inside the frame. Put the spacer (V6103) in between frame and breaker and tighten hex bolt M12 x45 (V6104). Mount 24 plug assly. (V6105) on truck frame and interlocking assly (V6106) as shown in drg 10. Complete the Emergency trip assly (V6107). Adjust the length of actuators. Confirm operation of emergency trip and interlocking rod assembly. 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 +/- 1 . Also measure the distance between upper and lower terminal and it shall be 367 +/- 2. Check the parallelity of the connection bars and

other dimensions as per assembly drg. 10. Once again check the breaker for completeness and also paint seal the key assemblies like interlocks, Auxiliary switches, Motor assembly, Push rod assembly. 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. socket head bolt with the washer.

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. The main features of this combination are:

. . .

The Rack-in mechanism is made as a part of the circuit breaker. Hence, the problems related to interchangeability are eliminated. The contact arrangement adapted for this breaker is Tulip contact system and hence better alignment, flexibility and contact engagement with cubicle contact can be achieved. The panel contacts are mounted in the bushing and the metallic shutters are provided hence, better compartmentalization is achieved.

Drg 1A shows General Arrangement and basic dimensions of the breaker type VD4 / VD4E suitable for Unisafe panel.

31

32

E. LIST OF DRAWINGS & COMPONENT PART Nos.

E. LIST OF DRAWING & COMPONENT PART NUMBERS List of Drawings

Pg.No. 34

Component Part Numbers

35

33

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

NAME OF ITEM
POLE HOUSING VACUUM BOTTLE ASSY. GROUP VG2S OPERATING STUD CONN. BAR (TOP) CONN.BAR(BOTTOM) BUSH LABEL STICKER FLEXIBLE CONDUCTOR SUPPORTING PLATE SUPPORTING PLATE CONTACT TERMINAL SPECIAL NUT CONTACT NUT SPRING WAVE WASHER SAFETY WASHER HEX. SOCKET HD. CAP SCREW HEX. SOCKET HD. CAP SCREW CONICAL SP. WASHER HEX. NUT HEX. SOCKET HD. CAP SCREW POLE HOUSING VACUUM BOTTLE ASSY. GROUP VC2 OPERATING STUD CONNECTION PART CHAMBER SUPPORT CONTACT FLANGE CONTACT PISTON ROLLER CONTACT COMP. SAFETY WASHER CONICAL SP. WASHER SPRING WASHER SPECIAL WASHER SPRING WASHER PRESSURE PLATE HEX. SOCKET HD. CAP SCREW HEX. SC. HD. CAP SCREW HEX. SC. HD. CAP SCREW

REFERENCE No.
V1001 V1002

DRG. No.
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

E. LIST OF DRAWINGS & COMPONENT PART Nos.

NAME OF ITEM
HEX. SC. HD. CAP SCREW CONICAL SP. WASHER HEX. NUT GREASE SPRING HOLDER SPRING GUIDE COMPRESSION SPRING COMPRESSION SPRING OPERATING DISC SEPARATING PLATE HEX. SOCKET HD. CAP SCREW SPRING WASHER SPRING DRUM SPRING SPROCKET WHEEL DISC ROLLER CHAIN CURVE WASHER CURVE WASHER DAMPER CYLINDRICAL PIN STOP WASHER LATCH ASSY. LATCH LINK CIRCLES FISH PLATE CYLINDRICAL PIN D-SHAFT CRANK SPRING DOWEL PIN CAM DISC SPRING PIN SPRING PIN HEX. SOCKET HD. CAP SCREW CRANK FISHPLATE-OFF FISHPLATE-ON PLAIN WASHER SPRING WASHER NYLOCK HEX. NUT HALFSHAFT

REFERENCE No.
V2018 V2019 V2020 ISOFLEX TOPAS N852. 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. No.
4B 4B 4B 4B 6A 6A,6E 6E 6E 6A,6C 6C 6A,6C 6C 6C 6A 6A,6C,7 6C 6A,6B 6A,6B 6B 6B 6A,6B 6A,6B 6B 6A,6B 6A 6A,6B 6A 6B 6A,6B 6B 6A,6E 6E 6E 6A,6B 6A,6B 6A 6A,6B 6A,6B 6A,6B 6A,6B,6D,9 6A,6B

NAME OF ITEM
SPRING PIN TORSION SPRING TORSION SPRING COUNTER ANGLE SLOTTED CHEESE HD. SCREW SPRING WASHER TENSION SPRING BLOCKING CRANK BLOCKING CRANK BLOCKING ROLLER CYLINDRICAL PIN SPACER GROOVED PIN SHAFT HEX. SOCKET HEAD SCREW HEX. SOCKET HEAD SCREW SPACER SLOTTED CH. HEAD SCREW TUBULAR RIVET CONICAL PLATE SUPPORT PLATE SLOTTED CH. HEAD SCREW TUBULAR RIVET CYLINDRICAL PIN SPROCKET LATCH TORSION SPRING CHARGING LEVER NYLOCK HEX. NUT NYLOCK HEX. NUT SPRING WASHER PLAIN WASHER LEVER LEVER BOLT ROLLER BEARING RETAINING CIRCLIP SPECIAL PIN HOUSING BUSH AUXILIARY SWITCH PLATE TORSION SPRING

REFERENCE No.
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. No.
6A,6B 6A 6A 6A,6B 6A,6B 6A,6B 6A,6B,6C 6A,6B 6A 6A,6B 6A,6B,6C 6B 6A,6B 6B,6C 6C 6A,6C 6C 6C 6A,6C 6A,6C 6A,6C 6A,6C 6C 6C 6A,6C 6A,6C 6A,6C 6C 6A,6C 6C 6A,6C 6A,6C 6A 6A,6B,6E 6A,6B,6E 6A 6E 6A,6E 6B,6E 6A 6A,6B,6D 7 6A,6B

E. LIST OF DRAWINGS & COMPONENT PART Nos.

NAME OF ITEM
BUSH BRACKET HEX. SOCKET HEADED CAP SCREW HEX.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. BOLT LOCKOUTLEVER PIN SPRING 38

REFERENCE No.
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. No.
6B 6B 6B 6A,6B,6C 6C 6A,6E 6A,6E 6E 6D 6A,6C,6D 6D 6A,6B 6B,6D 6A,6B 6A,6B 6A,6B 6A,6B 6A,6C 6A,6E 6A,6C 6A,6D,6E 6D 6D 6D 6C 6C 6D 6A,6B 6B 6A,6B 6A,6B 6E 6A,6C 6C 6A,6C 6C 6C 6A,6C 6A,6C 6A,6B,6C 6B 6B 6A,6B

NAME OF ITEM
SPECIAL PIN PLAIN WASHER PIN TORSION SPRING RETAINING CIRCLIP BUSH CRANK LOCKOUTLEVER ASSEMBLY TORSION SPRING CRANK SPACER HEX. SO.HEADED SCREW CYLINDRICAL PIN ON- OFF INDICATOR SOCKET HD.CAP SCREW PIN SPACER HEX.SOCKET HEADED SCREW SELF LOCKING NUT EARTHING STRIP SPECIAL PIN CYLINDRICAL PIN RETAINING CIRCLIP RETAINING CIRCLIP RUBBER WASHER AUXILIARY SWITCH AUXILIARY SWITCH HEX.SOCKET HEADED SCREW SPRING WASHER PLAIN WASHER CLOSING COIL TRIPPING COIL MAGNET SUPPORT HEX.SOCKET HEADED SCREW BRACKET SPECIAL CIRCLIP PIN HEX. SOCKET HD SCREW SPRING WASHER CRANK COVER PLATE CYLINDRICAL PIN DOWEL PIN 39

REFERENCE No.
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. No.
6A,6B 6B 6B 6A,6B 6A,6B,6C 6D 6D 6A 6B,6D 6A,6B 6B 6D 6D 6A,6D 6A,6D 6A,6D 7 7 7 7 7 7 6D,7 7 7 7 7 7 7,8 7,8,9 8 8 8 8 7 7 7 9 9 9 9 9 9

E. LIST OF DRAWINGS & COMPONENT PART Nos.

NAME OF ITEM
GROOVED PIN RETAINING CIRCLIP HEX.SOCKET HEAD SCREW FRAME SPACER HEX.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.
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. No.
9 9 9 9 9 10 10 10 10 10 10 10 10 10 10 10 10 10 6A 6A,6C 6B 6B 6C 7A 7A 7A 7A 7A 7A 7A 7A 7A 7A

40

VD4E Breaker

41

VD4 Breaker

Drg. No. 1

VD4E Breaker for UNISAFE cubicle

42

VD4 Breaker for UNISAFE cubicle

Drg. No. 1A

43 Cross sectional view of VD4E CB

Cross sectional view of VD4 CB

1 1.1 12 13 14

Breaker mechanism housing Front cover - removable Insulating material pole tube Upper breaker terminal Lower breaker terminal

15 Vacuum interrupter 16.2 Roller contact / Flexible conductor 17 Contact pressure spring 18 Insulated coupling rod 19 Operating spring 20 Shift lever pair

Drg. No. 2

15.1 15.2 15.3 15.4 15.5 15.6 15.7

Insulator Fixed contact Movable contact Metal bellows Screen Guide cylinder Lid

Cross section of vacuum interrupter

Drg. No.3
44

45

Drg. No. 4A Pole assembly

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

1. 2. 3. 4. 5. Typical circuit diagram 6. 7. 8.

Drg. No.5
46

Spring charging motor Closing coil Tripping coil (S3, S4) CB Auxiliary switch contacts Microswitch operates in T or S positionm Plug & socket (S1) Motor cut-off switch Breaker

47

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

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

49

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

50

Operating Mechanism Assembly for VD4E / VD4 breaker

Drg. No. 6D

51

Operating Mechanism Assembly for VD4E / VD4 breaker

Drg. No. 6E

Auxiliary Switch assembly Drg. No. 7

52

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

53

54 Opening coil assembly Drg. No. 8

Motor mounting assembly Drg. No. 9

55

56 Truck assembly Drg. No.10

No liability is accepted for the accuracy of the information contained in the publication. We reserve the right to make amendments in the course of technical progress.

ABB Limited Plot No. 79, Street No. 17 MIDC Estate, Satpur, Nashik - 422 007 Tel: +91 235 2351095 to 8 +91 253 2351261 to 4 Fax: +91 253 2350644 / 2351249

1VDU09001-YN

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