s Doc. No.

AI /400/ PG / 020
Revision 1

s
ASSEMBLY INSTRUCTIONS
Pantograph Disconnector

Rated voltage 420 / 245 kV

Date (rev-1) 20.08.2014 20.08.2014 20.08.2014

Date (rev-0) 10.09.2013 08.01.2014 09.01.2014

Name Syed Jaweed Ikram Ch.SubbaReddy P.RamaMurthy

Signature SJI CSR PRM

Prepared By Reviewed By Approved By

Address: M/s Siemens Limited,

Plot No.89&90,
IDA Gandhinagar,
Balanagar Post,
Hyderabad-500037.
Mail: energysupport.in@siemens.com
Tel.: 0091-40-33507000/7001
Fax: 0091-40-23079992
Toll Free Ph No: 1 800 2667 480

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CONTENTS PAGE

1 General 3
1.1 Introduction 3
1.2 Safety Instructions 3
1.3 Technical Data 3
2 Description 4
2.1 General 4
2.2 Design of disconnector 5
3 Delivery and Storage 5
3.1 Scope of Delivery 5
3.2 Material 5
4 Packing and Storage 6
5 Erection and Assembly instructions 6
5.1 Transport 7
5.2 Assembly Preparation 9
6 Assembly 9
6.1 Checking 9
6.2 Assembly of disconnector 11
6.3 Adjustment of disconnector 23
6.4 Assembly of earth switch (If Applicable) 24
6.5 Adjustment of Earth switch 34
6.6 Assembly of Mechanical interlock 34
6.7 Adjustment of Mechanical interlock 36
7 Motor Operating Mechanism 39
7.1 Adjustment of Motor Operating Mechanism 39
8 Inspection and commissioning 40
9 Check sheet for Erection and Commissioning 40

IMPORTANT NOTES
 Read these operating instructions carefully before starting erection work.
Erection work must only be carried out by personnel familiar with the
operating instructions.
 Images, drawings & line diagrams shown in this manual are for your
reference , original design may vary as per GA drawings
 Failure to comply with warnings and other alerts can cause serious bodily
injury and extensive damage to property and the environment can even
cause death.

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1. General

1.1 Introduction

These operating instructions apply to the type and design of the disconnector listed on the
title page. They are intended to make the operating personnel familiar with the
construction and operation of the disconnector. They are also instructions for operation
and provide information about installation and maintenance.
We recommend that operating personnel become acquainted with the operating
instructions and other documentation that is supplied so that they are well informed
concerning the disconnector and any other operational features involved.

1.2 Safety Instructions

During operation, certain parts of the disconnector are live and hazardous as a high
voltage is present. Personnel must be thoroughly familiar with all warnings and procedures
for installation, operation, maintenance repair contained in these operating instructions.
The user of the disconnector must ensure that the maintenance and relevant operating
directives to the appropriate activity, local safety regulations and information on what to do
in the event of an accident are available or displayed, e.g. on a notice board so that they
can be referred to at any time.

1.3 Technical Data

The disconnector is a three disconnector for outdoor installation. It may be used for the
technical data specified on the name plate and in this operating instruction. Disconnectors
are used to produce a dielectrically strong and visible isolating distance in an outdoor
switchgear; for this purpose, they may be operated only when free of current and voltage
(off-Load).
The add-on earthing switch is a three pole auxiliary device to the disconnector for outdoor
installation. It may only be used for the technical data specified on the rating plate of the
disconnector and in this operating manual. Earthing switches establish a conductive
connection from line sections produced by opening the disconnector to the system ground,
for this they may only be operated in no-current and no-load status.

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Rated Rated
Technical Particulars of Disconnector Unit Values Values
Rated voltage (kV) [kV] 420 245
Rated frequency [Hz] 50 50
2000- 2000-
Rated current [A] 4000 3150
Rated short circuit withstand value [kA] 40/50 40
Rated short circuit duration S 3/1 3
Rated PF withstand voltage across isolating distance [kVr] 610 589
Rated PF withstand voltage between live terminals and ground [kVr] 520 511
Lightning Impulse withstand across Isolating distance [kVp] 1425 1166
Lightning Impulse withstand between live terminals and ground [kVp] 1665 1332
Switching Impulse withstand across Isolating distance [kVp] 1245 -
Switching Impulse withstand across between live terminals and ground [kVp] 1050 -

2. Description

2.1 General
The Pantograph disconnector is a disconnector which breaks at the top to provide the
required insulating distance. The corrosion-protected outdoor disconnector consists of
three individual poles electrically ganged through master and follower motor drive.
Disconnector operation is either motorized or by hand (Manual). The switching position
of the disconnector in motor or manual drive mode is indicated by an auxiliary switch
integrated in the drive housing.

The disconnectors are designed to withstand the horizontal and vertical service
loads specified in IEC 62271-102, table 3.
 The Disconnector comply with IEC 62271-102 latest edition.
 Technical changes are possible as and when design modifications
are made.
 No claims can be made on the basis of data, drawings or descriptions
even though every care has been taken in providing inputs.

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2.2 Design of the Disconnector

Each of the three disconnector pole has a separate operating mechanism.

The control is located additionally in the operating mechanism box.
The disconnector (page 10) consists of the sub-structures, the operating box, the support
insulators, operating insulator and the main circuit, the operating insulator transmits the
operating mechanism movement from the substructure to the contacts of the main circuit.
The main contact consists of Moving contact and Fixed contact which are placed opposite
to each other. The Moving and Fixed contacts on both the sides carry a high voltage
terminal.

The support insulators and Operating insulator are made up of a multi shield insulator with
metal flanges.
The operating mechanism movement of the disconnector is initially transmitted by the
operating box via the MS down pipe on which the Operating insulator is mounted. The
Operating insulator transmits the rotary movement to the Moving contact.

The energy required for operating the disconnector is provided by the electro-motor in the
motor operating box.

3. Delivery and storage

3.1 Scope Of Delivery

The delivery includes:

 Disconnector subassemblies (current path, shielding, substructures (If Applicable),
insulators (If Applicable), operating mechanism, metallic’s)
 Earthing switch subassemblies ( mating contacts, Metallic’s, operating mechanism
and interlock assembly)
 Accessories pack
 Transport information sheet, dispatch note and check list

All installation parts and materials required for setting up and operating the disconnector
belongs in the scope of delivery are contained in the accessories pack.

3.2 Material

The Pantograph disconnector poles are delivered in knock down condition.

The material has to be checked as per the packing list.

Possible damages of material occurred during transportation must be recorded on back

side of LR & communicate to the respective Siemens representative.

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4. Packaging and storage

 The equipment is packed on transport planks, in wooden crates or cases. The drives are
wrapped with plastic film and are placed on pallets.
 If the equipment is stored outdoors, it must be put on a level higher than ground to
avoid entry of water and dust in essential components and assemblies.

C A U T I O N!
Motor and manual drives must be stored indoor for the time until installation. The heating
system must be started immediately after completion of installation as described in the drive
manual.

5. Erection and Assembly Instructions:

WARNING!
Erection work must only be carried out by personnel familiar with these operating
instructions. Risks to erection personnel can be caused by
 Electric voltage
 Falling and tilting of parts or person or other moving parts. 


C A U T I O N!
 Ensure that safety procedures are followed during installation, inspection and
maintenance based on the risk identified for these activities.
 Use Personal protective Equipments / Tool like safety shoes, safety helmets, safety
harness (for height works), insulation gloves and safety goggles.

C A U T I O N!
Electric voltage – when approaching live components, there is risk of electric shock and
burning due to electric arc.

Bolted Connections

Apply specified grease to all bolted connections before installation refer table-1:

Make sure that all friction surfaces (e. g.: threads, contact surfaces of nuts and washers)
are coated with grease of the specified grade.
Basically, tighten all bolts with a torque wrench. For tightening torque, refer table-2:

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WARNING!
If nuts are tightened without torque control, there is risk of damage or slackening of the bolted
connection.

Treatment of Contacts

Contacts fingers are provided with a special silver coating in the factory.

The contacts need to be lubricated with a thin layer of grease as specified in table 1:
Application of excess grease on the contact system does not have a negative impact on
sliding characteristics. However dirt and sand particles may do stick to lubricated surfaces
thereby causing increased risk of contact surface wear and tear which calls for further
maintenance.

TABLE:1

TYPES OF GREASE TO BE USED APPLICATION

Rivolta SKD 3602 (or) Centoplex 24 DL (or) For parts on contact system.
Graphite oil
For threads of hot dip galvanized
Rivolta SKD 3602 (or) parts.
Molycote longterm 2 plus
For all lubrication points on Operating
Rivolta SKD 3602 (or) Isoflex Topas L32 mechanism, gears.

5.1 Transport

All subassemblies put together in a packaging unit should be transported to the installation
site in the package if possible and unpacked directly before assembly.

To unload and move the transport units, use fork lift or crane. Inspect the contents of each unit
for any missing items. Using of steel ropes is prohibited since there is possibility of damaging
corrosion protection layers and porcelain elements.

When unloading and transporting the base structure make sure that lifting slings are fixed at
right place.

The tightening torque values in the table:2 apply to all bolted connections unless otherwise
specified in respective area. All bolted connections made in the factory use the specified
lubricating grease.

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TABLE:2

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5.2 Assembly Preparation

The following documents must be available to perform the assembly according to this
instruction

 Assembly part List for Disconnector & Earth switch.

 GA drawings of disconnector with earth.
 Schematic and wiring diagram of disconnector drive & Earth switch.
 Check sheet for Erecting and commissioning (Table-3).
 Instruction for Tightening torques for all hardware.

Check the foundation plan with respect to the GA drawing

The sub- structure should meet the following requirements:

 Flatness of support plates for pole frame of disconnector  1 mm

 Height of support plates  3mm
 Drilling plan dimensions for the attachment of pole frame according layout drawing  1 mm
 Drilling plan dimensions for the attachment of drives according GA drawings  1mm
 The support plates must be rectangular  15’ to the fixing support of drives
Pay attention to tightening torques for screws according to instruction as per the instructions
enclosed.

6. Assembly
6.1 Checking

Check the Assembly of the Base frame for the following:

 The base frame mounting dimensions with respect to the layout drawing supplied.
 The position of the base frame with ref to the GA drawing supplied with respect to
the drive box positions and earth switch position.
 Check the structure top surface to sprit level/ water lever.

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GENERAL ASSEMBLY OF PANTOGRAPH ISOLATOR

CONNECTORS ASSEMBLY

FIXED CONTACT
ASSEMBLY
INTERLOCK
ASSEMBLY

E.S BASE
ASSEMBLY
MOVING CONTACT ASSEMBLY

SPRING
ASSEMBLY

E.S PUSH PIPE

ASSEMBLY
DETAIL – ‘A’

TERMINAL PAD FOR LOWER BUS BAR

E.S FIXED CONTACT CORONA RING

ASSEMBLY

OPERATING ROD INSULATOR SUPPORT INSULATOR

‘A’
ELEVATOR PLATE ASSEMBLY

E.S TOM ASSEMBLY

E.S TOGGLE ASSEMBLY
SUPPORT STRUCTURE
E.S MOVING CONTACT
ASSEMBLY
M.S OPERATING PIPE
ASSEMBLY

E.S OPERATING PIPE ASSEMBLY

M.S OPERATING
MECHANISM BOX
E.S OPERATING
MECHENISM BOX

Fig. 01 General Arrangement

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6.2 Assembly of disconnector

Determine the installation location of the disconnector pole using the pole marking and
Transport the substructures to the installation location. Screw the substructures on the pillars,
so they are hand-tight to start with, Check that the sub-structure are lying flat on the pillars
using a spirit level and screw them until secure.

Deviation in flatness of sub structure must be leveled by placing spacers (e.g. zinc sheet)
between Base and sub structure.

Now place the Elevator plate assembly on to the horizontally aligned sub structure and screw
them on using Elevator studs so they are hand-tight to start with.

Elevator plate assembly

Guide Plate

Toggle fixing holes

Earth base fixing Holes Elevator Studs

Fig. 02 Elevator Plate Assembly

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Now place the Operating mechanism box next to the assembly console and secure it. To do
this, first attach the operating mechanism box using screws, washers and nuts without
tightening it. Now align the operating mechanism box using a spirit level. Also align the
center axis of operating mechanism box with the center axis of Guide plate as shown in the
figure 04 .Now tighten the fixing screws.

Guide Plate

Operating
mechanism box

Fig. 03 Operating mechanism box assembly

Adjust the MS down pipe length and mount it between the operating mechanism box and
the Guide plate. To do this, proceed as follows.

Check the length of the enclosed MS down pipe. Measure the ‘A’ between the Elevator
Plate and the Operating mechanism box top flange. If necessary, shorten the pipe on the
end opposite of the flange to the proper length ‘A’ by cutting it. After cutting it to the required
size, insert the down pipe in to the Guide plate and mount the E/S Interlocking cam (If
applicable) on the pipe.
Now concentrically attach the operating pipe to the flange and weld it and protect the welded
surface against corrosion with a coating of zinc and paint.

Note: Adjustment of Operating mechanism Box should be done such that Center Line of the
Operating Box flange and MS down pipe should not be adjusted with reference to Guide
Plate.

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Elevator Plate
E/S Interlocking
Cam

Center axis of
Box and Guide
plate

Drive box top

flange

MS Down Pipe Operating pipe to the flange weld

Fig. 04 MS Down pipe

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Using the hand crank in the Operated mechanism box manually set the drive into the OFF
position.

Now mount the down pipe on the Operating mechanism box by ensure that any of two holes
of the drive-coupling flange are coupled with MS down pipe flange and secure using screws,
washers and nut provided on Operating mechanism box flange.

MS Down Pipe

MS down pipe flange

Fig. 05 MS Down pipe Assembly

Next assemble the Support insulator stack (2 insulators) on Elevator plate, for doing this,
suspend the insulators stack (2 insulators) together vertically from the crane on a sling or
tackle, set them down on the Elevator plate and tighten them until secure.

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Support Insulator
stack (2 insulators)

Elevator Plate

Fig. 06 Support Insulators Mounting

Align the insulator column top most flange horizontally. To do this, place a spirit level on the
insulator columns topmost flange in 2 directions offset at 90°, check the horizontal position
and align it using studs on elevator plate.

Keeping the drive in OFF position, assemble the Operating insulator stack (2 insulators) on
MS down Pipe Flange, for doing this, suspend the insulators stack (2 insulators) together
vertically from the crane on a sling or tackle, set them down on the MS down Pipe Flange and
tighten them until secure.

Now secure the operating insulators vertical position using the support insulator. To do this,
clamp the wooden block between insulator column and rotary insulator using a rope/
tensioning belt. Secure the wooden block from slipping out by looping the ends of the rope
/tensioning belt around it. Only when you have done this the operating insulator can be
released from the crane.

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Wooden Block

Support Operating
insulator insulator

Fig. 07 Securing the operating insulator

MS down pipe
flange

Fig. 08 Operating Insulators Mounting

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Installing the current path:

Warning!
Do not take off / Remove the Binding wire tide to the moving contact until the moving
contact is installed.

First Remove the Cover form the moving contact by loosening the M8 screws.

Cover

Fig. 09 Cover

Pay attention to position of current carrying parts according to the GA drawing.

To start with, place the corona ring on to the Top insulator and mount the moving contact
on the corona ring and secure it to the holes provided on insulator. To do this, use screws
and washers.

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Moving Contact

Corona ring

Top Support Insulator

Fig. 10 Moving contact mounting

Once the moving contact is secured on support insulator replace the cover. And mount the
top Operating insulator under the Flange and secure it to the holes provided on Flange. To
do this, use screws and washers.

Cover

Flange

Top Operating Insulator

Fig. 11 Moving contacts Setup

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Keeping the drive in OFF position and moving contact in fully open position, assemble the
Moving Contacts setup on the Middle insulators, for doing this, suspend the Moving Contacts
setup from the crane on a sling or tackle, set them down on the Middle Insulators and tighten
them until secure.

Now take off / remove the Binding wire tide to the moving contact.

Note:
If the operating insulator holes do not match, manual move the drive towards open / close
position for the insulator hole to match.

Top Insulators

Middle Insulators

Fig. 12 Moving contacts mounting

Attach the contact corona shields to the contact (refer GA, Main Contact assembly
drawings for the positions of corona shields) through Corona fixing brackets and secure it
using screws and washers and nuts.

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Corona fixing bracket

Corona shield

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Corona fixing bracket

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Fig. 13 Corona shield assembly

Fixed Contact Assembly:

Fix the Dropper Pipes and FC Corona Rings to the Fixed contact using screws , washer
and nuts and Fix the fixed contact assembly through connectors to the top bus.

Connector

Dropper Pipe

FC Corona ring

Fixed Contact

FOR FLEXIBLE CONNECTOR FOR RIGID BUS BAR

Fig. 14 Fixed Contact assembly

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6.3 Adjustment of Disconnector

Using the hand crank in the motor-operated box manually move the disconnector pole to
close Position, until the moving contact catches the fixed contact.

 At this closed position ensure that Drive fork is in dead locked position.

For doing this follow the below given steps:

- Move the Main switch towards close position until the Moving contact catches the
Fixed contact.
- Adjust the length of Tension rod to achieve dead lock position of Drive fork.
- Adjust the stopper bolt provided on the Housing Casting and Drive fork in both open
and close positions.
- Now make OPEN and CLOSE cycles and check that the Drive fork crosses its dead
lock position again.
- If necessary, repeat the setting.

Ensure proper course of motion of contacts and apply contact grease for
lubrication.

Dead locked position

Housing casting

Stopper bolt
(For Close
position)

Drive Fork

Tension Rod

Fig. 15 Drive Fork in Close Position.

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Housing casting

Stopper bolt
(For Open position)

Fig. 16 Drive Fork in Open Position

6.4.1.1 Assembly of Earth switch (Not Applicable for Disconnector Without

Earthing Switch)

And if the disconnector is without earthing switch skip to Heading 7) Motor Operating
Mechanism (Page No: 39)

Refer GA drawings for the side in which the ESFC is to be fixed.

Clean the surfaces (upon which the ESFC is to be fixed) to remove any scales formed on
the surfaces and apply contact grease to the contact.

Now mount the Earth switch fixed contact to Moving contact and secure it, to do this, use 4
screws, 4 nuts and 8 washers.

Moving Contact

Earth switch
fixed contact
(ESFC)

Fig. 17 Earth switch fixed contact

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Attach the ESFC corona shields to the ESFC and secure it using 2 screws and 4 washers
provided with the ESFC Assembly.

ESFC Corona
Shield-1

ESFC Corona
Shield-2

Fig. 18 Earth Switch Fixed contacts corona ring mounting

Fix the Earth base assembly on to the Elevator plate assembly Support plate using screws,
washers and nuts. Align it and Tighten all bolts to the specified tightening torque.

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Support plate

Earth Base

Fig. 19 Earth base assembly mounting

Place spring fixing bracket on to the other side of the support plate and attach the Toggle
to the support plate using screws, washers and nuts. Align it and Tighten all bolts to the
specified tightening torque.

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Toggle

Support
Plate
Spring
Fixing
Bracket

Spring Fixing Bracket

Earth Base

Fig. 20 Toggle lever assembly mounting

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Fix the E/S TOM to the Support plate using screws, washers and nuts. Align it using sprit level
and Tighten all bolts to the specified tightening torque.

Support
Plate

ES TOM

Fig. 21 ES TOM mounting

Connect the Push pipe between Toggle and E/S TOM lever for doing this use the SS studs on
Toggle and TOM lever.

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E/S Push pipe

Fig. 22 Earth push pipe assembly

Place the ES operating box next to the assembly console and secure it. To do this, first attach
the ES operating box using screws, washers and nut (from the accessory pack) without
tightening it. Now align the operating mechanism. To do this, use a spirit level parallel to the
longitudinal axis of the disconnector pole to adjust it horizontal position. Now tighten the fixing
screws.

Now adjust the ES down pipe length and mount it between the ES operating box and the ES
TOM. To do this, proceed as follows.

Check the length of the enclosed pipe. To do this, measure the ‘A’ between the ES TOM shaft
and the drive box top flange. If necessary, shorten the pipe on the end opposite the flange to
the proper length ‘A’ by cutting it. After cutting it to the required size, concentrically attach the
operating pipe to the flange and weld it and protect the welded surface against corrosion with
a coating of zinc and paint.

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Operating pipe to the flange weld

Fig. 23 Operating pipe Length

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Using the hand crank in the motor-operated mechanism box manually set the drive into the
OFF position.

Now mount the down pipe between the ES operating box and the ES TOM by ensuring that
any of two holes of the drive-coupling flange are coupled with down pipe flange and secure
using screws, washers and nut provided on Operating mechanism box.
Before installing the ES Moving Contact ensure that Motor drive box is in off position. And the
TOM pin lever is kept in open position.

Slide and mount the ES moving Contact on the Earth base with the help of SS clamps
provided on the earth base.
keeping the ES moving Contact in open position, while the ES moving Contact rests on the
damping pad provided on the toggle, connect the ES moving Contact with the toggle clamp
for doing this use the SS stud on the toggle clamp.

Toggle Clamp

ES moving
contact

SS ‘U” Clamp

Fig. 24 Earth moving contact mounting

Keeping the Earth Switch towards CLOSED position connect the counter balance springs
between the Spring fixing Bracket and Earth Base using screws, washers and nuts (from the
accessory pack). Align it and tighten all bolts.

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ES spring fixing
Counter balance spring bracket

Fig. 25 Counter balance springs assembly

Dead center position

Fig. 26 Toggle lever dead center

Take the free ends of copper braids flexible on ES moving Contact and connect them to the
earthing holes provided on the base frame. For doing this use Screws, washers and nuts
(from the accessory pack). Align it and Tighten all bolts to the specified tightening torque.

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6.5 Adjustment of Earth switch:

Apply specified grease to the contacts before the operation, refer Table 1:

When the earthing switch is fully CLOSED following things should be ensured:

 The contact tip must move centrally in to contact fingers at the right height. Across the
length of contact tip, uniform contact of individual pair of contacts fingers should be
ensured.

For doing this follow the below given steps:

- Manually move the earthing switch towards close position using the hand crank in the
motor operating mechanism until it is positioned just before where the contact tip enters
the contact fingers.
- Loosen the screws on earth base and adjust the height of entry of Moving contact.
- With the help of screws on earth base align the contact arm and check that the contact tip
enters the contact fingers centrally. Now tighten the screw.

Make OPEN and CLOSE cycles manually and check that the entry is central again. If
necessary, repeat the setting.

 When the earthing switch is fully CLOSED it should be ensured that the toggle crosses it
dead center which ensures that the Earth switch is locked in CLOSE position.

For doing this follow the below given steps:

- Manually switch the earthing switch towards CLOSED position until the contact tip
enters the fixed contact and touches the stopper.
- Loosen the screws on toggle clamp until it starts to slide on the moving contact .
- Now adjust the clamp by sliding it vertically on the contact arm till the toggle crosses it
dead center.
- Now tighten the screw on clams to the specified torque.
- Now make OPEN and CLOSE cycles and check that the toggle crosses its dead
center again.
- If necessary, repeat the setting.

6.6 Assembly of Mechanical interlock.

Manually move the earth switch to open position and mount the interlock cam on Earth base
shaft as shown in the figure below and hand tight the grub screw on it using Allen key.

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ES Interlock cam

Fig. 27 ES Interlock cam

Mount the Interlock guide on to the Elevator Plate using screws, washers and nuts of Guide
plate as shown in the figure below.

Interlock guide

Guide Plate

Fig. 28 Interlock Guide

Now place the Interlocking rod as shown in the figure below.

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Interlocking rod

Fig. 29 Interlock link pipe assembly

6.7 Adjustment of Mechanical Interlock:

When the Main switch is in fully closed position it should be ensured that the closing operation
of earthing switch is obstructed by mechanical interlock.

Main switch
Earth switch
interlock cam
Interlock cam

Fig. 30 Interlock Position for Disconnector Closed & Earth switch open condition

Likewise when the Earthing switch is in closed position it should be ensured that the closing
operation of main switch should be obstructed by mechanical interlock.

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Fig. 31 Interlock Position for Earth switch Closed & Disconnector open condition

For doing this follow the below given steps:

- Keeping the earth switch in fully open position and Move the main switch towards open
position.
- Loosen the grub screw provided on the collar of interlock cam.
- Rotate and set the interlock cam’s such that the cut on the interlock cam is in-line with
the hole on Guide/ Support Plate.

Main switch
interlock cam Earth switch
Interlock cam

Fig. 32 Interlock cam adjustment

- Keeping the interlock cam at this position tighten the grub screw.
- Set the length interlock rod such that it enters either of the two cut on the interlock
cam.

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Main switch
interlock cam
Earth switch
Interlock cam

Fig. 33 Interlock cam adjustment

- Now make OPEN and CLOSE cycles to ensure the functioning of Mechanical
interlock.
- If necessary, repeat the setting.

Drill Ø10 hole through cam and shaft at the site and insert dowel pin/Grub screw after
setting the cam or weld the cams after adjustments and apply zinc spray on welded
portion

Interlock cam to Interlock cam to

be adjusted and be adjusted and
then insert grub then insert grub
screw/ weld the screw/ weld the
area and apply area and apply
cold zinc spray. cold zinc spray.
Fig. 34 Interlock Cam Locking.

© Siemens - 37 -
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Revision 1

7. Motor Operating Mechanism

The motor with the gear unit is located in operating mechanism cubicle
The movement of the motor-operated mechanism is transferred to the disconnector and the
auxiliary switch in the operating mechanism cabinet. The Down Pipe is attached to the
operating mechanism and transmits the rotary movement from the operating mechanism to
operating insulator.

The operating drive mechanism contains all the components necessary for operating,
monitoring and controlling the disconnector.
All the electrical connections should be as per the schematic diagram.

The anti-condensation heater prevent condensation forming on the components in the

operating mechanism cubicle. Since condensation can generally take place at any ambient
temperature, the anti-condensation heaters (heating resistors) must be permanently in
operation.

Note: The operator is responsible for the fuse protection for the auxiliary circuits, unless
otherwise agreed with the manufacturer.

Manual operation of motor-operated operating box for disconnectors and earthing switches is
possible during commissioning and maintenance as well as in emergency operation, when the
control voltage fails or a defect occurs.
Before each manual operation, check the defined interlocking conditions with the switching
position.

7.1 Adjustment of Motor Operating Mechanism

Adjustment for Close Position

- With the help of operating handle manually move the Disconnector / Earthing
switch toward fully closed position.
- Using a Allen key, loosen the grub screw on the Red color limit switch actuator.
- Adjust the limit switch actuator such that it just actuates the close limit switch
(LS1) and tighten the grub screw until secure.

Adjustment for Open Position

- With the help of operating handle manually move the Disconnector / Earthing
switch toward fully Open position.
- Using a Allen key, loosen the grub screw on the Green color limit switch
actuator.
- Adjust the limit switch actuator such that it just actuates the Open limit switch
(LS2) and tighten the grub screw until secure.

Now make the electrical connections as per the schematic and wiring diagram of
disconnector and earthing switch.

© Siemens - 38 -
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Revision 1

8. Inspection and Commissioning:

After fixing the conductors, the following checks must be performed:

 Adjustment of disconnector and earthing switch and ensure all the conditions are met as
described above.
 All bearing should be greased
 All contacts should be lubricated
Perform few operating cycles.

9. Check Sheet for Erecting and Commissioning

The check list is to be used during Erecting and Commissioning.

It is meant to ensure that all the instructions given in the manual have been followed.

© Siemens - 39 -
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TABLE:3

SIEMENS
HYDERABAD WORKS
Check Sheet for Errection and Commissioning
Stande
Observe
S.No Check Points Done rd Remark
d Value
Value
STRUCTURE BASE CHANNEL AND INSULATOR
1 Check the level of the structure with spirit level
Ensure the distance between the Structure Pillars
2
is as per layout
Refer
Check the height of the elevator plate assembly on GA
3
the sub structure drawin
g
Refer
4 Check the dimension between center of elevator 350±10 page
plate assembly and center of guide plate no: 11
5 Check for the spirit level of the elevator plate.
Check the Drive box flange is vertically aligned to
6
the downpipe and C/L of guide plate hole.
Ensure that the position of the Drive box(On/Off) is
7 same as the position of the Moving Contact arms of
the isolator
See that any of the two holes on the drive flange
8 and down pipe flange will coinside to do the bolting
of both the flanges.
Ensure any two diagonal holes on top insulator are
9
in-line with elevator plate axis.
10 Check the verrticality of the insulator.
Manually rotate the Moving contact arms towards
11 close position untill the arms catches the fixed
contact.
Ensure that drive fork is in dead lock position in
12
close condition
Ensure to adjust the open stopper bolt in open
13
condition also
EARTH SWITCH CONTACT
Check the Drive box flange is vertically aligned to
14 the downpipe.
(Earth Switch)

15 Ensure the Earth Moving contact Blade(Plated Tip)

is covered by the jaws in the middle.
Ensure the Earth Moving contact is smoothly
16 entering into the Earth Switch Fixed Contact.
(Adjust the U bolts on the earth base to achieve

© Siemens - 40 -
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Revision 1

this).

Ensure the toggle is locked/achieved the dead

17 centre position when Earth Switch Moving Contact
is in Closed Condition
Ensure that the position of the Drive box(On/Off) is
18 same as the position of the Moving Contacts of the
earth switch
See that any of the two holes on the drive flange
19 and down pipe falnge will coinside to do the bolting
of both the flanges.
Ensure to fix the flanges tightely and operate the
earth switch manually to see if the closing and
20
opening is happening as described in the opearion
manual.
Operate the earth switch manually and check for
21
the alignment.
Ensure the isolator is in open condition and earth
switch is in open condition and fix the mechanical
22
interlock rod as per the GA Drawing/Instruction
manual
Ensure the wiring in the drive boxes is done as per
23
the drawing.
Ensure to keep the position of the Isolator manually
in half closed condition and check for phase
24
sequence of the three phase supply w.r.t Isolator
position (For the first cycle)
Ensure that limit switches setting in main switch
operating box is syncronised with the stopper bolts
25
(both open & close) provided in moving contact
housing
COMISSIONING CHECKS
Ensure the tightness of the bolts and nuts in the
current is as per the torque sheet given in the
26
manual (The bolts and nuts may become loose in
transportation)
Check the contact of the silver plated components
in the moving contact with the fixed contact is
27
intact.Ensure to avoid any sligtest gap between the
tips.
Ensure the petrolium jelly is applied to all the
28
contact portion.
Ensure that there is no corrosion on the contact
29
portion
Ensure that there are no scrathes on the
30
silverplated components
31 Check the closing time of the isolator
32 Check the opening time of the isolator
33 Check the Current drawn by the motor in the rated

© Siemens - 41 -
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Revision 1

voltage

34 Check the contact resistance of the isolator and

ensure it is with in the permissible limits.
Ensure that both mechanical and electrical
35
interlocking is done

Check sheet should be filled for each Isolator

Any deviation form the GA drawing and Instruction manual is to be highlited to the factory
Torque required
16MM GI bolts -
12MM GI bolts -
10mm SS bolts -

Siemens
Site Representatives
Representatives
Name: Name:
Contac
t: Contact:

© Siemens - 42 -
s
MAINTAINANCE INSTRUCTIONS

Date (Rev-5) 25.11.2013 26.11.2013 26.11.2013

Name Syed Jaweed Ikam Ch.SubbaReddy P.RamaMurthy

Signature SJI CSR PRM

Prepared By Reviewed By Approved By

Address: M/s Siemens Limited,

Plot No.89&90,
IDA Gandhinagar,
Balanagar Post,
Hyderabad-500037.
Mail: energysupport.in@siemens.com
Tel.: 0091-40-33507000/7001
Fax: 0091-40-23079992
Toll Free Ph No: 1 800 2667 480
 s Doc. No. DOC /407/ED/A1
Revision 5

PAGE
CONTENTS
1 Scope 3
2 Installation 3
Table:1 4
3 Startup 4
4 Documents 4
Table:2 5
5 Extent and frequency of inspection and maintenance 6
6 Inspection 7
7 Maintenance 8
8 Disposal of the product 8
9 Recommended spares 9
10 Replacement of parts / Spare Parts 10

IMPORTANT NOTES
• Failure to comply with warnings and other alerts can cause death, serious
bodily injury and extensive damage to property and the environment.

© Siemens -2-
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Revision 5

1. Scope
This manual specifies the inspection and maintenance work to be done on Following
Disconnectors

• Double break disconnector with earthing switch

• Horizontal break disconnector with earthing switch
• Pantograph disconnector with earthing switch

2. Installation
Installation may only be carried out by personnel familiar with these operating instructions.

Risks to erection personnel may be caused by:

• Electricity
• Falling and or tilting or other moving parts.

C A U T I O N!
• Ensure that safety procedures are followed during installation, inspection and
maintenance.
• Use Personal protective Equipments / Tool.

CAUTION!
Electric voltage there is a risk of electric shock and burning due to arcing when approaching
live components.

The poles of disconnectors, if necessary with mounted earthing switches, are assembled and
preconfigured in the factory, installation on site consists of the following main activities:
• Assembling and setting up of poles.
• Mounting the drives.
• Coupling the drive linkage and adjusting.

The serial numbers of the disconnector are indicated on the nameplates. The nameplates are
located on the drive cover of drives operating mechanism box.

CAUTION!
Before establishing connections, use brush/ cloth to clean live connections and apply a thin
layer of graphite oil or petroleum jelly as specified I Table:1

© Siemens -3-
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Revision 5

TABLE:1

TYPES OF GREASE TO BE USED APPLICATION

Rivolta or SKD 3602 (or) Centoplex 24 DL For parts on contact system.
(or) Graphite oil
For threads of hot dip galvanized
Rivolta SKD 3602 (or) parts.
Molycote longterm 2 plus
For all lubrication points on Operating
Rivolta SKD 3602 (or) Isoflex Topas L32 mechanism, gears.

3. Start Up
Make the following checks and inspections before start-up:
• Inspect all bolted connections, locks and reference dimensions.
• Perform manual switching operations and monitor all movements.
• Perform electrical switching operations.

4. Documents
The following documents must be available to perform the work described in this instruction:
• Layout drawing.
• Assembly instruction of disconnector & earth switches.
• GA drawings of disconnector with earth.
• Instruction for Tightening torques for all hardware (Table-2).

© Siemens -4-
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TABLE:2

© Siemens -5-
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5. Extent and frequency of inspection and maintenance

The following indications are related to places of installation with moderate up to heavy pollution
and a maximum number of 500 operating cycles for the disconnector per year.

Yearly Inspection (Refer Heading 6. Inspection).

Every 3 years Maintenance work Refer Heading (Refer Heading 7.

Maintenance).

For other than the above described conditions, extent and frequency of maintenance must be
adapted accordingly.

• Depending on the service conditions, an inspection should be made after every

12 to18 months.
• At very high switching frequency, latest however after 1000 switching operations.
• After several loads near the short-time withstand current.
• In severe service environments.

CAUTION!
Observe all safety instructions before starting work. Under normal service conditions,
maintenance is required after about every 1000 operations or 3 years.
Carry out the following maintenance activities:
• Visual inspection for damage due to external factors.
• Inspect and retighten all bolted connections to the prescribed tightening torque (Refer Table:2).
• Clean the post insulators.
• Inspect the paint, repair if necessary.
• Check all electric control functions.
• Carry out switching operations and check the current path setting.
• Clean the contact system.

5.1 Recommended place for the maintenance work

All maintenance work on the disconnector may be performed at the place of installation.

5.2 Special tools

No special tools are required to perform the maintenance work.

© Siemens -6-
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6. Inspection
6.1 Transmission

Step Description of activities Requirement

During a normal operation cycle, the transmission parts

of the disconnector and if applicable of the earthing
switch, shall be checked as follows:
• Proper course of motion No unusual noise
• Possible damage of parts None
• Possible loose joining elements None
(screws, pins, etc.,)

6.2 Current carrying parts:

Step Description of activities Requirement

During a normal operation cycle, the current carrying The main contacts shall close
parts of the disconnector, shall be checked as follows: properly
• Proper course of motion
No damages or heavy dirt
• Condition of main contacts accumulation

During a normal operation cycle of the earthing switch, Proper movement of earthing
the following shall be checked blade into the contact carrier
• Proper course of motion
No damage or heavy dirt
• Condition of earthing blade accumulation

• Condition of flexible connectors No damage, good flexibility.

If inspection shows deviation to the requirement, appropriate corrective action must be taken, i.e.,
• Perform maintenance work (Cleaning, greasing – Refer Table:1 for type of Grease)
• Tighten the screws. (Refer Table:2 for tightening torque)
• Adjust disconnector or earthing switch.
• Replace damaged parts.
• Pay attention to the information given in the appropriate assembly instructions.
• Inspect the contact system and replace the current path if necessary due to wear.
• Check the rotating stool mechanisms for free movement.

© Siemens -7-
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7. Maintenance
7.1 Maintenance of the transmission:

Lubricate all bearings and joints

Perform the inspection per par (Heading 6. Inspection)

7.2 Maintenance of current carrying parts:

• Perform the inspection per par. (Heading 6. Inspection)

• Clean the main contacts using brush / cloth
• Lubricate the main contacts with a thin layer of specified lubricant (Refer Table:2).
• Lubricate the bearings of current carrying parts with specified lubricant (Refer Table:2).

7.3 Maintenance of earthing switch:

Step Description of activities Requirement

Perform the inspection per par. (Heading

6. Inspection)

Clean the earthing blades and contact

springs

Lubricate the earthing blades and Apply Lubricant (Refer Table:2)

contact springs

Note: While using lubricants the respective MSDS (Material Safety Data Sheets) should be
referred.

Note:
In case any rework is done on a galvanized part that area is to be first sprayed with VCI
spray and then zinc primer is to be applied.

8. Disposal of product:
The product is environmentally compatible.
The following materials have used to make up the device steel, copper, aluminium, cast-resin,
porcelain, greases etc.

In as-supplied condition, the product does not incorporate any hazardous substances.

© Siemens -8-
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Revision 5

In operation, the product does not emit any hazardous materials or gases.
During disposal of the product, care must be taken to dismantle and segregate as far as possible
in more environmentally accepted way as recyclable raw materials and non recyclable materials
like synthetic ,lubricants and materials soaked in lubricants.

The disposal of non recyclable materials should be in line with the legal and statutory
requirements of the local area.

Local customer support-Siemens office will be able to answer any questions concerning disposal.

9. Recommended Spare Parts:

Double break disconnector

Quantity
in
S.No Part / Assembly (Poles)
1 Main Switch Moving contact assembly 3
2 Main Switch Fixed contact assembly 3
3 Main Switch Contact Tip/Blade 1
4 Main Switch Fixed contact jaws with spring and spring guide 1
5 Main Switch Fixed contact terminal pad/ jumper pad 1
6 Main Switch Operating mechanism box 1
7 Earth switch Moving contact assembly 3
8 Earth switch Fixed contact assembly 3
9 Earth switch Moving Contact Tip/Blade 1
10 Earth switch Fixed contact jaws with spring and spring guide 1
11 Earth switch Operating mechanism box 1

Horizontal break disconnector

Quantity
in
S.No Part / Assembly (Poles)
1 Main Switch Male contact assembly 3
2 Main Switch Female contact assembly 3
3 Main Switch Male Contact Tip/Blade 1
Main Switch Female contact jaws with spring and spring
4 guide 1
6 Main Switch Operating mechanism box 1
7 Earth switch Moving contact assembly 3
8 Earth switch Fixed contact assembly 3
9 Earth switch Moving Contact Tip/Blade 1
10 Earth switch Fixed contact jaws with spring and spring guide 1
11 Earth switch Operating mechanism box 1

© Siemens -9-
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Revision 5

Pantograph disconnector

Quantity
in
S.No Part / Assembly (Poles)
1 Main Switch Moving contact assembly 3
2 Main Switch Fixed contact assembly with dropper pipe 3
3 Main Switch Contact Tip/Blade 1
4 Main Switch Fixed contact 1
6 Main Switch Operating mechanism box 1
7 Earth switch Moving contact assembly 3
8 Earth switch Fixed contact assembly 3
9 Earth switch Moving Contact Tip/Blade 1
10 Earth switch Fixed contact jaws with spring and spring guide 1
11 Earth switch Operating mechanism box 1

10. Replacement of parts / Spare Parts:

For queries, replacement parts orders or faults, please, contact our service department giving
details of all nameplate data:

Address: M/s Siemens Limited,

Plot No.89&90,
IDA Gandhinagar,
Balanagar Post,
Hyderabad-500037.
Mail: energysupport.in@siemens.com
Tel.: 0091-40-33507000/7001
Fax: 0091-40-23079992
Toll Free Ph No: 1 800 2667 480

© Siemens - 10 -