INDEX

1.0. INDEX 1
2.0. GENERAL 2
3.0. GENERAL DESCRIPTION EQUIPMENT 2
SECTION: A TRANSPORTATION
4.1. TRANSPORTATION, UNPACKING & STORAGE 3
SECTION: B CONSTRUCTION
5.0. SUPPORT STRUCTURE 5
6.0. BASE ASSEMBLY 5
7.0. INSULATOR ASSEMBLY 6
8.0. MALE & FEMALE HAMPER ASSEMBLY 6
9.0. OPERATING MECHANISM 6
10.0. DOWN OPERATING PIPE (MAIN & EARTH) 7
11.0. TANDEM PIPE (MAIN & EARTH) 7
12.0. EARTH SWITCH ASSEMBLY. TYPE, DIRECT ENTRY (DEE) 7
SECTION- C ERECTION, OPERATION & SETTING INSTRUCTION
13.0 STRUCTURE 7
14.0 BASE ASSEMBLY 8
15.0 INSULATORS 8
16.0 HAMPER ASSEMBLY (MALE AND FEMALE ASSEMBLY) 9
17.0 DOWN OPERATING PIPE AND OPERATING MECHANISM (MAIN) 9
18.0 TANDEM PIPE ASSEMBLY (MAIN) 12
19.0 EARTH SWITCH ASSEMBLY 12
20.0 DOWN OPERATING PIPE AND OPERATING MECHANISM (EARTH) 13
21.0 TANDEM PIPE ASSEMBLY (EARTH) 13
SECTION-D MAITENANCE
22.0 MAIN DISCONNECTOR & EARTH 13
23.0 RECOMMENDED SPARES 14
24.0 LUBRICANTS RECOMMENDED 14
25.0 DRIVE MECHANISM 14
SECTION-E REFERENCE DRAWINGS 15 to29


2.0 GENERAL

The Equipment described in this publication is designed, manufactured and tested with care and will
give satisfactory service if it is installed, operated and maintained in accordance with the instructions,
by fully skilled personnel duly authorised to carryout this work.

Efforts are constantly being made to improve design and manufacturing, the equipment supplied may
differ in minor detail from the data given in this publication.

3.0 EQUIPMENT DESCRIPTION
a. Disconnectors are Primarily offload mechanical switching devices used to isolate equipments and
lines in electrical network. They can be able to Make or break a current <0.7 Amp. At 0.15
power factor.

b. 123 KV Centre Break Disconnectors are designed for independent single pole operation or three
pole electrically / Mechanically ganged operation. Single or Double Earth Switches, as required,
can be fitted on to them. These Disconnectors and Earth Switches can be operated either
manually or by motor.

c. 123 KV Centre Break Disconnectors are checked for satisfactory operation at the works before
they are supplied in knock down condition and are assembled at site. The relevant standards for
these are IS: 9921 and IEC: 62271-102. Insulators, which constitute a part, conforms to IS: 2544
and IEC: 273/168








SECTION- A
TRANSPORTATION
4.1. TRANSPORTATION, UNPACKING & STORAGE
4.1.1. MODE OF PACKING:
Disconnector parts are packed in different cases / crates in knock down condition along with loose
items required for that assembly.
4.1.2 CASE / CRATE WISE PACKING:
Crate 1 (For Main Switch without Earth Switches)
3 Base assemblies- (one complete switch)
3 Male / Female hamper assembly (1 set)
1 Down operating pipe assembly
Loose bolt & nut for
a) Base & Insulator
b) Insulator & Hamper assembly are packed in crate 1
Crate 2 (For Main Switch with one Earth Switch)
3 Base assemblies (one complete in with earth switch)
3 Male / Female hamper assembly (1 Set) along with earth fixed contact fixing
bracket.
2 Down operating pipe assembly (1 for main / 1 for each)
Loose items like, bolt & nut for
a) Base & Insulator
b) Insulator & Hamper assembly are packed in crate 2
Crate 3 (For Main Switch without Earth Switch)
2 Tandem Pipe assembly for main are packed in crate 3
Crate 4 (For Main Switch with one Earth Switch)
3 Tandem pipe assembly (2 for main / 2 for earth) are packed together in crate4
Case 5 (For Main Switch without Earth Switch / with Earth Switch)
Mechanism box is packed separately in Case 5



The following loose items are kept inside the box,
1) Key for operating the cap (Left side of box) for manual handle insertion.
2) Drain plug to be fixed at the left side rear leg after the Errection.
3) Earth bolt to fix earth connection at site.
Case 6 (For Main Switch with one Earth Switch)
3 Poles of earth switch assembly
3 Earth fixed contact assembly
3 No. of counter weight
1 No. push pipe assembly
1 No. manual handle to operate earth switch,
All Items are packed in Case 6.
CONDITION DURING PACKING & TRANSPORTATION
a) At the time of despatch, all the components are packed in such a way to avoid rubbing with
each other by wooden packing.

b) Moisture absorbant material is provided where protection is required.

c) For handling during packing, transportation & unloading, a crane with slings or fork lift
having adequate capacity to be deployed.

d) Upon receipt, the packages shall be visually inspected for external damages, and if found the
same to be reported to insurance agent / supplier by customer within three days. However,
if the packing cases are intact, unpacking of the cases for further checks of internal damages
may be carried out.

e) Once the wooden packing and the polythene sheet cover or corrosion- proof packing used inside
are removed check for damages to contact etc. Check and verify the items as per the relevant
despatch note.

f) In case the requirement is to be further stored before being used, the consignments may be
repacked after certifying for transit damages and shortages. They shall then be stored under
permanent cover, free from moisture and dust. Silicagel may be kept in the packages to facilitate
dry atmosphere. Please ensure that the items covered under cl.4.1 are safely reaching the
ultimate user at actual site.
- All the Items should be stored in up right position only.
- All the Items should be stored on ramps / platform only.




SECTION B
CONSTRUCTION
Our 123 KV Centre Break Disconnector comprises the following:
5. Support structure (Optional)
6. Base Assemblies
7. Insulators (Optional)
8. Male and Female Hamper Assemblies
9. Operating Mechanism (Main & Earth)
10. Down Operating Pipes (Main & Earth)
11. Tandem Pipe Assemblies (Main & Earth)
12. Earth Switch Assemblies (Optional)
13. Terminal Connector (Optional)
5. SUPPORT STRUCTURE

5.1 Support structure, when ordered, shall be designed and manufactured to meet customer specification.
They are assembled on the civil foundations of the customer and shall meet the dimensions of the
Disconnectors / Earth Switches with their respective drives etc.,

5.2 Structures are hot dip galvanised to meet (IS 4759-1984). B.S.729 Specifications.

5.3 Structure are designed with necessary factor of safety to withstand all forces i.e., short circuit force,
wind force and dead load etc. etc.

6. BASE ASSEMBLY

6.1 Each 3 pole Disconnectors (R, Y, B) are Supplied with 2 types of base Assemblies.
a. One base Assembly (say R pole) with Drive arrangement and interlock
arrangement (if the switch is with earth)
b. Other two bases (i.e. Y& B) without drive arrangement.
6.2 Base Assemblies are made out of MS Channels (C Types) (fabricated).
6.3 Both bearing shafts are assembled in a bearing housing made out of Aluminium casting.
6.4 Mechanical stoppers are provided in base assembly to control the travel of the hamper Assembly in
both close and open conditions.
6.5 All ferrous parts in base assembly are hot-dip galvanised to IS 4759-1984 / BS 729.








Base assemblies are supplied with:
a) Bearing shafts assembled and aligned condition.
b) Inter post coupling pipe assembled and aligned condition.
c) Tee Bar arrangement Main and Drive Mechanism for Earth in assembled condition
(only for drive end)
d) Inter lock arrangement in pre-set condition. (For position refer Fig.6)
d) Lever and hinges with pins, Friction Washers, Brass Washers and Split pins.
7. INSULATOR ASSEMBLY
7.1 Insulators are selected to meet the Basic insulation level, minimum creepage and minimum bending
load to suit the customer / Design requirement.

8. MALE & FEMALE HAMPER ASSEMBLY.
8.1 Current Carrying (arms) are made with Aluminium tube. (Electrical grade)
8.2 Male and Female (reverse loop design) contacts are made of Electrolytic Copper with Silver Plating.
(Contact surface)
8.3 Connector stem is made out of Electrolytic copper with in plating or Aluminium rod according current
rating.
8.4 The current Transfer part, flexible [Connecting the aluminium casting (Hinge Housing) and Connector
Stem] is made out of Copper Foils with Tin Plating.
8.5 Provision for Earth fixed contact fixing is arranged according to customer requirement (Male / female
side or both sides)
8.6 Current carrying arms (Aluminium Tube) are welded with Hinge Housing at one end and with male /
female contact support casting at the other end.
9. OPERATING MECHANISM
Geared motor operating mechanism consists of a final worm reduction gear driven bt a 3 phase
induction motor AC or DC motor to meet customer needs. Necessary overload protection, Control
Switches for local / remote operation, Limit Switches are provided. In the event of supply failure, the
Mechanism can be operated manually.

Manual operating mechanisms are supplied with or without reduction gear against specific customer
requirements.
The Mechanisms are housed in a cabinet made of MS Sheet or Aluminium having a thickness of 3mm.
Auxillary switches having silver-plated contacts with positive wiping action with adequate number of NO,
NC and long wipe contacts as per specific requirements will be provided. Suitable blank gland plate is
provided at the bottom for cable terminal.
Suitable terminal blocks made out of highly non-inflammable thermosetting plastic are provided for
terminating control and auxillary wiring. Front door of the mechanism box is provided with good quality
Seal which, when closed, ensure high degree of protection against polluted atmosphere. All the Cubicles
undergo metal treatment before they are taken up for painting. (If it is MS.)



10. DOWN OPERATING PIPE (MAIN & EARTH)

10.1 This assembly is used to connect the Tee bar Drive Mechanism Assembly fitted in Base and Flange
fitted in Operating Mechanism Box Assembly.
10.2 The above assemblies are made out of ERW Pipe with T Bar Welded in topside .
10.3 The above welded Assembly is hot dip galvanised.


11. TANDEM PIPE (Main & Earth)

11.1 The above pipe assembly is used to connect adjustment poles for gang operation of all the three
poles with the drive mechanism. The lengths are adjustable to variation at site.
11.2 These Parts are hot-dip galvanised and assembled with necessary pins & bushes etc.

12. EARTH SWITCH ASSEMBLY- TYPE FREE ENTRY (FEE)

12.1 Free Entry Earth Switch is operated through levers .
12.2 Moving Blade made out of Aluminium tube and contacts are made out of Electrolytic copper with
Silver plating.
12.3 Mounting Base and all other parts are Hot-Dip galvanised and supplied in Assembled Condition with
bar.
12.4 Moving blade to be Assembled at site.

SECTION C
INSTALLATION & SETTING INSTRUCTION
13. STRUCTURES: (Where scope is included)
13.1 Refer the site layout and identify the structures of the respective disconnector to meet the Sub-station
lay-out.
13.2 Assemble the members on their respective foundations as per their general layout.
13.3 Complete the assembly and tighten all the bolts with nuts, washers etc.
13.4 Check for levels at the top of the Structure in both directions by using spirit levels. If required give
shims below the base plate of structure and tighten the nuts.
13.5 Similarly complete erection of all structures.
13.6 After erection, Check for the following:
a. All fixing dimensions with respect to the centre of the structure.
b. Diagonal distance to match as per contracts drawing.


14. BASE ASSEMBLY

14.1 Identify the base assembly from contracts General Assembly Drawing with the help of packing list
and open the crate carefully.
14.2 Remove down operating pipe from the crate and keep it separately.
14.3 Lift the base Assembly along with hamper Assembly and keep it outside on a levelled platform.
14.4 Remove the Hamper Assembly from base assembly by removing the bolt and nut (do not use the
Same bolt for the assembly, these are only for transit purpose).
14.5 Lift the Base Assembly by using proper handling methods / equipments and install it over the
relevant structure. Fig.2.
14.6 Move the same carefully to the fixing position on the structure and assemble the base firmly on the
top of the structure.
14.7 Check for level on both Insulator seating flanges in both directions by using sprit level.
14.8 If necessary add shims below the leg of the base by loosening the fixing bolts and nuts and align it.
Fig.3.
14.9 Tighten all the Bolts and Nuts.
14.10 Repeat the same for other two poles also.
Note:
1. Ensure the correctness of centre line of same poles and Centre line of other phases.
2. After completing the installation keep all the base assemblies in open position.

15. INSULATORS
15.1 Identify the Insulator by using Insulator Drawing and open the packing carefully.
15.2 Lift the insulator by using proper hook and place (ensure the top 4 holes position) it over the Base
Assembly. (Ensure top 4 holes of both insulators on each side are parallel to base center line fig.4.
15.3 Without removing the hook match the bottom fixing holes and fix all bolts.
15.4 Remove the hook and check for level of the top surface of insulator by sprit level / plumb.
15.5 If necessary add shims below the bottom flange of the insulator. Fig.5.
15.6 Rotate the shaft assembly and check for the rotation of insulator (eccentricity) ensure the vertically.
15.7 Repeat the same for other stacks also.
Note:
After completing the installation and alignment keep the base Assembly in open
condition.
16. HAMPER ASSEMBLY (Male and Female Assembly)
16.1 Identify the hamper assembly as per contracts General Assembly Drawing.

16.2 Lift the male Hamper Assembly by using proper rope and place it over the Insulator. Fig.7. (If it is
with earth switch, place the earth fixed contact adopter / spacer plate in between hamper and
Insulator.)
16.3 Without removing the rope align the holes and fix the M 16 Screw and hand tight with insulator.
16.4 Repeat 16.2. To 16.3 for female Hamper Assembly.
16.5 Rotate the Bearing Shaft Assembly and check for alignment of hamper Assembly.
a. If the entry is not smooth, loosen the hamper Mounting Screw and push the
Hamper forward or backward to get free entry. Fig.8.
b. After achieving the smooth entry, check for centre line of male and female in both directions.
Fig.9.
c. To Correct X axis, add shims between Insulator mounting flange of Hamper Assembly and top
of the Insulator at relevant side. Fig.9.
d. To Correct Y axis, add necessary shims between Insulator bottom flange and top of shaft
assembly flange. Fig.9.
16.6 Operate 2 to 3 times and ensure the alignment.
16.7 Repeat the same for other two poles also.

17. DOWN OPERATING PIPE AND OPERATING MECHANISM
Identify the mechanism box with the help of drawing and packing list, open the case carefully.

MOUNTING:
Do not attempt to lift mechanism by drive coupling flange. Use slings or forklift at base of
cubicle. Lift Mechanism box into position and fix with structure. At this stage tightens fixing
bolts only hand tight.

CONNECTING DISCONNECTOR
Check for centre line and vertical line between Tee Bar flange and drive flange with a plumb.
Introduce Diaphragm plate as called for in the General Arrangement Drawing. Measure exact
height. Cut the operating pipe (x-10-1) with the clearance of 1mm.to facilitate smooth entry.
Welded the venier flange properly, keeping the flange perpendicular to centre line of the pipe. Level
and bolt the same. The drive is now ready for operation.
If the down operating pipe is supplied to correct length, the above cutting and welding operation is
not required, Instead, the J ack bolt (Long bolt) to be set to the correct Height.
Mounting angles of mechanism to structure are slotted to provide horizontal adjustment. Adjust the
mechanism so that the vertical drive tube rotates TRUE.

ADJUSTMENT
A. MANUAL
By use of emergency handle, operate the coupled Disconnector and observe whether it is fully
OPEN or CLOSE at each and of its operating cycle. (Ensure minimum 10mm gape between pad
lock brackets)
If the disconnector does not CLOSE fully remove clamping bolts and turn mechanism slightly
towards / OPEN and retighten bolts proceed turning of Disconnector towards closing. Repeat until
satisfactory operation is obtained.


B. ELECTRICAL
Make electrical connections-refer to contract diagram of connections-of incoming supply. Do not
attempt to operate the Disconnector under power at this stage.
When selector switch is fitted, set it to LOCAL.
When AC Motor is fitted, Manually set Mechanism to mid Position and:-
a. Operate Control Switch and at the same time observe whether the mechanism rotates towards
the selected position.
b. If it rotates in opposite direction to that selected, stop motor immediately, by switching off
power supply using Emergency push button switch.
c. Reverse phase connection of motor supply.

ELECTRICAL OPERATING EQUIPMENT
A hinged panel on the left hand or right hand side of the cabinet carries the electrical control, for operation
of the mechanism, which is accessible immediately after the cabinet outer door is opened.

THESE COMPRISES:
LOCAL OPEN AND CLOSE CONTROL SWITCH:
Incase of individual pole drives, the master control cabinet will have push buttons for opening / closing also.

OPEN AND CLOSE SWITCH
The Control Switch determines the direction of travel of the Disconnector. When a cycle is initiated by
Switching to the Appropriate position, the Disconnector will open or close. Once the mechanism has
received a signal the push botton / Leaver can be released. The Mechanism will complete the operation and
will not respond to further signals until it has completed its operation. An indicator outside top sheet of the
cabinet below the output shaft to show the Disconnector is OPEN or CLOSE.

SELECTOR SWITCH
When the selector switch is set to local, operation of the Mechanism will be governed by the controls in the
cabinet. Setting the selector switch to Remote transfers controls of the mechanism to remote control point.

HEATER AND HEATER SWITCH:
An anti-condensation heater is fitted in the bottom of the cabinet. It should be switched on all times,
ensuring that the temperature inside the cabinet exceeds the temerature outside. The heated air leaves
cabinet by way of a breather. A switch is mounted on the front of the control panel for the control of heater
through a thermostat.



OPEN AND CLOSE CONTACTORS

These contactors are mounted side by side on the rear of the control panel. They directly control the
reversing operation of the motor. Further contacts are used for electrically interlocking the contactors,
providing circuit across the OPEN and CLOSE Push Bottons / Cam Switch.

AUXILLARY SWITCHES

Silver plated contacts with a positive wiping action are used for giving reliable making low current
signalling circuits under adverse climatic conditions.

TERMINAL BLOCKS

Terminal Blocks are designed for use with 2.5 Sqmm. cable.
Miniature circuit Breaker is mounted in the panel door.
The current ratings of fuse-links are shown on the schematic diagram.

FOR CLOSING OPERATION OF DISCONNECTOR

Set the electrical remote selector to local execution as required and then Operate the cam switch for closing,
there by causing the closing contactor (CC) to pick up. The Hold on

contact of closing contactor (CC) will now be closed there by retaining the supply after the cam switch is
released. Simultaneously, when you operate for opening, the opening contactor (OC) will pickup. The hold
on contact of opening contactor (OC) will now be closed there by retaining the supply after the cam switch
is released Ensure motor direction is towards closing. Otherwise change the phase sequence of motor
terminal box. The Disconnector will start to close, at the end of the closing operation limit switch for
closing (LSC) will open, de-emergising the closing contactor (CC). The circuit is now de-energised and the
closing operation is completed.

Kindly note to prevent-mal functioning, contact (CC) of the closing contactor will isolate the opening
circuit, once contactor (CC) is energised.

FOR OPENING THE DISCONNECTOR
A Similar sequence of operation will be executed by operating the cam switch in other direction.

MANUAL OPERATION

The mechanism may be operated manually in the event of a motor power failure with the help of manual
operating handle.
Once the circuit Breaker is opened supply will be available to inter lock coil switch for
main (MPB). When you press the switch (MPB) the interlock coil get supply and release the interlock.
Take the key from the panel door and open the cap provided for the handle entry. Insert the handle and

rotate. Rotation of the handle will make the second stage worm screw shaft to rotate, which in turn rotates
the main output shafts.

18. TANDEM PIPE ASSEMBLY
18.1 After single pole trial with motor keep the pole in closed condition.
18.2 Fix other poles also in closed condition (set the stopper screws).
18.3 Measure the distance between the levers of two adjacent poles (R & Y).
18.4 Identify the case with packing list, open the case carefully.
Check and set the Tandem pipe length in floor it self.
18.5 Lift the Tandem Pipe by using proper rope and fix one side first by using suitable antifriction
washer, brass washer and split pins.
18.6 Then fix other side in the same manner.
18.7 Operate the operating Mechanism and check for proper closing and opening of both poles. If
required do motor adjustment in Tandem Pipe length using adjusting screw and check nut. Fig.10.
18.8 Repeat 18.3 to 18.7 for the other poles (Y & B).

19. EARTH SWITCH ASSEMBLY (COMPLETE)

19.1 FIXED CONTACT ASSEMBLY

19.1.1. Identify the Hamper Assembly to fix the fixed contact Assembly through contracts GA Drawing.
Identify the case with the help of packing list and open the case carefully. Fig.11.
19.1.2. Take the Earth Contact Assembly and fix it with Hamper Assembly bracket by using M12 Bolts and
Nuts as per GA Drawings.

Note: -
The above Assembly can be carried out before installing the Hamper Assembly
over the Insulator also.

19.2. EARTH SWITCH ASSEMBLY

19.2.1. Identify the side of the Earth Switch by refering GA Drawing.
19.2.2. Lift the Earth Switch Assembly by using rope and fix it with Base Assembly by using M12 Bolts
and Nuts.
19.2.3. Operate the Earth Switch by using Lever and check for the alignment.

a. If all extrusion (Moving Contact) is not in center, lower or raise the earth blade by the U bolt.
b. If the centre line of the moving Blade and fixed contact is not straight adjust the moving Blade
assembly by using necessary shims. Fig.13.
c. Tighten all Bolts.
19.2.4. Repeat the same for the other two poles also.

20. OPERATING MECHANISM AND DOWN OPERATING PIPE.
Refer the instruction mentioned for Main Assembly.



21. TANDEM PIPE ASSEMBLY
Refer the instruction mentioned for Main Assembly.

SECTION D

MAINTENANCE

22. MAIN DISCONNECTOR & EARTH
Maintenance is recommended on an annual basis for normal working conditions. For highly
polluted environment, more frequent maintenance is envisaged, which may be done along with
periodic inspection.
The following points are to be attended during the maintenance:
a. Wash or wipe the porcelain insulators and inspect for craks or chip off.
b. Open the Disconnector and earthning switch and inspect the contacts. (Wipe the contact
surfaces with solvent).
c. Check for contact surface soundness. (Bare copper / plating peel off should not visible). If
necessary replace.
d. Check contact gap 34 -36mm If found inadequate, replace contact spring.
e. If any connections and bi-mettallic joints are to be made, general purpose electrical jointing.
f. After maintenance and inspection, smear contact surface lightly with contact lubricant.
g. Check for tightness of bolts and nuts. Drive tube locknuts. Drive lever and phase coupling
clamp bolts etc.
h. Check for split pins in clevis if damaged replaces the same.
i. Lubricate all clevis pins.

23. RECOMMENDED SPARES
Keep adequate quantity of following spares at all times.
a. Fixed Contact (Male contact)
b. Moving Contact Fingers.
c. Clevis Pins with nylon washer, split pins
d. Contact springs.

24. LUBRICANTS RECOMMENED
- For contact surface - Clean contact surface with plain cloth and
apply. Contact grease
- For external drive linkage - Servo Gem MP



25. DRIVE MECHANISM

Maintenance is recommended at twelve monthly intervals.
25.01. Apply grease on the teeth of the spur gear and GEAR box / Lead screw and guide nut incase of
leads screw type.
25.02. Oil auxillary switch linkage and pivot on the guard aperture for manual operation.
25.03. Grease the contacts of auxillary switch if it is open type.
25.04. Check that all the electrical components are firmly fixed and that the contactors operate freely.
25.05. Check all electrical connections for tightness.
25.06. Check all mounting bolts for tightness.
25.07. Apply grease to mechanical interlock-cam groove, if the Disconnector is with earth switch.

RECOMMENDED LUBRICANTS
- Gearbox - Servo Gem MP
- Pivot Pins and Bearings - Shell Alvania Grease


.