Professional Documents
Culture Documents
A. General 5
B. Design 9
3
4
A. GENERAL
5
A. GENERAL
The Vacuum Circuit Breaker type VD4E / Type VD4 / VD4-E vacuum circuit breakers
VD4 are intended for indoor installation in air- are suitable for auto-reclosing, and have
insulated switchboards. exceptionally high operating reliability and
long life.
Vacuum circuit breakers are advantageous
to use in distribution networks especially The guaranteed technical particulars have
where there is a high switching frequency in been confirmed by numerous tests in our
the working current range and/or where a collaborators own laboratory & other
certain number of short circuit breaking independent laboratories of world repute.
operations are expected.
VD4 12 06 25 E
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
6
Information on Rating Plate
Weight in Kgs.
7
A. GENERAL
..
publication 694.
be transported or stored in an upright
The following limit values apply :
position. The circuit breaker is transhipped
Ambient temperature :
in packing in the open (OFF) position and
with the closing spring discharged. .. Maximum
Maximum 24 hour average
Minimum
+ 40°C
+ 35°C
- 5°C
Condition on delivery
..
(according to "minus 5 indoor " class)
The factory assembled circuit breakers are
checked at the works for completeness of
Humidity :
the equipment and simultaneously
Maximum average relative humidity
subjected to a routine test in accordance
with the IEC publication 56, thus verifying . measured over 24 hours:
Maximum average relative humidity
95%
their correct structure and function.
Receipt
. measured over 1 month:
Maximum site altitude :
90%
<1000m
(above MSL)
Each delivery is to be checked on receipt
Note: The ambient air should not be
for :
excessively contaminated by dust, smoke,
- Completeness and correctness (Check
corrosive or combustible gases, vapours
against order and delivery documents).
or salt.
- Any possible damage in transit and
material losses.
Special Operating Conditions
Abnormality, if any, must be notified
Special operating conditions are to be agreed
immediately to:
on by the manufacturer and user.
-The manufacturer
-The forwarding agent and the
The manufacturers must be consulted in
insurance company.
advance about each special operating
-The responsible claims inspector
.
condition.
according to the insurance
certificate for the purpose of making
Site altitude over 1000 m :
out a damage or loss Certificate.
- Allow for the reduction in the dielectric
.
strength of the air.
Unloading
Unloading of the package units must only
Increased ambient temperature :
be carried out with a crane, fork lift truck
- Current carrying capacity is reduced.
and / or transport trolley jack.
- Provide additional ventilation for heat
.
dissipation.
Storage Rules and Regulations
The material shall be stored in a well
Climate :
ventilated storage room and to be protected
- To minimize risk of corrosion avoid areas
against dirt, damage and water ingression.
with:
The original packing can be used for storage,
- With high humidity
however, without the plastic sheet.
- Major rapid temperature fluctuations.
- Implement preventive measures (e.g.
electric heaters) to preclude condensation.
8
B. DESIGN
General features 10
Constructional details 10
Pole assembly 10
Operating mechanism 10
Truck assembly 10
9
B. DESIGN
.
requirement are accordingly negligible. Operating Mechanism
The operating mechanism consists of :
Structure and Function A spring charging unit which can be
.
(Drg.2 & 3, pg.no. 43 & 44) charged manually or electrically by a
The poles, which are constructed in column geared motor.
.
form, are mounted on the bracket shaped rear Mechanical indicator showing spring
part of the breaker mechanism housing 1. The charged / discharged condition.
.
live parts of the breaker poles are located in Indicator for open / close position of the
the insulating material pole tubes 12 and circuit breaker.
protected from impact and other external Closing / tripping magnet for performing
.
influences. closing / opening operation of the circuit
breaker electrically.
..
With the breaker closed, the current path Operation counter showing total number
leads from the breaker upper terminal 13 and of operations performed by the breaker.
a chamber holder fixed in the pole tube to the Motor cut-off switch and auxiliary switch.
.
fixed contact 15.2 in the vacuum interrupter Switch for annunciation and control of
15, then via the moving contact 15.3 and the auxiliary circuits.
flexible conductor / roller contact 16.2 to the Optional items like under voltage trip
breaker lower terminal 14. The switching additional trip coil and blocking magnet.
motion is effected by means of the insulated
coupling rod 18 with internal contact pressure The spring charging mechanism ensures that
springs 17. 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
Constructional details charged. As soon as the energy is removed
from the spring charging mechanism, the NO
.
Vacuum circuit breaker type VD4-E / VD4
consists of : contact of the cut-off switch is opened
Breaker poles of epoxy resin firmly interrupting the motor circuit. The spring
holding and protecting the vacuum charging mechanism can also be recharged
manually by means of a charging handle.
..
interrupter assembly from impacts and
other external influences.
..
A spring charged operating mechanism . Truck assembly (Drg.1, pg.no. 41)
A truck assembly with relevant interlock This assembly consists of :
.
features. Frame assembly
Wheel rack assembly
Pole assembly (Drg.4A & 4B, pg.nos. 45)
..
Automatic secondary plug & socket
Pole assembly consists of a vacuum assembly.
interrupter (V1002 / V2002) mounted
.
Interlocking rod assembly
firmly in the Pole housing Bottom plate assembly
(V1001/ V2001) made out of epoxy resin. Emergency trip assembly
The interrupter is firmly fixed on the top
connection bar and the moving contact The above assembly provides the
of the interrupter is connected to the following features :
bottom connection bar with a Flexible
10
.
.
Closed breaker can not be moved from test operating levers driven by the individual
to service position or vice-versa. cam discs mounted on the common shaft.
.
Breaker can not be closed when it is in Very high contact pressure is maintained
intermittent position. through the spring washer assembly housed
.
The movement of the selector is blocked in a operating stud.
when the breaker is in the closed condition.
A closed breaker can not be pushed into Principle of interruption
test position from withdrawn position. Due to the extremely low static interrupter
chamber pressure of 10-4 to 10-8 in mbars,
Working Principle of pole assembly only a relatively small contact gap is required
Contact operation to achieve a high dielectric strength. The arc
The closing and opening operations can be is extinguished on one of the first natural
carried out by means of the energy stored current zeros.
in the operating mechanism. One common
spiral spring is used to carry out the closing Due to small contact gap and high
and opening operation of the breaker and conductivity of the metal vapour plasma, the
three individual compression spring arc drop voltage, and additionally, due to short
assemblies are used to assist the opening arcing time, the associated arc energy, are
operation of the three poles.The movement extremely low, which has advantageous
/ stroke of the moving contact of the effects on the life of the contacts and thus on
vacuum interrupter is achieved through the that of the vacuum interrupters.
11
12
C. INSTALLATION & COMMISSIONING
Preparatory work 14
Tools & accessories 14
Technical documents 14
Erection 14
Electrical connections 14
High voltage connections 14
Low voltage connections 14
Earthing 14
Commissioning 15
General checks 15
Table 1: Precommissioning checks 15
Functional checks 16
Final Checks 16
Handing over 16
13
C. ERECTION & COMMISSIONING
..
Technical documents checked as per the relevant schematic
diagram for correctness.
..
Assembly drawings.
Customer’s order reference drawings.
Circuit diagram. Earthing
Dimensional drawings. The permanent earthing is provided by
means of earthing busbar in all the
Erection switchgear cubicles. There are terminals
For erection of switchgear cubicle, refer the for connecting external earthings to this
busbar. The stations earthing terminal is
.
relevant instruction manual for the particular
cubicle type. connected only in the end cubicle. Each
When all the panels are erected correctly, circuit breaker is provided with earthing
check that the cubicle fronts are in line and finger contacts mounted on, the top of
the breaker truck. These finger contacts
.
that the cubicle doors with the interlocking
devices work correctly. engage and slide against the wedge
type contact provided in the switchgear
.
The movement of all the handles should be
easy and smooth. cubicle, which is, in turn, connected to
Put the breaker into the cubicle and check the cubicle main earth busbar.
the following : Lubricate the earthing contacts on the
breaker truck and cubicle with a thin film
of vaselene or contact grease and
ensure proper contact engagement.
14
Commissioning . To gain access to the operating
mechanism safely, discharge the closing
General procedures
Before putting the circuit breaker into service springs (by closing & opening the circuit
.
carry out the following checks :
Check the tightness of the power
connections on the circuit breaker .
breaker), then remove the cover of the
operating mechanism.
Check that air circulation in the circuit
. terminals.
Check that the value of the supply voltage
for the auxiliary circuit is with in 85% and ..
breaker installation site is adequate so
that there is no danger of overheating.
Remove the transport caps from the poles,
110%, of the rated voltage, of the Ensure that the instruction manual is
. electrical devices.
Check that no foreign material has got
into the moving parts.
.
available to the operator at all the
times.
Carry out the checks indicated in table
no. 1 :
1. Manual Carry out a few closing and opening The operations and the
operating operation NOTE : Connect the relevant indications occur
mechanism undervoltage release with the relative correctly.
rated auxiliary supply voltage (if provided)
2. Motor Connect the geared motor for spring The geared motor
operated charging with the relative rated auxiliary recharges the spring after
mechanism supply voltage. Carry out a few closing each closing operation.
(if provided) and opening operations. . NOTE: Connect
the undervoltage release with the relative
rated auxiliary supply voltage (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) carry out the circuit breaker closing occur correctly. The circuit
operation. Disconnect the power supply breaker opens and the
from the release. relevant indication occur
correctly.
4. Shunt opening Close the circuit breaker. Connect the The circuit breaker opens
release shunt opening release with the relative and the relevant indication
rated auxiliary supply voltage. occur correctly.
5. Shunt closing Open the circuit breaker. Connect the The circuit breaker closes
release shunt closing release with the relative correctly and the relevant
rated auxiliary supply voltage. indications occur correctly.
15
C. ERECTION & COMMISSIONING
6. Auxiliary Insert the auxiliary contacts into suitable Signals occur correctly
contacts in the signaling circuits. Carry out a few closing
operating and opening operations of the circuit
mechanism breaker.
7. Test service Move the breaker from test to service Test service position
position limit few times. indications occur correctly.
switch
operation
.
Functional checks must only be carried out
when: command point.
.
The circuit breaker is disconnected from
the high voltage network and is correctly
.
Final checks
.
earthed. Rack in the breaker into the switchgear
.
The breaker mounting screws are well cubicle.
tightened. Re-check all electrical connections,
terminals and connecting leads.
.
Any foreign material that is likely to
disturb operations is removed.
The functional check is to be performed Handing over
in accordance with the instructions for After the checks are completed, the circuit
operation and maintenance of the breaker can be handed over for
commissioning.
16
D. OPERATION & MAINTENANCE
17
D. OPERATION & MAINTENANCE
General features
. Any circuit breaker which operates only a
few times, that is remains closed (ON) or
During normal service the circuit breakers
require only limited maintenance. The open (OFF) for long periods, should be
frequency and the sort of inspections and operated from time to time to prevent clogging.
maintenance basically depend on the service Clogging may cause a reduction in the closing
conditions. Various factors must be taken into or opening speed.
account. e.g. frequency of operations,
interrupted current values and relative power
. When the circuit breaker is in service it
should be visually inspected from outside to
factor as well as the ambient conditions.
detect any dust, dirt or damage of any kind.
Table no. 2 gives the maintenance schedule
18
General Inspection of the Circuit Breaker
19
D. OPERATION & MAINTENANCE
20
Operation & Maintenance of Pole Replacement of complete pole assembly
assembly Note To order the complete pole assembly for
circuit breaker type VD4E / VD4, the following
General
Weight of each pole assembly is approximately ..
details should be furnished :
Rated voltage
12 Kg for VD4-E and 17 Kg for V D4.
..
consists of the following components :
Pole housing (V1001 / V2001)
Order reference number
Dismantling :
..
Vacuum interrupter
Operating stud
(V1002 / V2002)
(V1003 / V2003)
Before dismantling the pole, ensure that the
breaker is in 'open' condition and closing
..
Flexible conductor (V1008)
spring is discharged. To fully discharge the
Roller contact assly.
Top connection bar / Support
(V2008)
.
closing spring, refer instruction 13(pg. No. 30).
Remove the special circlip (V6089) and
. (V1004 / V2004)
Bottom connection bar/Contact flange assly.
the pin (V6090) which connects the
operating stud (V1003 / V2003) end to the
(V1005 / V2006)
. lever assembly from the bottom side.
Remove the Hex. socket head screw
Maintenance . (V6091) from the bottom side of the breaker.
Take care to hold the pole assembly
The breaker pole with vacuum interrupter
is maintenance free upto reaching the
permissible number of vacuum interrupter
. properly while dismantling the screw.
Separate the pole assembly from the
operating mechanism assembly (V1000 /
operating cycles.
V2000).
Checking of the vacuum is only necessary
when there is a good cause to suspect that
force applied externally to a pole tube has
.
Assembly:
Hold the pole assembly in a proper position
and match the holes on the housing with the
caused damage to the vacuum interrupter
holes on the bottom side of the breaker
inside.
. frame.
Tighten the Hex. socket head screw (V6091)
.
Before commencing the maintenance work,
and spring washer(V6092) from bottom side.
ensure that the circuit breaker :
21
D. OPERATION & MAINTENANCE
22
Caution 8. Counter assembly (V4800)
Outer spring dowel pin slit should be pressed (Drg. 6B, pg.no. 48)
in such a way that the slit is kept towards Take a counter assembly - item no.
the center of the cam and the inner spring (V4801 ). Position the arm of the counter
dowel pin slit should be kept opposite to the suitably and tighten it with a screw driver.
outer one. Now mount this counter on a mounting
angle (V4802) with M3 cheese head
7. Half shaft assembly (V4700) screw (V4803) and spring washer
(Drg. 6B, pg.no. 48) (V4804).
Take the hex. socket head screw M4x16
(V4701 ) as shown in drg. 68. Hold 2 cranks Now hang the tension spring (V4805) in
(V4702) as shown in the drg. Mount the fish the hole provided on the arm and crimp its
plate (V4703) on tripping side and fish plate end suitably so that it will not come out of
(V4704) on the closing side of the crank. the hole.
23
D. OPERATION & MAINTENANCE
Now in a small hole of the conical plate 12. Operating mechanism assembly(V5200)
(V5107), insert V5105 - M3x25 cheese head (Drg. 6A-6E, pg.no. 47 - 51)
screw M3x25 (V5105) and a tubular rivet The operating mechanism assembly is
(V5106). Above that insert support plate sub-divided into different sub-assemblies :
(V5108) with cheese head screw (V5109) and
tubular rivet (V5110)fixed on it. After this, insert 1 ) Half shaft assembly.
the cylindrical pin (V5111 ) and locate the 2) D-shaft assembly.
sprocket (V5112) with the right direction. Apply 3) Operating lever assembly.
a light coat of grease on the pin and in 4) Control shaft assembly.
between the conical plate and support plate. 5) Supporting crank assembly.
Now take 2 nos. latch (V5113), hook both 6) Main shaft assembly.
the latches to the spring (V5114) properly and 7) Charging ratchet assembly.
fix it in the special slots provided on the 8) Blocking lever assembly.
support plate and conical plate one each. The 9) Auxiliary shaft assembly.
charging lever (V5115) shall be located on two 10) Coil assembly.
hex.socket head screws fixed earlier. Repeat
the assembly of support plate and conical After keeping all sub-assemblies ready for
plate duly greased and fix the other end of two main assembly, we shall start the main
latches in the slots. Put another tubular rivet assembly of operating mechanism. Refer drg.
(V5110) and lock the small cheese head 6A to 6E for the mechanism assembly.
screws with a nylock nut (V5116) of size M3. 12.1 Take operating housing (V6001 ) and fix
Do not excessively tighten the nylock nuts. the special bush (V6002) as shown
in drg. (6B & 6D). Apply a light coat of
Also fix the nylock hex. nut (V5117) on hex. grease and mount the half shaft
socket head screw M6 on the longer screw put assembly as shown in the drg. 6B & 6D
two plain washers (V5118) and then one big
washer (V5119) and tighten it with t he nylock 12.2 After this assembly, the D Shaft assembly
nut (V5117). (V4500) shall be mounted as shown in
drg. 6A & 6B. Place the bush (V6003) in
Check the assembly for its operation by the hole provided in the side sheet. Insert
charging it through the hole provided on the the D-shaft assembly with torsion spring
charging lever (V5115) for its movement (V6004) and push the bush (V6005) from
in the right direction. Also check the assembly outside the sheet and hold it in the proper
for spring action for the latches. position as shown in fig 6B. Once the
positioning is done, clamp the bush with
11. Operating lever assembly (V5200) bracket (V6006), and hold the bracket
(Drg. 6E, pg.no. 51) with hex. Socket headed screw (V6007)
Take the operating levers (V5201 [A/B] & with spring washer & hexagonal nut
V5202 [A/B]) and pair it on the basis of LH (V6008 & V6009).
side 8 RH side. Locate the tripping spring
assembly as shown in the fig. 6E. 12.3 After this assembly, the assembly of 3
operating levers (V5200) shall be done.
Now take the bolt (V5203) and insert the bolt The assembled levers are to be inserted
through LH side lever and pass it through in the pivot plates of the operating
the roller bearing (V5204). Put the circlip housing as shown in the drg. 6E. With the
(V5205) and clamp it. For R-pole operating spacer (V6010) and the duly greased
lever special pin(V5206), shall be used instead grooved pin (V6011 ), which is to be
of (V5203). clamped on both the ends by a special
circlip (V6012). Ensure that the spring
guide is well located in the hole provided
24
on the operating housing as well as the this stage.
free movement of the lever assembly in
the operating mechanism. Use stepped Fix the bush / spacer (V6021/ V6063)
bush (V6062) for the assembly of Refer assembly fig. 6B in the hole
R-pole operating lever. provided on operating housing. Apply a
light coat of grease from the inner
12.4 Now the assembly of the control shaft surface of the bush / spacer and take
shall be carried out in the following steps. the assembly of supporting crank made,
First of all, fix the bush (V6013) duly as explained in point no.9 (V4900).
greased from inside - as shown in drg 6D, Remove the grooved pin (V4906 [A/B])
in the middle partition of the operating without disturbing the whole assembly
mechanism. Now insert the control shaft and hold it in the proper position and
(V6014) as shown and put torsion spring insert the same pin through the middle
(V6015) in the other end of the control partition of the operating mechanism
shaft and then fix the bush (V6002) and pass it through the supporting
from outside and locate the control shaft cranks and bushes (V6064 & V6065)
in it. Apply a light coat of grease inside mounted on the other plate of the
the bush, place one or two washers mechanism. Hook the long leg of the
(V6016), depending on the space torsion spring (V6015) in the groove
available next to the bush. Now insert provided on the pin (V4906 [A/B]) with a
the spiral dowel pin (V6017) in the holes special fixing screw driver carefully.
to locate the control shaft and to hold the
torsion spring in a position. Now insert the Check : Check for the free movement of
lockout lever (V6018) with the torsion the supporting crank inside the grooved
spring (V6019) inside the lockout lever pin (V4906 [A/B]).
as shown in Fig.6B. Position the dowel
pin (V6020) well above the leg of the 12.6 After this assembly, the assembly of
torsion spring and press the dowel pin main shaft shall be carried out in the
until it comes out from the other end. following sequence.
25
D. OPERATION & MAINTENANCE
which is mounted on the spring drum. from LH side. Align the assembly with
As soon as the roller (V6030) rests on a main shaft and insert the key (V6034)
operating disc, remove the clip and first on the inner cam disc and push the
release the roller. Push the main shaft shaft ahead. Then, locate the other key
till it comes out of the cam disc (V6024). on the outer cam disc and push the main
The next component on the main shaft shaft still ahead. Now as the main shaft
is the cam disc assembly (V4600). Fix comes out of the position, fix the bush
the cam disc assembly as per point 6 (V6035). Let the shaft guide properly in
and as shown in drg. 6C & 6E. The the bush as shown in fig. 6B and insert
dowel pin position with respect to the the spacer (V6025) and then fix the cam
key way of cam disc is very important disc assembly (V4600) as described
here. When the cam disc is inserted in Point-3 and one more spacer (V6025)
the main shaft, the dowel pin shall be on on the other side of the cam disc. Push
the rear side and it shall be well located the main shaft still further and fix the
in between operating lever assembly retainer circlip (V6036) with a special
(V5200) of the Y-Pole (middle pole). circlip plier. Ensure the circlip is fixed
After this insertion, the spacer tube properly in the groove of the main shaft
(V6025) and the special washer (V6026) as shown in the drg 6E.
shall be inserted as shown in fig 6D.
Now, the lever assembly (V6027) shall After this, push the main shaft still ahead
be mounted on the shaft and fix the and repeat the assembly of cam disc
roller (V6028), duly greased, on the pin (V4600) in the same way as done earlier
of the lever assembly. and put the retainer circlip on the right
hand side of the shaft.
Now take the control washer (V6031),
apply a light coat of grease in the CAUTION : Ensure that both the circlips
groove of rolling surface and hold it on are fixed properly in the groove of the
the roller (V6028) and insert the main shaft.
shaft through the control washer as Once this assembly is completed, check
shown in fig. 6D. The next step is to that all the items on the main shaft are
insert the spacer tube (V6032). This mounted correctly and nothing is missed
spacer shall be inserted in such a way out.
that the longer edge from the cutout is The next step is to roll the cam disc
inserted in the shaft from left hand side. (V6024), in its proper position and lock it
Then insert the stop (V6033) in the shaft with the hex. socket head bolt (V6037)
key way and the cutout of the spacer. and nylock nut - item no. (V5117). This
Push the shaft still further till it comes to completes the assembly of main shaft.
the end of the spacer. The next
assembly on the main shaft is the CAUTION
assembly of stop washer (V4300) A) As the roller (V6030) is a friction roller,
(refer point-3) on the main shaft. grease shall not be applied on the
Fix the assembly of stop washer in line surface of the roller.
with the main shaft and position it in B) While inserting the main shaft from
such a way that out of two noses of the right hand side, ensure that the hole on
stop washer the 1st nose is hold against the main shaft comes to a right position.
For this purpose, the main shaft shall be
The roller of the above assembly, i.e. inserted in such a way that longer
supporting crank assembly (V4900). The distance from the edge of the shaft
second nose of the stop washer shall be enters from right hand side.
in the clockwise direction while looking
26
12.7 Assembly of charging ratchet : push ahead the pin through the lockout
The charging ratchet assembly which is lever. Now, insert the torsion spring
made as per point no. 10, shall be (V6051) in such a way that one free end
mounted in the spring drum compartment shall be lifting the pin (V4904) of the
of the operating housing. supporting crank assembly. Push the pin
further to pass it through the other sheet
First of all, fix the bush (V6038) on both and fix the circlip (V6052). Now, pull the
the side plates and mount the indicator free end of the torsion spring (V6051)
lever assembly (V6039) in the bush, at and hook it to the LH side sheet with the
the same time, the pin on the lever special tool.
assembly shall be inserted in the hole of
the control shaft (V6014) and lock it with 12.9 Auxiliary Shaft Assembly :
a circlip (V4404). Now insert another (Drg. 6D& 6B, pg.no. 50 & 48)
bush (V6040) in the slot of the lever and The auxiliary shaft assembly is done on
insert the ratchet shaft in the bush. The the upper side of the operating
ratchet shaft shall be mounted with a mechanism and is used for operating the
sprocket wheel, (V6041 ), with chain auxiliary switch as well as the ON-OFF
(V4208) on it and also the torsion spring indicator.
(V6042). Slide the cylindrical pin (V5111)
in the hole of the charging shaft and This assembly shall be started from right
match the sprocket wheel to hold by the hand side.
pin and fix the sprocket wheel. Ensure,
the position of the sprocket wheel by CAUTION: While inserting the auxiliary
locking it with the special circlip (V6012). shaft (V6066), check the hole position of
the shaft. Fix the bush (V6053) on the
Once this assembly is completed, hold RH side plate of the operating housing
the non-return plate, (V6043) in a proper and insert the auxiliary shaft through the
position and insert the duly greased pin bush. Then insert 2 nos. crank (V6054)
(V6068) in the hole of charging shaft as in the opposite direction. Let the shaft
shown in drg. 6C and fix the other end pass through the next plate of the
with Hex. bolt (V6044). After this, hook operating housing and then pass it
one end of the torsion spring (V6042) through the ON-OFF indicator(V6061 ).
against this bolt and the other end in
between the washers on the charging Let the auxiliary shaft to come out from
ratchet assembly as shown in drg 6C. the next plate and add washer (V6016).
Now, insert the lockout lever (V6055)
12.8 Lockout Lever Assembly duly hooked with the torsion spring
Refer drg. (6B, pg.no. 48). (V6056). Now insert the washer (V6016)
Take lockout lever (V6045), insert pin again and insert the crank (V6057). Now,
(V6046). Now hold the torsion spring push the auxiliary shaft, align the latch
(V6047) within the lockout lever. Insert assembly as made earlier in point no. 4
the special pin (V6048) from right hand in a proper position and insert the
side. Put the thick washer (V6049) after auxiliary shaft through a spacer (V6058).
the middle partition and insert the Now, insert the bush (V6002) on the
lockout lever with the spring mounted in plate of operating housing from inside
the pin. Now, hook one end of the duly greased and then push the auxiliary
torsion spring (V6004) wound on the shaft through the bush.
D-shaft assembly on a special pin
(V6050) and pull the other end of the Push the shaft till it matches with the
spring on the special pin(V6048) then hole on crank (V6057) and fix the dowel
27
D. OPERATION & MAINTENANCE
pin (V6017) through the shaft. Also Now place the rubber washer - item no.
hammer the same dowel pin to fix the (V6078) on the tapped holes of the
ON-OFF indicator (V6061). auxiliary switch plate. Then place the
auxiliary switches (V6079 & V6080) as
Now position the two cranks (V6054) in identified earlier and tighten it with the
the appropriate position and fix it with hardware - item no. (V6081, V6082 &
hexagonal socket head bolt (M4x25) V6083) hex. Socket head screw M4x30,
(V6059) with the nylock nut (V4707). M4 spring washer and M4 plain washer
respectively. This hardware shall be
CHECK kept loose and shall be tightened after
Check that the whole assembly of the the setting of the auxiliary switch.
auxiliary shaft is correct as per drawing
and no part is missing in it. CAUTION :While inserting the auxiliary
switch plate, ensure that the fork of the
Now connect the other end of the lever auxiliary switch is properly guided in
assembly (V6027) to the ON-OFF the operating crank of the auxiliary
indicator with a pin (V6060) and a shaft and there is no undue stresses on
special clip (V6076). the auxiliary switch fork otherwise it
may break.
12.10 Auxiliary Switch Assembly
(Drg.7; pg.no. 52) CHECKING : Once the fixing is done,
Totally there are three auxiliary switches the auxiliary switches, which are
used in this circuit breaker. Out of the mounted loosely, shall be fixed after
three auxiliary switches, one is used as a setting of the stroke.
motor cut-off switch and other two are
used for closing & tripping circuit and for Setting-1 : For motor cut-off switch :
annunciation. Charge the spring of the circuit breaker,
as it charges the bracket lifts (V6088)
Take item no. (V4207) - auxiliary switch up the auxiliary switch fork. You should
plate and on the top side of the plate, fix measure the gap between moving fork
two spacers (V6070) with the help of and the fixed body of the auxiliary. The
M5x25 hexagonal socket head screw gap shall be set at 1.0 to 1.5 mm. After
(V6071) and self locking nut (V6072). this, fasten the screws of the auxiliary
Do not forget to fix the earthing strip switch.
(V6073) and fix the special pin (V6074).
Setting-2 : Switches for annunciation
Note-1 : The auxiliary switch used for scheme.
motor cut-off have a contact combination This setting shall be done when the
of 2N0+3NC. breaker is in closed condition.
Note-2 : The other two switches have a Close the breaker and set the gap
combination of 2NO+3NC and 3N0+2NC. between the forks of the auxiliary
Thus, the total number of contacts are switches and the body to 1 to 2 mm
5NO+5NC. approx. and fasten the screws
completely.
First of all, insert the cylindrical pin - item
no. V6075) in the fork of the auxiliary 12.10.A - Auxiliary Switch Assembly
switch and lock it with the circlip - item (Drg. 7A, pg.no.53)
no. (V6077). 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 There are different coils available for
in construction and it consists of one different voltage ratings and one should
auxiliary switch containing 6N0+6NC ensure while ordering/mounting of coils
contact configuration having a rotary on the circuit breaker for the for the
action and rotates 90° between two end right coils as per specifications.
positions.
Once the appropriate coils (as per
The auxiliary switch (V6122) is mounted specified voltages in the order) are
in a inverted position on the top sheet of identified, they are fixed in the proper
the breaker frame and the movement to position and shall be located in the
operate the auxiliary switch is taken from holes provided on the fixing plate.
the main shaft instead of an auxiliary Now, hold the magnet support (V6086)
shaft as in earlier version. A simple such a way that it backs-up the coils.
Aluminium link (V6124) is connected to Insert the hexagonal socket head screw
transfer the motion from shaft to the M4x35 (V6087) along with the plain &
auxiliary switch shaft through an arm spring washers (V6083 & V6082). The
(V6123). fixing plate is provided with a tapped
holes to mount these screws.
Dismantling of Auxiliary switch:
Remove the M6 bolt from top of the CAUTION
breaker frame and remove the pin While fixing the closing coil (V6084) &
connecting the Aluminium link with the tripping coil (V6085), check the
operating lever. following:
a) Direction of rotation of coil.
Assembly of the Auxiliary switch: b) Roll pin on the plunger shaft is
Mount the auxiliary switch in the inverted guided properly in the half shaft
position on the breaker frame and fix it slits.
with the M6 hardware. Now position the
arm of the auxiliary switch in the CHECK
respected position and fix the aluminium Once both the coils are mounted on the
link to connect it to the operating lever of breaker, check the movement of the
the breaker, push the pin in the link and fix push button levers is smooth and proper.
the split pin. Ensure the bending of the
split pin is proper. After this, take the wires of the coil out
and connect it to the appropriate
12.11 Operating Coil Assembly auxiliary switch position or on the
(Drg 8; pg.no. 54): terminals as per order related
Normally the two coils are mounted on schematics or typical circuit diagram
each circuit breaker to facilitate the refer. drg. 5
Electrical closing and electrical tripping of
the circuit breaker. Vacuum circuit breaker 12.11.A - Operating magnet assembly
type VD4E & VD4 is mounted with a (Drg. 7A, pg.no. 53 )
special type of coil in which electrical The new operating coil assembly
energy is converted into a rotary motion consists of two different operating coils
to operate the closing and tripping mounted independently and operate the
mechanism of the circuit breaker. Refer closing & tripping latches
drg.8 which shows general arrangement independently. The axial movement
of mounting of the operating coils. of plunger of the coil is converted
to the rotary movement of the latching
29
D. OPERATION & MAINTENANCE
shafts, thus executing the closing and mechanism. The collar of motor should be
opening command. properly located in the hole provided on the
motor support plate.
Dismantling of magnets: Remove the Now tighten the hexagonal socket head
M6 bolt from top of the breaker frame and screw M6x16 (V6093) along with spring
remove the closing coil (V6125) / opening washer (V6094). The crank (V6095)
coil (V6126) from the breaker as shown in along with cover plate and cylindrical pin.
the Fig No 7A. (V6097) are assembled with the help of
dowel pin (V6098) as shown in drg.9.
Assembly of magnets: Ensure the rating One end of cover plate is connected to the
of the closing magnet l opening magnet is charging ratchet assly. with help of Grooved
as specified in the drawing. Mount the pin(V6099) and circlip (V6100).
closing magnet / opening magnet Then Fix the crank with motor shaft by using
mounting bracket in the inverted position Hex socket head cap screw M4x35 (V6101 )
on the breaker frame and fix it with the M6 washer (V6083) and self locking nut (V4707).
hardware. Now set the setting screw
provided on the closing f lap (V6127) and 12.13.A Motor cutoff Switch
opening flap (V6128) which is connected Assembly :
to the half shaft and lock the same with The motor cut-off switch assembly is now an
nut. Ensure the bending of the split pin of independent assembly where the bracket
the plunger is proper. (V6088) drives the Lever assembly (V6129)
and operate a set of snap-action switch
12.12 Coupling of drive and pole : (V6130) by a lever-fulcrum mechanism.
Coupling of drive and poles is possible Drg7A shows the arrangement of motor cut-off
only when the operating mechanism and switch and its function. There are normally 3
poles are assembled completely. switches mounted on the micro switch
mounting bracket (V6131) consisting of
Once the drive assembly is completed, 1 NO + 2 NC contacts used for Motor cut-off
discharge the tripping springs, which are spring charge indication and closing interlock
precharged for assembly easiness. The purpose.
discharging shall be done by removing
the hexagonal socket head bolt from the 13. Instruction for discharging and charging:
rear side by unscrewing it. As you unscrew Before starting any maintenance work or
these three bolts, the opening springs replacement of components of operating
get discharged and spring holder cap mechanism. One shall ensure that the closing
seats in a hole provided on the operating spring is in completely discharged condition.
housing. For coupling the poles with the Without discharging the closing spring to its
operating mechanism refer the zero energy level it is very dangerous to work
assembly instruction as described in on mechanism. Follow the steps given below
clause A of the pole assembly. to discharge the spring.
12.13 Motor Assembly : (Drg. 9; pg.no.55) 1) The spring is normally charged for 4 turns.
There are different motors available for 2) Charge the spring manually and carry out
different voltage ratings. One should be ON-OFF operation.
very careful while ordering / mounting 3) Using the screw driver press the roller
motor on the circuit breaker for the (V6030) against the compression spring
specified voltage as per the order (V6029) which is mounted on the lever
specification. Once the appropriate motor assembly (V6014), the roller will drop down
is identified, fix the motor properly on the
motor support plate of the operating
30
and then carry out the ON -OFF operation. other dimensions as per assembly drg. 10.
4) Repeat the same three times.
5) Last one or two operations may not Once again check the breaker for
complete on its own as the energy level in the completeness and also paint seal the key
spring gets reduced. assemblies like interlocks, Auxiliary switches,
6) Using a special tool rotate the shaft after Motor assembly, Push rod assembly. Ensure
each ON -OFF command to complete the that greasing is done properly on all the rolling
operation. surfaces and then fix the front cover assembly
7) Check the freeness of the spring drum, thus (V6116) by hanging it on the top and fix it with
the spring is completely discharged. the hex. socket head bolt with the washer.
.
problems related to interchangeability
charging manually.
are eliminated.
4) Complete 4 rotations of the spring drum and
The contact arrangement adapted for
release the lever assembly.
this breaker is Tulip contact system
5) For the next charging the roller (V6030) will
and hence better alignment, flexibility
drop in the pocket and spring charging
.
and contact engagement with cubicle
indicator will show the position
contact can be achieved.
"SPRING CHARGED" .
The panel contacts are mounted in
the bushing and the metallic shutters
Now the circuit breaker is ready for operation.
are provided hence, better
compartmentalization is achieved.
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 Drg 1A shows General Arrangement and
the frame. Put the spacer (V6103) in between basic dimensions of the breaker type
frame and breaker and tighten hex bolt M12 VD4 / VD4E suitable for Unisafe panel.
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
31
32
E. LIST OF DRAWINGS & COMPONENT PART Nos.
List of Drawings 34
33
E. LIST OF DRAWINGS & COMPONENT PART Nos.
List of Drawings
6A to 6E Operating Mechanism
10 Truck Assembly
34
NAME OF ITEM REFERENCE No. DRG. No.
GROUP VG2S
OPERATING STUD V1003 4A
CONN. BAR (TOP) V1004 4A
CONN.BAR(BOTTOM) V1005 4A
BUSH V1006 4A
LABEL STICKER V1007 4A
FLEXIBLE CONDUCTOR V 1008 4A
SUPPORTING PLATE V1009 4A
SUPPORTING PLATE V1010 4A
CONTACT TERMINAL V1011 4A
SPECIAL NUT V1012 4A
CONTACT NUT V1013 4A
SPRING WAVE WASHER V1014 4A
SAFETY WASHER V1015 4A
HEX. SOCKET HD. CAP SCREW V1016 4A
HEX. SOCKET HD. CAP SCREW V1017 4A
CONICAL SP. WASHER V1018 (Unplated) 4A
HEX. NUT V1019 4A
HEX. SOCKET HD. CAP SCREW V 1020 4A
POLE HOUSING V2001 4B
VACUUM BOTTLE ASSY. V2002 4B
GROUP VC2
OPERATING STUD V2003 4B
CONNECTION PART V2004 4B
CHAMBER SUPPORT V2005 48
CONTACT FLANGE V2006 4B
CONTACT PISTON V2007 4B
ROLLER CONTACT COMP. V2008 4B
SAFETY WASHER V2009 4B
CONICAL SP. WASHER V2010 4B
SPRING WASHER V2011 4B
SPECIAL WASHER V2012 4B
SPRING WASHER V2013 4B
PRESSURE PLATE V2014 4B
HEX. SOCKET HD. CAP SCREW V2015 4B
HEX. SC. HD. CAP SCREW V2016 4B
HEX. SC. HD. CAP SCREW V2017 4B
35
E. LIST OF DRAWINGS & COMPONENT PART Nos.
36
NAME OF ITEM REFERENCE No. DRG. No.
SPRING PIN V4709 6A,6B
TORSION SPRING V4710 6A
TORSION SPRING V4711 6A
COUNTER V4801 6A,6B
ANGLE V4802 6A,6B
SLOTTED CHEESE HD. SCREW V4803 6A,6B
SPRING WASHER V4804 6A,6B,6C
TENSION SPRING V4805 6A,6B
BLOCKING CRANK V4901A/B 6A
BLOCKING CRANK V4902A/B 6A,6B
BLOCKING ROLLER V4903A/B 6A,6B,6C
CYLINDRICAL PIN V4904 6B
SPACER V4905A/B 6A,6B
GROOVED PIN V4906A/B 6B,6C
SHAFT V5101 6C
HEX. SOCKET HEAD SCREW V5102 6A,6C
HEX. SOCKET HEAD SCREW V5103 6C
SPACER V5104 6C
SLOTTED CH. HEAD SCREW V5105 6A,6C
TUBULAR RIVET V5106 6A,6C
CONICAL PLATE V5107 6A,6C
SUPPORT PLATE V5108 6A,6C
SLOTTED CH. HEAD SCREW V5109 6C
TUBULAR RIVET V5110 6C
CYLINDRICAL PIN V5111 6A,6C
SPROCKET V5112 6A,6C
LATCH V5113 6A,6C
TORSION SPRING V5114 6C
CHARGING LEVER V5115 6A,6C
NYLOCK HEX. NUT V5116 6C
NYLOCK HEX. NUT V5117 6A,6C
SPRING WASHER V5118 6A,6C
PLAIN WASHER V5119 6A
LEVER V5201 6A,6B,6E
LEVER V5202 6A,6B,6E
BOLT V5203 6A
ROLLER BEARING V5204 6E
RETAINING CIRCLIP V5205 6A,6E
SPECIAL PIN V5206 6B,6E
HOUSING V6001 6A
BUSH V6002 6A,6B,6D
AUXILIARY SWITCH PLATE V6003 7
TORSION SPRING V6004 6A,6B
37
E. LIST OF DRAWINGS & COMPONENT PART Nos.
38
NAME OF ITEM REFERENCE No. DRG. No.
SPECIAL PIN V6048 6A,6B
PLAIN WASHER V6049 6B
PIN V6050 6B
TORSION SPRING V6051 6A,6B
RETAINING CIRCLIP V6052 6A,6B,6C
BUSH V6053 6D
CRANK V6054 6D
LOCKOUTLEVER ASSEMBLY V6055 6A
TORSION SPRING V6056 6B,6D
CRANK V6057 6A,6B
SPACER V6058 6B
HEX. SO.HEADED SCREW V6059 6D
CYLINDRICAL PIN V6060 6D
ON- OFF INDICATOR V6061 6A,6D
SOCKET HD.CAP SCREW V6066 6A,6D
PIN V6068 6A,6D
SPACER V6070 7
HEX.SOCKET HEADED SCREW V6071 7
SELF LOCKING NUT V6072 7
EARTHING STRIP V6073 7
SPECIAL PIN V6074 7
CYLINDRICAL PIN V6075 7
RETAINING CIRCLIP V6076 6D,7
RETAINING CIRCLIP V6077 7
RUBBER WASHER V6078 7
AUXILIARY SWITCH V6079 7
AUXILIARY SWITCH V6080 7
HEX.SOCKET HEADED SCREW V6081 7
SPRING WASHER V6082 7,8
PLAIN WASHER V6083 7,8,9
CLOSING COIL V6084 8
TRIPPING COIL V6085 8
MAGNET SUPPORT V6086 8
HEX.SOCKET HEADED SCREW V6087 8
BRACKET V6088 7
SPECIAL CIRCLIP V6089 7
PIN V6090 7
HEX. SOCKET HD SCREW V6093 9
SPRING WASHER V6094 9
CRANK V6095 9
COVER PLATE V6096 9
CYLINDRICAL PIN V6097 9
DOWEL PIN V6098 9
39
E. LIST OF DRAWINGS & COMPONENT PART Nos.
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 VD4 CB Cross sectional view of VD4E CB
Drg. No.3
44
45
Drg. No. 4A Pole assembly
46
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