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Indoor Vacuum Circuit Breaker - Type VD4 / VD4E

Instruction for Installation, Operation & Maintenance


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

Contents Pg. No.

A. General 5

B. Design 9

C. Installation & Commissioning 13

D. Operation & Maintenance 17

E. Drawings & Spare Parts Reference 33

3
4
A. GENERAL

A. GENERAL Pg. No.

Key to type designation 6

Information on rating plate 7

Weight of circuit breaker 7

Handling & storage 8


Condition on delivery 8
Receipt 8
Unloading 8
Storage rules & regulations 8

Normal operating conditions 8

Special operating conditions 8

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.

Key to type Designation

As an example the type designation for VD4 12.06.25E is illustrated below

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

For entry level rated


current (up to 800A)

6
Information on Rating Plate

Type Circuit Breaker VD4 or VD4-E


Sr. No. Breaker Production Serial No.
Year Year of Manufacture
Standard IEC : 60056 / 62271-100
Rated voltage 12kV
Frequency 50Hz
Insulation level 28 / 75kVp
Normal current 800 or 1250 or 1600 Amps
Short circuit breaking current 13.1 or 20 or 26.3 kA
Duration of short circuit 3sec.
Short circuit making current 63kA or 80kA
Operating sequence O-0.3S-CO-3min-CO
Weight 100Kgs for VD4E or 125Kgs for Vd4
Auxiliary voltage:
Closing coil Rated voltage for closing coil
Opening coil Rated voltage for opening coil
Motor Rated voltage for spring charging motor
Instruction Manual 1VDU09001-YN

Break-up of the weight of the circuit breaker

Weight in Kgs.

Component VD4E VD4


3 Poles (Kgs) 35 50
Operating mechanism (Kgs) 50 60
Structure (Kgs) 15 15
Total(Kgs) 100 125

7
A. GENERAL

Handling & Storage Normal Operating Conditions


The vacuum circuit breakers of type VD4 are
General
basically suitable for normal operating
The Medium Voltage circuit breakers are
conditions for indoor Switchgear and
delivered firmly screwed to the floor of
switchboard in accordance with IEC
their containers or crates and must always

..
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

B. DESIGN Pg. No.

General features 10

Structure & function 10

Constructional details 10

Pole assembly 10

Operating mechanism 10

Truck assembly 10

Working principle of pole assembly 11


- Contact operation 11
- Principle of interruption 11

9
B. DESIGN

General Features conductor (V1008). The moving contact of


The vacuum interrupter in VD4 / VD4E circuit the interrupter is connected to the operating
breakers are designed such that the contact mechanism through a Operating stud (V1003/
speed, travel and mass is low, subsequently 2003). The disc springs inside the operating
low spring forces are sufficient for operation. studs exerts the required contact pressure on
The breaker operating mechanism is thus the contacts.
extremely low in wear, and the maintenance

.
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

C. INSTALLATION & COMMISSIONING Pg. No.

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

Erection . Free movement of the breaker from


withdrawn position to Test and from
Preparatory work
The following items should be held in . Test to Service and vice versa.
Proper engagement of secondary
readiness before the circuit breaker is placed
in position. .. plug and socket.
Proper functioning of various interlocks.
Proper engagement of earthing
Tools and Accessories
- Torque wrenches
- Ratchet
Range 0 -150Nm . contacts.
Proper engagement of connection bars
with the cubicle contacts.
- Torque screw drives Range 0 - 10Nm
- Extensions Range 0 - 250mm
- Allen keys size - 3 - 9 (1set) Electrical connection
- Open end & ring spanners High voltage connections
size - 5-32 (1set) Clean and degrease the silver plated
- Screw drivers size - 00-5 (1set) contacts with a clean, non-linting linen
- Flat nose plier with side cutter cloth and cleaning agent. Let dry well,
size - 120mm (1no) With a linen cloth. Apply a thin film of
- Circlip plier (1no) contact grease / Vaselene to the contact
- Extractor plier (1no) surfaces.
- Loctite 290,270,
- Grease ISOFLEX TOPAS NB 52 The high voltage connections are
- Cleaning cloth provided by means of assembly of
- Special tools connection bars on the breaker side and
- Main shaft rotation tool. finger pocket assembly on the cubicle
- Special screw driver for torsion side. Cleaning and degreasing are to be
spring. carried out in the same manner.
- Special socket for M6 nylock nut
assembly. Low voltage connections
The auxiliary circuit connection shall be

..
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 :

Table 1: Precommissioning Checks

SUBJECT OF PROCEDURE POSITIVE CHECK


INSPECTION

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

SUBJECT OF PROCEDURE POSITIVE CHECK


INSPECTION

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

8. Insulation With 2500V Meggar, measure insulation The insulation resistance


resistance resistance between phases and phase to should be at least 50 Mega
earth. Ohm & if the value is less
find out the cause.

9. Functions of Check interlock functions Interlock should function


various correctly.
interlocks

Functional checks Operating mechanism and to be


repeated for every remote controlled

.
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

D. OPERATION & MAINTENANCE Pg. No.


General Features 18
Table 2 - Maintenance schedule 18
Table 3 - Inspection details & actions 19
Table 4 - Inspection periodicity 20
Lubrication 20

Operation & maintenance of pole assembly 21


General 21
Maintenance 21
Replacement of complete pole assembly 21
Dismantling 21
Assembly 21

Operation & Maintenance of Operating mechanism 22


1. Tripping spring assembly 22
2. Closing spring assembly 22
3. Stop washer assembly 22
4. Latch assembly 22
5. D-shaft assembly 22
6. Cam disc assembly 22
7. Half shaft assembly 23
8. Counter assembly 23
9. Supporting crank assembly 23
10. Ratchet assembly 23
11. Operating lever assembly 24
12. Operating mechanism assembly 24
12.1 - 12.6 Assembly process 24
12.7 Assembly of charging ratchet 27
12.8 Lockout lever assembly 27
12.9 Auxiliary shaft assembly 27
12.10 Auxiliary switch assembly 28
12.10A Auxiliary switch 28
12.11 Operating coil assembly 29
12.11A Operating magnet 29
12.12 Coupling of drive pole 30
12.13 Motor assembly 30
12.13A Motor cut-off switch assembly 30
13. Instruction for discharging and charging 30
14. Instruction for discharging and charging 31
15. Truck assembly 31

VD4 / VD4E breaker for Unisafe panel 31

17
D. OPERATION & MAINTENANCE

OPERATION & MAINTENANCE showing the time intervals after which


Caution : maintenance work is generally required.
Before carrying out any maintenance work it is
essential to follow the procedures given below : On the basis of the results obtained during
Open the circuit breaker and check that the the periodic inspections, it is possible to set
closing springs are discharged . the optimal time limits for carrying out
Work must only be carried out when maintenance work.
the circuit breaker is withdrawn from the
enclosure. These rules should also be followed:

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

Table 2 Maintenance schedule

Maintenance Installation in normal ambient Installation in dusty


operations (or polluted) ambient
Carry out the One year Six months
general inspection
Carry out visual inspection
One year Six months
from outside and inspect
the medium voltage parts
Measure the insulation Three years Six months
resistance
Lubricate the sliding One year Six months
points
Carry out the operating Five years or every 10000 Three years or every 5000
mechanism maintenance operations operations
Complete overhaul Ten years or every 20000 Five years or every 10000
operations operations

18
General Inspection of the Circuit Breaker

Table 3 Inspection details and actions

Parts subjected to Abnormalities noticed Remedies

1. Operating Presence of dust on the Clean with a dry brush or cloth


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

19
D. OPERATION & MAINTENANCE

Table 4 : Inspection periodicity

Task/Parts tobe Based On years Based on No. Of As Points to Note


maintained operations reqd.
Occasionally After 5,000 10,000 20,000
Year
INSPECTIONS:
Operating mechanism 1 1 X XX X
X X General inspection
complete /lubrication
Screw connections 5 5 X X For tightness
Cable connections 5 5 X X For tightness
Return springs X X For Deformation
Circlips and Retaining 5 5 X X X X For Deformation
rings & Intactness
Interlocking rod assly. X X For proper
functioning
Microswitch assly. X X For proper
functioning
Motor cut off switch X X For proper
functioning
MAINTENANCE:
Lubrication 1 1 X X X X X
Closing spring assly. X X For Deformation
Spring charging X X For proper
motor functioning and
arcing level
Return springs X X For Deformation
Stop washer X X For Deformation
Auxiliary switch 2 2 X X X For gap setting
setting
Flexible X X X For tightness
Trip coil X
Close Coil X
Undervoltage coil X For proper
Blocking coil X functioning
Additional trip coil X
Major overhaul X

Lubrication grease type ISOFLEX TOPAS N852 shall be


All the sliding parts subject to friction must used for operating mechanism lubrication. The
be lubricated at the scheduled time. sliding parts shall be operated a few times
after lubrication so that the lubricant will
The lubrication shall be carried out as per penetrate properly through out the sliding /
the schedule given in table 2 , clause no. 6.3. rolling surface.
Clean brush or soft cloth shall be used to
carry out the lubrication. The special

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.

The pole assembly (Drg.4a & 4b,pg. No. 45)


..Rated normal current
Breaker type & serial number

..
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 :

. Is disconnected from the high voltage


and auxiliary voltage terminals.
. Tightening torque for these bolts is 45 Nm.
Insert the special tool in the main shaft, and
rotate the main shaft in the opposite
Is in the open position and the closing
direction. Also pull the lower end of the
. spring of the operating mechanism is fully
discharged.
operating stud from bottom side and match
the hole of operating stud with the holes on
Is fully withdrawn from the cubicle.
. the pair of levers.
Insert the pin in the operating stud and put
Caution
This service work may only be performed
by switchgear manufacturer's servicing
. the special circlip on it.
Similarly, couple all the poles one by one to
the mechanism and bring the mechanism to
personnel or adequately trained specialist staff.
a completely open position by rotating the
main shaft in reverse direction.

21
D. OPERATION & MAINTENANCE

Operation and Maintenance of 3. Stop washer assembly (V4300)


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

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.

Caution 9. Supporting crank assembly (V4900)


While mounting these fish plates, ensure that (Drg. 6B, pg.no. 48)
the slots provided on the fish plate are well Take the supporting crank ( V4901 [A/B]
guided in the boss provided on the crank and V4902[A/B]) and identify it as LH side
( V4702). and RH side on the basis of chamfer
provided. The chamfers of both the
Now insert 1 no. plain washer (V4705)and 1 supporting cranks should be face to face
no. plain thick washer (V4706). Again insert to each other and then - fix the locking
(V4705) and lock it with nylock nut (V4707). roller (V4903 [A/B]) and the cylindrical pin
Similarly for the other crank, put washer (V4904) a light coat of grease Isoflex
(V4705) and lock it with nylock nut. Topas N852 .
Now put the spacer (V4905[A/B]) in
Now take that half shaft (V4708). Apply a light between the two supporting cranks duly
coat of grease on both the ends. Insert a roll greased on from inside and then insert a
pin(V4709)on the hole provided on the slit end grooved pin (V4906[A/B]) through the
of the half shaft. The role pin insertion should given hole of the supporting crank as
be such that it should equally come out of the shown in drg.6B from the RH side. Apply a
half shaft from both the sides. Now insert the light coat of grease on the rolling area of
half shaft in the crank (V4702) as shown in the supporting crank and the locking roller.
drawing.
10. Ratchet assembly (V5100)
Insert the torsion springs (V4711 ) and (V4710) (Drg. 6C, pg.no. 49)
in each shaft and lock one end of the spring Refer to drg. 6C showing the assembly of
in between the washer (V4705) and lock the the ratchet for charging.
other end with the half shaft itself. First of all take a shaft (V5101 ) and place
it in such a way that the groove side of the
CHECK : shaft is up and then put the items in
Holding one of the fish plates, check the free sequence as given below :
movement of the other fish plate and half shaft.
First take Hex. socket head cap screw
After checking for both the half shafts, apply M6x45 & M6x30 (V5102 & V5103) insert
a light coat of grease on the rolling & moving spacer (V5104), longer screw.
areas of fish plate.

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.

Check: Refer, (6A,6C & 6D), separate out all the


1) Check the movement of the control items to be mounted on the main shaft
shaft. It shall be free in the two end and clean them thoroughly, apply a light
bushes. coat of grease ISOFLEX TOPAZ N852.
2) Check the action of the torsion
spring by applying a force on the Fix the bush (V6022). Apply a light coat
lockout lever. of grease and insert a main shaft
3) Check the dowel pin - item no. (V6023) through it. Now, before inserting
(V6020) is well located in the groove the assembly of closing spring (V4200),
of the lockout lever and on the leg of Insert the cam disc (V6024), as shown
the torsion spring. Also check the in drg. 6C. The cam disc crest profile
projection of dowel pin from the rear side. shall be kept towards the front side or
4)Check the other two roll pins (V6017), operator side. Mount the compression
are equally out of the control shaft from spring (V6029) and the roller (V6030) on
both the sides and dowel pins are not the control shaft (V6014) and hold it with
rubbing on the bush (V6013). a clip and now insert the closing spring
as explained in point no. 2, align the
12.5 As per the sequence of assembly, hook of the spiral spring with the shaft
supporting crank assembly shall be keyway and insert the shaft through the
mounted on the operating mechanism at spring drum and the operating disc,

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.

14. Instruction for discharging and charging:


Follow the procedure to charge the closing VD4 / VD4E Breaker for Unisafe Panel:
spring. The switchgear panel type Unisafe and the
1) Normally 4 complete turns are stored in a vacuum circuit breaker type VD4 / VD4E are
closing spring and a last turn to operate the of a very compact design. The main features
breaker.
2) Press the lever assembly(V6039) and hold
it while charging.
3) Mark a line on the spring drum and start
.
of this combination are:
The Rack-in mechanism is made as a
part of the circuit breaker. Hence, the

.
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.

E. LIST OF DRAWING & COMPONENT PART NUMBERS Pg.No.

List of Drawings 34

Component Part Numbers 35

33
E. LIST OF DRAWINGS & COMPONENT PART Nos.

List of Drawings

Fig No. Description


1 VD4 / VD4-E Circuit Breaker Drawing

1A VD4 / VD4-E Breakers for Unisafe Cubicle

2 Cross Sectional View Of VD4 Circuit Breaker

3 Cross Sectional View Of VD Interrupter

4A Pole Assembly Of VD4-E Breaker

4B Pole Assembly Of VD4 Breaker

5 Typical Circuit Diagram

6A to 6E Operating Mechanism

7 Auxiliary Switch Assembly

7A Coil & Aux. Switch Arrangement (New)

8 Operating Coil Assembly

9 Motor Mounting Assembly

10 Truck Assembly

34
NAME OF ITEM REFERENCE No. DRG. No.

POLE HOUSING V1001 4A


VACUUM BOTTLE ASSY. V1002 4A

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.

NAME OF ITEM REFERENCE No. DRG. No.

HEX. SC. HD. CAP SCREW V2018 4B


CONICAL SP. WASHER V2019 4B
HEX. NUT V2020 4B
GREASE ISOFLEX TOPAS N852. 4B
SPRING HOLDER V4101 6A
SPRING GUIDE V4102 6A,6E
COMPRESSION SPRING V4103 6E
COMPRESSION SPRING V4104 6E
OPERATING DISC V4201 6A,6C
SEPARATING PLATE V4202 6C
HEX. SOCKET HD. CAP SCREW V4203 6A,6C
SPRING WASHER V4204 6C
SPRING DRUM V4205 6C
SPRING V4206 6A
SPROCKET WHEEL DISC V4207 6A,6C,7
ROLLER CHAIN V4208 6C
CURVE WASHER V4301A/B 6A,6B
CURVE WASHER V43O2A/B 6A,6B
DAMPER V4303A 6B
CYLINDRICAL PIN V4304A/B 6B
STOP WASHER V43O5A/B 6A,6B
LATCH ASSY. V4401 6A,6B
LATCH V4402 6B
LINK V4403 6A,6B
CIRCLES V4404 6A
FISH PLATE V4405 6A,6B
CYLINDRICAL PIN V4406 6A
D-SHAFT V4501 6B
CRANK V4502 6A,6B
SPRING DOWEL PIN V4503 6B
CAM DISC V4601 6A,6E
SPRING PIN V4602 6E
SPRING PIN V4603 6E
HEX. SOCKET HD. CAP SCREW V4701 6A,6B
CRANK V4702 6A,6B
FISHPLATE-OFF V4703 6A
FISHPLATE-ON V4704 6A,6B
PLAIN WASHER V4705 6A,6B
SPRING WASHER V4706 6A,6B
NYLOCK HEX. NUT V4707 6A,6B,6D,9
HALFSHAFT V4708 6A,6B

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.

NAME OF ITEM REFERENCE No. DRG. No.


BUSH V6005 6B
BRACKET V6006 6B
HEX. SOCKET HEADED CAP SCREW V6007 6B
HEX.NUT V6008 6A,6B,6C
SPRING WASHER V6009 6C
TUBE V6010 6A,6E
CYLINDRICAL PIN V6011 6A,6E
RETAINING WASHER V6012 6E
BUSH V6013 6D
LEVER ASSEMBLY V6014 6A,6C,6D
TORSION SPRING V6015 6D
WASHER V6016 6A,6B
SPRING PIN V6017 6B,6D
LOCKOUTLEVER V6018 6A,6B
TORSION SPRING V6019 6A,6B
SPRING PIN V6020 6A,6B
BUSH V6021 6A,6B
BUSH V6022 6A,6C
SHAFT V6023 6A,6E
CAM DISC V6024 6A,6C
SPACER V6025 6A,6D,6E
SPECIAL WASHER V6026 6D
LEVER ASSEMBLY V6027 6D
ROLLER V6028 6D
COMPRESSION SPRING V6029 6C
ROLLER V6030 6C
CONTROL WASHER V6031 6D
SPACER TUBE V6032 6A,6B
STOP V6033 6B
FORK LOCK (KEY) V6034 6A,6B
BUSH V6035 6A,6B
CIRCLIP V6036 6E
MOTOR V6037 6A,6C
BUSHING V6038 6C
LEVER ASSEMBLY V6039 6A,6C
BUSH V6040 6C
SPROCKET WHEEL V6041 6C
TORSION SPRING V6042 6A,6C
NON RETURN PLATE V6043 6A,6C
HEX. BOLT V6044 6A,6B,6C
LOCKOUTLEVER V6045 6B
PIN V6046 6B
SPRING V6047 6A,6B

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.

NAME OF ITEM REFERENCE No. DRG. No.


GROOVED PIN V6099 9
RETAINING CIRCLIP V6100 9
HEX.SOCKET HEAD SCREW V6101 9
FRAME V6102 9
SPACER V6103 9
HEX.BOLT V6104 10
24 PIN PLUG ASSEMBLY V6105 10
INTERLOCKING ASSEMBLY V6106 10
EMERGENCY TRIP ASSEMBLY V6107 10
BARRIER PLATE V6108 10
CONNECTION PIECE V6109 10
CONNECTION BAR V6110 10
CONNECTION BAR V6111 10
CONNECTION BAR V6112 10
CONNECTION BAR V6113 10
CONNECTION BAR V6114 10
CONNECTION BAR V6115 10
FRONT COVER ASSEMBLY V6116 10
HEX. BOLT V6117 6A
HALFSHAFT V6118 6A,6C
DOWEL PIN V6119 6B
LOCKING LEVER V6120 6B
BLOCKING LEVER V6121 6C
AUXILIARY SWITCH V6122 7A
AUXILIARY SWITCH ARM V6123 7A
ALUMINIUM LINK V6124 7A
CLOSING MAGNET (NEW) V6125 7A
OPENING MAGNET (NEW) V6126 7A
CLOSING FLAP V6127 7A
OPENING FLAP V6128 7A
LEVER ASSEMBLY V6129 7A
SET OF MICROSWITCH V6130 7A
M/S MTG BRACKET V6131 7A

40
VD4E Breaker

41
VD4 Breaker

Drg. No. 1
VD4E Breaker
for UNISAFE
cubicle

42
VD4 Breaker
for UNISAFE
cubicle

Drg. No. 1A
43
Cross sectional view of VD4 CB Cross sectional view of VD4E CB

1 Breaker mechanism housing 15 Vacuum interrupter


1.1 Front cover - removable 16.2 Roller contact / Flexible conductor
12 Insulating material pole tube 17 Contact pressure spring
13 Upper breaker terminal 18 Insulated coupling rod
14 Lower breaker terminal 19 Operating spring
20 Shift lever pair Drg. No. 2
15.1 Insulator
15.2 Fixed contact
15.3 Movable contact
15.4 Metal bellows
15.5 Screen
15.6 Guide cylinder
15.7 Lid

Cross section of vacuum interrupter

Drg. No.3

44
45
Drg. No. 4A Pole assembly

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


1. Spring charging motor
2. Closing coil
3. Tripping coil
4. (S3, S4) CB Auxiliary
switch contacts
5. Microswitch operates in
T or S positionm
6. Plug & socket
Typical circuit diagram 7. (S1) Motor cut-off
switch
Drg. No.5 8. Breaker

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

Tel: +91 235 2351095 to 8


+91 253 2351261 to 4
Fax: +91 253 2350644 / 2351249 1VDU09001-YN

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