vd4 1vdu09001-yn manual

Indoor Vacuum Circuit Breaker - Type VD4 / VD4E

Instruction for Installation, Operation & Maintenance

Contents Pg. No.

A. General

B. Design

C. Installation & Commissioning

D. Operation & Maintenance

E. Drawings & Spare Parts Reference

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

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A. GENERAL Pg. No.

Key to type designation

Information on rating plate

Weight of circuit breaker

Handling & storage

Normal operating conditions

Special operating conditions

A. GENERAL

Condition on delivery

Receipt

Unloading

Storage rules & regulations

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A. GENERAL

The Vacuum Circuit Breaker type VD4E /

VD4 are intended for indoor installation in air-

insulated switchboards.

Vacuum circuit breakers are advantageous

to use in distribution networks especially

where there is a high switching frequency in

the working current range and/or where a

certain number of short circuit breaking

operations are expected.

Type VD4 / VD4-E vacuum circuit breakers

are suitable for auto-reclosing, and have

exceptionally high operating reliability and

long life.

The guaranteed technical particulars have

been confirmed by numerous tests in our

collaborators own laboratory & other

independent laboratories of world repute.

Key to type Designation

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)

VD4 12 06 25 E

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

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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 kADuration 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 Vd4Auxiliary 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

Component VD4E VD4

3 Poles (Kgs) 35 50

Operating mechanism (Kgs) 50 60

Structure (Kgs) 15 15

Total(Kgs) 100 125

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Weight in Kgs.

A. GENERAL

General

The Medium Voltage circuit breakers are

delivered firmly screwed to the floor of

their containers or crates and must always

be transported or stored in an upright

position. The circuit breaker is transhipped

in packing in the open (OFF) position and

with the closing spring discharged.

Condition on delivery

The factory assembled circuit breakers are

checked at the works for completeness of

the equipment and simultaneously

subjected to a routine test in accordance

with the IEC publication 56, thus verifying

their correct structure and function.

Receipt

Each delivery is to be checked on receipt

for :

- Completeness and correctness (Check

against order and delivery documents).

- Any possible damage in transit and

material losses.

Abnormality, if any, must be notified

immediately to:

-The manufacturer

-The forwarding agent and the

insurance company.

-The responsible claims inspector

according to the insurance

certificate for the purpose of making

out a damage or loss Certificate.

Unloading

Unloading of the package units must only

be carried out with a crane, fork lift truck

and / or transport trolley jack.

Storage Rules and Regulations

The material shall be stored in a well

ventilated storage room and to be protected

against dirt, damage and water ingression.

The original packing can be used for storage,

however, without the plastic sheet.

Normal Operating Conditions

The vacuum circuit breakers of type VD4 are

basically suitable for normal operating

conditions for indoor Switchgear and

switchboard in accordance with IEC

publication 694.

The following limit values apply :

Ambient temperature :

Maximum + 40°C

Maximum 24 hour average + 35°C

Minimum - 5°C

(according to "minus 5 indoor " class)

Humidity :

Maximum average relative humidity

measured over 24 hours: 95%

Maximum average relative humidity

measured over 1 month: 90%

Maximum site altitude : <1000m

(above MSL)

Note: The ambient air should not be

excessively contaminated by dust, smoke,

corrosive or combustible gases, vapours

or salt.

Special Operating Conditions

Special operating conditions are to be agreed

on by the manufacturer and user.

The manufacturers must be consulted in

advance about each special operating

condition.

Site altitude over 1000 m :

- Allow for the reduction in the dielectric

strength of the air.

Increased ambient temperature :

- Current carrying capacity is reduced.

- Provide additional ventilation for heat

dissipation.

Climate :

- To minimize risk of corrosion avoid areas

with:

- With high humidity

- Major rapid temperature fluctuations.

- Implement preventive measures (e.g.

electric heaters) to preclude condensation.

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Handling & Storage

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B. DESIGN

B. DESIGN Pg. No.

General features

Structure & function

Constructional details

Pole assembly

Operating mechanism

Truck assembly

Working principle of pole assembly

- Contact operation

- Principle of interruption

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B. DESIGN

General Features

The vacuum interrupter in VD4 / VD4E circuit

breakers are designed such that the contact

speed, travel and mass is low, subsequently

low spring forces are sufficient for operation.

The breaker operating mechanism is thus

extremely low in wear, and the maintenance

requirement are accordingly negligible.

Structure and Function (Drg.2 & 3, pg.no. 43 & 44)

The poles, which are constructed in column

form, are mounted on the bracket shaped rear

part of the breaker mechanism housing 1. The

live parts of the breaker poles are located in

the insulating material pole tubes 12 and

protected from impact and other external

influences.

With the breaker closed, the current path

leads from the breaker upper terminal 13 and

a chamber holder fixed in the pole tube to the

fixed contact 15.2 in the vacuum interrupter

15, then via the moving contact 15.3 and the

flexible conductor / roller contact 16.2 to the

breaker lower terminal 14. The switching

motion is effected by means of the insulated

coupling rod 18 with internal contact pressure

springs 17.

Constructional details

Vacuum circuit breaker type VD4-E / VD4

consists of :

Breaker poles of epoxy resin firmly

holding and protecting the vacuum

interrupter assembly from impacts and

other external influences.

A spring charged operating mechanism .

A truck assembly with relevant interlock

features.

conductor (V1008). The moving contact of

the interrupter is connected to the operating

mechanism through a Operating stud (V1003/

2003). The disc springs inside the operating

studs exerts the required contact pressure on

the contacts.

Operating Mechanism

The operating mechanism consists of :

A spring charging unit which can be

charged manually or electrically by a

geared motor.

Mechanical indicator showing spring

charged / discharged condition.

Indicator for open / close position of the

circuit breaker.

Closing / tripping magnet for performing

closing / opening operation of the circuit

breaker electrically.

Operation counter showing total number

of operations performed by the breaker.

Motor cut-off switch and auxiliary switch.

Switch for annunciation and control of

auxiliary circuits.

Optional items like under voltage trip

additional trip coil and blocking magnet.

The spring charging mechanism ensures that

the breaker can perform O-C-O operation if it

is closed and charged. The breaker can

perform C-O operation if it is open and

charged. As soon as the energy is removed

from the spring charging mechanism, the NO

contact of the cut-off switch is opened

interrupting the motor circuit. The spring

charging mechanism can also be recharged

manually by means of a charging handle.

Truck assembly (Drg.1, pg.no. 41)

This assembly consists of :

Frame assembly

Wheel rack assembly

Automatic secondary plug & socket

assembly.

Interlocking rod assembly

Bottom plate assembly

Emergency trip assembly

The above assembly provides the

following features :

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Pole assembly (Drg.4A & 4B, pg.nos. 45)

Pole assembly consists of a vacuum

interrupter (V1002 / V2002) mounted

firmly in the Pole housing

(V1001/ V2001) made out of epoxy resin.

The interrupter is firmly fixed on the top

connection bar and the moving contact

of the interrupter is connected to the

bottom connection bar with a Flexible

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Closed breaker can not be moved from test

to service position or vice-versa.

Breaker can not be closed when it is in

intermittent position.

The movement of the selector is blocked

when the breaker is in the closed condition.

A closed breaker can not be pushed into

test position from withdrawn position.

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operating levers driven by the individual

cam discs mounted on the common shaft.

Very high contact pressure is maintained

through the spring washer assembly housed

in a operating stud.

Principle of interruption

Due to the extremely low static interrupter -4 -8 chamber pressure of 10 to 10 in mbars,

only a relatively small contact gap is required

to achieve a high dielectric strength. The arc

is extinguished on one of the first natural

current zeros.

Due to small contact gap and high

conductivity of the metal vapour plasma, the

arc drop voltage, and additionally, due to short

arcing time, the associated arc energy, are

extremely low, which has advantageous

effects on the life of the contacts and thus on

that of the vacuum interrupters.

Working Principle of pole assembly

Contact operation

The closing and opening operations can be

carried out by means of the energy stored

in the operating mechanism. One common

spiral spring is used to carry out the closing

and opening operation of the breaker and

three individual compression spring

assemblies are used to assist the opening

operation of the three poles.The movement

/ stroke of the moving contact of the

vacuum interrupter is achieved through the

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C. INSTALLATION & COMMISSIONING

Preparatory work

Tools & accessories

Technical documents

Erection

Electrical connections

High voltage connections

Low voltage connections

Earthing

Commissioning

General checks

Table 1: Precommissioning checks

Functional checks

Final Checks

Handing over

C. INSTALLATION & COMMISSIONING Pg. No.

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C. ERECTION & COMMISSIONING

Erection

Preparatory work

The following items should be held in

readiness before the circuit breaker is placed

in position.

Tools and Accessories

- Torque wrenches Range 0 -150Nm

- Ratchet

- Torque screw drives Range 0 - 10Nm

- Extensions Range 0 - 250mm

- Allen keys size - 3 - 9 (1set)

- Open end & ring spanners

size - 5-32 (1set)

- Screw drivers size - 00-5 (1set)

- Flat nose plier with side cutter

size - 120mm (1no)

- Circlip plier (1no)

- Extractor plier (1no)

- Loctite 290,270,

- Grease ISOFLEX TOPAS NB 52

- Cleaning cloth

- Special tools

- Main shaft rotation tool.

- Special screw driver for torsion

spring.

- Special socket for M6 nylock nut

assembly.

Technical documents

Assembly drawings.

Customer’s order reference drawings.

Circuit diagram.

Dimensional drawings.

Erection

For erection of switchgear cubicle, refer the

relevant instruction manual for the particular

cubicle type.

When all the panels are erected correctly,

check that the cubicle fronts are in line and

that the cubicle doors with the interlocking

devices work correctly.

The movement of all the handles should be

easy and smooth.

Put the breaker into the cubicle and check

the following :

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Free movement of the breaker from

withdrawn position to Test and from

Test to Service and vice versa.

Proper engagement of secondary

plug and socket.

Proper functioning of various interlocks.

Proper engagement of earthing

contacts.

Proper engagement of connection bars

with the cubicle contacts.

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Electrical connection

High voltage connections

Clean and degrease the silver plated

contacts with a clean, non-linting linen

cloth and cleaning agent. Let dry well,

With a linen cloth. Apply a thin film of

contact grease / Vaselene to the contact

surfaces.

The high voltage connections are

provided by means of assembly of

connection bars on the breaker side and

finger pocket assembly on the cubicle

side. Cleaning and degreasing are to be

carried out in the same manner.

Low voltage connections

The auxiliary circuit connection shall be

checked as per the relevant schematic

diagram for correctness.

Earthing

The permanent earthing is provided by

means of earthing busbar in all the

switchgear cubicles. There are terminals

for connecting external earthings to this

busbar. The stations earthing terminal is

connected only in the end cubicle. Each

circuit breaker is provided with earthing

finger contacts mounted on, the top of

the breaker truck. These finger contacts

engage and slide against the wedge

type contact provided in the switchgear

cubicle, which is, in turn, connected to

the cubicle main earth busbar.

Lubricate the earthing contacts on the

breaker truck and cubicle with a thin film

of vaselene or contact grease and

ensure proper contact engagement.

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General procedures

Before putting the circuit breaker into service

carry out the following checks :

Check the tightness of the power

connections on the circuit breaker

terminals.

Check that the value of the supply voltage

for the auxiliary circuit is with in 85% and

110%, of the rated voltage, of the

electrical devices.

Check that no foreign material has got

into the moving parts.

Commissioning

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To gain access to the operating

mechanism safely, discharge the closing

springs (by closing & opening the circuit

breaker), then remove the cover of the

operating mechanism.

Check that air circulation in the circuit

breaker installation site is adequate so

that there is no danger of overheating.

Remove the transport caps from the poles,

Ensure that the instruction manual is

available to the operator at all the

times.

Carry out the checks indicated in table

no. 1 :

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Carry out a few closing and opening operation NOTE : Connect theundervoltage release with the relative rated auxiliary supply voltage (if provided)

Connect the geared motor for spring charging with the relative rated auxiliary supply voltage. Carry out a few closing and opening operations. . NOTE: Connect the undervoltage release with the relative rated auxiliary supply voltage (if provided)

Connect the undervoltage release with therelative rated auxiliary supply voltage and carry out the circuit breaker closing operation. Disconnect the power supply from the release.

Close the circuit breaker. Connect the shunt opening release with the relative rated auxiliary supply voltage.

Open the circuit breaker. Connect the shunt closing release with the relative rated auxiliary supply voltage.

The operations and the relevant indications occur correctly.

The geared motor recharges the spring after each closing operation.

The circuit breaker closes and the relevant indications occur correctly. The circuit breaker opens and the relevant indication occur correctly.

The circuit breaker opens and the relevant indication occur correctly.

The circuit breaker closes correctly and the relevant indications occur correctly.

SUBJECT OFINSPECTION

PROCEDURE POSITIVE CHECK

1. Manual operating mechanism

2. Motor operated mechanism (if provided)

3. Undertvoltage release (if provided)

4. Shunt opening release

5. Shunt closing release

Table 1: Precommissioning Checks

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SUBJECT OFINSPECTION

PROCEDURE POSITIVE CHECK

6. Auxiliary contacts in the operating mechanism

7. Test service position limit switch operation

8. Insulation resistance

9. Functions of various interlocks

Insert the auxiliary contacts into suitable signaling circuits. Carry out a few closingand opening operations of the circuitbreaker.

Move the breaker from test to service few times.

With 2500V Meggar, measure insulation resistance between phases and phase to earth.

Check interlock functions

Signals occur correctly

Test service position indications occur correctly.

The insulation resistance should be at least 50 Mega Ohm & if the value is less find out the cause.

Interlock should function correctly.

Functional checks must only be carried out

when:

The circuit breaker is disconnected from

the high voltage network and is correctly

earthed.

The breaker mounting screws are well

tightened.

Any foreign material that is likely to

disturb operations is removed.

The functional check is to be performed

in accordance with the instructions for

operation and maintenance of the

Functional checks Operating mechanism and to be

repeated for every remote controlled

command point.

Rack in the breaker into the switchgear

cubicle.

Re-check all electrical connections,

terminals and connecting leads.

After the checks are completed, the circuit

breaker can be handed over for

commissioning.

Final checks

Handing over

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C. ERECTION & COMMISSIONING

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D. OPERATION & MAINTENANCE

General Features

Table 2 - Maintenance schedule

Table 3 - Inspection details & actions

Table 4 - Inspection periodicity

Lubrication

Operation & maintenance of pole assembly

General

Maintenance

Replacement of complete pole assembly

Dismantling

Assembly

Operation & Maintenance of Operating mechanism

1. Tripping spring assembly

2. Closing spring assembly

3. Stop washer assembly

4. Latch assembly

5. D-shaft assembly

6. Cam disc assembly

7. Half shaft assembly

8. Counter assembly

9. Supporting crank assembly

10. Ratchet assembly

11. Operating lever assembly

12. Operating mechanism assembly

12.1 - 12.6 Assembly process

12.7 Assembly of charging ratchet

12.8 Lockout lever assembly

12.9 Auxiliary shaft assembly

12.10 Auxiliary switch assembly

12.10A Auxiliary switch

12.11 Operating coil assembly

12.11A Operating magnet

12.12 Coupling of drive pole

12.13 Motor assembly

12.13A Motor cut-off switch assembly

13. Instruction for discharging and charging

14. Instruction for discharging and charging

15. Truck assembly

VD4 / VD4E breaker for Unisafe panel

D. OPERATION & MAINTENANCE Pg. No.

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Caution :

Before carrying out any maintenance work it is

essential to follow the procedures given below :

Open the circuit breaker and check that the

closing springs are discharged .

Work must only be carried out when

the circuit breaker is withdrawn from the

enclosure.

General features

During normal service the circuit breakers

require only limited maintenance. The

frequency and the sort of inspections and

maintenance basically depend on the service

conditions. Various factors must be taken into

account. e.g. frequency of operations,

interrupted current values and relative power

factor as well as the ambient conditions.

Table no. 2 gives the maintenance schedule

OPERATION & MAINTENANCE


showing the time intervals after which

maintenance work is generally required.

On the basis of the results obtained during

the periodic inspections, it is possible to set

the optimal time limits for carrying out

maintenance work.

These rules should also be followed:

Any circuit breaker which operates only a

few times, that is remains closed (ON) or

open (OFF) for long periods, should be

operated from time to time to prevent clogging.

Clogging may cause a reduction in the closing

or opening speed.

When the circuit breaker is in service it

should be visually inspected from outside to

detect any dust, dirt or damage of any kind.

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Maintenanceoperations

Installation in normal ambient Installation in dusty(or polluted) ambient

Carry out thegeneral inspection

One year

One year

Three years

One year

Five years or every 10000operations

Six months

Six months

Six months

Six months

Three years or every 5000operations

Table 2 Maintenance schedule

Carry out visual inspection from outside and inspectthe medium voltage parts

Measure the insulationresistance

Lubricate the sliding points

Carry out the operatingmechanism maintenance

Complete overhaul Ten years or every 20000operations

Five years or every 10000operations

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Parts subjected to Abnormalities noticed Remedies

General Inspection of the Circuit Breaker

Table 3 Inspection details and actions

Presence of dust on themechanism

Clean with a dry brush or cloth

2. Medium voltage compartment parts

Distorted or oxidized springs

Locking rings out of place, loose nuts or screws

Wires and relative fasteners detached

Presence of dust or dirt on the insulating parts

Locking rings out of place. Loose nuts or screws

Replace the damaged spring

Refix the locking rings in their position and tighten the nuts or screw suitably.

Replace the wires fasteners and reconnect the detached wire correctly.

Clean with a dry brush or cloth

Refix the locking rings in their position and tighten the nuts or screws.

3. Earthing isolating contact

Distortion or cracking of the insulating parts

Ask manufacturer for replacement of the damaged parts

Oxidized isolating contacts

Traces of overheating or loose screws on the connections of the circuit breaker terminals

Traces of oxidation

Traces of oxidation and/or loose nut

Check the supply voltage of the operating mechanism electrical accessories

Carry out the functional tests

4. Earthing connection

5. Auxiliary circuit supply voltage

6. Operating and control elements

Clean with a rough cloth soaked in a suitable solvent and lubricate moderately with neutral / contact grease.

Clean the connections and breaker terminals with a rough rag soaked in a suitable solvent. Cover them with neutral grease and tighten the screws.

Clean with a rough cloth soaked in a suitable solvent and lubricate moderately with neutral grease.Clean with a rough cloth soaked in suitable solvent. Tighten the earthing connection fully and cover it with neutral grease.

The releases and the electrical interlocking devices must work correctly for values between 85% and 110% of the relative rated voltage.

Replace the damaged or faulty elements (if necessary ask manufacturer)

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1. Operating mechanism


INSPECTIONS:

Operating mechanism 1 X X X General inspection

complete /lubrication

Screw connections 5 X For tightness

Cable connections 5 X For tightness

Return springs X For Deformation

Circlips and Retaining 5 X X For Deformation

rings & Intactness

Interlocking rod assly. X For proper

functioning

Microswitch assly. X For proper

functioning

Motor cut off switch X For proper

functioning

MAINTENANCE:

Lubrication 1 X X X

Closing spring assly. X For Deformation

Spring charging X For proper

motor functioning and

arcing level

Return springs X For Deformation

Stop washer X For Deformation

Auxiliary switch 2 X For gap setting

setting

Flexible X For tightness

Trip coil

Close Coil

Undervoltage coil For proper

Blocking coil functioning

Additional trip coil

Major overhaul

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

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Table 4 : Inspection periodicity

Lubrication

All the sliding parts subject to friction must

be lubricated at the scheduled time.

The lubrication shall be carried out as per

the schedule given in table 2 , clause no. 6.3.

Clean brush or soft cloth shall be used to

carry out the lubrication. The special

grease type ISOFLEX TOPAS N852 shall be

used for operating mechanism lubrication. The

sliding parts shall be operated a few times

after lubrication so that the lubricant will

penetrate properly through out the sliding /

rolling surface.

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General

Weight of each pole assembly is approximately

12 Kg for VD4-E and 17 Kg for V D4.

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

consists of the following components :

Pole housing (V1001 / V2001)

Vacuum interrupter (V1002 / V2002)

Operating stud (V1003 / V2003)

Flexible conductor (V1008)

Roller contact assly. (V2008)

Top connection bar / Support

(V1004 / V2004)

Bottom connection bar/Contact flange assly.

(V1005 / V2006)

Maintenance

The breaker pole with vacuum interrupter

is maintenance free upto reaching the

permissible number of vacuum interrupter

operating cycles.

Checking of the vacuum is only necessary

when there is a good cause to suspect that

force applied externally to a pole tube has

caused damage to the vacuum interrupter

inside.

Before commencing the maintenance work,

ensure that the circuit breaker :

Is disconnected from the high voltage

and auxiliary voltage terminals.

Is in the open position and the closing

spring of the operating mechanism is fully

discharged.

Is fully withdrawn from the cubicle.

Caution

This service work may only be performed

by switchgear manufacturer's servicing

personnel or adequately trained specialist staff.

Operation & Maintenance of Pole

assembly

Replacement of complete pole assembly

Note To order the complete pole assembly for

circuit breaker type VD4E / VD4, the following

details should be furnished :

Rated voltage

Rated normal current

Breaker type & serial number

Order reference number

Dismantling :

Before dismantling the pole, ensure that the

breaker is in 'open' condition and closing

spring is discharged. To fully discharge the

closing spring, refer instruction 13(pg. No. 30).

Remove the special circlip (V6089) and

the pin (V6090) which connects the

operating stud (V1003 / V2003) end to the

lever assembly from the bottom side.

Remove the Hex. socket head screw

(V6091) from the bottom side of the breaker.

Take care to hold the pole assembly

properly while dismantling the screw.

Separate the pole assembly from the

operating mechanism assembly (V1000 /

V2000).

Assembly:

Hold the pole assembly in a proper position

and match the holes on the housing with the

holes on the bottom side of the breaker

frame.

Tighten the Hex. socket head screw (V6091)

and spring washer(V6092) from bottom side.

Tightening torque for these bolts is 45 Nm.

Insert the special tool in the main shaft, and

rotate the main shaft in the opposite

direction. Also pull the lower end of the

operating stud from bottom side and match

the hole of operating stud with the holes on

the pair of levers.

Insert the pin in the operating stud and put

the special circlip on it.

Similarly, couple all the poles one by one to

the mechanism and bring the mechanism to

a completely open position by rotating the

main shaft in reverse direction.

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Operation and Maintenance of

Operating Mechanism (Drg. 6A to 6E, pg.nos. 47 to 51)

Refer to the assembly drawings 6A to 6E.

The assembly drawing is self explanatory and

shows different assemblies in different sheets.

First of all make the sub-assemblies ready for

the final assembly as given below:

1. Tripping spring assembly (V4100)(Drg. 6E; pg.no. 51)

Take the spring holder (V4101), place the

compression springs (V4103 and V4104) ,

assembled one inside the other, on it place the

spring guide (V4102) on top of the spring.

Check that the springs are in vertical position

and tighten the socket head bolt M6x70 to

clamp the spring in the compressed position.

Apply a light coat of grease on the outer and

inner surface of the springs.

2. Closing spring assembly (V4200)

(Drg. 6C; pg.no. 49)

Take operating disc (V4201) and insert

separating plate (V4202) in the operating

disc as shown in figure 6C. Hold the plate in

a position and tighten it with a hex. socket

head screw (V4203) with spring washer

(V4204).

Now put this assembly of operating disc on the

spring drum (V4205) on the close side of the

drum and check that it rotates on the drum

easily.

Caution : The hex. socket head screw should

be tightened after the complete assembly of

the breaker before charging the spring to its

required precharge value. Now apply a light

layer of grease on the spiral spring surface

and fix the spiral spring (V4206) with one end

of the spring latched in a groove provided on

the drum and cover the open end of the drum

with the sprocket wheel disc (4207). Mount

the roller chain (V4208) and tie it with wire

so that it will not come out from the sprocket

wheel disc.


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

Take curve washers LHS & RHS (V4301[A/B]

/ V4302 [A/B]) and insert 6 nos. dampers

(V4303) in each curve washer. Now insert 6

cylindrical pins (V4304 [A/B]) in the curve

washer LHS with a light coat of grease. Press

the pins completely in the curve washer.

Now insert the stop washer (V4305 [A/B]) in

such a way that stopper nose of curve washer

and stop washer are in opposite direction to

each other and at 45° apart, refer fig. 6B.Once

the stop washer is inserted in the pins, also

press the right hand curve washer in the pins

and press the assembly so that there is no gap

between the three cam discs. After the

assembly, apply a light coat of grease on the

periphery of the cam disc.

4. Latch assembly (V4400) (Drg. 6B, pg.no. 48)

Take the latches (V4401 and V4402)

respectively, mount them on the common pin.

On the other end of the latch, insert link one

each (V4403) and put the circlip (V4404) on

both the latches. Now, hold both the free ends

of the links in the fish plate (V4405) and pass a

cylindrical pin (V4406) and lock it with the

circlip (V4404).

Apply a light coat of grease Isoflex Topas

N852 on the moving area of latch for free

movement of the latches.

5. D-Shaft Assembly (V4500) (Drg. 6B, pg.no. 48)

Take a D-Shaft (V4501 ), as shown in drg. 6B.

Insert the shaft in the crank (V4502) as shown

in fig. 6B. The position of the crank is very

important. Hold the assembly properly and

insert the spring dowel pin O5x30 (V4503)

and fix the crank by a dowel pin. Hammering

to be done very carefully so that it will not

damage the crank.

6. Cam disc Assembly (V4600)(Drg.6E, pg.no. 51)

Hold the cam disc (V4601) firmly on the

working table and press the spring dowel pin

(V4602 and V4603) respectively, one inside

the other.

/

22

Caution

Outer spring dowel pin slit should be pressed

in such a way that the slit is kept towards

the center of the cam and the inner spring

dowel pin slit should be kept opposite to the

outer one.

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

Take the hex. socket head screw M4x16

(V4701 ) as shown in drg. 68. Hold 2 cranks

(V4702) as shown in the drg. Mount the fish

plate (V4703) on tripping side and fish plate

(V4704) on the closing side of the crank.

Caution

While mounting these fish plates, ensure that

the slots provided on the fish plate are well

guided in the boss provided on the crank

( V4702).

Now insert 1 no. plain washer (V4705)and 1

no. plain thick washer (V4706). Again insert

(V4705) and lock it with nylock nut (V4707).

Similarly for the other crank, put washer

(V4705) and lock it with nylock nut.

Now take that half shaft (V4708). Apply a light

coat of grease on both the ends. Insert a roll

pin(V4709)on the hole provided on the slit end

of the half shaft. The role pin insertion should

be such that it should equally come out of the

half shaft from both the sides. Now insert the

half shaft in the crank (V4702) as shown in

drawing.

Insert the torsion springs (V4711 ) and (V4710)

in each shaft and lock one end of the spring

in between the washer (V4705) and lock the

other end with the half shaft itself.

CHECK :

Holding one of the fish plates, check the free

movement of the other fish plate and half shaft.

After checking for both the half shafts, apply

a light coat of grease on the rolling & moving

areas of fish plate.

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

Take a counter assembly - item no.

(V4801 ). Position the arm of the counter

suitably and tighten it with a screw driver.

Now mount this counter on a mounting

angle (V4802) with M3 cheese head

screw (V4803) and spring washer

(V4804).

Now hang the tension spring (V4805) in

the hole provided on the arm and crimp its

end suitably so that it will not come out of

the hole.

9. Supporting crank assembly (V4900)(Drg. 6B, pg.no. 48)

Take the supporting crank ( V4901 [A/B]

and V4902[A/B]) and identify it as LH side

and RH side on the basis of chamfer

provided. The chamfers of both the

supporting cranks should be face to face

to each other and then - fix the locking

roller (V4903 [A/B]) and the cylindrical pin

(V4904) a light coat of grease Isoflex

Topas N852 .

Now put the spacer (V4905[A/B]) in

between the two supporting cranks duly

greased on from inside and then insert a

grooved pin (V4906[A/B]) through the

given hole of the supporting crank as

shown in drg.6B from the RH side. Apply a

light coat of grease on the rolling area of

the supporting crank and the locking roller.

10. Ratchet assembly (V5100) (Drg. 6C, pg.no. 49)

Refer to drg. 6C showing the assembly of

the ratchet for charging.

First of all take a shaft (V5101 ) and place

it in such a way that the groove side of the

shaft is up and then put the items in

sequence as given below :

First take Hex. socket head cap screw

M6x45 & M6x30 (V5102 & V5103) insert

spacer (V5104), longer screw.

23


Now in a small hole of the conical plate

(V5107), insert V5105 - M3x25 cheese head

screw M3x25 (V5105) and a tubular rivet

(V5106). Above that insert support plate

(V5108) with cheese head screw (V5109) and

tubular rivet (V5110)fixed on it. After this, insert

the cylindrical pin (V5111 ) and locate the

sprocket (V5112) with the right direction. Apply

a light coat of grease on the pin and in

between the conical plate and support plate.

Now take 2 nos. latch (V5113), hook both

the latches to the spring (V5114) properly and

fix it in the special slots provided on the

support plate and conical plate one each. The

charging lever (V5115) shall be located on two

hex.socket head screws fixed earlier. Repeat

the assembly of support plate and conical

plate duly greased and fix the other end of two

latches in the slots. Put another tubular rivet

(V5110) and lock the small cheese head

screws with a nylock nut (V5116) of size M3.

Do not excessively tighten the nylock nuts.

Also fix the nylock hex. nut (V5117) on hex.

socket head screw M6 on the longer screw put

two plain washers (V5118) and then one big

washer (V5119) and tighten it with t he nylock

nut (V5117).

Check the assembly for its operation by

charging it through the hole provided on the

charging lever (V5115) for its movement

in the right direction. Also check the assembly

for spring action for the latches.

11. Operating lever assembly (V5200) (Drg. 6E, pg.no. 51)

Take the operating levers (V5201 [A/B] &

V5202 [A/B]) and pair it on the basis of LH

side 8 RH side. Locate the tripping spring

assembly as shown in the fig. 6E.

Now take the bolt (V5203) and insert the bolt

through LH side lever and pass it through

the roller bearing (V5204). Put the circlip

(V5205) and clamp it. For R-pole operating

lever special pin(V5206), shall be used instead

of (V5203).

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

The operating mechanism assembly is

sub-divided into different sub-assemblies :

1 ) Half shaft assembly.

2) D-shaft assembly.

3) Operating lever assembly.

4) Control shaft assembly.

5) Supporting crank assembly.

6) Main shaft assembly.

7) Charging ratchet assembly.

8) Blocking lever assembly.

9) Auxiliary shaft assembly.

10) Coil assembly.

After keeping all sub-assemblies ready for

main assembly, we shall start the main

assembly of operating mechanism. Refer drg.

6A to 6E for the mechanism assembly.

Take operating housing (V6001 ) and fix

the special bush (V6002) as shown

in drg. (6B & 6D). Apply a light coat of

grease and mount the half shaft

assembly as shown in the drg. 6B & 6D

After this assembly, the D Shaft assembly

(V4500) shall be mounted as shown in

drg. 6A & 6B. Place the bush (V6003) in

the hole provided in the side sheet. Insert

the D-shaft assembly with torsion spring

(V6004) and push the bush (V6005) from

outside the sheet and hold it in the proper

position as shown in fig 6B. Once the

positioning is done, clamp the bush with

bracket (V6006), and hold the bracket

with hex. Socket headed screw (V6007)

with spring washer & hexagonal nut

(V6008 & V6009).

After this assembly, the assembly of 3

operating levers (V5200) shall be done.

The assembled levers are to be inserted

in the pivot plates of the operating

housing as shown in the drg. 6E. With the

spacer (V6010) and the duly greased

grooved pin (V6011 ), which is to be

clamped on both the ends by a special

circlip (V6012). Ensure that the spring

guide is well located in the hole provided

12.1

12.2

12.3

24

on the operating housing as well as the

free movement of the lever assembly in

the operating mechanism. Use stepped

bush (V6062) for the assembly of

R-pole operating lever.

Now the assembly of the control shaft

shall be carried out in the following steps.

First of all, fix the bush (V6013) duly

greased from inside - as shown in drg 6D,

in the middle partition of the operating

mechanism. Now insert the control shaft

(V6014) as shown and put torsion spring

(V6015) in the other end of the control

shaft and then fix the bush (V6002)

from outside and locate the control shaft

in it. Apply a light coat of grease inside

the bush, place one or two washers

(V6016), depending on the space

available next to the bush. Now insert

the spiral dowel pin (V6017) in the holes

to locate the control shaft and to hold the

torsion spring in a position. Now insert the

lockout lever (V6018) with the torsion

spring (V6019) inside the lockout lever

as shown in Fig.6B. Position the dowel

pin (V6020) well above the leg of the

torsion spring and press the dowel pin

until it comes out from the other end.

Check:

1) Check the movement of the control

shaft. It shall be free in the two end

bushes.

2) Check the action of the torsion

spring by applying a force on the

lockout lever.

3) Check the dowel pin - item no.

(V6020) is well located in the groove

of the lockout lever and on the leg of

the torsion spring. Also check the

projection of dowel pin from the rear side.

4)Check the other two roll pins (V6017),

are equally out of the control shaft from

both the sides and dowel pins are not

rubbing on the bush (V6013).

As per the sequence of assembly,

supporting crank assembly shall be

mounted on the operating mechanism at

12.4

this stage.

Fix the bush / spacer (V6021/ V6063)

Refer assembly fig. 6B in the hole

provided on operating housing. Apply a

light coat of grease from the inner

surface of the bush / spacer and take

the assembly of supporting crank made,

as explained in point no.9 (V4900).

Remove the grooved pin (V4906 [A/B])

without disturbing the whole assembly

and hold it in the proper position and

insert the same pin through the middle

partition of the operating mechanism

and pass it through the supporting

cranks and bushes (V6064 & V6065)

mounted on the other plate of the

mechanism. Hook the long leg of the

torsion spring (V6015) in the groove

provided on the pin (V4906 [A/B]) with a

special fixing screw driver carefully.

Check : Check for the free movement of

the supporting crank inside the grooved

pin (V4906 [A/B]).

After this assembly, the assembly of

main shaft shall be carried out in the

following sequence.

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

items to be mounted on the main shaft

and clean them thoroughly, apply a light

coat of grease ISOFLEX TOPAZ N852.

Fix the bush (V6022). Apply a light coat

of grease and insert a main shaft

(V6023) through it. Now, before inserting

the assembly of closing spring (V4200),

Insert the cam disc (V6024), as shown

in drg. 6C. The cam disc crest profile

shall be kept towards the front side or

operator side. Mount the compression

spring (V6029) and the roller (V6030) on

the control shaft (V6014) and hold it with

a clip and now insert the closing spring

as explained in point no. 2, align the

hook of the spiral spring with the shaft

keyway and insert the shaft through the

spring drum and the operating disc,

12.5

12.6

25

which is mounted on the spring drum.

As soon as the roller (V6030) rests on a

operating disc, remove the clip and

release the roller. Push the main shaft

till it comes out of the cam disc (V6024).

The next component on the main shaft

is the cam disc assembly (V4600). Fix

the cam disc assembly as per point 6

and as shown in drg. 6C & 6E. The

dowel pin position with respect to the

key way of cam disc is very important

here. When the cam disc is inserted in

the main shaft, the dowel pin shall be on

the rear side and it shall be well located

in between operating lever assembly

(V5200) of the Y-Pole (middle pole).

After this insertion, the spacer tube

(V6025) and the special washer (V6026)

shall be inserted as shown in fig 6D.

Now, the lever assembly (V6027) shall

be mounted on the shaft and fix the

roller (V6028), duly greased, on the pin

of the lever assembly.

Now take the control washer (V6031),

apply a light coat of grease in the

groove of rolling surface and hold it on

the roller (V6028) and insert the main

shaft through the control washer as

shown in fig. 6D. The next step is to

insert the spacer tube (V6032). This

spacer shall be inserted in such a way

that the longer edge from the cutout is

inserted in the shaft from left hand side.

Then insert the stop (V6033) in the shaft

key way and the cutout of the spacer.

Push the shaft still further till it comes to

the end of the spacer. The next

assembly on the main shaft is the

assembly of stop washer (V4300)

(refer point-3) on the main shaft.

Fix the assembly of stop washer in line

with the main shaft and position it in

such a way that out of two noses of the

stop washer the 1st nose is hold against

The roller of the above assembly, i.e.

supporting crank assembly (V4900). The

second nose of the stop washer shall be

in the clockwise direction while looking

from LH side. Align the assembly with

main shaft and insert the key (V6034)

first on the inner cam disc and push the

shaft ahead. Then, locate the other key

on the outer cam disc and push the main

shaft still ahead. Now as the main shaft

comes out of the position, fix the bush

(V6035). Let the shaft guide properly in

the bush as shown in fig. 6B and insert

the spacer (V6025) and then fix the cam

disc assembly (V4600) as described

Point-3 and one more spacer (V6025)

on the other side of the cam disc. Push

the main shaft still further and fix the

retainer circlip (V6036) with a special

circlip plier. Ensure the circlip is fixed

properly in the groove of the main shaft

as shown in the drg 6E.

After this, push the main shaft still ahead

and repeat the assembly of cam disc

(V4600) in the same way as done earlier

and put the retainer circlip on the right

hand side of the shaft.

CAUTION : Ensure that both the circlips

are fixed properly in the groove of the

shaft.

Once this assembly is completed, check

that all the items on the main shaft are

mounted correctly and nothing is missed

out.

The next step is to roll the cam disc

(V6024), in its proper position and lock it

with the hex. socket head bolt (V6037)

and nylock nut - item no. (V5117). This

completes the assembly of main shaft.

CAUTION

A) As the roller (V6030) is a friction roller,

grease shall not be applied on the

surface of the roller.

B) While inserting the main shaft from

right hand side, ensure that the hole on

the main shaft comes to a right position.

For this purpose, the main shaft shall be

inserted in such a way that longer

distance from the edge of the shaft

enters from right hand side.


26

12.7 Assembly of charging ratchet :

The charging ratchet assembly which is

made as per point no. 10, shall be

mounted in the spring drum compartment

of the operating housing.

First of all, fix the bush (V6038) on both

the side plates and mount the indicator

lever assembly (V6039) in the bush, at

the same time, the pin on the lever

assembly shall be inserted in the hole of

the control shaft (V6014) and lock it with

a circlip (V4404). Now insert another

bush (V6040) in the slot of the lever and

insert the ratchet shaft in the bush. The

ratchet shaft shall be mounted with a

sprocket wheel, (V6041 ), with chain

(V4208) on it and also the torsion spring

(V6042). Slide the cylindrical pin (V5111)

in the hole of the charging shaft and

match the sprocket wheel to hold by the

pin and fix the sprocket wheel. Ensure,

the position of the sprocket wheel by

locking it with the special circlip (V6012).

Once this assembly is completed, hold

the non-return plate, (V6043) in a proper

position and insert the duly greased pin

(V6068) in the hole of charging shaft as

shown in drg. 6C and fix the other end

with Hex. bolt (V6044). After this, hook

one end of the torsion spring (V6042)

against this bolt and the other end in

between the washers on the charging

ratchet assembly as shown in drg 6C.

Lockout Lever Assembly

Refer drg. (6B, pg.no. 48).

Take lockout lever (V6045), insert pin

(V6046). Now hold the torsion spring

(V6047) within the lockout lever. Insert

the special pin (V6048) from right hand

side. Put the thick washer (V6049) after

the middle partition and insert the

lockout lever with the spring mounted in

the pin. Now, hook one end of the

torsion spring (V6004) wound on the

D-shaft assembly on a special pin

(V6050) and pull the other end of the

spring on the special pin(V6048) then

12.8

push ahead the pin through the lockout

lever. Now, insert the torsion spring

(V6051) in such a way that one free end

shall be lifting the pin (V4904) of the

supporting crank assembly. Push the pin

further to pass it through the other sheet

and fix the circlip (V6052). Now, pull the

free end of the torsion spring (V6051)

and hook it to the LH side sheet with the

special tool.

Auxiliary Shaft Assembly :

(Drg. 6D& 6B, pg.no. 50 & 48)

The auxiliary shaft assembly is done on

the upper side of the operating

mechanism and is used for operating the

auxiliary switch as well as the ON-OFF

indicator.

This assembly shall be started from right

hand side.

CAUTION: While inserting the auxiliary

shaft (V6066), check the hole position of

the shaft. Fix the bush (V6053) on the

RH side plate of the operating housing

and insert the auxiliary shaft through the

bush. Then insert 2 nos. crank (V6054)

in the opposite direction. Let the shaft

pass through the next plate of the

operating housing and then pass it

through the ON-OFF indicator(V6061 ).

Let the auxiliary shaft to come out from

the next plate and add washer (V6016).

Now, insert the lockout lever (V6055)

duly hooked with the torsion spring

(V6056). Now insert the washer (V6016)

again and insert the crank (V6057). Now,

push the auxiliary shaft, align the latch

assembly as made earlier in point no. 4

in a proper position and insert the

auxiliary shaft through a spacer (V6058).

Now, insert the bush (V6002) on the

plate of operating housing from inside

duly greased and then push the auxiliary

shaft through the bush.

Push the shaft till it matches with the

hole on crank (V6057) and fix the dowel

12.9

27

pin (V6017) through the shaft. Also

hammer the same dowel pin to fix the

ON-OFF indicator (V6061).

Now position the two cranks (V6054) in

the appropriate position and fix it with

hexagonal socket head bolt (M4x25)

(V6059) with the nylock nut (V4707).

CHECK

Check that the whole assembly of the

auxiliary shaft is correct as per drawing

and no part is missing in it.

Now connect the other end of the lever

assembly (V6027) to the ON-OFF

indicator with a pin (V6060) and a

special clip (V6076).

Auxiliary Switch Assembly

(Drg.7; pg.no. 52)

Totally there are three auxiliary switches

used in this circuit breaker. Out of the

three auxiliary switches, one is used as a

motor cut-off switch and other two are

used for closing & tripping circuit and for

annunciation.

Take item no. (V4207) - auxiliary switch

plate and on the top side of the plate, fix

two spacers (V6070) with the help of

M5x25 hexagonal socket head screw

(V6071) and self locking nut (V6072).

Do not forget to fix the earthing strip

(V6073) and fix the special pin (V6074).

Note-1 : The auxiliary switch used for

motor cut-off have a contact combination

of 2N0+3NC.

Note-2 : The other two switches have a

combination of 2NO+3NC and 3N0+2NC.

Thus, the total number of contacts are

5NO+5NC.

First of all, insert the cylindrical pin - item

no. V6075) in the fork of the auxiliary

switch and lock it with the circlip - item

no. (V6077).

12.10

Now place the rubber washer - item no.

(V6078) on the tapped holes of the

auxiliary switch plate. Then place the

auxiliary switches (V6079 & V6080) as

identified earlier and tighten it with the

hardware - item no. (V6081, V6082 &

V6083) hex. Socket head screw M4x30,

M4 spring washer and M4 plain washer

respectively. This hardware shall be

kept loose and shall be tightened after

the setting of the auxiliary switch.

CAUTION :While inserting the auxiliary

switch plate, ensure that the fork of the

auxiliary switch is properly guided in

the operating crank of the auxiliary

shaft and there is no undue stresses on

the auxiliary switch fork otherwise it

may break.

CHECKING : Once the fixing is done,

the auxiliary switches, which are

mounted loosely, shall be fixed after

setting of the stroke.

Setting-1 : For motor cut-off switch :

Charge the spring of the circuit breaker,

as it charges the bracket lifts (V6088)

up the auxiliary switch fork. You should

measure the gap between moving fork

and the fixed body of the auxiliary. The

gap shall be set at 1.0 to 1.5 mm. After

this, fasten the screws of the auxiliary

switch.

Setting-2 : Switches for annunciation

scheme.

This setting shall be done when the

breaker is in closed condition.

Close the breaker and set the gap

between the forks of the auxiliary

switches and the body to 1 to 2 mm

approx. and fasten the screws

completely.

12.10.A - Auxiliary Switch Assembly

(Drg. 7A, pg.no.53)

The new arrangement of Auxiliary Switch

is recently introduced in these breakers


28

Operating Coil Assembly

(Drg 8; pg.no. 54):

Normally the two coils are mounted on

each circuit breaker to facilitate the

Electrical closing and electrical tripping of

the circuit breaker. Vacuum circuit breaker

type VD4E & VD4 is mounted with a

special type of coil in which electrical

energy is converted into a rotary motion

to operate the closing and tripping

mechanism of the circuit breaker. Refer

drg.8 which shows general arrangement

of mounting of the operating coils.

12.11

and the constructional details are shown

in the drg: 7A. This arrangement is simple

in construction and it consists of one

auxiliary switch containing 6N0+6NC

contact configuration having a rotary

action and rotates 90° between two end

positions.

The auxiliary switch (V6122) is mounted

in a inverted position on the top sheet of

the breaker frame and the movement to

operate the auxiliary switch is taken from

the main shaft instead of an auxiliary

shaft as in earlier version. A simple

Aluminium link (V6124) is connected to

transfer the motion from shaft to the

auxiliary switch shaft through an arm

(V6123).

Dismantling of Auxiliary switch:

Remove the M6 bolt from top of the

breaker frame and remove the pin

connecting the Aluminium link with the

operating lever.

Assembly of the Auxiliary switch:

Mount the auxiliary switch in the inverted

position on the breaker frame and fix it

with the M6 hardware. Now position the

arm of the auxiliary switch in the

respected position and fix the aluminium

link to connect it to the operating lever of

the breaker, push the pin in the link and fix

the split pin. Ensure the bending of the

split pin is proper.

There are different coils available for

different voltage ratings and one should

ensure while ordering/mounting of coils

on the circuit breaker for the for the

right coils as per specifications.

Once the appropriate coils (as per

specified voltages in the order) are

identified, they are fixed in the proper

position and shall be located in the

holes provided on the fixing plate.

Now, hold the magnet support (V6086)

such a way that it backs-up the coils.

Insert the hexagonal socket head screw

M4x35 (V6087) along with the plain &

spring washers (V6083 & V6082). The

fixing plate is provided with a tapped

holes to mount these screws.

CAUTION

While fixing the closing coil (V6084) &

tripping coil (V6085), check the

following:

a) Direction of rotation of coil.

b) Roll pin on the plunger shaft is

guided properly in the half shaft

slits.

CHECK

Once both the coils are mounted on the

breaker, check the movement of the

push button levers is smooth and proper.

After this, take the wires of the coil out

and connect it to the appropriate

auxiliary switch position or on the

terminals as per order related

schematics or typical circuit diagram

refer. drg. 5

12.11.A - Operating magnet assembly

(Drg. 7A, pg.no. 53 )

The new operating coil assembly

consists of two different operating coils

mounted independently and operate the

closing & tripping latches

independently. The axial movement

of plunger of the coil is converted

to the rotary movement of the latching

29


12.12

mechanism. The collar of motor should be

properly located in the hole provided on the

motor support plate.

Now tighten the hexagonal socket head

screw M6x16 (V6093) along with spring

washer (V6094). The crank (V6095)

along with cover plate and cylindrical pin.

(V6097) are assembled with the help of

dowel pin (V6098) as shown in drg.9.

One end of cover plate is connected to the

charging ratchet assly. with help of Grooved

pin(V6099) and circlip (V6100).

Then Fix the crank with motor shaft by using

Hex socket head cap screw M4x35 (V6101 )

washer (V6083) and self locking nut (V4707).

12.13.A Motor cutoff Switch

Assembly :

The motor cut-off switch assembly is now an

independent assembly where the bracket

(V6088) drives the Lever assembly (V6129)

and operate a set of snap-action switch

(V6130) by a lever-fulcrum mechanism.

Drg7A shows the arrangement of motor cut-off

switch and its function. There are normally 3

switches mounted on the micro switch

mounting bracket (V6131) consisting of

1 NO + 2 NC contacts used for Motor cut-off

spring charge indication and closing interlock

purpose.

12.13

13. Instruction for discharging and charging:

Before starting any maintenance work or

replacement of components of operating

mechanism. One shall ensure that the closing

spring is in completely discharged condition.

Without discharging the closing spring to its

zero energy level it is very dangerous to work

on mechanism. Follow the steps given below

to discharge the spring.

1) The spring is normally charged for 4 turns.

2) Charge the spring manually and carry out

ON-OFF operation.

3) Using the screw driver press the roller

(V6030) against the compression spring

(V6029) which is mounted on the lever

assembly (V6014), the roller will drop down

shafts, thus executing the closing and

opening command.

Dismantling of magnets: Remove the

M6 bolt from top of the breaker frame and

remove the closing coil (V6125) / opening

coil (V6126) from the breaker as shown in

the Fig No 7A.

Assembly of magnets: Ensure the rating

of the closing magnet l opening magnet is

as specified in the drawing. Mount the

closing magnet / opening magnet

mounting bracket in the inverted position

on the breaker frame and fix it with the M6

hardware. Now set the setting screw

provided on the closing f lap (V6127) and

opening flap (V6128) which is connected

to the half shaft and lock the same with

nut. Ensure the bending of the split pin of

the plunger is proper.

Coupling of drive and pole :

Coupling of drive and poles is possible

only when the operating mechanism and

poles are assembled completely.

Once the drive assembly is completed,

discharge the tripping springs, which are

precharged for assembly easiness. The

discharging shall be done by removing

the hexagonal socket head bolt from the

rear side by unscrewing it. As you unscrew

these three bolts, the opening springs

get discharged and spring holder cap

seats in a hole provided on the operating

housing. For coupling the poles with the

operating mechanism refer the

assembly instruction as described in

clause A of the pole assembly.

Motor Assembly : (Drg. 9; pg.no.55)

There are different motors available for

different voltage ratings. One should be

very careful while ordering / mounting

motor on the circuit breaker for the

specified voltage as per the order

specification. Once the appropriate motor

is identified, fix the motor properly on the

motor support plate of the operating

30

and then carry out the ON -OFF operation.

4) Repeat the same three times.

5) Last one or two operations may not

complete on its own as the energy level in the

spring gets reduced.

6) Using a special tool rotate the shaft after

each ON -OFF command to complete the

operation.

7) Check the freeness of the spring drum, thus

the spring is completely discharged.

14. Instruction for discharging and charging:

Follow the procedure to charge the closing

spring.

1) Normally 4 complete turns are stored in a

closing spring and a last turn to operate the

breaker.

2) Press the lever assembly(V6039) and hold

it while charging.

3) Mark a line on the spring drum and start

charging manually.

4) Complete 4 rotations of the spring drum and

release the lever assembly.

5) For the next charging the roller (V6030) will

drop in the pocket and spring charging

indicator will show the position

"SPRING CHARGED" .

Now the circuit breaker is ready for operation.

15. Truck assembly (ref. Drg.no. 10; pg.no. 56)

Place the frame assly.(V6102) on the working

table and insert the breaker with pole inside

the frame. Put the spacer (V6103) in between

frame and breaker and tighten hex bolt M12

x45 (V6104). Mount 24 plug assly. (V6105)

on truck frame and interlocking assly (V6106)

as shown in drg 10. Complete the Emergency

trip assly (V6107). Adjust the length of

actuators. Confirm operation of emergency

trip and interlocking rod assembly. Mount

the barrier plate (V6108) from the rear side of

the breaker frame and fix the connection

pieces (V6109) on each terminal and the

connection bars item no (V6110 to V6115)

on each phase upper and lower terminals and

maintain the center distance of 185 +/- 1 . Also

measure the distance between upper and

lower terminal and it shall be 367 +/- 2. Check

the parallelity of the connection bars and

other dimensions as per assembly drg. 10.

Once again check the breaker for

completeness and also paint seal the key

assemblies like interlocks, Auxiliary switches,

Motor assembly, Push rod assembly. Ensure

that greasing is done properly on all the rolling

surfaces and then fix the front cover assembly

(V6116) by hanging it on the top and fix it with

the hex. socket head bolt with the washer.

VD4 / VD4E Breaker for Unisafe Panel:

The switchgear panel type Unisafe and the

vacuum circuit breaker type VD4 / VD4E are

of a very compact design. The main features

of this combination are:

The Rack-in mechanism is made as a

part of the circuit breaker. Hence, the

problems related to interchangeability

are eliminated.

The contact arrangement adapted for

this breaker is Tulip contact system

and hence better alignment, flexibility

and contact engagement with cubicle

contact can be achieved.

The panel contacts are mounted in

the bushing and the metallic shutters

are provided hence, better

compartmentalization is achieved.

Drg 1A shows General Arrangement and

basic dimensions of the breaker type

VD4 / VD4E suitable for Unisafe panel.

.

.

.

31

E. LIST OF DRAWINGS & COMPONENT PART Nos.

List of Drawings

Component Part Numbers

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

33

34

35

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

List of Drawings


34

NAME OF ITEM REFERENCE No. DRG. No.

POLE HOUSING

VACUUM BOTTLE ASSY.

GROUP VG2S

OPERATING STUD

CONN. BAR (TOP)

CONN.BAR(BOTTOM)

BUSH

LABEL STICKER

FLEXIBLE CONDUCTOR

SUPPORTING PLATE

SUPPORTING PLATE

CONTACT TERMINAL

SPECIAL NUT

CONTACT NUT

SPRING WAVE WASHER

SAFETY WASHER

HEX. SOCKET HD. CAP SCREW


CONICAL SP. WASHER

HEX. NUT


POLE HOUSING

VACUUM BOTTLE ASSY.

GROUP VC2

OPERATING STUD

CONNECTION PART

CHAMBER SUPPORT

CONTACT FLANGE

CONTACT PISTON

ROLLER CONTACT COMP.

SAFETY WASHER

CONICAL SP. WASHER

SPRING WASHER

SPECIAL WASHER

SPRING WASHER

PRESSURE PLATE


HEX. SC. HD. CAP SCREW


V1001

V1002

V1003

V1004

V1005

V1006

V1007

V 1008

V1009

V1010

V1011

V1012

V1013

V1014

V1015

V1016

V1017

V1018 (Unplated)

V1019

V 1020

V2001

V2002

V2003

V2004

V2005

V2006

V2007

V2008

V2009

V2010

V2011

V2012

V2013

V2014

V2015

V2016

V2017

4A

4A

4A

4A

4A

4A

4A

4A

4A

4A

4A

4A

4A

4A

4A

4A

4A

4A

4A

4A

4B

4B

4B

4B

48

4B

4B

4B

4B

4B

4B

4B

4B

4B

4B

4B

4B

35



CONICAL SP. WASHER

HEX. NUT

GREASE

SPRING HOLDER

SPRING GUIDE

COMPRESSION SPRING

COMPRESSION SPRING

OPERATING DISC

SEPARATING PLATE


SPRING WASHER

SPRING DRUM

SPRING

SPROCKET WHEEL DISC

ROLLER CHAIN

CURVE WASHER

CURVE WASHER

DAMPER

CYLINDRICAL PIN

STOP WASHER

LATCH ASSY.

LATCH

LINK

CIRCLES

FISH PLATE

CYLINDRICAL PIN

D-SHAFT

CRANK

SPRING DOWEL PIN

CAM DISC

SPRING PIN

SPRING PIN


CRANK

FISHPLATE-OFF

FISHPLATE-ON

PLAIN WASHER

SPRING WASHER

NYLOCK HEX. NUT

HALFSHAFT

V2018

V2019

V2020

ISOFLEX TOPAS N852.

V4101

V4102

V4103

V4104

V4201

V4202

V4203

V4204

V4205

V4206

V4207

V4208

V4301A/B

V43O2A/B

V4303A

V4304A/B

V43O5A/B

V4401

V4402

V4403

V4404

V4405

V4406

V4501

V4502

V4503

V4601

V4602

V4603

V4701

V4702

V4703

V4704

V4705

V4706

V4707

V4708

4B

4B

4B

4B

6A

6A,6E

6E

6E

6A,6C

6C

6A,6C

6C

6C

6A

6A,6C,7

6C

6A,6B

6A,6B

6B

6B

6A,6B

6A,6B

6B

6A,6B

6A

6A,6B

6A

6B

6A,6B

6B

6A,6E

6E

6E

6A,6B

6A,6B

6A

6A,6B

6A,6B

6A,6B

6A,6B,6D,9

6A,6B


36


SPRING PIN

TORSION SPRING

TORSION SPRING

COUNTER

ANGLE

SLOTTED CHEESE HD. SCREW

SPRING WASHER

TENSION SPRING

BLOCKING CRANK

BLOCKING CRANK

BLOCKING ROLLER

CYLINDRICAL PIN

SPACER

GROOVED PIN

SHAFT

HEX. SOCKET HEAD SCREW

HEX. SOCKET HEAD SCREW

SPACER

SLOTTED CH. HEAD SCREW

TUBULAR RIVET

CONICAL PLATE

SUPPORT PLATE

SLOTTED CH. HEAD SCREW

TUBULAR RIVET

CYLINDRICAL PIN

SPROCKET

LATCH

TORSION SPRING

CHARGING LEVER

NYLOCK HEX. NUT

NYLOCK HEX. NUT

SPRING WASHER

PLAIN WASHER

LEVER

LEVER

BOLT

ROLLER BEARING

RETAINING CIRCLIP

SPECIAL PIN

HOUSING

BUSH

AUXILIARY SWITCH PLATE

TORSION SPRING

V4709

V4710

V4711

V4801

V4802

V4803

V4804

V4805

V4901A/B

V4902A/B

V4903A/B

V4904

V4905A/B

V4906A/B

V5101

V5102

V5103

V5104

V5105

V5106

V5107

V5108

V5109

V5110

V5111

V5112

V5113

V5114

V5115

V5116

V5117

V5118

V5119

V5201

V5202

V5203

V5204

V5205

V5206

V6001

V6002

V6003

V6004

6A,6B

6A

6A

6A,6B

6A,6B

6A,6B

6A,6B,6C

6A,6B

6A

6A,6B

6A,6B,6C

6B

6A,6B

6B,6C

6C

6A,6C

6C

6C

6A,6C

6A,6C

6A,6C

6A,6C

6C

6C

6A,6C

6A,6C

6A,6C

6C

6A,6C

6C

6A,6C

6A,6C

6A

6A,6B,6E

6A,6B,6E

6A

6E

6A,6E

6B,6E

6A

6A,6B,6D

7

6A,6B

37


BUSH

BRACKET

HEX. SOCKET HEADED CAP SCREW

HEX.NUT

SPRING WASHER

TUBE

CYLINDRICAL PIN

RETAINING WASHER

BUSH

LEVER ASSEMBLY

TORSION SPRING

WASHER

SPRING PIN

LOCKOUTLEVER

TORSION SPRING

SPRING PIN

BUSH

BUSH

SHAFT

CAM DISC

SPACER

SPECIAL WASHER

LEVER ASSEMBLY

ROLLER

COMPRESSION SPRING

ROLLER

CONTROL WASHER

SPACER TUBE

STOP

FORK LOCK (KEY)

BUSH

CIRCLIP

MOTOR

BUSHING

LEVER ASSEMBLY

BUSH

SPROCKET WHEEL

TORSION SPRING

NON RETURN PLATE

HEX. BOLT

LOCKOUTLEVER

PIN

SPRING

V6005

V6006

V6007

V6008

V6009

V6010

V6011

V6012

V6013

V6014

V6015

V6016

V6017

V6018

V6019

V6020

V6021

V6022

V6023

V6024

V6025

V6026

V6027

V6028

V6029

V6030

V6031

V6032

V6033

V6034

V6035

V6036

V6037

V6038

V6039

V6040

V6041

V6042

V6043

V6044

V6045

V6046

V6047

6B

6B

6B

6A,6B,6C

6C

6A,6E

6A,6E

6E

6D

6A,6C,6D

6D

6A,6B

6B,6D

6A,6B

6A,6B

6A,6B

6A,6B

6A,6C

6A,6E

6A,6C

6A,6D,6E

6D

6D

6D

6C

6C

6D

6A,6B

6B

6A,6B

6A,6B

6E

6A,6C

6C

6A,6C

6C

6C

6A,6C

6A,6C

6A,6B,6C

6B

6B

6A,6B


38


SPECIAL PIN

PLAIN WASHER

PIN

TORSION SPRING

RETAINING CIRCLIP

BUSH

CRANK

LOCKOUTLEVER ASSEMBLY

TORSION SPRING

CRANK

SPACER

HEX. SO.HEADED SCREW

CYLINDRICAL PIN

ON- OFF INDICATOR

SOCKET HD.CAP SCREW

PIN

SPACER

HEX.SOCKET HEADED SCREW

SELF LOCKING NUT

EARTHING STRIP

SPECIAL PIN

CYLINDRICAL PIN

RETAINING CIRCLIP

RETAINING CIRCLIP

RUBBER WASHER

AUXILIARY SWITCH

AUXILIARY SWITCH


SPRING WASHER

PLAIN WASHER

CLOSING COIL

TRIPPING COIL

MAGNET SUPPORT


BRACKET

SPECIAL CIRCLIP

PIN

HEX. SOCKET HD SCREW

SPRING WASHER

CRANK

COVER PLATE

CYLINDRICAL PIN

DOWEL PIN

V6048

V6049

V6050

V6051

V6052

V6053

V6054

V6055

V6056

V6057

V6058

V6059

V6060

V6061

V6066

V6068

V6070

V6071

V6072

V6073

V6074

V6075

V6076

V6077

V6078

V6079

V6080

V6081

V6082

V6083

V6084

V6085

V6086

V6087

V6088

V6089

V6090

V6093

V6094

V6095

V6096

V6097

V6098

6A,6B

6B

6B

6A,6B

6A,6B,6C

6D

6D

6A

6B,6D

6A,6B

6B

6D

6D

6A,6D

6A,6D

6A,6D

7

7

7

7

7

7

6D,7

7

7

7

7

7

7,8

7,8,9

8

8

8

8

7

7

7

9

9

9

9

9

9

39


GROOVED PIN

RETAINING CIRCLIP

HEX.SOCKET HEAD SCREW

FRAME

SPACER

HEX.BOLT

24 PIN PLUG ASSEMBLY

INTERLOCKING ASSEMBLY

EMERGENCY TRIP ASSEMBLY

BARRIER PLATE

CONNECTION PIECE

CONNECTION BAR

CONNECTION BAR

CONNECTION BAR

CONNECTION BAR

CONNECTION BAR

CONNECTION BAR

FRONT COVER ASSEMBLY

HEX. BOLT

HALFSHAFT

DOWEL PIN

LOCKING LEVER

BLOCKING LEVER

AUXILIARY SWITCH

AUXILIARY SWITCH ARM

ALUMINIUM LINK

CLOSING MAGNET (NEW)

OPENING MAGNET (NEW)

CLOSING FLAP

OPENING FLAP

LEVER ASSEMBLY

SET OF MICROSWITCH

M/S MTG BRACKET

V6099

V6100

V6101

V6102

V6103

V6104

V6105

V6106

V6107

V6108

V6109

V6110

V6111

V6112

V6113

V6114

V6115

V6116

V6117

V6118

V6119

V6120

V6121

V6122

V6123

V6124

V6125

V6126

V6127

V6128

V6129

V6130

V6131

9

9

9

9

9

10

10

10

10

10

10

10

10

10

10

10

10

10

6A

6A,6C

6B

6B

6C

7A

7A

7A

7A

7A

7A

7A

7A

7A

7A


40

VD

4E

Bre

ake

r

VD

4 B

rea

ke

r

Drg

. N

o. 1

41

VD

4E

Bre

ake

rfo

r U

NIS

AF

E

cu

bic

le

VD

4 B

rea

ke

rfo

r U

NIS

AF

Ecu

bic

le

Drg

. N

o. 1

A

42

Cro

ss s

ectio

na

l vie

w o

f V

D4

CB

C

ross

sectio

na

l vie

w o

f V

D4

E C

B

Drg

. N

o. 2

1 B

rea

ker

me

cha

nis

m h

ou

sin

g1

.1 F

ron

t co

ve

r -

rem

ova

ble

12

In

su

latin

g m

ate

ria

l po

le tu

be

13

U

pp

er

bre

ake

r te

rmin

al

14

L

ow

er

bre

ake

r te

rmin

al

15

V

acu

um

inte

rru

pte

r1

6.2

Ro

ller

con

tact

/ F

lexib

le c

on

du

cto

r1

7 C

on

tact

pre

ssu

re s

prin

g1

8 In

su

late

d c

ou

plin

g r

od

19

O

pe

ratin

g s

prin

g2

0 S

hift

leve

r pa

ir

43

Drg. No.3

15.1 Insulator15.2 Fixed contact15.3 Movable contact15.4 Metal bellows15.5 Screen15.6 Guide cylinder15.7 Lid

Cross section of vacuum interrupter

44

Drg

. N

o. 4

A P

ole

ass

em

bly

Drg

. N

o. 4

B

Po

le a

sse

mb

ly fo

r V

D4

E / V

D4

bre

ake

r

45

Drg. No.5

Typical circuit diagram

1. Spring charging motor2. Closing coil3. Tripping coil4. (S3, S4) CB Auxiliary switch contacts5. Microswitch operates in T or S positionm6. Plug & socket7. (S1) Motor cut-off switch8. Breaker

46

47

Drg

. N

o. 6

A O

pe

ratin

g M

ech

an

ism

Asse

mb

ly fo

r V

D4

E / V

D4

bre

ake

r

48

Drg

. N

o. 6

B O

pe

ratin

g M

ech

an

ism

Ass

em

bly

fo

r V

D4

E / V

D4

bre

ake

r

49

Drg

. N

o. 6

C O

pe

ratin

g M

ech

an

ism

Asse

mb

ly fo

r V

D4

E / V

D4

bre

ake

r

50

Op

era

ting

Me

cha

nis

m A

sse

mb

ly

fo

r V

D4

E / V

D4

bre

ake

r

D

rg. N

o. 6

D

51

Op

era

ting

Me

cha

nis

m A

sse

mb

ly

fo

r V

D4

E / V

D4

bre

ake

r

D

rg. N

o. 6

E

52

Auxiliary Switch assembly

Drg. No. 7

53

Arrangement drawing withcoil and auxiliary switch

Drg. No. 7

54

Op

en

ing

co

il a

sse

mb

ly

D

rg. N

o. 8

55

Motor mounting assembly

Drg. No. 9

56

Tru

ck a

sse

mb

ly

D

rg. N

o.1

0

ABB LimitedPlot No. 79, Street No. 17MIDC Estate, Satpur,Nashik - 422 007

Tel: +91 235 2351095 to 8 +91 253 2351261 to 4Fax: +91 253 2350644 / 2351249

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

1VDU09001-YN

vd4 1vdu09001-yn manual

Documents

normal operating

vacuum circuit

circuit breaker

handling amp

operation

type designation

rating plate

installation