400kv DBR Assembly & Maintenance Instructions-R6 PDF

s Doc. No.
DOC /407/ED/A1
Revision 6
s
ASSEMBLY INSTRUCTIONS
Double Side Break Disconnector
Rated voltage 400kV
Date (Rev-6) 24.07.2014 24.07.2014 24.07.2014

Date (Rev-5) 20.11.2013 26.11.2013 26.11.2013
Name Syed Jaweed Ikram Ch.SubbaReddy P.RamaMurthy

Signature SJI CSR PRM
Prepared By Reviewed By Approved By
Address: M/s Siemens Limited,

Plot No.89&90,
IDA Gandhinagar,
Balanagar Post,
Hyderabad-500037.
Mail: energysupport.in@siemens.com
Tel.: 0091-40-33507000/7001
Fax: 0091-40-23079992
Toll Free Ph No: 1 800 2667 480
© Siemens -1-
s Doc. No. DOC /407/ED/A1
Revision 6
CONTENTS PAGE
1 General 3
1.1 Introduction 3
1.2 Safety Instructions 3
1.3 Technical Data 3
2 Description 4
2.1 General 4
2.2 Design of disconnector 5
3 Delivery and Storage 5
3.1 Scope of Delivery 5
3.2 Material 5
4 Packing and Storage 6
5 Erection and Assembly instructions 6
5.1 Transport 7
5.2 Assembly Preparation 9
6 Assembly 9
6.1 Checking 9
6.2 Assembly of disconnector 11
6.3 Adjustment of disconnector 25
6.4 Assembly of earth switch (If Applicable) 27
6.5 Adjustment of Earth switch 32
6.6 Assembly of Mechanical interlock 33
6.7 Adjustment of Mechanical interlock 35
7 Motor Operating Mechanism 38
7.1 Adjustment of Motor Operating Mechanism 38
8 Inspection and commissioning 40
9 Check sheet for Erection and Commissioning 40
IMPORTANT NOTES
 Read these operating instructions carefully before starting erection work.
Erection work must only be carried out by personnel familiar with the
operating instructions.
 Images, drawings & line diagrams shown in this manual are for your
reference , original design may vary as per GA drawings
 Failure to comply with warnings and other alerts can cause serious bodily
injury and extensive damage to property and the environment can even
cause death.
© Siemens -2-
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1. General
1.1 Introduction
These operating instructions apply to the type and design of the disconnector listed on the
title page. They are intended to make the operating personnel familiar with the
construction and operation of the disconnector. They are also instructions for operation
and provide information about installation and maintenance.
We recommend that operating personnel become acquainted with the operating
instructions and other documentation that is supplied so that they are well informed
concerning the disconnector and any other operational features involved.
1.2 Safety Instructions
During operation, certain parts of the disconnector are live and hazardous as a high
voltage is present. Personnel must be thoroughly familiar with all warnings and procedures
for installation, operation, maintenance repair contained in these operating instructions.
The user of the disconnector must ensure that the maintenance and relevant operating
directives to the appropriate activity, local safety regulations and information on what to do
in the event of an accident are available or displayed, e.g. on a notice board so that they
can be referred to at any time.
1.3 Technical Data
The disconnector is a three disconnector for outdoor installation. It may be used for the
technical data specified on the name plate and in this operating instruction. Disconnectors
are used to produce a dielectrically strong and visible isolating distance in an outdoor
switchgear; for this purpose, they may be operated only when free of current and voltage
(off-Load).
The add-on earthing switch is a three pole auxiliary device to the disconnector for outdoor
installation. It may only be used for the technical data specified on the rating plate of the
disconnector and in this operating manual. Earthing switches establish a conductive
connection from line sections produced by opening the disconnector to the system ground,
for this they may only be operated in no-current and no-load status.
© Siemens -3-
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Rated
Technical Particulars of Disconnector Unit Values
Rated voltage (kV) [kV] 420kV
Rated frequency [Hz] 50
2000-
Rated current [A] 4000
Rated short circuit withstand value [kA] 40/50
Rated short circuit duration S 3/1
Rated PF withstand voltage across isolating distance [kVr] 610
Rated PF withstand voltage between live terminals and ground [kVr] 520
Lightning Impulse withstand across Isolating distance [kVp] 1425
Lightning Impulse withstand between live terminals and ground [kVp] 1665
Switching Impulse withstand across Isolating distance [kVp] 1245
Switching Impulse withstand across between live terminals and ground [kVp] 1050
2. Description
2.1 General
The double side break disconnector is a disconnector in 3-post insulator design with
double insulating distance. The corrosion-protected outdoor disconnector consists of three
individual poles either mechanically ganged through mechanical linkages (or) electrically
ganged through master and follower motor drive.
Disconnector operation is either motorized or by hand (Manual). The switching position
of the disconnector in motor or manual drive mode is indicated by an auxiliary switch
integrated in the drive housing.
The disconnectors are designed to withstand the horizontal and vertical service
loads specified in IEC 62271-102, table 3.
 The Disconnector comply with IEC 62271-102 latest edition.
 Technical changes are possible as and when design modifications
are made.
 No claims can be made on the basis of data, drawings or
descriptions even though every care has been taken in providing
inputs.
© Siemens -4-
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2.2 Design of the Disconnector
Each of the three disconnector pole has a separate operating mechanism or can be
mechanically ganged.
The control is located additionally in the operating mechanism box.
The disconnector (page 12) consists of the sub-structures, the operating box, the support
insulators and the main circuit, the rotating insulator, arranged parallel to the support
insulator transmits the operating mechanism movement from the substructure to the
Moving contact of the main circuit. On the opposite sides of Moving contact the fixed
contact is located. The fixed contacts on both the sides carry a high voltage terminal to the
main circuit.
The support insulators are made up of a multi shield insulator with metal flanges.
The operating mechanism movement of the disconnector is initially transmitted by the
operating box via the MS down pipe to the MS TOM which converts it into the movement
of the R/S Base on which the rotating insulator is mounted. The rotating insulator transmits
the rotary movement to the moving contact.
The energy required for operating the disconnector is provided by the electro-motor in the
motor operating box.
3. Delivery and storage
3.1 Scope Of Delivery
The delivery includes:

 Disconnector subassemblies (current path, shielding, substructures (If Applicable),
insulators (If Applicable), operating mechanism, metallic’s)
 Earthing switch subassemblies ( mating contacts, Metallic’s, operating mechanism
and interlock assembly)
 Accessories pack
 Transport information sheet, dispatch note and check list
All installation parts and materials required for setting up and operating the disconnector
belong in the scope of delivery are contained in the accessories pack.
3.2 Material
The double side break disconnector poles are delivered in knock down condition.
The material has to be checked as per the packing list.
Possible damages of material occurred during transportation must be recorded on back

side of LR & communicate to the respective Siemens representative.
© Siemens -5-
Revision 6
4. Packaging and storage

 The equipment is packed on transport planks, in wooden crates or cases. The drives are
wrapped with plastic film and are placed on pallets.
 If the equipment is stored outdoors, it must be put on a level higher than ground to
avoid entry of water and dust in essential components and assemblies.
C A U T I O N! Motor and manual drives must be stored indoor for the time until
installation. The heating system must be started immediately after completion of
installation as described in the drive manual.
5. Erection and Assembly Instructions:
WARNING!
Erection work must only be carried out by personnel familiar with these operating
instructions. Risks to erection personnel can be caused by
 Electric voltage
 Falling and tilting of parts or person or other moving parts. 

C A U T I O N!
 Ensure that safety procedures are followed during installation, inspection and
maintenance based on the risk identified for these activities.
 Use Personal protective Equipments / Tool like safety shoes, safety helmets, safety
harness (for height works), insulation gloves and safety goggles.
C A U T I O N!
Electric voltage – when approaching live components, there is risk of electric shock and
burning due to electric arc.
Bolted Connections
Apply specified grease to all bolted connections before installation refer table-1:
Make sure that all friction surfaces (e. g.: threads, contact surfaces of nuts and washers)
are coated with grease of the specified grade.
Basically, tighten all bolts with a torque wrench. For tightening torque, refer table-2:
© Siemens -6-
Revision 6
WARNING!
If nuts are tightened without torque control, there is risk of damage or slackening of
the bolted connection.
Treatment of Contacts
Contacts fingers are provided with a special silver coating in the factory.
The contacts need to be lubricated with a thin layer of grease as specified in table 1:
Application of excess grease on the contact system does not have a negative impact on
sliding characteristics. However dirt and sand particles may do stick to lubricated surfaces
thereby causing increased risk of contact surface wear and tear which calls for further
maintenance.
TABLE:1
TYPES OF GREASE TO BE USED APPLICATION

Rivolta or SKD 3602 (or) Centoplex 24 DL For parts on contact system.
(or) Graphite oil
For threads of hot dip galvanized
Rivolta SKD 3602 (or) parts.
Molycote longterm 2 plus
For all lubrication points on Operating
Rivolta SKD 3602 (or) Isoflex Topas L32 mechanism, gears.
5.1 Transport
All subassemblies put together in a packaging unit should be transported to the installation
site in the package if possible and unpacked directly before assembly.
To unload and move the transport units, use fork lift or crane. Inspect the contents of each unit
for any missing items. Using of steel ropes is prohibited since there is possibility of damaging
corrosion protection layers and porcelain elements.
When unloading and transporting the base structure make sure that lifting slings are fixed at
right place.
The tightening torque values in the table:2 apply to all bolted connections unless otherwise
specified in respective area. All bolted connections made in the factory use the specified
lubricating grease.
© Siemens -7-
Revision 6
TABLE:2
© Siemens -8-
Revision 6
5.2 Assembly Preparation
The following documents must be available to perform the assembly according to this
instruction
 Assembly part List for Disconnector & Earth switch.

 GA drawings of disconnector with earth.
 Schematic and wiring diagram of disconnector drive & Earth switch.
 Check sheet for Erecting and commissioning (Table-3, Page No: 34).
 Instruction for Tightening torques for all hardware.
Check the foundation plan with respect to the GA drawing

The substructure should meet the following requirements:
 Flatness of support plates for pole frame of disconnector  1 mm

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

 The base frame mounting dimensions with respect to the layout drawing supplied.
 The position of the base frame with ref to the GA drawing supplied with respect to
the drive box positions and earth switch position.
 Check the structure top surface to sprit level/ water lever.
© Siemens -9-
Revision 6
Earth switch fixed

Contact Assembly
Corona ring
Fixed Contact Assembly
Moving Contact Assembly
Supporting Insulator
ES Moving Contact
Supporting Insulator
Toggle Assembly
ES TOM
Toggle Assembly
Base Channel Assembly MS Push Pipe ES Push Pipe
MS TOM
Sub-Structure
MS Down Pipe Assembly Sub-Structure
E S Operating Box
M S Operating Box
Fig. 01 General Arrangement
© Siemens - 10 -
Revision 6
6.2 Assembly of disconnector
Determine the installation location of the disconnector pole using the pole marking and
Transport the substructures to the installation location. Screw the substructures on the
pillars, so they are hand-tight to start with, Check that the sub-structure are lying flat on the
pillars using a spirit level and screw them until secure.
Now place the Base Channel on to the horizontally aligned sub structure and screw them
on so they are hand-tight to start with. Set the centre distance of the base channel with the
two sub structure columns (see figure given below) using the elongated holes (Slots) in the
base channel and tighten the fixing screws until secure.
Deviation in flatness of sub structure must be leveled by placing spacers (e.g. zinc sheet)
between Base channel and sub structure.
Base channel MS TOM Holes
Sub- Structure
Fig. 02 Base channel mounting
Mount the Rotating Stool base on the base channel and screw until secure, using screws,
washers and nuts.
© Siemens - 11 -
Revision 6
Rotating stool base
Base channel
Fig. 03 Rotating Stool base mounting
Now mount the elevator plate on either side of base channel using studs bolt. Set the
height of the Elevator Plate as mentioned in the GA drawing. Align the plates for fixing the
insulator columns horizontally with the help of spirit level. Check this in two directions
offset at 90°.
Elevator plate
Stud bolt
Fig. 04 Elevator plate mounting
Now using the crane, suspend the support insulators together vertically from the crane on
a sling or tackle, set them down on the elevator plate and tighten them.
© Siemens - 12 -
Revision 6
Note:
While mounting the insulator stacks, ensure that the holes position of the top most
insulator flange is as shown in figure Fig. 5
RS base Drive lever

Fig. 05 Insulators top most flanges Holes & drive lever position in open condition
Align the insulator column top most flange horizontally. To do this, place a spirit level on
the insulator columns topmost flange in 2 directions offset at 90°, check the horizontal
position and align it using stud bolts on the elevator plate. Do this on each insulator stack
on the elevator plates.
Next assemble the insulator stack on RS base, for doing this, suspend the insulators stack
together vertically from the crane on a sling or tackle, set them down on the rotating stool
base flange, set position of RS base drive lever as in figure Fig.5 and tighten them until
secure
Support insulator
© Siemens - 13 -
Revision 6
Middle insulator
stack
Fig. 06 Insulators Mounting
Installing the current path:
Pay attention to position of current carrying parts according to the GA drawing.

To start with take off the cover, this can be done by removing the M6 screws and place the
corona Shields/rings on to the middle insulator stack and mount the moving contact on the
corona Shields/rings and secure it to the holes provided on insulator. To do this, use
screws and washers provided on the moving contact. Once the moving contact is secured
replace the cover. The clamp assembly position should be as per the GA drawing.
Moving contact
Clamp Assembly
Corona ring
© Siemens - 14 -
Revision 6
Cover
Fig. 07 Main contacts mounting
Place the corona Shields/rings on both support insulator
Note:
Refer GA drawing for the type of Earthing Switch Fixed Contact Design.
i.e Type-1 and Type-2 (refer page-47 for images).
And if the disconnector is without earthing switch skip to 3) For Disconnector without
Earthing Switch
© Siemens - 15 -
Revision 6
1) For Earthing Switch fixed contact Type-1 design
Place the earth fixed contact over corona shield such that if seen from above it should be
as shown in the figure below.
MS MOVING
CONTACT
TOP VIEW
ES Fixed Contact
Corona ring
Fig. 08 Earth switch fixed contact
© Siemens - 16 -
Revision 6
Now mount the fixed contact on the E/S fixed contact as per GA drawing and secure it, To
do this, use 4 screws and 4 washers.
Attach the Fixed contact corona rings/ shields on top of the fixed contact and secure it
using 4 screws and 4 washers. Do this on each of the two sides.
Fixed contact
corona ring
Fixed contact
Fig. 09 Fixed contact
Connect the connecting pad between the earth switch fixed contact and terminal pad as
shown in the figure below. Do this on each of the two sides for double earthing switch.
Terminal pad
Connecting pad
Earth switch
fixed contact
Fig. 10 Connecting Pad Mounting
Clean the surfaces of terminal pad to remove any scales formed on the surfaces and apply
contact grease to the terminal contact.
© Siemens - 17 -
Revision 6
2) For Earthing Switch fixed contact Type-2 design
Mount the fixed contact on the corona Shield/rings as per GA drawing and secure it, To do
this, use 4 screws and 4 washers. Do this on each of the two sides.
Fixed contact
Fig. 11 Fixed contacts Mounting
Fixed contact
corona ring
Fig. 12 Fixed contacts corona ring mounting
© Siemens - 18 -
Revision 6
Now mount the E/S fixed contact to the terminal pad as per GA drawing and secure it, To
do this, use 4 screws and 8 washers. Do this on each of the two sides for double earthing
switch.
Earth switch
fixed contact
Terminal pad
Fig. 13 Earth switch fixed contact
© Siemens - 19 -
Revision 6
3) For Disconnector without Earthing Switch
Mount the fixed contact on the corona Shield/rings as per GA drawing and secure it, To do
this, use 4 screws and 4 washers . Do this on each of the two sides.
Fixed contact
Fixed contact
corona ring
Terminal pad
© Siemens - 20 -
Revision 6
Mounting the MS TOM on the Base channel assembly and adjust the horizontal position
using sprit lever and secure it using screws, nuts and washers.
MS TOM
Fig. 16 TOM mounting
Now place the operating mechanism box next to the assembly console and secure it. To do
this, first attach the operating mechanism box using screws, washers and nuts without
tightening it. Now align the operating mechanism parallel to the longitudinal axis of the base
channel. To do this, use a spirit level. Now tighten the fixing screws.
Adjust the MS down pipe length and mount it between the operating box and the MS TOM.
To do this, proceed as follows.
Check the length of the enclosed pipe. To do this, measure the ‘A’ between the TOM shaft
and the drive box top flange. If necessary, shorten the pipe on the end opposite of the flange
to the proper length ‘A’ by cutting it. After cutting it to the required size, concentrically attach
the operating pipe to the flange and weld it and protect the welded surface against corrosion
with a coating of zinc and paint.
Note: Adjustment of Operating Box should be done such that Center Line of the Operating
pipe and Operating Box flange and down should not be adjusted with reference to operating
box.
© Siemens - 21 -
Revision 6
MS Down pipe
Flange Type Design
© Siemens - 22 -
Revision 6
Drill 10.2mm
up to 35 mm
and tap M12
during
installation at
site, then fix the
MS Down pipe
bolt.
"L” Bracket Type Design
Fig. 17 Down pipe
using the hand crank in the motor-operated mechanism box, manually set the drive into the
OFF position and set the MS TOM lever such that if seen from above makes an angle of
about 900 as shown in the figure below.
MS TOM lever
Fig. 18 MS TOM LEVER
© Siemens - 23 -
Revision 6
Now mount the down pipe between the operating box and the MS TOM by ensure that any of
two holes of the drive-coupling flange are coupled with operating pipe flange and secure using
screws, washers and nut provided on Operating mechanism box flange.
Now manually move the Moving Contact towards OPEN position, such that if seen from top
the drive lever makes an angle of about 100 to the Parallel axis of disconnector as shown in
the figure below.
Drive Lever
MS TOM lever
Fig. 19 Drive Lever
Now connect the push pipe between drive lever and the TOM lever using screws, washers
and nut provided on the Push pipe.
© Siemens - 24 -
Revision 6
MS Push pipe
Fig. 20 Push pipe assembly
6.3 Adjustment of Disconnector
Using the hand crank in the motor-operated box manually move the disconnector pole to
close Position, until the current carrying part just enters the fixed contact.
Fig. 21 Contact alignment
 Ensure that the contact blade enters the fixed contact without touching the jaws.
© Siemens - 25 -
Revision 6
For doing this follow the below given steps:

- Loosening the nuts on the rear side of fixed contact; adjust the height of jaws by sliding
it between the elongated holes (slots) and secure the nuts to the specified torque
(Refer Table:2)
- Further adjustment in height can be achieved changing the height of Elevator plate
using stud blots.
 When the Main switch is in close position, ensure that TOM lever is in dead locked position.
- Move the Main switch towards close position until the moving contacts slides into the
fixed contact and turn and twist of moving contact takes place.
- Adjust the length of Push pipe to achieve dead lock position of TOM lever.
- Adjust the stopper bolt provided on the MS TOM.
- Now make OPEN and CLOSE cycles and check that the TOM lever crosses its dead
lock position again.
- If necessary, repeat the setting.
Dead lock position of

the TOM lever
Fig. 22 TOM Adjustment
© Siemens - 26 -
Revision 6
6.4 Assembly of Earth switch (Not Applicable for Disconnector Without Earthing
Switch)
Fix the Earth base assembly on to the Base channel using screws, washers and nuts. Align it
and Tighten all bolts to the specified tightening torque.
Earth Base
Fig. 23 Earth base assembly mounting
Place spring fixing bracket on to the toggle and Attach the Toggle to the Base channel
using screws, washers and nuts. Align it and Tighten all bolts to the specified tightening
torque.
© Siemens - 27 -
Revision 6
Earth Base
Spring Fixing Bracket

Toggle
Fig. 24 Toggle lever assembly mounting
Fix the TOM to the Base channel using screws, washers and nuts. Align it and Tighten all
bolts to the specified tightening torque and sprit level.
© Siemens - 28 -
Revision 6
ES TOM
Fig. 25 ES TOM mounting
Ensure the perpendicularity of the TOM pin with respect to the base frame for doing this use
zinc sheets and secure with bolts.
Connect the Push pipe between Toggle and E/S TOM lever for doing this use the SS studs on
Toggle and TOM lever.
E/S Push pipe
Fig. 26 Earth push pipe assembly
© Siemens - 29 -
Revision 6
Place the ES operating box next to the assembly console and secure it. To do this, first attach
the ES operating box using screws, washers and nut (from the accessory pack) without
tightening it. Now align the operating mechanism. To do this, use a spirit level parallel to the
longitudinal axis of the disconnector pole to adjust it horizontal position. Now tighten the fixing
screws.
Now adjust the ES down pipe length and mount it between the ES operating box and the ES
TOM. To do this, proceed as follows.
Check the length of the enclosed pipe. To do this, measure the ‘A’ between the ES TOM shaft
and the drive box top flange. If necessary, shorten the pipe on the end opposite the flange to
the proper length ‘A’ by cutting it. After cutting it to the required size, concentrically attach the
operating pipe to the flange and weld it and protect the welded surface against corrosion with
a coating of zinc and paint.
Flange Type Design
© Siemens - 30 -
Revision 6
"L” Bracket Type Design
Fig. 27 Operating pipe Length

Using the hand crank in the motor-operated mechanism box manually set the drive into the
OFF position.
Now mount the down pipe between the ES operating box and the ES TOM by ensuring that
any of two holes of the drive-coupling flange are coupled with down pipe flange and secure
using screws, washers and nut provided on Operating mechanism box.
Before installing the ES Moving Contact ensure that Motor drive box is in off position. And the
TOM pin lever is kept in open position.
Slide and mount the ES moving Contact on the earth base with the help of SS clamps
provided on the earth base.
keeping the contact arm in open position, while the arm rests on the damping pad provided
on the toggle, connect the arm with the toggle clamp for doing this use the SS stud on the
toggle clamp.
© Siemens - 31 -
Revision 6
ES moving contact
Fig. 28 Earth moving contact mounting
Keeping the Earth Switch towards CLOSED position connect the counter balance springs
between the Spring fixing Bracket and Earth Base using screws, washers and nuts (from the
accessory pack). Align it and tighten all bolts.
ES spring fixing Counter

bracket balance
spring
Fig. 29 Counter balance springs assembly
© Siemens - 32 -
Revision 6
Dead center position
Fig. 30 Toggle lever dead center
Take the free ends of copper braids flexible on contact arm and connect them to the earthing
holes provided on the base frame. For doing this use Screws, washers and nuts (from the
accessory pack). Align it and Tighten all bolts to the specified tightening torque.
6.5 Adjustment of Earth switch:
Apply specified grease to the contacts before the operation, refer Table 1:
When the earthing switch is fully CLOSED following things should be ensured:
 The contact tip must move centrally in to contact fingers at the right height. Across the
length of contact tip, uniform contact of individual pair of contacts fingers should be
ensured.

- Manually move the earthing switch towards close position using the hand crank in the
motor operating mechanism until it is positioned just before where the contact tip enters
the contact fingers.
- Loosen the screws on earth base and adjust the height of entry of Moving contact.
- With the help of screws on earth base align the contact arm and check that the contact tip
enters the contact fingers centrally. Now tighten the screw.
Make OPEN and CLOSE cycles manually and check that the entry is central again. If
necessary, repeat the setting.
 When the earthing switch is fully CLOSED it should be ensured that the toggle crosses it
dead center which ensures that the Earth switch is locked in CLOSE position.
© Siemens - 33 -
Revision 6

- Manually switch the earthing switch towards CLOSED position until the contact tip
enters the fixed contact and touches the stopper.
- Loosen the screws on toggle clamp until it starts to slide on the moving contact .
- Now adjust the clamp by sliding it vertically on the contact arm till the toggle crosses it
dead center.
- Now tighten the screw on clams to the specified torque.
- Now make OPEN and CLOSE cycles and check that the toggle crosses its dead
center again.
6.6 Assembly of Mechanical interlock.
Manually move the earth switch to open position and mount the interlock cam on Earth base
shaft as shown in the figure below and hand tight the grub screw on it using Allen key.
Interlock
cam
when
E/S in
open
Position
Fig. 31 Interlock cam
Mount the support bracket-1 and 2 on the base channel and connect the interlock pipe
between them. Align and secure the brackets using screws, washers and nuts (from the
accessory pack).
© Siemens - 34 -
Revision 6
Braket-1
Braket-2
Interlock
Pipe
Fig. 32 Interlock Assembly
Manually move the Main switch to close position and as shown in the figure below connect
the link pipe between the Rotating stool base and Lever of interlock pipe using washers
and nuts provided on the link pipe.
© Siemens - 35 -
Revision 6
Link pipe
Fig. 33 Interlock link pipe assembly
6.7 Adjustment of Mechanical Interlock:
When the Main switch is in fully closed position it should be ensured that the closing operation
of earthing switch is obstructed by mechanical interlock.
Likewise when the Earthing switch is in closed position it should be ensured that the closing
operation of main switch should be obstructed by mechanical interlock.

- Move the main switch towards closed position (till the TOM lever crosses it dead
center) and earth switch in fully open position.
- Loosen the grub screw provided on the collar of interlock cam.
- Move the interlock cam towards base channel and stop it just before it touches the
base channel.
- Keeping the interlock cam at this position tighten the grub screw.
- Ensure that the interlock rod touches the interlock cam. This can be done by adjusting
the length of link pipe.
- Now make OPEN and CLOSE cycles to ensure the functioning of Mechanical
interlock.
Interlock cam when

E/S in open Position
Interlock Rod when

M/S in Close Position
© Siemens - 36 -
Revision 6
Fig. 34 Interlock Adjustment
Dead center position of

the TOM lever
Interlock lever to be adjusted and

then insert dowel pin/grub screw/
weld the area and apply cold zinc
spray.
Fig. 35 Interlock Position for Disconnector Closed & Earth switch open condition
© Siemens - 37 -
Revision 6
Fig. 36 Interlock Position for Disconnector Open & Earth switch close condition
7. Motor Operating Mechanism
The motor with the gear unit is located in operating mechanism cubicle
The movement of the motor-operated mechanism is transferred to the disconnector and the
auxiliary switch in the operating mechanism cabinet. The Down Pipe is attached to the
operating mechanism and transmits the rotary movement from the operating mechanism to
Rotation Stool Base.
The operating drive mechanism contains all the components necessary for operating,
monitoring and controlling the disconnector.
All the electrical connections should be as per the schematic diagram.
The anti-condensation heaters prevent condensation forming on the components in the

operating mechanism cubicle. Since condensation can generally take place at any ambient
temperature, the anti-condensation heaters (heating resistors) must be permanently in
operation.
Note: The operator is responsible for the fuse protection for the auxiliary circuits, unless other
Wise agreed with the manufacturer.
Manual operation of motor-operated operating box for disconnectors and earthing switches is
possible during commissioning and maintenance as well as in emergency operation, when the
control voltage fails or a defect occurs.
Before each manual operation, check the defined interlocking conditions with the switching
position.
7.1 Adjustment of Motor Operating Mechanism
Adjustment for Close Position

- With the help of operating handle manually move the Disconnector / Earthing
switch toward fully closed position.
- Using a M6 Allen key, loosen the grub screw on the Red color limit switch
actuator.
- Adjust the limit switch actuator such that it just actuates the close limit switch
(LS2) and tighten the grub screw until secure.
Adjustment for Open Position

- With the help of operating handle manually move the Disconnector / Earthing
switch toward fully Open position.
- Using a M6 Allen key, loosen the grub screw on the Green color limit switch
actuator.
- Adjust the limit switch actuator such that it just actuates the Open limit switch
(LS1) and tighten the grub screw until secure.
Now make the electrical connections as per the schematic and wiring diagram of
disconnector and earthing switch.
© Siemens - 38 -
Revision 6
Schematic and
wiring diagram
Limit
switch
actuators
Limit
switches
Fig. 30 Adjustment of Operating Mechanism Box
Note:
Only perform complete switching operation up to the corresponding end positions
(ON and OFF). Do not change the motors direction of rotation in intermediate
positions.
© Siemens - 39 -
Revision 6
Failure to comply with this note can cause damage to the gear components of the
motor operating mechanism and switching devices due to the fact that the
switching devices and the motor drive have different end position.
- Now perform OPEN and CLOSE electrical operations to ensure the functioning of
motor operating mechanism.
8. Inspection and Commissioning:
After fixing the conductors, the following checks must be performed:

 Adjustment of disconnector and earthing switch and ensure all the conditions are met as
described above.
 All bearing should be greased
 All contacts should be lubricated
Perform few operating cycles.
9. Check Sheet for Erecting and Commissioning
The check list is to be used during Erecting and Commissioning.

It is meant to ensure that all the instructions given in the manual have been followed.
TABLE:3
© Siemens - 40 -
Revision 6
SIEMENS
HYDERABAD WORKS
Check Sheet for Erection and Commissioning
Standerd Observed
S.No Check Points Done Value Value Remark
STRUCTURE BASE CHANNEL AND INSULATOR
1 Check the level of the structure with spirit level
Ensure the "Centre distance" between the Structure Pillars is the as per the GA S in the GA
2 Drawing Drawing
3 Fix the base channel at the given slots
Check the height of the elevator plate on the base channel on both the sides (both Refer GA
4 should be at same height) drawing.
5 Check for the spirit level of the elevator plate.
Ensure the orientation of the any two colinear holes of the top Insulator stack are
6 parallel to the base channel edge.
7 Check the vertically of the insulator.
S in the GA
8 Check the "S" distance is as per the drawing between the end insulators. Drawing
Ensure the Tom and Drive lever is connected as per the Instruction Manual to operate
9 the isolator.
MAIN CONTACT
10 Ensure to fix the the Moving contact and fixed contact as per the Instruction manual
Manually rotate the Moving contact to see if the blades are moving into the Fixed
contact without hitting the top or bottom of the jaws( If Moving contact is hitting the
jaws first adjust the position of the jaws in fixed contact slots.If the Slot length is not
11 enough then adjust the height of the elevator plate.)
12 Check the Drive box flange is vertically aligned to the downpipe.( Main Switch)
Ensure the position of the moving contact is closed condition to connect the drive box
13 flange to the doun pipe.
Ensure the drive box is in closed condition by operating the box manually and referring
14 the ON-OFF LABELS show the same position.
See that any of the two holes on the drive flange and doun pipe flange will coincide to
15 do the bolting of both the flanges.
Ensure to fix the flanges tightly and operate the isolator manually to see if the closing
16 and opening is happening as described in the operation manual.
17 Operate the Isolator manually and check for the alignment of the isolator.
EARTH SWITCH CONTACT
18 Check the Drive box flange is vertically aligned to the downpipe.(Earth Switch)
Ensure the Earth Moving contact Blade(Plated Tip) is converged by the jaws in the
19 middle.
Ensure the Earth Moving contact is smoothly entering into the Earth Switch Fixed
20 Contact.(Adjust the U bolts on the earth base to achieve this)
Ensure the toggle is locked/achieved the dead centre position when Earth Switch
21 Moving Contact is in Closed Condition
Ensure the drive box is in closed condition by operating the box manually and referring
22 the ON-OFF LABELS show the same position.
See that any of the two holes on the drive flange and doun pipe flange will coincide to
23 do the bolting of both the flanges.
Ensure to fix the flanges tightly and operate the isolator manually to see if the closing
24 and opening is happening as described in the operation manual.
25 Operate the Isolator manually and check for the alignment of the Earth switch.
Ensure the isolator is in closed condition and earth switch is in open condition and fix
26 the mechanical interlock as per the GA Drawing/Instruction manual
27 Ensure the wiring in the drive box done as per the drawing.
© Siemens - 41 -
Revision 6
Ensure to position the isolator manually in half closed condition and check for phase
28 sequence of the three phase supply w.r.t isolator position.
COMISSIONING CHECKS
Ensure the tightness of the bolts and nuts in the current is as per the torque sheet
29 given in the manual (The bolts and nuts may become loose in transportation)
Check the contact of the silver plated components in the moving contact with the
30 fixed contact is intact.Ensure to avoid any sligtest gap between the tips.
31 Ensure the petrolium jelly is applied to all the contact portion.
32 Ensure that there is no corrosion on the contact portion
33 Ensure that there are no scrathes on the silverplated components
34 Check the closing time of the isolator
35 Check the opening time of the isolator
36 Check the Current drawn by the motor in the rated voltage
Check the contact resistance of the isolator and ensure it is with in the permissible
37 limits.
Check sheet should be filled for each isolator

Any deviation form the GA drawing and Instruction manual is to be highlited to the factory
The End
© Siemens - 42 -
s
MAINTAINANCE INSTRUCTIONS
Date (Rev-5) 25.11.2013 26.11.2013 26.11.2013
Name Syed Jaweed Ikam Ch.SubbaReddy P.RamaMurthy

Signature SJI CSR PRM
Prepared By Reviewed By Approved By

Plot No.89&90,
IDA Gandhinagar,
Balanagar Post,
Hyderabad-500037.
Tel.: 0091-40-33507000/7001
Fax: 0091-40-23079992
Toll Free Ph No: 1 800 2667 480
Revision 5
PAGE
CONTENTS
1 Scope 3
2 Installation 3
Table:1 4
3 Startup 4
4 Documents 4
Table:2 5
5 Extent and frequency of inspection and maintenance 6
6 Inspection 7
7 Maintenance 8
8 Disposal of the product 8
9 Recommended spares 9
10 Replacement of parts / Spare Parts 10
IMPORTANT NOTES
• Failure to comply with warnings and other alerts can cause death, serious
bodily injury and extensive damage to property and the environment.
© Siemens -2-
Revision 5
1. Scope
This manual specifies the inspection and maintenance work to be done on Following
Disconnectors
• Double break disconnector with earthing switch

• Horizontal break disconnector with earthing switch
• Pantograph disconnector with earthing switch
2. Installation
Installation may only be carried out by personnel familiar with these operating instructions.
Risks to erection personnel may be caused by:

• Electricity
• Falling and or tilting or other moving parts.
C A U T I O N!
• Ensure that safety procedures are followed during installation, inspection and
maintenance.
• Use Personal protective Equipments / Tool.
CAUTION!
Electric voltage there is a risk of electric shock and burning due to arcing when approaching
live components.
The poles of disconnectors, if necessary with mounted earthing switches, are assembled and
preconfigured in the factory, installation on site consists of the following main activities:
• Assembling and setting up of poles.
• Mounting the drives.
• Coupling the drive linkage and adjusting.
The serial numbers of the disconnector are indicated on the nameplates. The nameplates are
located on the drive cover of drives operating mechanism box.
CAUTION!
Before establishing connections, use brush/ cloth to clean live connections and apply a thin
layer of graphite oil or petroleum jelly as specified I Table:1
© Siemens -3-
Revision 5
TABLE:1
TYPES OF GREASE TO BE USED APPLICATION

Rivolta or SKD 3602 (or) Centoplex 24 DL For parts on contact system.
(or) Graphite oil
For threads of hot dip galvanized
Rivolta SKD 3602 (or) parts.
Molycote longterm 2 plus
For all lubrication points on Operating
Rivolta SKD 3602 (or) Isoflex Topas L32 mechanism, gears.
3. Start Up
Make the following checks and inspections before start-up:
• Inspect all bolted connections, locks and reference dimensions.
• Perform manual switching operations and monitor all movements.
• Perform electrical switching operations.
4. Documents
The following documents must be available to perform the work described in this instruction:
• Layout drawing.
• Assembly instruction of disconnector & earth switches.
• GA drawings of disconnector with earth.
• Instruction for Tightening torques for all hardware (Table-2).
© Siemens -4-
Revision 5
TABLE:2
© Siemens -5-
Revision 5
5. Extent and frequency of inspection and maintenance

The following indications are related to places of installation with moderate up to heavy pollution
and a maximum number of 500 operating cycles for the disconnector per year.
Yearly Inspection (Refer Heading 6. Inspection).
Every 3 years Maintenance work Refer Heading (Refer Heading 7.

Maintenance).
For other than the above described conditions, extent and frequency of maintenance must be
adapted accordingly.
• Depending on the service conditions, an inspection should be made after every

12 to18 months.
• At very high switching frequency, latest however after 1000 switching operations.
• After several loads near the short-time withstand current.
• In severe service environments.
CAUTION!
Observe all safety instructions before starting work. Under normal service conditions,
maintenance is required after about every 1000 operations or 3 years.
Carry out the following maintenance activities:
• Visual inspection for damage due to external factors.
• Inspect and retighten all bolted connections to the prescribed tightening torque (Refer Table:2).
• Clean the post insulators.
• Inspect the paint, repair if necessary.
• Check all electric control functions.
• Carry out switching operations and check the current path setting.
• Clean the contact system.
5.1 Recommended place for the maintenance work
All maintenance work on the disconnector may be performed at the place of installation.
5.2 Special tools
No special tools are required to perform the maintenance work.
© Siemens -6-
Revision 5
6. Inspection
6.1 Transmission
Step Description of activities Requirement
During a normal operation cycle, the transmission parts

of the disconnector and if applicable of the earthing
switch, shall be checked as follows:
• Proper course of motion No unusual noise
• Possible damage of parts None
• Possible loose joining elements None
(screws, pins, etc.,)
6.2 Current carrying parts:
During a normal operation cycle, the current carrying The main contacts shall close
parts of the disconnector, shall be checked as follows: properly
• Proper course of motion
No damages or heavy dirt
• Condition of main contacts accumulation
During a normal operation cycle of the earthing switch, Proper movement of earthing
the following shall be checked blade into the contact carrier
• Proper course of motion
No damage or heavy dirt
• Condition of earthing blade accumulation
• Condition of flexible connectors No damage, good flexibility.
If inspection shows deviation to the requirement, appropriate corrective action must be taken, i.e.,
• Perform maintenance work (Cleaning, greasing – Refer Table:1 for type of Grease)
• Tighten the screws. (Refer Table:2 for tightening torque)
• Adjust disconnector or earthing switch.
• Replace damaged parts.
• Pay attention to the information given in the appropriate assembly instructions.
• Inspect the contact system and replace the current path if necessary due to wear.
• Check the rotating stool mechanisms for free movement.
© Siemens -7-
Revision 5
7. Maintenance
7.1 Maintenance of the transmission:
Lubricate all bearings and joints
Perform the inspection per par (Heading 6. Inspection)
7.2 Maintenance of current carrying parts:
• Perform the inspection per par. (Heading 6. Inspection)

• Clean the main contacts using brush / cloth
• Lubricate the main contacts with a thin layer of specified lubricant (Refer Table:2).
• Lubricate the bearings of current carrying parts with specified lubricant (Refer Table:2).
7.3 Maintenance of earthing switch:
Perform the inspection per par. (Heading

6. Inspection)
Clean the earthing blades and contact

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

contact springs
Note: While using lubricants the respective MSDS (Material Safety Data Sheets) should be
referred.
Note:
In case any rework is done on a galvanized part that area is to be first sprayed with VCI
spray and then zinc primer is to be applied.
8. Disposal of product:
The product is environmentally compatible.
The following materials have used to make up the device steel, copper, aluminium, cast-resin,
porcelain, greases etc.
In as-supplied condition, the product does not incorporate any hazardous substances.
© Siemens -8-
Revision 5
In operation, the product does not emit any hazardous materials or gases.
During disposal of the product, care must be taken to dismantle and segregate as far as possible
in more environmentally accepted way as recyclable raw materials and non recyclable materials
like synthetic ,lubricants and materials soaked in lubricants.
The disposal of non recyclable materials should be in line with the legal and statutory
requirements of the local area.
Local customer support-Siemens office will be able to answer any questions concerning disposal.
9. Recommended Spare Parts:
Double break disconnector
Quantity
in
S.No Part / Assembly (Poles)
1 Main Switch Moving contact assembly 3
2 Main Switch Fixed contact assembly 3
3 Main Switch Contact Tip/Blade 1
4 Main Switch Fixed contact jaws with spring and spring guide 1
5 Main Switch Fixed contact terminal pad/ jumper pad 1
6 Main Switch Operating mechanism box 1
7 Earth switch Moving contact assembly 3
8 Earth switch Fixed contact assembly 3
9 Earth switch Moving Contact Tip/Blade 1
10 Earth switch Fixed contact jaws with spring and spring guide 1
11 Earth switch Operating mechanism box 1
Horizontal break disconnector
Quantity
in
1 Main Switch Male contact assembly 3
2 Main Switch Female contact assembly 3
3 Main Switch Male Contact Tip/Blade 1
Main Switch Female contact jaws with spring and spring
4 guide 1
© Siemens -9-
Revision 5
Pantograph disconnector
Quantity
in
1 Main Switch Moving contact assembly 3
2 Main Switch Fixed contact assembly with dropper pipe 3
3 Main Switch Contact Tip/Blade 1
4 Main Switch Fixed contact 1
10. Replacement of parts / Spare Parts:

For queries, replacement parts orders or faults, please, contact our service department giving
details of all nameplate data:
Plot No.89&90,
IDA Gandhinagar,
Balanagar Post,
Hyderabad-500037.
Tel.: 0091-40-33507000/7001
Fax: 0091-40-23079992
Toll Free Ph No: 1 800 2667 480
© Siemens - 10 -

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s Doc. No.

Rated voltage 400kV

Date (Rev-6) 24.07.2014 24.07.2014 24.07.2014

Name Syed Jaweed Ikram Ch.SubbaReddy P.RamaMurthy

Prepared By Reviewed By Approved By

Address: M/s Siemens Limited,

1.2 Safety Instructions

1.3 Technical Data

2.2 Design of the Disconnector

3. Delivery and storage

3.1 Scope Of Delivery

The delivery includes:

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

4. Packaging and storage

5. Erection and Assembly Instructions:

TYPES OF GREASE TO BE USED APPLICATION

5.2 Assembly Preparation

 Assembly part List for Disconnector & Earth switch.

Check the foundation plan with respect to the GA drawing

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

Check the Assembly of the Base frame for the following:

Earth switch fixed

Moving Contact Assembly

Base Channel Assembly MS Push Pipe ES Push Pipe

MS Down Pipe Assembly Sub-Structure

Fig. 01 General Arrangement

6.2 Assembly of disconnector

Base channel MS TOM Holes

Fig. 02 Base channel mounting

Rotating stool base

Fig. 03 Rotating Stool base mounting

Fig. 04 Elevator plate mounting

RS base Drive lever

Fig. 06 Insulators Mounting

Installing the current path:

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

Fig. 07 Main contacts mounting

Place the corona Shields/rings on both support insulator

1) For Earthing Switch fixed contact Type-1 design

Fig. 08 Earth switch fixed contact

Fig. 09 Fixed contact

Fig. 10 Connecting Pad Mounting

2) For Earthing Switch fixed contact Type-2 design

Fig. 11 Fixed contacts Mounting

Fig. 12 Fixed contacts corona ring mounting

Fig. 13 Earth switch fixed contact

3) For Disconnector without Earthing Switch

Fig. 14 Fixed contacts Mounting

Fig. 15 Fixed contacts Mounting

Fig. 16 TOM mounting

Flange Type Design

"L” Bracket Type Design

Fig. 17 Down pipe

Fig. 18 MS TOM LEVER

Fig. 19 Drive Lever

Fig. 20 Push pipe assembly

6.3 Adjustment of Disconnector

Fig. 21 Contact alignment

For doing this follow the below given steps:

For doing this follow the below given steps:

Dead lock position of

Fig. 22 TOM Adjustment

Fig. 23 Earth base assembly mounting