SIEMENS Doe. No. DOC /407/ED/AL Revision 4 ASSEMBLY INSTRUCTIONS Double Side Break Disconnector Rated voltage 400kV Date (Rev-4) 20.12.2012 26.12.2012 26.12.2012 Name Syed Jaweed Ikram ChSubbaReddy | P-RamaMurthy Signature SJL CSR PRM Prepared By Reviewed By Approved By Address: M/s Siemens Limited, Plot No.89890, IDA Gandhinagar, Balanagar Post, Hyderabad-500037. Mall: eneraysuoport [email protected] Tel.: 0091-40-83507000/7001 Fax: 0091-40-23079992 Toll Free Ph No: 1 800 2667 480 © SiemensSIEMENS CONTENTS 1 10 General 1.1 Introduction 1.2 _ Safety Instructions 1.3. Technical Data Description 21 General 2.2. Design of disconnector Delivery and Storage 3.1. Scope of Delivery 3.2 Material Packing and Storage Erection and Assembly instructions 5.1. Transport 5.2 Assembly Preparation Assembly 6.1 Checking 6.2. Assembly of disconnector 6.3. Adjustment of disconnector 6.4 Assembly of earth switch (If Applicable) 6.5 Adjustment of Earth switch 6.6 Assembly of Mechanical interlock 6.7 Adjustment of Mechanical interlock Motor Operating Mechanism 7.1 Adjustment of Motor Operating Mechanism Inspection and commissioning Check sheet for Erection and Commissioning ‘Assembly part list IMPORTANT NOTES Doe. No. DOC /407/ED/AL Revision 4 Be wevaouuuessuwwule 25 27 32 33 35 37 37 38 38 a ‘+ 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, inal 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SIEMENS Doe. No. DOC /407/ED/AL 1 Revision 4 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 Instru 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 23SIEMENS Doe. No. DOC /407/ED/AL Revision 4 [Technical Particulars of Disconnector Unit [Values [Rated voltage (KV) tev) | a20Kv [Rated frequency (i) | 50 72000- [Rated current (Al | 4000 Rated short circuit withstand value tka] [400501 [Rated short circuit duration s [ou Rated PF withstand voltage across isolating distance Teva | 610) Rated PF withstand voltage between live terminals and_ground Teva [5201 Lightning Impulse withstand across Isolating distance tev) [1425 Lightning Impulse withstand between live terminals and ground eve] | 1665) Switching Impulse withstand across Isolating distance tev) | 1245, Switching Impulse withstand across between live terminals and ground | (kVp] | 1050 [Technical Particulars of Moor drive MECHANISM [MOTOR DRIVE GAR ROX )oToR SUPPL Ai5v |RATEDOPERATINGVOLTAGE _|AC.CONTROL SUPPLY.220V DC [RATED MOTORFOWER [psa 2. Description 2:4 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SIEMENS Doe. No. DOC /407/ED/AL Revision 4 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 muti 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 Al 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+SIEMENS Doe. No. DOC /407/ED/AL Revision 4 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. A. AU T10 NE! 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 catried out by personnel familiar with these operating instructions. Risks to erection personnel can be caused by + Electric voltage + Falling and/or ting or other moving parts. Acaution 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: WARNING! If nuts are tightened without torque control, there is risk of damage or slackening of the bolted connection. © SiemensSIEMENS Doe. No. DOC /407/ED/AL Revision 4 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 slick 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 SD 3602 (or) ‘Centoplex 24DL For parts on contact system. For threads of hot dip Rivolta SKD 3602 (or) Molycote longterm 2 plus galvanized parts, For all lubrication points on Rivolta SKD 3602 (or) Isoflex Topas L32, Operating 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 lft 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SIEMENS Doe. No. DOC /407/ED/AL Revision 4 TABLE: Tightningterqune rN for ended connections es orate naire) Bote and mt - f cuz:cu3 | Forgenera use mtr nestgon | veo! araed sccnebece | "comectons) screwseg | _Nus*® Onst3, DN | 29. ON G34 Sia | snibINess | Bolts 10:9 0f ometeana | “Botsee | gg Boye | ARrAS Diets | egdwest on | Shane | “cus hexagon | GiB and binsoe | ONS —— m Bolts 10.9" countersun ne haadeap | ‘Nontorrous screw | nendero £9/01N791 | 9g omgs8, ON satin | SizaraDN Sst bisse sed ON 809 aaa a8 a | a r aor Taso 0 $ ys 07 2502 moa [tesor[aas0r[ tas or] 3 #03 S$03 wos _|-aze oa} 3 sor] sss] es 08 Sous Ms [a s0sl sree] s-fos[ es 1 [weal set 8 a7 | os |e ae 0 esa a] ee aa fe asa [es | tos | OST 46 00810 | “70-20 | 28025170820 M20 340+ 30 ‘500 + 50_| 340 230 ae exo s-60 ato 5-60 Reet ring inornaton fr tread gauges > 24 2) iccarnea ih VO12239 59004 3 Kyeetae Reema tec) Dr, pn to onanza pase vs bots bated wn ‘grate containing adced MoS (e.g. Malykto Longer 2). 3) Seengin grace as per DIN 267/OIN 150 298. 44) Including icking nuts of tength grade 8 to DIN 257 / DIN ISO 886, For othe strong gredes, front sghtening torques must be specifed fr leckng nuts, eg. Clveloc nuts, and Indeatod nthe rowing 5) Where ols of stengt grade 10.9 and higher are serewed into auminiom, use oni the ohtaing torques specied for bots of strengh grade 8.8 (c. QW repon 22171778 cated 73.1878), 8) using a put the bolt mast peru by st eat one vend tu 7) Apples nerton. Rt oe ightned acoring tthe apicabe value, ©) Tensile strength at est 700 N/m © Siemens -8-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 5.2 Assembly Preparation The following documents must be available to perform the assembly according to this instruction + Assembly patt List for Disconnector & Earth switch. + GAdrawings 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 sub- structure 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 Driling 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SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 ‘Caac Ase Serna Fred connec Assomay ES tovra Conte FsToW ‘Toga Aosonsy Bue ChamelAsenbiy ESPs Ws Dow Pow Aan. 5 opnatng Box Fig. 01 General Arrangement The pictorial view of the above mentioned assemblies can be seen in 9. Assembly Part List (Page-34). © Siemens =10-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 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 shee!) between Base channel and sub structure. Base channel MS TOM Holes Sub- Structure qo pa Fig. 02 Base channel mounting Mount the Rotating Stoo! base on the base channel and screw until secure, using screws, washers and nuts. © SiemensSIEMENS Doc. No. DOC /M07/EDIAL Revision 4 Rotating stool base Fig. 08 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 siing or tackle, set them down on the elevator plate and tighten them. © Siemens -12-SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 Note: While mounting the insulator stacks, ensure that the holes posi insulator flange is as shown in figure Fig. 5 Nn of the top most Se 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 213+SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 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+SIEMENS Doe. No. DOC /407/ED/AL Revision 4 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. Le Type-t 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-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 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 ~. Z Corona ring Fig. 08 Earth switch fixed contact © Siemens = 16-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 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-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 2) For Earthing Switch fixed contact Type-2 desian Mount the fixed contact on the corona Shieldirings 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 Attach the Fixed contact corona rings/ shields on top of the fixed contact and secure it using 2 screws and 4 washers. Do this on each of the two sides. Fixed contact corona ring Fig. 12 Fixed contacts corona ring mounting © Siemens -18-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 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 Clean the surfaces of terminal pad to remove any scales formed on the surfaces and apply contact grease to the terminal contact. © Siemens -19-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 3) For Disconnector without Earthing Switch Mount the fixed contact on the corona Shielditings 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. 14 Fixed contacts Mounting Attach the Fixed contact corona rings! shields on top of the fixed contact and secure it using 2 scrows and 4 washers. Do this on each of the two sides. Fixed contact, corona ring Terminal pad Fig. 15 Fixed contacts Mounting Clean the surfaces of terminal pad to remove any scales formed on the surfaces and apply contact grease to the terminal contact. 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. © Siemens = 20SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 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 zine 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 <2SIEMENS Doe. No. DOC /407/ED/AL Revision 4 MS Down pipe / Ties etl 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 90° as shown in the figure below. © SiemensSIEMENS Doe. No. DOC /407/ED/AL Revision 4 — MS TOM lever Fig. 18 MS TOM LEVER 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 10° to the Parallel axis of disconnector as shown in the figure below. © Siemens “2B.SIEMENS Doe. No. DOC /407/ED/AL Revision 4 Lt 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SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 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SIEMENS Doe. No. DOC /407/ED/AL Revision 4 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 itbetween 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. For doing this follow the below given steps: - 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SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 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-SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 Spring Fixing Bracket 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SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 Fig. 25 ES TOM mounting Ensure the perpendicularity of the TOM pin with respect to the base frame for doing this use zine 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-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 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 zine and paint. + Fig. 27 Operating pipe Length © Siemens -30-SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 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, ES moving contact Fig. 28 Earth moving contact mounting Keeping the Earth Switch towards CLOSED posttion 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 al SL Fig. 29 Counter balance springs assembly © Siemens <31-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 Dead center position Fig, 30 Toggle lever dead center Take the tree 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, For doing this follow the below given steps: = Manually move the earthing switch towards close position using the hand crank in the motor operating mechanism untl itis 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SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 For doing this follow the below given steps: - Manually switch the earthing switch towards CLOSED position until the contact tip centers the fixed contact and touches the stopper. - Loosen the screws on toggle clamp unti 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 sorew on clams to the specified torque. = Now make OPEN and CLOSE cycles and check that the toggle crosse: center again. - If necessary, repeat the setting, its dead 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 ES 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 -33-SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 < Ke Braket-1 Braket-2 Interlock Pipe Fig. 82 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 -34-SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 Link pipe Fig. 88 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. For doing this follow the below given steps: Move the main switch towards closed position (til 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 ink pipe. - Now make OPEN and CLOSE cycles to ensure the functioning of Mechanical interlock. if necessary, repeat the setting. PR Interlock cam when B/S in open Position Interlock Rod when MIS in Close Position © Siemens -35-SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 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 zine spray. Fig. 35 Interlock Position for Disconnector Closed & Earth switch open condition © Siemens -36-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 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 controling 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 ant-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 switeh 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 -37-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 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. 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 - Ifnecessary, repeat the setting 8. Inspection and Commissioning: Atter 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 -38-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 ‘SIEMENS HYDERABAD WORKS ‘Check Sheet for Erection and Commissioning sno check Points bone |vatue __|vatue _|Remare [STRUCTURE BASE CHANNEL AND INSULATOR T[eneck the level ofthe structure with spr lve IFrsure the "Centre distance” between the Stuctore Plarsis he as per the GE Sin the Ga 2 Jocawing rang 3 [Fite bare channel atthe gen Sots [creck te height ofthe elevator plate onthe base channel on Bow Ce sides BOTA een 4_foula be atsame height érawing ' [check forte spr level of he elevator pate Insure the orientation ofthe any two colnear holes af he Yop nsuator lack re 6 [paral tothe base channel edge. 7 [check the vertical of the insulator Isinthe Ga Frsure the Tom and Drive levers connected as pr the Irsiruction Manuaito operate 8 bheisobtor. IMAIN CONTACT 120 [ensure to fx the she Moving contact and fied contact a nr the instruction manus Manually rotate the Moving contact to see ifthe blades are moving into the Fsed Jontact without niting the top of bottom of he jaws I Moving contacts iting the awe rst adjust the poston ofthe jaws in xed contact sats the Sot length snot 11 Jenough then aust the height ofthe elevator pate) 2 lcneck te Drive box lange i verily aligned tothe downsipe. Main Switch) Ensure the positon of the moving contacts loses canton te connect the dive box fang tothe coun pi. Insure the drive box sin Glsed condition by operating the box manual and refering le ON-OFF LABELS show the same poston lee that any ofthe two holes on the ave lange and doun pe Flange wil COneaeTS | the bolting of bth the fanges. IEARTH SWITCH CONTACT [creck te Drive box lange is vertically signed to the downpipe (arth Switch) Frsure the Earth Moving contact Bade[Patec Tp] is converged byte jaws ine ne Insure the Earth Moving contacts smootlyentring int he Earth Swich Fed [contact (Aut the U bots on the earth baze to achieve tis) IFrsure the toggles lockea/acheved the Gead cane postion when EaAhSwich oving Contac isn Closed Condition ensure the dive box sin sed conalton by operating the ox mancal and reTern| 2 Ice that any ofthe two holes n the ive ange and doun pe Farge wil cOneae TS lo the boing of both the fans Ersure to fx the anges Hehty and operate the Wolstor Manca tone Fhe Goa lan openings happening as desrbed inthe operation manual loperate the soltor manvaly and check forthe alignment ofthe Earth switch ensure the boltor isn closed condition and earth switchs in open condition nd fx lhe mechanical interlock as per he GA Drawing/nstrution manual © Siemens =39-SIEMENS Doe. No. DOC /407/ED/AL Revision 4 28 [sequence ofthe three phase supply wr isolator postion. [comission CHECKS Ensure the ghtnes ofthe bots and nuts inthe current i as per the toraue sheet 29 [even inthe manual (The bolts and nuts may become lose int |cneck the contact of the sver plated components inthe moving contact with the 30 fixed contacts intact ensure to avoid any slgtest gap between the tps. Si_[Easure the pelolum ely applied to all tre contact portion. 32 [Ensure that there sno corrosion onthe contact potion 33 [Ensure that there arenosrathes onthe sverplated components 32 [check te closing time ofthe seater 35_[check the opening tine ofthe Soltor 36_[Check the Current drawn by the motor a te rated volage 237 fis, [Gis heet shouldbe fed foreach waator [any deviation form the GA drawing and insrocian manual tobe highited To We Tecory © Siemens -40-SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 10. Assembly part list. BASE CHANNEL ASSEMBLY Fig. 37 ROTATING STOOL BASE RS Drive Lever Fig. 38 © Siemens 241+SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 MOVING CONTACT ASSEMBLY Fig. 39 FIXED CONTACT ASSEMBLY Fig. 40 © Siemens = 42-SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 M/S TOM ASSEMBLY Fig. 41 E/S TOM ASSEMBLY Fig. 42 © Siemens 4BSIEMENS Doc. No. DOC /M07/EDIAL Revision 4 DOWN PIPE ASEMBLY AFTER WELDING Fig, 43 EARTHSWITCH TOGGLE ASSEMBLY © SiemensSIEMENS Doc. No. DOC /M07/EDIAL Revision 4 E.S BASE ASSEMBLY Fig. 45 E.S MOVING CONTACT Fig. 46 © Siemens 245 -SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 E.S PUSH PIPE ASSEMBLY Fig. 47 INTERLOCK ARRANGEMENT 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 zine spray, Fig. 48 © SiemensSIEMENS Doc. No. DOC /M07/EDIAL Revision 4 EARTH SWITCH FIXED CONTACT Earthing Switch fixed contact n ae With Corona Shields oe With corona rings Fig, 49 Earthing Switeh fi Fig. 50 © Siemens -47-SIEMENS Doc. No. DOC /M07/EDIAL Revision 4 CORONA RING FOR INSULATORS Fig. 51 MAIN SWITCH PUSH PIPE ASSEMBLY Fig. 52 SPRING FIXING ASSEMBLY ees, SS Fig. 53 © SiemensSIEMENS Doc. No. DOC /M07/EDIAL Revision 4 MOM ASSEMBLY Fig. 54 © Siemens = 49-SIEMENS MAINTAINANCE INSTRUCTIONS Double Side Break Disconnector Rated voltage 400kV Date (Rev-4) 20.12.2012 26.12.2012 26.12.2012 Name Syed Jaweed Ikam Ch.SubbaReddy P.RamaMurthy Signature Si CSR PRM Prepared By Reviewed By Approved By Address: Mis Siemens Limited, Plot No.89&90, IDA Gandhinagar, Balanagar Post, Hyderabad-500037. Mail: eneraysupport [email protected] Tel: 0091-40-33507000/7001 Fax: 0091-40-23079992 Toll Free Ph No: 1 800 2667 480SIEMENS Doc. No. DOC /407/ED/AL Revision 4 PAGE CONTENTS 1 Scope 26 2 Installation 26 3 Startup 27 4 Documents 7 5 Extent and frequency of inspection and maintenance 7 6 —_ Inspection 7 7 Maintenance 29 8 Disposal of the product 30 9 Replacement of parts / Spare Parts 30 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SIEMENS Doe. No. DOC /407/ED/AL Revision 4 1. Scope This manual specifies the inspection and maintenance work to be done on Double Break Disconnectors with rated voltage 400kV type: * Double break disconnector ‘© Double break disconnector with one earthing switch © Double break disconnector with two earthing switches 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 ting or other moving parts. Acaution! Elastic vatage there i ask of eletic shock and burning due to arcing when approaching ie 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 motor drives. Acaution Before establishing connections, use brush to clean live connections and apply a thin layer of graphite oil or petroleum jelly to be used. 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. © Siemens