Page 1 of 9

IM-6101 INSTRUCTION MANUAL OF 36/11kV DBR DISCONNECTOR

Manual: IM-6101
Issue: 1

Date: Jan 2015

Manufacturer:
SWITCHGEAR MANUFACTURING COMPANY PRIVATE LIMITED
Flat no 303, Aditya Gardenia, D. No. 8-2-334/1/A
Road no. 5, Banjara Hills, HYDERABAD-500034
e-mail: smc.isolator@gmail.com

Scope

The instruction manual and equipment drawings contain important and useful information for
correct functioning and maintenance of the product. They also contain important instructions for
installation of this disconnector, to prevent possible accidents, damage and to ensure satisfactory
service. Read this manual carefully and follow the instructions in this manual.

All information in this instruction manual is based on the most recent information. This
information is subject to change without notice.

Figure 1

The technical information, supplied drawings and technical descriptions shall not be used (other
than for installation and maintenance of this product), or passed to third parties or reproduced in
any form or by any means without prior written permission.

SWITCHGEAR MANUFACTURING COMPANY PVT.LTD.

 Page 2 of 9
IM-6101 INSTRUCTION MANUAL OF 36/11kV DBR DISCONNECTOR
1.0 Introduction

1.1 General

The 3-pole Double break type 36/11 kV disconnector type is designed for use in outdoor High Voltage
Substations. The design consists of three nos. post insulator on each pole. This type of disconnector is of
simple design of centre post rotating double break contact having excellent short time current rating.

Earthing switches can be fitted to the disconnector and swing in a plane, which is perpendicular to the base
frame. Disconnector and earthing switch may have common /separate operating mechanism as required.

Figure 2
The disconnector is shipped in units. The individual units are marked with a number, which is indicated in the
packing list.
1.2 Specifications

The disconnector and the earthing switch have been designed, tested and approved according to IEC: 62271-
102 / IS: 9921 specifications.

SWITCHGEAR MANUFACTURING COMPANY PVT.LTD.

 Page 3 of 9
IM-6101 INSTRUCTION MANUAL OF 36/11kV DBR DISCONNECTOR

2. Installation of disconnector :

Warning: Safety precautions shall be carefully followed. Make absolutely sure the line on which men
are working or erecting equipment is de-energized. During installation all local installation
and safety regulations shall be followed.

Caution: When unpacking the equipment, it shall be remembered that many parts are fragile and can
be broken by sudden jars and rough handling. Care should be exercised to prevent damage
or distortion, which could result in delay, trouble or inconvenience in assembly.

The table below shows the torque to be used for all bolted connections, unless specified otherwise in the text.
Bolt Bolted connection steel/steel Bolted connection Steel/Other
diameter materials
Hot dip galvanized Stainless steel Hot dip galvanized and stainless steel
bolts bolts bolts
M8 23 Nm 22 Nm 22 Nm
M 10 46 Nm 33 Nm 33 Nm
M 12 79 Nm 56 Nm 56 Nm
M 16* 195 Nm 136 Nm 120 Nm
M 20 390 Nm 274 Nm 206 Nm
* Maximum torque for M16 bolts used in pivots (Linkages) is 120NM

2.1 Base

Figure 3
1. Make sure the structure on which to mount the disconnector is checked and approved.

Caution: Switches must be carefully aligned on the supporting structure. The surface on which the
base will be mounted must be flat and true; otherwise the base may become twisted when
bolted on the structure. Such twisting could cause operating difficulties of the equipment.
Operating parts, which are out of alignment, could cause undue strain on the
insulators. All bases and associated stationary parts must be rigidly bolted in place.
All bases must be grounded.
2. Dismantle the fixed and male contact from the base frame (If mounted)

SWITCHGEAR MANUFACTURING COMPANY PVT.LTD.

 Page 4 of 9
IM-6101 INSTRUCTION MANUAL OF 36/11kV DBR DISCONNECTOR

3. Mount the base frames to the structure & check for proper alignment. Check the dimensions
X as shown in fig.4

Figure 4
2.2 Insulators

1. Take the post insulators out of the crate. Make sure the correct insulators are provided with the
dimensions such as height, fixing holes (PCD) at top & bottom as per the approved drawing.

2. Put the insulators on top of the base. Tighten the bolts.

2.3 Main Contact

The main contact set consists of a male contact and female contacts.

1. Mount the female contact and male contact assembly on the top of the post insulators. Refer the
General Arrangement drawing for the correct position of the male and female contact. Tighten
the bolts, finger tight.

2. Rotate the rotating stool to put the moving

contact in the position as shown in fig. 5.
In this position the moving contact has to
insert into the female contact smoothly. If
required adjust the same by inserting
proper filling washers at the bottom of the
fixing bolt. After adjustment, tighten the
contact mounting bolts.
Figure 5

SWITCHGEAR MANUFACTURING COMPANY PVT.LTD.

 Page 5 of 9
IM-6101 INSTRUCTION MANUAL OF 36/11kV DBR DISCONNECTOR
3. Check the distance between the contacts as shown in fig. 6. This distance must be S ± 5mm. If
necessary adjust by loosing the Insulator fixing bolts at the elevator channel and insert an appropriate
shims / filling washers at the bottom of Insulator stack as shown in the figure 6

Figure 6
4. Repeat similar steps for the other two poles. After adjustment put all the three poles in closed
position.

2.4 Phase Coupling Pipe / Tandem Pipe

1. Put all the three poles in closed position.

2. Remove the top clamps from the clamp assembly, which is fixed on the base channels. Do not
remove the clamp bottom from the base, which is factory assembled.

3. Put the tandem pipe on the clamp bottoms as shown in figure 7 & fix the top clamps. Tighten the
bolts (Torque: 120 Nm).

Figure 7

SWITCHGEAR MANUFACTURING COMPANY PVT.LTD.

 Page 6 of 9
IM-6101 INSTRUCTION MANUAL OF 36/11kV DBR DISCONNECTOR
2.5 Operating Mechanism
1. Fix the top operating mechanism on the structure
& tighten the bolt finger tight. Keep the lever
position as shown in fig. 2.

2. Mount the operating mechanism box on the

structure.

3. Check that the output shaft of the operating

mechanism box is in line with the top operating
mechanism shaft as shown in Figure.

4. Fix the operating pipe by suitable sizing the height.

Connect one end to the top operating mechanism
and the other flanged end to the operating
mechanism box through Vernier flange
arrangement. Ensure that the operating mechanism
box is in closed position during this process.
Tighten the bolts (Torque: 195 Nm)

Figure 8

3. Checking of Operation

1. Operate the Isolator manually. Ensure that the plunger inside the operating mechanism box, if
provided is lifted manually or electrically before operating the Isolator.
2. Check the following points
3. Whether all the poles are closed simultaneously.
4. Whether the closing is uniform.
5. Whether the stopper bolts are touching the lever in both close and open position and the
operating handle strip is inserting into the grove, if provided on the top of the operating
mechanism box.
6. NO & NC contacts are working satisfactory in both close and open position.
7. After completion of alignment, remove the lock bolt provided on clamp top. Then drill 11mm
hole on the tandem pipe through clamp top hole. Then put the bolt back in to the clamp top and
tighten it so that the alignment of tandem pipe will not disturbed at any time

SWITCHGEAR MANUFACTURING COMPANY PVT.LTD.

 Page 7 of 9
IM-6101 INSTRUCTION MANUAL OF 36/11kV DBR DISCONNECTOR
4. Installation of Earth Switch

At first place the disconnector in open position.

4.1 Earth Switch Contact
1. Take the rotating pipe mechanism out of the crate.
Remove the bolts provided for fixing.
2. Fix the rotating pipe mechanism to the base
channel as shown in fig.. Tighten the bolt (Torque:
79 Nm).
3. Take the E/S male contact out of the crate and fix
it to the rotating pipe mechanism as shown in fig.
10. Tighten the ‘U’ clamps. (Torque 46Nm)
4. Fix the E/s Female contact on the top of the
Female contact Jumper pad as shown in fig 9

Figure 9
4.2 Earth Switch Operating Mechanism

1. Mount the earth switch top operating

mechanism & manual operating mechanism
on the structure.

2. Check that the output shaft of the E/s

operating mechanism is in line with the E/s
top operating mechanism shaft (See Figure 8).
Put the earth switch operating mechanism in
the ‘CLOSE’ condition & tighten the bolts.

3. Fix the one end of E/s operating pipe to the

E/s top operating mechanism. Tighten the
bolt.

4. Measure the distance from the hole to the

flange of manual operating mechanism
(Distance B as shown in figure 10). Cut the
operating pipe to the required length & weld
to the flange, which is bolted to the operating
mechanism.
Figure 10

SWITCHGEAR MANUFACTURING COMPANY PVT.LTD.

 Page 8 of 9
IM-6101 INSTRUCTION MANUAL OF 36/11kV DBR DISCONNECTOR
4.3 Earth Switch Phase coupling Pipe:

1. Ensure that all the three pole of earth switches are in close position.

2. Fix the E/s phase coupling pipe to clamps of each pole & tighten the bolts.

3. Fix the one end of the auxiliary tandem pipe to the E/s top operating mechanism and
other end to the earth switch phase coupling pipe. The auxiliary tandem pipe shall be
parallel to the E/s phase coupling pipe.

4. After adjustment tighten the bolts.

5. Final inspection

After having been installed but before putting in service, the equipment should be carefully inspected and
checked.

a. Check all insulator units for cracked or defective parts.

b. Check all contacts for alignment
c. Check all bolted connections for tightness.
d. Check isolating distances, clearances between live parts of equipment and travel of
equipment.
e. Check the earthing switch (if provided) for mounting and operation.
f. Check the electrical connection to the operating mechanism (If applicable).
g. Check all operating mechanisms (disconnector & earthing switch) for proper operation,
lubrication and travel. Also for lost motion, mechanical connections and excessive
deflection of controls or mounting.
h. Examine all switch locks (when applicable) for security, proper functioning and ease of
operation.
i. Check if the insulators, moving parts, etc. are clean

Perform 50 mechanical operations at nominal operating voltage as per IEC-62271-102, 2001 / IS: 9921
(Part 4), 1985

6. Maintenance

Caution: Before starting maintenance work all safety precautions and local and general regulations
should be followed. Be sure that the switch is disconnected from all electric power sources. Make sure
the drive mechanism is locked and secured and the power supply for the motor drive is interrupted.
Ground leads or the equivalent should be attached (on both sides) to the equipment

Switches manufactured by Switchgears & Structurals are almost maintenance free. However,
to improve the reliability under all circumstances it is recommended to inspect the equipment
every 5 years or at least after every 1000 operations. Depending on the local atmospheric

SWITCHGEAR MANUFACTURING COMPANY PVT.LTD.

 Page 9 of 9
IM-6101 INSTRUCTION MANUAL OF 36/11kV DBR DISCONNECTOR

conditions inspection at shorter (or longer) intervals may be necessary. If the equipment cannot be
inspected periodically, it is recommended to open and close the switches whenever it is possible to do
so, in order to clean the contacts and free the moving parts. During periodical maintenance the
following actions should be carried out:

7. Contacts

Clean the contacts and apply a thin and uniform film of petroleum jelly paste to the contact surfaces.
Remove the excessive petroleum jelly paste. Check for proper contact in ‘CLOSED’ position. When
contacts show damage or are badly eroded due to mechanical load, arcing etc. it may be necessary to
replace those parts.

8. General Inspection

Inspect the equipment and operating mechanism for good working condition. Check the bolts, nuts;
washers and terminal connectors are in place and in good condition. Replace items showing
excessive wear or corrosion. Inspect and check all safety interlocks and test for proper operation.
Check if the insulators are in good condition and that the surfaces are clean.

Caution: After maintenance or inspection make sure that all safety precaution and local and general
regulation are followed before re-energising the equipment.

SWITCHGEAR MANUFACTURING COMPANY PVT.LTD.