INSTALLATION, SERVICE AND MAINTENANCE INSTRUCTION

MANUAL
FOR
12KV OUTDOOR PORCELAIN CLAD VCB
(TYPE-VC32)

Stelmec

INDEX
INDEX
1.0
1.1
1.2
2.0
3.0
4.0
4.1
4.2
4.3
4.4
4.5
5.0
5.1
5.3
6.0
6.1
6.2
6.3
6.4
7.0
8.0
9.0
10.0
11.0

PAGE
INTRODUCTION
GENERAL
TECHNICAL SPECIFICATION
DESPATCH & RECEIPT
STORAGE & HANDLING
CONSTRUCTION
STRUCTURE
POLE ASSEMBLY
OPERATING MECHANISM WORKING OF
OPERATING MECHANISM
DRIVE CHAMBER ASSEMBLY
OUTDOOR CONTROL & RELAY PANEL
INSTALLATION
GENERAL
ERECTION
PRE-COMMISSIONING TESTS
MECHANICAL OPERATION
INSULATION RESISTANCE TEST
ELECTRICAL OPERATION
INSTRUCTION FOR MECH. OPERATION
MAINTENANCECE AND INSPECTION
VACUUM CIRCUIT BREAKER
MEASURMENT OF CONTACT WEAR
REPLACEMENT OF PARTS
ACCESSORIES
RECOMMENDED SPARES
CHECK POINTS

DEAR CUSTOMER
2

3
3
3
4
4
4
4
4
4-8
8
8
8
8
8
8
8
9
9
9
9
9-10
10
10
10
11
12-14

We are honored to have a valued customer like you. With great pleasure, we present
this INSTRUCTION MANUAL for your ready reference. We the people at stelmec,
will be at your technical service, any support you and help you.
We advice you to go through the manual carefully to understand the product and its
installation correctly. It may please to be noted that no further technical constructional
variations in the PCVCB and its components made by the customer without prior
consultation with stelmec. For further information, kindly refer to the latest technical
documents such as GA drawings, schematic diagram, assembly drawings, literature of
production , instrumentation coordination , etc. the apparatus supplied may slightly
differ from the data given in this manual. Additional information may be given on
request by the customer.
At stelmec, efforts are constantly being made to improve the designs and services of the
products. Stelmec is strongly committed to improve continually across all its operations.
We welcome valuable suggestions from the customer to support our commitment. we, at
stelmec follow the principle of working as a team with customer, so that we can
determine their needs and are able to satisfy the same to the fullest extent..
1.0

INTRODUCTION

1.1

GENERAL
This manual contains detailed information required for the installation, operation and
maintenance of stelmec make outdoor porcelain clad VCB along with the integrated
control panel, the vacuum circuit breaker, complete with its closing and tripping
mechanism are assembled on a pedestal pole structure and the outdoor unit gives
complete protection from atmosphere conditions. Please read the manual carefully to
understand the product correctly. please refer the latest technical documentation such as
GA drawing , schematic diagram, any literature of protection and instrumentation
coordination etc. efforts are constantly being made to improve design & service and the
apparatus supplied may differ in minor details from the data given in this manual . the
outdoor VCB undergoes all the stringent quality checks and tests as per IEC62271-100
at the manufacturing unit before dispatch, in order to ensure its proper functioning at
customers end.

1.2

TECHNICAL SPECIFICATION

1.
2.
3.
4.
5.
6.
7.
8.

RATED VOLTAGE
RATED NORMAL CURRENT
RATED FREQUENCY
RATED BRAKING CAPACITY UPTO
RATED MAKING CAPACITY UPTO
RATED STC FOR 3 SECS.UPTO
RATED INSULATION LEVEL
RATED OPERATING DUTY CYCLE

2.0

DESPATCH AND RECEIPT

12kV
1250A
50Hz
25KA
62.5KA
25KA
12/28/75kV
O-0.3s-CO-3M-CO

The switchgear is normally shipped complete with mechanism, VCB pole assembly.
Drive chamber assembly, etc. are fitted with pedestal structure such that the factory
setting remains the same, The additional base structure , CT mounting structure etc. are
packed separately.
On receipt, the equipment should be checked according to the instruction on the relative
order acknowledgement. if any damage or irregularity in the supply is noticed the
company should be informed immediately.
3.0

STORAGE AND HANDLING

When immediate installation is not possible and the VCB does not have special packing,
store it. In a dry and dust free place. If possible, cover it with tarpaulin or sheets of
waterproof material. If the storage gets prolonged by more than 4 months form the date
of receipt, then routine inspection and examination should be carried out. Temperature
and humidity should be such that condensation does not occur.

4.0

CONSTRUCTION

4.1

STRUCTURE
The pedestal structure are fabricated in two section so that the total assembly housed in
one section can be dispatched with the factory setting. The other section are bolted at
site to match the required height and for fixing the CTs. The structure made by angles
and channel are epoxy painted and bolted with galvanized hardware. The structure is
bolted as per relevant general arrangement drawing supplied.

4.2

POLE ASSEMBLY
The vacuum interrupter, drive insulator, shunt, tie rod, etc. are assembled in porcelain
bushings with the attachment of aluminum flanges with aluminum terminals for
incoming and outgoing terminations.

4.3

OPERATING MECHANISM
A spring operating mechanism mounted inside a sheet steel cabinet is used to provide
energy required for breaker operation. The closing springs, which are charged manually
or through a motor provide the energy for closing the VCB and for applying sufficient
contact pressure on moving contacts of vacuum interrupters through the contact loading
springs. The contact loading spring provide the initial energy during the opening of the
VCB. The opening springs which get charged on closing the VCB, provide energy
opening the VCB.

The mechanism energy transmitted to the vacuum interrupters via insulating links
during closing as well as opening there is a dashpot in the mechanism which provides
sufficient damping during the opening operation of the VCB
4

The VCB is provided with ON/OFF and CHARGED/FREE indicators on its front side.
A green colour push button is provided for the manual opening and red colour push
button is provided for manual closing of the VCB. When received at site it is in open
condition and the springs are DISCH.\received/ free. A charging handled is provided for
manual spring charging.
The VCB has closing coil, shunt trip coil and breaker operated auxiliary switch.
The moving contact of the vacuum interrupters connected the bottom contact through
flexible jumpers; the fixed contact of the vacuum interrupter is assembled with the top
contact.
WORKING OF OPERATING MECHANISM
4.3.1

CHARGING OPERATION
Initially, the VCB is open and closing springs are DISCHARGED/FREE. Charging of
closing springs is done either manually with the help of charging handle or Electrically
through a motor. The CHARGED/ FREE indicator show the status of the closing
springs

A.

MANUAL CHARGING
Hold the charging handle and move it up by approximately 30 degree till it stops. This
will rotate gear which in turn will rotate gear. Gear will rotate shaft. The closing springs
which are hinged at one end , will start getting charged due to crank fitted on the cam
shaft.
Now, return the charging handle back to its original position and move it up again.
Repeat this till the springs is fully charged. A distinct clicking sound will be heard as
soon as springs are fully charged and the CHARGED / FREE indicator changes to
CHARGED position. The VCB is now ready for closing.

.
In order to prevent overcharging, STOP the handle movement as soon as a distinct
click sound is heard and indicator changes over to CHARGED position.
The number of time charging handle is to be moved up and down for full charging of
the closing springs depends on the angle of handle movement.
B.

MOTOR CHARGING OPERATION

As soon as electrical supply is given to the charging motor, it will rotate the shaft which
in turn will rotate the gear. The remaining changing operation is similar to the manual
charging.
When the springs are about to get charged fully, the crank arm mounted on the crank
shaft will operate the limit switch through lever, and supply to the motor will be cut-off.
The motor takes about 6 to 8 seconds to charge the springs.
The closing springs will get automatically recharged through the spring charging motor
5
as soon as they get discharged on closing of the breaker.

4.3.2

CLOSING OPERATION
When the springs are fully CHAGED, Now the VCB is ready for closing operation.

A.

Manual closing
Push the closing push button. The closing shaft will turn about its axis. thus releasing
the closing latch. Now, energy of the closing spring will cause the crank arm to rotate
as the fast speed. The rotation of crank shaft will turn the main shaft and the breaker
will get CLOSED. The opening spring, mounted on the main shaft will get charged
during closing operation. The breaker position indicator changes to ON and the
charging indicator changes to FREE.
It is possible to re-charge the closing springs in this position.

B.

ELECTRICAL CLOSING
When supply is given to closing coil, the plunger of closing coil will push the closing
paddle. This will cause the closing shaft to turn.
The remaining closing operation is similar to manual closing operation. the supply to
the motor is re-connected immediately on closing of the breaker due to rotation of
shaft lever and limit switch and the closing spring get re-charged.
The breaker position indicator changes over to ON, and after immediate re-charging,
the charging indicator will show CHARGED.

C.

SLOW CLOSING
The operating mechanism has been provided with slow closing feature. This has been
provided only for testing purpose. Before slow closing the breaker, ensure that the
upstream / down stream breaker open insert the handle on the rod provided on left side
of operating mechanism. Lift the handle upward to close the breaker. The mechanical
indicator on the mechanism changes to ON position.

USE THIS FEATURE ONLY FOR TESTING WHEN THE CIRCUIT IS NOT LIVE.

4.3.3

OPENING OPERATION
When the VCB is CLOSED and the breaker is ready for opening.

A.

MANUAL OPENING

Push the trip button this will turn the trip shaft through tripping paddle, which in turn
release the tripping catch, and the energy of opening springs and contact loading
springs (mounted in drive chamber)will cause the linkages.
The mechanism is held in the ON position (i.e. circuit breaker is in closed position) by
a Latch and Over Toggle Linkage. Tripping is achieved by upsetting the over toggle
linkage. The energy required for opening the circuit breaker is provided by Opening
Spring. The opening spring gets compressed during closing operation. The Circuit
breaker can be opened with closing spring either in the charged or free condition. The
Latch lever is automatically disengaged during the opening stroke and tension spring
automatically resets the toggle linkage ready for re-closing. Manual tripping via Trip
push button and Electrical Tripping via a Shunt Trip Coil is provided.
This movement of linkages will turn the main shaft and the circuit breaker will OPEN.

B.

ELECTRICAL OPENING
When supply is given to tripping coil, the plunger of tripping coil will push the tripping
shaft, causing it to turn. The remaining operation to similar to manual opening
operation.

4.3.4

AUXILARY CONTACTS
These are normally open (NO) and normally closed (NC) contacts when the VCB is
OPEN and the mechanism is DISCHARGED.
These contacts are breaker operated and driven by a link attached with the main shaft.
there are 16 contacts (8 NO+ 8 NC). With in the VCB one pair of these contacts are
used to cut-off the control supply to the closing coil (or opening coil) as soon as the
breaker is (CLOSED) (or OPENED.)
When the circuit breaker is CLOSED, NC contacts opens. When the VCB is
OPENED the auxiliary contacts regain their original status.
The main shaft, contact loading springs Dashpot, are assembled in upper side in
Mechanism box, and the pole assemblies are mounted on the top of this chamber. Main
shaft is connected with mechanism through tie rod.
The contact pressure between the Fixed contact and moving contact of the interrupter is
applied in closed position by Contact Pressure Springs. Open Spring Assembly which is
expended during closing operation provides opening force during tripping of the
breaker.

4.4

OUTDOOR CONTROL & RELAY PANEL

In this, all the instruments, indicating lamps, etc are mounted and all the control wires
7
from VCB mechanism CTs, etc, are brought into this chamber and wired as per

schematic diagram, for more details please refer to the relevant schematic diagram and
general arrangement drawing supplied.
5.0

INSTALLATION

5.1

General
Proper installation of VCB structural plays an important role. The manufacturing
instruction must be studied & followed carefully. The Drawings of overall views, cross
sectional views, foundation plan, etc are provided so that suitable preparation of the
infrastructure can be made prior to installation.

5.2

Foundation
The base or foundation must be strong enough to support the weight of the Switchgear.
The foundation must be laid well in advance before the installation so that the
Switchgear is installed on a smooth and leveled surface. Refer GA drawing for marking
foundation.

5.3

Erection
Properly grout the base frame on a leveled foundation area as per the foundation plan
shown in GA drawing and place the complete VCB structure on the foundation and bolt
it. It must be handled with suitable lifting and moving arrangement so that the porcelain
bushings are not damaged.
Connect earthing terminal of the VCB to the main earth of the station. Check LV wiring
and connect the control cables as per the schematic diagram. Connect HT line to the
terminal conductor of incoming and outgoing terminals.

6.0

PRE COMMISSIONING
Warning : Before commissioning the equipment makes sure that the HT incoming /
outgoing terminals are isolated.

6.1

Mechanical Operation
Operate the breaker several times to ensure that the operating mechanism
closes, trips, charge the closing spring, drive the auxiliary switches, etc. Measure the
contact wear indication and mechanical operation counter reading.

6.2

Insulation Resistance Test

Primary Insulation: This indicates the insulation associated with the high voltage
circuit. Measure the insulation resistance to earth to each phase in turn using 2.5 K.V
Megger.
8

Insulation resistance measured in both phase to phase and phase to earth condition
should be more than 100 Mega Ohms.
Secondary Insulation: The secondary wiring associated with the unit should be tested
by first looping at all the ends of wires and at some convenient point such as terminal
board. Measure the insulation resistance between wiring terminals to earth using 500V
megger. Insulation resistance should be more than 1 Mega Ohms.
Note: While carrying out above testing it should be remembered that insulation
resistance varies considerably with atmospheric condition and dryness & cleanness of
the equipment. In such a case cleaning, moisture removal should be done to restore
required insulation resistance.
6.3

Electrical Operation
Check the wiring and complete circuitry for any damage/loose, wiring as per schematic
diagram provided. Check the control voltage, relay locking etc. before energizing the
circuit. Ensure that the CT secondary star point is earthed. Ensure the oil level of CT as
per the indication display. Connect required AC/DC supply and operate the VCB
through the control switches. And also check the indication circuits. The control
operation shall be carried out both from local and Remote. The Relay instrument
operation may be checked through secondary injection or otherwise ensure the setting
of the relay and rotate the disc for tripping operation.

6.4 Instruction for Mechanical Operation.

Top operate the circuit breaker:
Charge the spring by energizing the motor or by manual spring charging handle.

Operate the spring release electrically by pressing CLOSE push button or manually.
The motor will automatically re-charge the Spring after a closing operation, enabling
rapid close to be carried out after trip.
Press OPEN push button to trip electrically or manually, as necessary for checking.

7.0

MAINTENANCE AND INSPECTION

A. Vacuum Circuit Breaker
The stroke of vacuum circuit breaker being very small, the energy required to operate
the Vacuum interrupter at specified speed is very less as compared to other types of
circuit breakers of the same rating.
As operating energy required is very less, the VCB requires minimum maintenance.
The Various maintenance check points & methods to ensure consistent performance are
mentioned in Clouse No. 11.
9

The checking should be done for the first time after 2000 operations or one year,
whichever is earlier and thereafter every 3 year or 5000 operations, whichever is earlier.
The VI does not have any maintenance. However, they have to be replaced at the end of
contact wear limit or loss of vacuum or 20,000 mechanical operation is performed.
High Voltage test to check the health of VI should be carried out on all three VIs
separated by applying 22.4 KV rms for 30 seconds across open contacts.
Caution: The operators should not be within five meters of the equipment during this
test.
MEASUREMENT OF CONTACT WEAR
The contact wear of the VI is allowed for 3mm. The operator has to record the contact
loading spring compression before commissioning in all the three phases which can be
compared during maintenance schedule so that the VI Status would be known.
Close the VCB and check the dimension of the Contact loading spring and compare the
recorded value. If the difference is more than 3mm than VI should be charged.
8.0

REPLACEMENT OF PARTS
Customers are advised not to replace Vacuum Interrupter or any other components on
the pole part side of the VCB.
Replacement of other parts like coil, motors, micro switches, etc. should also be done
only by those personnel who are properly trained at our Works which can be arranged
on specific request.

9.0

ACCESSORIES
1. Slow closing handle

10.0

RECOMMENDED SPARES
Sr.
No
1.
2.
3.
4.
5.
6.
7.

Item Description.

Qty / Set

Porcelain Bushing
Vacuum Interrupter
Drive Insulator
Close Coil Assly.
Trip Coil Assly.
Motor Cut Off Switch
Motor

1Nos.
1Nos.
1Nos.
1Nos.
1Nos.
1Nos.
1Nos.

10

8.
9.
10.

SR.
NO.
1

Auxiliary Switch
Counter
Drive insulating rod

Check Point

1Nos
1Nos.
3Nos.

Checking
Criteria
Actions required
Method
Complete Circuit Screws, Bolts & By screw driver There should not be any Tighten if found
Breaker
Nuts
& wrench
loose
loose

Operating
Mechanism

Item

Dust & foreign Visual Check

Matter

The breaker should be

clean and should not
have any foreign matter
on any part

Clean
with
compressed
air
and wipe the
accessible parts
by clean and dry
lint free cloth

Deformation,
excessive wear

Visual Check

There should be no Remove

cause
deformation or excessive and replace the
wear or damage to any part
part

Dust & foreign Visual check

Matter
11

There should be no dust Clean

with
or foreign matter
compressed Air

Smooth
Operation

Manual
Operation

Operation
smooth

should

be

Lubrication of Visual Check

bearings pins,
latches etc.

Should be well lubricated

Apply
PTEF
grease,
Beacon
Q2 grease or its
equivalent

Closing
and Visual Check
tripping shaft

Must rotate freely

Apply
PTEF
Grease, Beacon
Q2 grease or its
equivalent

11.0

CHECK POINTS FOR PERIODICAL INSPECTON

SR.
NO.
3

Check Point

Item

Vacuum
Interrupter

Criteria

Contact wear

Checking
Method
Visual Check

Vacuum
Integrity

See check on
Vacuum (7.0)

The
Interrupter
Withstand

Number
of Counter
operations

12

Actions required

If it is less than
Wipe Should be 3.0 0.5
mm when breaker is in
closed position.
Interrupter
Should Vacuum
Should be replaced if
found defective.
The
manufacturer
Should be consulted for
replacing the vacuum
Interrupter

When
counter
reading
reaches 5000 check Vacuum.
If OK, continue to use and
check again when counter
reading reaches 10,000.
Check Vacuum and if OK,
continue to use till 20,000

Vacuum
Interrupter
Should be replaced, if
vacuum is not OK or
when counter reaches
20,000 operations.

operations.
4

Auxiliary
Switch

Terminal
Case
contacts

Tighten by
Screw driver
and Visual check

There should not be any Re- tighten if found

loose connection
loose
There should not
damage

Main Power
Circuit

Discoloration Visual Check

of
contact
surface
by
heat

Control
Circuit

Operate Check at test Smooth operation

Breaker
position
Electricity

be any Replace
damaged

There should not be any

discoloration

Insulation Resistance
500M Ohm or more

1000V

Control Circuit to ground

1M ohm or more

500V

Between main circuit terminals 1000M ohm or more

with
breaker OPEN

13

Megger

1000V

found

Check contacts and

joints. Apply petroleum
jelly, if required.
Check
circuit
operation of

7. Measurement of Insulation Resistance

Measuring Location
Main conductor to ground

if

and

14

STELMEC LIMITED.
(formerly STELMEC SWITHGEAR)
Regd. Office:
SEA QUEEN, 43- A,
BHABHA ROAD,
BANDRA (W)
MUMBAI 400 050
Phone: 022 26436127 / 28 / 29
Fax: 022 26436139
INS M 5 RO

Works:
UNIT :II, USGAON,
GAOTHANPADA,
H.K.
NO. 2 To 5,
VIRAR VAJRESHWARI ROAD,
USGAON, PO. BHATANE,
TAL. VASAI, DIST : THANE.
Phone: 0250 2571651
Fax : 0250 2571472

15