Manual VCB PDF

Autometers Alliance Ltd [ OM-VCB-01 Rev.
01 ]
AC VACUUM CIRCUIT BREAKER

Type VCBA25.10Tr
OPERATION & MAINTENANCE MANUAL

[OM-VCB-01 Rev.01]
Edition – March 2012
C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 1 ]

Autometers Alliance Ltd [ OM-VCB-01 Rev.01 ]
-: NOTE :-
 If you observe the recommendations contained in this << Operation &

Maintenance Manual >>, you will benefit from our experience and will
ensure the highest reliability for our products.
 A technical manual cannot foresee all the eventualities that may occur
during operation. We therefore strongly urge you to consult us
(Autometers Alliance Ltd, Noida), when there is any incident which is not
mentioned in this manual.
 We explicitly refuse to accept any responsibility relating to damage,
suffered by our devices, caused by incorrect operation and this applies
even if this manual does not include any instruction relating to the case
in question.
 We reserve all rights on this document, as well as on the object
appearing in it. Reproduction of this manual, even extracts from it, are
forbidden without our written permission.

Table of Contents
Chapters Page No.
1. General Description .......................................................................................................................................7

1.1 Introduction ........................................................................................................................................8
1.2 Construction .......................................................................................................................................9
1.2.1 Upper Part ...........................................................................................................................9
1.2.2 Intermediate Part .............................................................................................................. 10
1.2.3 Lower Part ......................................................................................................................... 10
1.3 Operation.......................................................................................................................................... 12
1.3.1 Closing of VCB.................................................................................................................. 12
1.3.2 Opening of VCB ................................................................................................................ 13
1.4 Vacuum Switch Tube Construction ................................................................................................ 16
1.5 Vacuum Characteristics .................................................................................................................. 17
1.6 Main Technical Data ........................................................................................................................ 18
1.7 Mounting Arrangement .................................................................................................................... 19
1.8 Overall and Mounting Dimensions .................................................................................................. 20
1.9 Electrical ........................................................................................................................................... 21
1.9.1 Breaking Capacity............................................................................................................. 21
1.9.2 Over Voltage ..................................................................................................................... 21
1.9.3 Dielectric Strength at 50Hz, 1 min. .................................................................................. 21
1.10 Control Diagram ............................................................................................................................... 22
1.11 Details of Construction .................................................................................................................... 23
1.12 Operational Sequence Diagram ..................................................................................................... 24
1.13 EP Valve Solenoid Coil Specification ............................................................................................. 25
1.14 Characteristics of the Auxiliary Switch ........................................................................................... 25
1.15 Dynamic ........................................................................................................................................... 26
1.15.1 Movement of Main Contact .............................................................................................. 26
1.15.2 VCB Specification ............................................................................................................. 27
1.15.3 Typical Closer Time .......................................................................................................... 27
1.15.4 Typical Opening Time ...................................................................................................... 28
1.16 Operating Conditions ....................................................................................................................... 29
1.16.1 Voltage Variation .............................................................................................................. 29
1.16.2 Pressure Variation ............................................................................................................ 29
1.16.3 Climatic Conditions ........................................................................................................... 29
1.16.4 Vibration and Mechanical Shocks ................................................................................... 29
2. Part List ........................................................................................................................................... 31

2.1 Drawing List ..................................................................................................................................... 32

3. Installation ........................................................................................................................................... 60
3.1 Unpacking ........................................................................................................................................ 64
3.2 Lifting ........................................................................................................................................... 64
3.3 Visual Inspection .............................................................................................................................. 64
3.4 Mounting........................................................................................................................................... 65
3.4.1 Recommendation of Pneumatic Installation.................................................................... 65
3.4.2 Fixing the Circuit Breaker in Place .................................................................................. 65
3.5 Commissioning ................................................................................................................................ 66
3.5.1 Connection of the High Voltage Circuit ........................................................................... 66
3.5.2 Earthing ............................................................................................................................. 66
3.5.3 Electrical connection......................................................................................................... 67
3.5.4 Air pipe connection ........................................................................................................... 68
3.5.5 Checking operation........................................................................................................... 69
3.6 Special Tools required for Installation & Commissioning .............................................................. 70
Annexure-1 ........................................................................................................................................... 71
4. Maintenance ........................................................................................................................................... 73
4.1 Searching for Fault Causes............................................................................................................. 74
4.2 Schedule of Preventive Maintenance ............................................................................................. 77
4.2.1 Visual Inspection ............................................................................................................... 79
4.2.2 Checking Tightening Torque ............................................................................................ 79
4.2.3 Inspection of Pneumatic Circuit ....................................................................................... 80
4.2.4 Checking of Vacuum in the Switch Tube ........................................................................ 81
4.2.5 Exchanging Filter Element of Pressure Regulator.......................................................... 83
4.2.6 Exchanging O-Ring for Side Cover ................................................................................. 84
4.2.7 Exchanging Auxiliary Switch ............................................................................................ 85
4.2.8 Exchanging Contact Spring.............................................................................................. 86
4.2.9 Procedure for the Lubrication of Shafting Head Guide .................................................. 87
4.3 Procedure for Fixing of Gasket of Driving Plate Assy. in Assembled VCB .................................. 88
4.4 Dismantling of VCB ......................................................................................................................... 89
4.4.1 High Voltage Parts Dismantling (Vacuum Switch Tube) ............................................... 89
4.4.2 Dismantling of Other Parts .............................................................................................. 93
4.5 Sub-Assemblies of VCB .................................................................................................................. 95
4.6 Main Assembly (VCB) ..................................................................................................................... 97
4.7 Setting of Regulator with Filter ....................................................................................................... 106
4.8 Setting of Pressure Switch ............................................................................................................. 106
4.9 Work instruction EP Valve Maintenance ....................................................................................... 107
4.9.1 Assy Details of EP Valve Maintenance ......................................................................................... 107
4.9.2 EP Valve Tools & test equipment ................................................................................................. 112

4.10 Tool List for VCB ............................................................................................................................. 113

4.10.1 Tool required for maintenance of VCB General Tool KIT 4300009700/05………………..……..113
4.10.2 Tool required for maintenance of VCB Assy Special Tool KIT 4300009700/06…………..…….115
4.10.3 Tools for installation & commissioning of VCB ............................................................................. 116
4.11 Tools kit for VCB Assy – Test Equipment ..................................................................................... 117
4.12 List for Torque and Required Tools ............................................................................................... 118
5. Testing .......................................................................................................................................... 119

5.1 Test Procedures ............................................................................................................................. 120
5.1.1 Test Procedure of Air Dryer ............................................................................................ 120
5.1.2 Test Procedure of RC Damping Panel ........................................................................... 121
5.1.3 Test Procedure for Main Contact Wear .......................................................................... 122
5.1.4 Procedure for the Checking of Pressure Switch ............................................................ 124
5.1.5 Sealing Test for Air Tank Assembly ............................................................................... 124
5.2 Test Procedure for Closing and Opening Speeds ........................................................................ 125
5.2.1 Closing Speed Measurement.......................................................................................... 126
5.2.2 Opening Speed Measurement ........................................................................................ 126
5.2.3 Main Contact Closure Time............................................................................................. 126
5.2.4 Opening Time of Main Contacts ..................................................................................... 127
5.3 Sealing Test for High Voltage Section........................................................................................... 127
5.4 High Voltage Test ........................................................................................................................... 127
5.4.1 High Voltage Test for H.T. Section ................................................................................. 127
5.4.2 High Voltage Test for L.T. Section ................................................................................. 128
6. Spare Parts .......................................................................................................................................... 129

6.1 AOH Kit -- 1 Year Maintenance 4300007100/10 .......................................................................... 130
6.2 IOH Kit -- 3 Years Maintenance 4300007100/32.......................................................................... 130
6.3 POH Kit -- 6 Years Maintenance 4300007100/33 ........................................................................ 131
6.4 Special Lubricants & Consumables 4300007100/29.................................................................... 133
7. Other Spares .......................................................................................................................................... 135

7.1 Kit of Pressure Switch assy (SG300146R0001) ........................................................................... 136
7.2 Kit of Pressure Regulator assy (SG300147R0001) ...................................................................... 136
7.3 Repair kit Pressure Regulator (4300021000) ............................................................................... 136
7.4 Kit of Flexible pipe assy. 700mm for WAG-7 (4300001200) ........................................................ 136
7.5 Kit of Flexible pipe assy. 700mm for ABB LOCO 4300001300) .................................................. 136
7.6 Kit of Flexible pipe assy. 2000mm for EMU (4300001900).......................................................... 137
7.7 Kit of Male Contact (4300007300) ................................................................................................. 137
7.8 Kit of Resistor for RC Damping panel assy. (4300007400) ......................................................... 137
7.9 Kit of Air dryer assy. (4300007500) ............................................................................................... 137

7.10 Kit for side covers LHS & RHS (430007100/23) ........................................................................... 137
7.11 Kit for Cover for Holding Cylinder assy. (4300007100/25)........................................................... 138
7.12 Kit for Aux Switch assy. (4300007100/26) .................................................................................... 138
7.13 Kit of Piston assy. (4300007100/27).............................................................................................. 138
7.14 Shafting head for spare assy. (replacing BVAC to AAL Shafting head) (4300007100/28) ........ 138
7.15 Kit of VST (VITZRO) (4300007100/31) ......................................................................................... 139
7.16 Kit of Rear Flange (4300007100/39) ............................................................................................. 140
7.17 Kit of AAL EP valve (4300007100/40) ........................................................................................... 140
7.18 Kit of Capacitor for RC Damping Panel assy. (4300007100/41) ................................................. 140
7.19 Kit of RC Damping Panel assy. (4300007100/42) ........................................................................ 140
7.20 Kit of Male Connector assy. (4300007200)................................................................................... 141
7.21 Complete Shafting Head (4300003800)........................................................................................ 141
Main Assembly – VCB

[1]
GENERAL DESCRIPTION

Figure - 1.1
1.1 Introduction
The Autometers vacuum circuit breaker (VCB) type VCBA25.10Tr is a single phase 25kV
AC circuit breaker used to protect power circuit for applications on electric locomotives and
electric multiple units (EMUs). This device is used as a line circuit breaker to close and open
the power circuit and also to break the circuit under overload, short circuit conditions or any
other abnormal working conditions defined and implemented for the application.
This device is intended for installation on the roof of a traction vehicle. The design and
implementation of this circuit breaker are perfectly adapted to the requirements and working
conditions of electric traction and service condition on Railways.
The distinguishing features of the circuit breaker are:
 Its vacuum switch tube (VST)
 Its electro-pneumatic control
It offers:
 A high degree of insensitivity to climatic conditions
 Compact design
 High rupture capacity
 Long lifespan
 Reduced maintenance
The device complies with IEC-60077 recommendations.

1.2 Construction
Figure - 1.2
The vacuum circuit breaker comprises three main parts which are:
1. The upper part, which is the high voltage circuit (HT)
2. The intermediate part, which assures isolation from earth
3. The lower part with the electro-pneumatic and the auxiliary circuit (LT).
1.2.1 Upper Part
It is outside the vehicle, on the roof, and comprises:
 A vacuum switch tube (VST), which houses the main switching contacts
 A horizontal ceramic insulator (HI) which is fixed
 To a shafting head (TR), which converts the vertical movement of the drive system into
horizontal movement? One of the electrical connections (HT) is mounted on this
conductive part
 A rear flange (B) which closes and seals the horizontal insulator and carries the second
electrical connection (HT).

 A vacuum switch tube moving contact is fitted with pushed screw, flexible shunts to carry
the current from moving contact to shafting head. Spring box houses the contact springs
and operating cam to transfer the vertical motion into Horizontal direction.
1.2.2 Intermediate Part
Serves to isolate the upper part (HT) from the lower part (LT) i.e. it isolates the vehicle roof,
which is earthed with the high tension part of the circuit breaker.
It comprises:
 A vertical insulator (VI) supporting the upper part and fixed to base plate (E) which is
mounted on the vehicle roof by means of 6nos. M12 hex screws. The lifting hooks 4nos.
are fitted in this base plate permanently.
 To ensure waterproof sealing between traction vehicle roof and the base plate of circuit
breaker, an o-ring is provided.
 An insulating drive rod (T) is connected between operating mechanism of vacuum switch
tube and drive mechanism.
1.2.3 Lower Part
This is inside the vehicle in a protection cover (PC) which includes the control and the drive
mechanism which consists of:
(a) The Pneumatic Circuit
It comprises:
 Air inlet connector (C)
 An air pressure regulator with filter (FR)

 An air reservoir (AR)
 A pressure switch (PS) for monitoring minimum pressure
 An electro-pneumatic valve (EP)
 A regulator (R) whose flow is proportional to the movement of the drive system
(b) The Drive Mechanism
It comprises:
 Pneumatic cylinder (PN)
 Piston (K) which is guided inside the cylinder to transfer the movement to
insulating drive rod

 Spring system (RS/CS) provided to keep the circuit breaker in open position.
 Non-return valve (N) is fitted with air cylinder for exhaust throttling.
(c) The Auxiliary Circuit (LT)
It comprises:
 Polarized circular connector (LT) for fail safe connection to the electrical circuit of
the vehicle.
 Auxiliary switch (AS) which changes its status depending on the circuit breaker
position. Auxiliary switch is configurable and is of proven fish bone type.
 Auxiliary switch drive (AD) mechanism which is linked with the drive rod (T).
 An electro-pneumatic valve assuring closing and opening function.

1.3 Operation
The method of operation of the circuit breaker is described in the following different
sequences:
1.3.1 Closing of VCB
(a) VCB Open (Figure-1.3)
 Status of VCB in open condition.
Figure - 1.3
(b) Order (Pulse) to Close the VCB (Figure-1.3 & Figure-1.4)
 Energizing of the electro-pneumatic valve solenoid coil.
 Operating of the electro-pneumatic valve (EP).
 Air flows from air tank (AR) to the piston drive.
Figure - 1.4

(c) Mechanism Movement (Figure-1.3, Figure-1.4 & Figure-1.5)
 Movement of the closing piston (K), the insulating rod (T) and the moving contact
(MC) along horizontal distance (X).
 Closing of the main contacts inside the vacuum bottle.
 Exerting extra pressure on the contact pressure spring (CPS) for desired contact
pressure.
(d) Holding of VCB in Close Position (Figure - 1.5)
 Holding of VCB in close position is achieved by the compressed air.
 VCB switched ON.
Figure - 1.5
1.3.2 Opening of VCB
(a) VCB Closed (Figure-1.5)
 Status of VCB in close condition.
(b) Interruption of Current Supply of EP Valve Solenoid Coil

(Figure-1.6 & Figure-1.7)
 De-energisation of EP valve solenoid coil results into changes in the status of the
valve.

 Air supply from air tank is blocked and exhausts port open of the EP valve.
 Exhaust of compressed air available in pneumatic cylinder (PN).
 The compressed springs release their store energy which acts as returning force
to the piston.
 Start of return of piston stroke through above mentioned action ensures safe
opening of the contacts.
Figure - 1.6
(c) Rapid Movement of Piston (Figure - 1.7)
 The piston is accelerated by the release of the air pressure and release of
contact pressure springs stored energy.
 The air displaced by the piston escapes fast via exhaust port of electro-
pneumatic valve (EP).
 The arc caused by the opening of the contacts is extinguished by the vacuum
inside the vacuum switch tube.
 Just before the end of piston travel, the piston travel is cushioned by the function
of non-return valve (N).

Figure - 1.7
(d) End of Piston Stroke (Figure - 1.8)
 VCB switched OFF (open position).
Figure - 1.8

1.4 Vacuum Switch Tube Construction
The vacuum switch tube comprises two copper alloy contacts, one fixed and the other
moving.
The fixed contact is mounted on a metal flange which carries the ceramic outer cover of the
chamber.
The ceramic cover is generally in two parts with a metal screen fixed between them. This
screen protects the ceramic parts against deposition of metallic vapor produced by the arc
when the contacts open.
The moving contact travels in a guide who assures its axial positioning and correct angle.
Sealing of the moving contact is assured by a metal bellows which is welded both to it and to
the end flange which is integral with the external cover. A metal screen is also provided
around the bellows as per Figure-1.9.
Figure - 1.9

1.5 Vacuum Characteristics
According to Paschen’s law, the voltage applied between contacts in a vacuum varies as a
function of the gas pressure and the distance between the contacts. The graph shows the
variation in voltage as a function of the vacuum for an inter-contact distance of 16mm. The
minimum value guaranteeing a sufficient vacuum to assure rupture of the arc must be
greater than 30kV.

1.6 Main Technical Data
Description Type : VCBA25.10Tr
Maximum rated voltage kV 30
Nominal rated voltage kV AC single phase 25
Power frequency withstand voltage (dry & wet) kV 75
Lightning impulse withstand voltage kV 175
Rated current A 1000
System frequency Hz 50
Short circuit rupturing capacity kA 16 (440MVA)
Making current kA 40
Short time current capacity kA (3 sec.) 16
Opening time ms ≤ 60
Closing time ms < 100
Control voltage VDC 110
Auxiliary contacts (type & no.) NO / NC 4NO + 4NC

(Fish bone type) configurable
contacts for
external circuit
and 1 No for
internal use
Input air supply pressure kg/cm² 4.5 to 10
Rated operating sequence -- O-3min-CO-3

min-CO
Weight kg  150
Power consumption (max.) W 23
 Opening time measured from opening command to the separation of main contacts (FC,
MC).

1.7 Mounting Arrangement
Figure - 1.10: Mounting Arrangement of VCB

1.8 Overall and Mounting Dimensions
Figure - 1.11: Overall and Mounting Dimensions of VCB

1.9 Electrical
1.9.1 Breaking Capacity
The breaking capacity depends on the rated operating voltages. The VCB also breaks low
currents.
1.9.2 Over Voltage
Voltage surges caused when the transformer's load is removed depend very much on the
characteristics of the transformer and of the installation. Measurements on the vehicle allow
the level of over voltage harmful to the vehicle electrical circuit to be defined. These should
be as close as possible to the transformer in order to avoid propagation of over voltage in
cables.
1.9.3 Dielectric Strength at 50Hz, 1 min.
Application of test voltage:
 Main circuit (closed) to earth: 75 kV
 Between input and output of main circuit (open): 75 kV
 Auxiliary circuit to earth: 2 kV
 Insulating distances
 Creepage
Outside Parts Calculated IEC 60077

Vertical insulator 25kV 970mm 687mm
Horizontal with earthing 1095mm 687mm
insulator switch
 Clearance
Min. value : 320 mm
IEC 60077 : 320 mm

1.10 Control Diagram
Legend :
FC Fixed contact
MC Moving contact
Figure - 1.12

1.11 Details of Construction
Legend :
HT High tension connections of the VCB
HI Horizontal insulator
VI Vertical insulator
VST Vacuum switch tube
TR Shafting head
CS, RS Opening spring
AR Air reservoir
T Operating rod
EP Electro-pneumatic valve
FR Air filter regulator
PS Pressure switch
C Air inlet
PN Pneumatic cylinder
AS Auxiliary switch
K Piston
LT Connector for connection to the electrical circuit of the vehicle
AD Auxiliary switch drive
PC Protection Cover
E Base plate
N Non-return valve
Figure - 1.13

1.12 Operational Sequence Diagram
Legend :
ON Command given by the vehicle schematic
EP Solenoid coil of electro-pneumatic valve
Cm Main contact of VST
A1 Auxiliary contact NO
OFF Command given by vehicle schematic.
Figure - 1.14

1.13 EP Valve Solenoid Coil Specifications
Resistance : 1510±8% at 35ºC
Operating voltage : 110V DC (+25%, –30%)
1.14 Characteristics of the Auxiliary Switch
The circuit breaker is equipped with 9 auxiliary contacts controlled by the cam drive linked
with operating rod. Auxiliary switch can be configured to any combination of NO & NC as per
requirement of application.
State of contacts : 5 NO (normally open)
4 NC (normally closed)
Number of contacts available for customer : 4 NO (normally open)
4 NC (normally closed)
Characteristics --
Test voltage : 2.0kV
Continuous current I th 2 : 10A
Nominal current and breaking capacity : 2A @ 110V DC L/R = 15ms

1.15 Dynamic
1.15.1 Movement of Main Contact
Legend:
U : Total contact pressure mechanism stroke.
S : Distance between new contacts.
S' : Distance between worn contacts.
VC : Closing speed.
UVC : Measurement distance to determine the VC.
tVC : Duration to determine the VC.
VO : Opening speed.
UVO : Measurement distance to determine the VO.
tVO : Duration to determine the VO.
tb : Main contact (HV) bounce duration.
tbr : Contact pressure duration.
0 : Circuit breaker open.
0-1 : Acceleration of the piston.
2-3 : Speed measurement of the closing time (VC).
3 : Closing of the main contact.
3-4 : Wear compensation (S'-S) and establishment of the over contact pressure.
4-5 : Establishment of the minimum contact pressure after wear (U-S').
5-6 : Circuit breaker closed.
6-7 : Time of the de-magnetization of solenoid coil and mechanical reaction.
7 : Opening of the main contact.
7-8 : Speed measurement of the opening time (VO).
9 : Pneumatic damping and circuit breaker open.
Figure - 1.15: Dynamic Operating Conditions

1.15.2 VCB Specification
U U-S tb tbr UVC VC tVC UVO VO tVO

(mm) (mm) (ms) (ms) (mm) (m/s) (ms) (mm) (m/s) (ms)
19-20.5 3.5-4.25 5  15 6.4 0.8-1.2 5.3-8.0 12.8 1.1-1.75 7.3-11.6
1.15.3 Typical Closer Time
tcm Mechanical time for contact closing
tce Total closing time
Figure - 1.16

1.15.4 Typical Opening Time
tcm Mechanical time for contact opening
tce Total opening time
Figure - 1.17

1.16 Operating Conditions
Mechanical, electrical and operating conditions are specified by Routine Test and Type Test.
Dynamic operating conditions are defined in Figure 1.15.
1.16.1 Voltage Variation
Permissible voltage variations for control of auxiliaries are defined according to IEC 60077,
namely -30% to +25% of rated battery voltage.
Available supply +25%

110V DC
voltages –30%
1.16.2 Pressure Variation
The circuit breaker is equipped with a reservoir assuring a volume of air in reserve for one
closure of the circuit breaker.
The pressure in this reservoir is set to a constant value during the production test, in order to
guarantee dynamic operating conditions that are always identical.
The permissible pressure variation in vehicle supply pipe is from 4.5 to 10kg/cm². If the
supply pressure falls below the minimum recommended value for circuit breaker closure, a
pressure switch opens and prevents the circuit breaker from re-closing.
1.16.3 Climatic Conditions
Height above sea level 1400 m

Mean annual relative humidity 75%
Operating temperature –40ºC to +70ºC
1.16.4 Vibration and Mechanical Shocks
The VCB is designed to withstand along three axes according to IEC 60077.


[2]
PART LIST

2.1 Drawing List
Part No. Description

4300003600 Assembled VCB
4300003700 Driving Plate Assy.
4300003900 Air Tank Assembled
4300004000 Assembled Vacuum Switch Tube
4300004200 High Voltage Part Assy.
4300004500 Assembled Protection Cover
4300004700 Side Cover Right Assy.
4300004800 Operating Rod Assembled (25kV)
4300004900 Base Plate Assy.
4300005200 Assy. Cover for Holding Cylinder
HSBA433496R0003 Rear Support for Tong
4300001100 35 Pole Female Connector Assy.
4310001000/01 RC Damping Panel Assy.
4320001000 Air Dryer

Assembled VCB (VCBA25.10TR) 4300003600
Position No. Part No. Description Qty.

1 4300004900 Base Plate Assembly 1
2 4300050100 Vertical Insulator Assy. 1
3 HSBA331677P0001 Vertical Sleeve 1
4 4302152655 Spacer 4
5 4300003700 Driving Plate Assembly 1
6 4302255155 Air Cylinder 1
7 4301154777 Piston Rod 1
8 4300004800 Operating Rod Assembled (25kV) 1
9 4300003900 Air Tank Assembled 1
10 4305256277 Plate For Auxiliary Switch 1
11 4302310166 Name Plate 1
12 4309056199 Auxiliary Switch 1
13 4300005200 Assy. Cover For Holding Cylinder 1
14 4301556088 Compression Spring 2
15 4302155955 Piston Rod Side 1
16 4301155877 Piston Spring Guide Pin 2
17 4302155555 Piston Cover Side-Machined 1
18 4302154855 Air Damper 1
19 4306055677 Piston Seal 1
20 4303153733 Plug 3/4" BSP 1
21 4301155033 Spring Shell 2
22 HSBA433467P0001 Curved Head M12x50 Screw 2
23 HSBA433467P0002 Curved Head M12x40 Screw 2
24 4300004500 Assembled Protection Cover 1
25 4300004700 Side Cover Right Assembly 1
26 4300004200 High Voltage Part Assembly 1
27 4300004100 Cable Fix Connector Assembly 1
28 4302252955 Side Cover (L.H.S) 1
29 9ADA271-3 Hex Nut M6 (A/F-10) 4
30 32.402.021/014 Ferrule `1' 8
31 32.402.031/014 Ferrule '2' 8


32 32.402.041/014 Ferrule '3' 9
33 32.402.051/014 Ferrule `4' 9
34 32.402.061/014 Ferrule `5' 2
35 4302314166 Name Plate (BVAC) 1
36 4306016700 Sleeve (O.D. : 26mm, I.D. : 22mm) 1
37 4305515766 Sticker (Pressure Switch) 1
38 9ADA220-10 Cable Contact 18
39 4301152277 Cam Rod 1
40 9ABA135-10 Retaining Ring Dia 12 2
41 HSBA432580P0002 O-Ring 95x4.5 1
42 CONTR000003 Counter 6 Digit 1
43 9AVA194-616 Conic Hd. M6x16 Screw (*) 4
44 HSBA432539P0001 Washer 4
45 HSBA432623P0001 Needle Bearing 12x24x13 2
46 9ADA299-6 Lock Nut M10 2
47 4305510966 Sticker (Air Regulator) 1
48 HSBA432510P0001 Plate To Flexible Connection 2
49 4306057477 O-Ring Dia 4x130 2
50 32.312.000/059 Cable Tie : 150mm 2
51 32.312.000/029 Cable Tie : 100mm 12
52 HSBA432531P0001 Cap G3/8 Viton 2
53 HSBA433496R0003 Rear Support For Tong 1
54 4301151977 Coupling Rod 1
55 4301210200 Male Stud Coupling G3/8 1
56 4302311766 Earthing Label 2
57 GMN316023P1078 Self Tapping M3x6 Screw 2
58 9ADA271-6 Hex Nut M12 4
59 9AVA330-6 Elastic Washer M12 10
60 9ADA187-26 Allen Hd M6x25 Screw 2
62 9AVA59-45 Hex Hd. M12x130 Screw 4
63 9ADA271-4 Hex Nut M8 4


64 HSBA433389P0001 Wedge Washer 30x10.5x0.2 (SS) 4
67 9AVA330-4 Elastic Washer M8 X18*1.4 4
68 9AVA330-12 Elastic Washer M8x16x1.4 1
69 SG300120P0001 Anti Breaking Screw M6x20 8
70 NB335805P0512 Spring Washer M10, S.S. 4
71 4300005300 Consumables And Lubricants Per VCB 1
72 NB335805P0509 Spring Lock Washer M6, S.S. 2
73 HSBA432463P0001 Compression Spring 1
74 4300021400 Male Adaptor G3/8EDXG1/2 1
75 4301219433 Connector 1
77 4306057177 O Ring Dia 3.5x10 1
78 4306057277 O Ring Dia 2.5x105 1
79 4305151677 Cam Spacer 2
80 4301158777 St. Steel Tube OD10 X ID 8mm 1
81 WASHR000008 Pl Cu Dia10.2x2mm Thk Washer 1
82 SCREW000017 Allen Hd M10x110 Screw Long 4
83 SCREW000018 Allen Hd. M10x120 Screw Half THD 1
85 4301157633 Hex Stud M12 x 19 2
86 4301157833 Hex Stud M12 x 154 2
87 32.402.071/014 Ferrule `6' 2
88 8.2127.122/50 Pop Rivet (2.5, 5.1l) 2
89 8.1168.306/10 Hex Hd. M4x10 Screw 1
90 9AVA330-100 Elastic Washer M4 (4.1x8.2) 19
91 HHIE025013 Wago Ferrules, 1mm² 2
92 CONNT000226 Lightning Connector 2
93 Y04739 Clip Cable Insuloid Nx3 1

Driving Plate Assy. (4300003700)

Driving Plate Assy. (4300003700)
1 4301255433 Cylinder Mounting Plate 1
2 4306054477 Shock Absorber Plate 1
3 4302255255 Cam Bracket 1
4 4302254955 Auxiliary Cam 1
5 4302251555 Driving Plate 1
6 4301154199 Bracket Pin 1
7 4301154299 Driving Plate Pin 1
8 9ADA187-25 Allen Hd Screw M6x20 2
10 CRCLP000005 Retaining Ring Dia 6 2
11 PINSX000002 Split Pin ø2 x 16mm 2
At Position No. 8, apply torque 10Nm.

Air Tank Assembled (4300003900)

Air Tank Assembled (4300003900)

1. 4301655733 Air Tank Welded 1
2. 4301153433 Tank Top Cover 1
3. 4303153222 Filter Tube 1
4. 4302253155 Connecting Block 1
5. HSBA432531P0001 Cap G3/8 Viton 1
6. 9ADA187-29 Allen Head M6x40 Screw 2
7. 9AVA330-11 Elastic Washer M6/6.1x12.2x1.2 8
8. HSBA432095P0020 O-Ring ø16.00x2.00 2
9. 4301158877 Nipple For Connecting Pipe 1
10. SG300073P0003 Ring BS ø21.5x28.6x2.5 1
11. HSBA432714P0001 Special Connection 1
12. SG300073P0002 Packing Ring 17.28x23.08x2.03 1
13. HSBA433890P0001 Pressure Regulator With Filter 1
14. HSBA432095P0026 O-Ring Dia 17.86 x 2.62 2
15. 4301257977/01 Coupling (Machined) 1
16. HSBA432553P0001 Pressure Switch-PEV-1/4-B 1
17. SG300067P0001 Union Bend 1
18. SG300066P0001 Screwed Socket 1
19. SG300071P0001 Gasket Kd-1/4 1
20. SG300070P0001 Hex Nut G 1/4" 1
21. 9ADA187-25 Allen Head M6x20 Screw 6
22. 4306057377 O Ring Dia 3.53x120.2 1
 At Position No. 6 & 21, apply torque 10Nm.

Assembled Vacuum Switch Tube (4300004000)

Assembled Vacuum Switch Tube (4300004000)

1. 4309016299 Vacuum Interrupters 25kV 1
2. 4305052077 VST Guiding Ring 1
3. 4300004300 Assembled Press Screw 1
4. HSBA432525P0001 Compression Spring 6
5. 4300004400 Complete Holder Spring 1
6. 4301152333 Screwed Bush 1

High Voltage Part Assy. (4300004200)

High Voltage Part Assy. (4300004200)

1. 4300003800 Complete Shafting Head 1
2. 4300004000 Assembled Vacuum Switch Tube 1
3. 4303152177 Lock Nut M36x1.5 1
4. 4300050200 Horizontal Insulator Assy. 1
5. HSBA331594P0001 Front Horizontal Sleeve 1
6. HSBA432580P0001 O-Ring ID 189.87x5.34mm 1
7. HSBA331593P0001 Rear Horizontal Sleeve 1
8. HSBA331585P0001 Rear Flange 1
9. NBT300226P0106 Helicoil M12x24 1
10. HSBA432579P0002 O-Ring ID 110x4mm 1
11. HSBA433467P0001 Curved Head Screw M12x50 4
12. 9ADA271-6 Hex Nut M12(A/F-19mm) 4
13. 9AVA330-6 Elastic Washer M12 12
14. 9ADA187-47 Allen Head Screw M8x80/28 2
15. NB335805P0511 Spring Washer M8 (Ht) 2
16. 9ADA187-39 Allen Head Screw M8x35 7
18. 9ADA123-58 Hex Head Screw M12x25 1
 At Position No. 12, 18 & 19, apply torque 67Nm.
 At Position No. 14 & 16, apply torque 19.3Nm.

Assembled Protection Cover (4300004500)

Assembled Protection Cover (4300004500)

1. 4301350944 Protection Cover 1
2. HSBA433458P0003 Edging Strip For Base Plate 1
3. 4300056700 Conic Head Screw M6x35 4
4. NB335805P0509 Spring Lock Washer M6 S.S. 4

Side Cover Right Assy. (4300004700)

Side Cover Right Assy. (4300004700)

1. 4302252855 Side Cover (R. H. S.) 1
2. HSBA331678P0003 Connection 25kV 1
3. HSBA432500P0001 Connection Support 1
4. HSBA433442P0001 Contact Spring 2
5. SG300073P0001 Packing Ring 8.6x13x1 2
7. 9AVA123-614 Hex Head Screw M6x14 2
8. 9ADA123-32 Hex Head Screw M8x20 2
 At Position No. 6 & 7, apply torque 8Nm.
 At Position No. 8, apply torque 19.3Nm.

Operating Rod Assembled (25kV) (4300004800)

Operating Rod Assembled (25kV) (4300004800)

1. 4300004800/01 Operating Rod With Socket 1
2. HSBA433475P0001 Bellow’s Support 1
3. 4306059177 Bellow 1

Base Plate Assy. (4300004900)

Base Plate Assy. (4300004900)

1. 4301351099 Main Frame 1
2. 9ADA271-4 Hex Nut M8 (A/F-13) 10
4. HSBA432577P0001 Ring Type Joint 1
5. 4301357099 Base Plate 1
 At Position No. 2, apply torque 15Nm.

Assy. Cover for Holding Cylinder (4300005200)

Assy. Cover for Holding Cylinder (4300005200)

1. 4302254555 Cover For Holding Cylinder 1
2. 4303058022 Non Return Valve 1/2" BSP (CIM) 1
3. 4301153577 Connecting Nipple For NRV 1/2"  2
4. 4302253655 NRV Block 2
5. 4301354644 Counter Plate 1
6. NB335805P0507 Spring Lock Washer M4 Form A Curve 8
7. 9ADA187-25 Allen Head M6x20 Screw 2
9. 9ADA187-10 Allen Head M4x40 Screw (Half Thread) 8
10. HSBA432095P0024 O-Ring ID 12x 2.0mm 2
11. 4306057577 O-Ring ID 26x2.5mm 1
12. HSBA432095P0025 O-Ring ID 13.95x2.62mm 2
13. 9ADA187-28 Allen Head Screw M6x35 4
14. 4300005400 EP Valve Assy. (110V DC) 1
15. 3506015577/06 O-Ring 45.69x2.62 1
16. 4305158977 Damper Seal 1
17. 4302159055 Seal Cover 1
18. GMN318833P3105 CSK Screw M5x16 Allen Head 4
 At Position No. 3, apply torque 39.4Nm.
 At Position No. 13, apply torque 10Nm.

Rear Support for Tong (HSBA433496R0003)

Rear Support for Tong (HSBA433496R0003)

1. HSBA433431P0001 Connection 1
2. HSBA433432P0001 Holder For Connection 1
3. SG300092P0001 Rear Contact Support 1
4. HSBA433442P0001 Contact Spring 2
5. F415788P0111 Sleeve 60mm
6. 9ADA123-34 Hex Head Screw M8×30 1
7. 9ADA271-4 Hexagon Nut M8 1
8. 9AVA330-12 Elastic Washer ø8.2 2
9. GMN318833P3206 Conic Head Screw M8×20 2
10. 9ADA123-21 Hexagon Head Screw M6×16 4
11. 9AVA330-11 Elastic Washer ø6.1 4

35 Pole Female Connector Assy. (4300001100)

35 Pole Female Connector Assy. (4300001100)

1. 3500002200/08 Connector Plug Size 40/35 1
2. 3505023977 Cable Support Size 40 1
3. 3503118399/05 Contact Socket 12/4.0mm² 25
4. 32.312.000/049 Cable Ties 6” 3
5. 32.203.039/010 Heat Shrinkable Sleeve 150mm
6. 32.202.164/01A Heat Shrink Sleeve ID 6.4mm 750mm

RC Damping Panel Assy. (4310001000/01)

RC Damping Panel Assy. (4310001000/01)

1 4315310177/01 Panel Board For Capacitor 1
2 4310001100 Resistor Assembly 4.7E/500W 1
3 8.1211.414/14 CSK Screw M5x20 6
4 62.115.210 Plain Washer Dia 5.3x0.8 17
5 63.215.005 Spring Washer Dia 5.1 15
6 64.115.008 Hex Nut M5.0 15
7 CAPST000134 Capacitor 25µF/600VAC 1
8 60.515.221 Csk Screw M5x50 3
9 4312310366 Name Plate 1
10 4315310477 Sealing Board 1
11 60.215.369 Hex Head Screw M10x40 4
12 62.115.514 Plain Washer Dia 10.5x1.5 8
13 63.215.010 Spring Washer Dia 10.5x1.5 4
14 64.115.011 Hex Nut M10 4
15 32.100.114/010 Elastomeric Power Cable 3mm² 0.8 mts.
16 68.419.034 Insulated Cable Lug M5 4
17 68.034.005 Receptacle 6.3/0.8 2
18 60.215.211 Hex Head Screw M5x10 2
19 GMN316023P1079 Slt. Ch. Hd. S. Tapping Screw M3x8 2
20 4311310733 Capacitor Clamp 2
21 4315210877 Supporting Block 1
22 Y04405 Cable Tie Mini-Base 4
23 32.312.000/029 Cable Tie 100mm 4

Air Dryer (4320001000)

Air Dryer (4320001000)

1. 4320001100 Welded Cylinder 1
2. 4320001200 Filter Cap Assy. 2
3. 4320010700 Molecular Sieves 4 kg
4. 4300021400 Connector 1/2'' x 3/8'' BSP 2
5. 4305010500 Plastic Cap 2
6. 4322311066 Name Plate 1
7. RIVET000004 Ham Drive Rivet Dia 2.89x6.35 2


[3]
INSTALLATION

3.1 Unpacking
Unpack the Circuit Breaker (VCB) case carefully & remove the side & top cover. Unscrew
the bolts provided on the base plate for holding the VCB with the pallet. Unscrew the 2 bolts
to remove air dryer assembly from pallet.
In case of damages to the packing during transit, carefully check the equipment for any
possible damage & it must be ensured that there is no damage to the VCB. If damage is
noticed in VCB, please inform M/s AAL immediately and also preserve damaged packing
case along with VCB.
3.2 Lifting
Lift VCB from 4 lifting hooks provided on the base plate using 4 synthetic slings (both sides
hooks) through a chain hoist capacity not less than 200kg (see Figure - 1).
Figure – 1
3.3 Visual Inspection
Carry out a visual inspection of the circuit breaker specially the ceramic insulator (A) for any
cracks or damage to enamel and connections (B) for earthing terminals.
Figure – 2

As required, using mild products and soft rags, clean all parts that are dirty.
Attention: Do not use cleaning products based on fluorated or chlorated compounds or

sodium metasilicate.
3.4 Mounting
3.4.1 Recommendation of Pneumatic Installation
Legend:
1. Buffer tank
2. Non-return valve
3. Connector for measurements
4. Isolating cock
5. Air Dryer (Exclusively for VCB)
6. Flexible connection
7. Vacuum circuit breaker
8. VCB reservoir drain plug
Figure-3: Schematic Diagram of Pneumatic Circuit
3.4.2 Fixing the Circuit Breaker in Place
 Lift the VCB in accordance to instructions at clause 3.2.
 Check that the Ring Type Joint is correctly fitted under the base of the VCB.
 Clean the mating surfaces on the VCB and on the roof of the vehicle.

 Gently lower the VCB (circuit breaker) on to the cut-out provided for this purpose on the
roof of the vehicle.
 Secure the VCB on the roof of the vehicle using 6 nos. M12×30 hex head screws
(Marked "C" in Figure - 4), tightened to a torque of 70 Nm, use spanners 19mm.
3.5 Commissioning
3.5.1 Connection of the High Voltage Circuit
Clean the surfaces of contacts with fine emery paper, apply grease (Syntheso Glep-1) on
contact surfaces then connect the vehicle cables or flexible bars to the two M12 screws, one
at the end of the horizontal insulator and the other on the Shafting Head (Marked "A" in
Figure - 4). Tightening torque 70 Nm.
Use the screws and washers supplied with the device.
3.5.2 Earthing
(a) Circuit breaker base
Connect the cable to one of the two M12 earthing studs provided on the base plate
of VCB by the side of the vertical insulator foot (Marked "B" in Figure - 4), tighten to
a torque of 70 Nm.
Recommended cable section: 95mm² or larger.
(b) Circuit Breaker Poles (using earthing switch)
If the circuit breaker is installed with a earthing switch, it is necessary to check the
position of the two blades in the circuit breaker jaws (in earth position). Lightly
lubricate the contact surfaces.
Figure – 4

Check tightening torque on the following parts
 High voltage connections
 Earthing connections
 Circuit breaker fixing screws
3.5.3 Electrical connection
(a) Auxiliary circuit
Preparation of Female Connector Loco side:
 Select appropriate wire numbers from loco control wiring.
 Strip the wire (approx. 10mm), insert shrinkable sleeve on wire.
 Hold pin in crimping tool (STOOL000022P0001) and die (4300032900), insert

wire in pin with utmost care and Crimp.
 Follow the above process for all the loco control wires to be terminated on
Female Connector.
 Insert all wires through heat shrinkable sleeve & cable clamp.
 Insert pins in female connector with insertion tool (4300032500).
Note: Pin assignment for the control connector is given in Annexure-1.
 Verify correctness of interfacing of vehicle side female connector prepared with

VCB connector pin assignment.
 Insert vehicle side female connector thus prepared & verified into the male
connector provided on VCB and ensure that the 35 pin circular connector lock is
correctly in place.
 Check VCB functioning.
 Shrink sleeve to make wire bunch rigid.
 Tight cable clamp to female connector.
 Fix cable ties & cut excess length.

Figure – 5
(b) RC Damping Panel
Connect 3nos. of RC damping panel in parallel across auxiliary winding of the loco
transformer.
3.5.4 Air pipe connection
Carefully clean the air supply pipes (with compressed air) before making any connection to
the circuit breaker.
 Connect the pipe coming from loco air reservoir (recommended diameter 10mm) at the
inlet of air dryer.
 Connect outlet of air dryer through the flexible connection generally supplied with VCB
duly aligned to avoid any type of mechanical forces on the connections (Refer Figure -
6).
 Connect flexible connection with connector.
 Pass air and ensure that there is no leakage.
 Open drain plug as shown with 8mm Allen key, while the reservoir is under pressure and
drain the condensate off.

 Close the plug when there is no condensate left in the reservoir. Ensure O-ring on the
plug is in place.
 Check that there is no leakage.
IT IS STRONGLY ADVISED THAT A NON-RETURN VALVE IS INSTALLED IN THE

VCB AIR SUPPLY PIPE, IN ORDER TO AVOID THE CIRCUIT BREAKER TANK
SERVING AS A BUFFER TANK FOR OTHER DEVICES (REFER FIGURE 3 & 6).
Figure – 6
3.5.5 Checking operation
After having made all connections, carry out a simulation (vehicle powered down) of circuit
breaker closure and opening and check the device for correct mechanical operation.

3.6 Special Tools Required for Installation & Commissioning
S. No. Part No. Description

1. -- Torque wrench 70Nm (open end)  for VCB fixing bolt, ht
connection earthing connection.
2. STOOL000022P0001 Crimping tool 
3. 4300032900 Die (4.0-6.0mm²) – For female pin 
4. 4300032500 Pin insertion tool (4.0-6.0mm²) – For female pin 
5. 4300033000 Pin extraction tool (Handle) 
6. 4300032300 Pin removed tool (M/F) 
7. -- Heat gun
8. -- Open ended spanner  22 for hose pipe, 27 for
connector.
 The torque is applied for –
 On VCB fixing bolt
 HT connection on VCB
 Earthing connections for VCB at base plate
 Open ended spanner – 22 for Hose pipe
27 for Connector
 These special tools are supplied by M/s AAL, Noida, on chargeable basis.

ANNEXURE-1
The External Connections of Control Wires on the Round Socket Connector of VCB
Pin No. on the External Female Round Socket Description of Pin Internal Connections
Connector on which User Control Cables to
be Terminated
1 Battery Negative
For momentary 'ON' signal for VCB. Connected
2
to EP solenoid coil
3 Left open, additional battery –ve terminal, if
required.
From battery +ve terminal, for VCB OFF
4
command.
5
Normally Closed Contact 2 (21-22)
6
7
Normally Open Contact 1 (53-54)
8
9
10
11
12
13 Not used
16
17
18
19
21
22
23
24
Note: Pins 14, 15, 20 & 25 to 35 are not connected inside VCB.


[4]
MAINTENANCE

4.1 Searching for Fault Causes
(A) Searching for Fault Causes (VCB does not close: Inspect the following Parts)
Element Inspect Result Causes Remedy
Unblock pipes
No pressure No air supply in vehicle
Check compressor
Air leakage Check air pipe

connection
Air pressure
Pneumatic
in air
Circuit Filter block Change filter
reservoir
Low pressure
Pressure regulator Adjust the pressure
setting disturbed regulator setting at
4.5±0.1 kg/cm²
Defective regulator Change regulator
Vehicle system Check schematic of

No voltage
the vehicle
Pressure switch setting Adjust the setting of

disturbed pressure switch
Voltage on
(3.3 - 3.6 kg/cm²)
electro-
±0.1 kg/cm²
pneumatic
Electrical valve
Voltage OK Defective pressure Change pressure
Circuit solenoid coil
switch switch
and continuity
of pressure
Defective electro- Change electro-
switch
pneumatic valve pneumatic valve
solenoid coil solenoid coil
Vehicle battery Check battery voltage

Low voltage < 77V
discharged
Pneumatic EP valve defective Change the EP valve

EP valve EP valve not working
Valve

(B) VCB does not Hold
Element Inspect Result Causes Remedy
Air pressure leakage Unblock pipes
Check compressor
Air pressure
Pressure Pressure regulator Adjust the pressure
in air Low pressure
Regulator disturbed regulator
reservoir
4.5±0.1 kg/cm²
Defective pressure Change the pressure

regulator regulator
No supply on pin Wire broken / not Change the wire /

nos. 1 & 4 of VCB connected Connect the wire
female connector
Wires No supply on wire Wire broken / Not Change the wire /

(Ferrule No. Voltage (ferrule no. 64 of connected of ferrule Connect the wire /
63 & 64) auxiliary switch) after no. 63 of auxiliary Change the auxiliary
VCB closing switch to pin no. 2 of switch
VCB connector /
Auxiliary switch
defective

(C) Check List
S. No. Check Point Required Parameter Remark

1. Air tank pressure using pressure Value as per sticker
gauge on tank
2. Voltage between 1 & 4 of female 110V DC when BLDJ is ON
connector of loco
3. Voltage between 1 & 2 of female 110V DC when BLRDJ switch is
connector of loco pressed
4. Continuity between 2 of male Continuity should be there
connector to ferrule no. 63 of
auxiliary contact NO
5. Continuity between 4 of male Continuity should be there
connector to ferrule no. 64 of
auxiliary contact NO
6. Resistance of solenoid valve coil Should show resistance
1510±8% at 35ºC
7. Test function of VCB VCB to operate
Note: When testing outside the loco, points 2 & 3 need not be checked.

4.2 Schedule of Preventive Maintenance

Attention: All Inspection and Maintenance Operations carried out on the Vacuum Circuit
Breaker must be done:
With the Power OFF, Pantograph Lowered, Circuit Breaker Earthed
S. Part to be Inspection Details IA IB IC AOH IOH POH Clause

No. Inspected (30 (60 (120 (1 (3 (6 No.
days) days) days) Year) Years) Years)
1. Insulator i. Check for cracks & flash marks       4.2.1
ii. Clean any parts that are dirty with soft, clean & dry       4.2.1
cloth (Do not use cleaning products based on
fluorated or chlorated compounds or sodium
metasilicate)
2. Connection i. Check for damage to connection of the earthing       4.2.1
for Earthing isolator
Isolator
ii. Cleaning & greasing, if necessary.       4.2.1
3. H.V. i. Check the tightening torque 70Nm       4.2.2
Connection
4. VCB Fixing i. Check the torque of fixing screw tightening torque       4.2.2
Screw 70Nm
5. Earthing i. Check the earthing connection tightening torque       4.2.2
Connection 70Nm
6. Pressure i. Drain the pressure regulator       4.2.3
Regulator
ii Check and set value of the regulator       4.8
iii. Change the filter cartridge with O-ring       4.2.5

7. Air Tank i. Drain the air tank       4.2.3
(Reservoir)
ii. Check for any air leakage in VCB       4.2.3
8. Pneumatic i. Check the sealing of connectors, flexible pipe,       4.2.3
Circuit regulator, air tank etc.
9. Auxiliary i. Check screw for breakage or other damage       4.2.7
Switch
ii. Check the moving contact for its continuity       4.2.7
Iii. Check the cables and lugs for broken cables, lugs       4.2.7
looseness
iv. Securing of auxiliary switch and support plate       4.2.7
(Tightening torque - 10Nm)
v. Check the working order of each auxiliary contacts       --
10. Vacuum i. Check the healthiness of VST       4.2.4
Switch (Di-electric test 40kV for 10 sec)
Tube (VST)
ii. Check closing & opening speed (First after 3 years       5.2
on new breaker & then every year).
iii. Inspections of main contacts wear in vacuum       5.1.3
switch tube. First after 3 years on new breaker &
then every year.

S. Part to be Inspection Details IA IB IC AOH IOH POH Clause

No. Inspected (30 (60 (120 (1 (3 (6 No.
days) days) days) Year) Years) Years)
11. Cabling & i. Check for any damages, cut & tightness of the       --
Connector connectors, connection, pins etc. including
pressure switch, EP valve solenoid coil and
connector
12. Cylinder i. Check proper fixing / sticking of shock absorber       --
Mounting plate
Plate
ii. Change the shock absorber plate       4.3
13. Piston i. Check air leakage       --
Assy.
ii. Replace piston seal       --
iii. Check compression springs       --
14. Side Cover i. Change the kit of O-ring of side cover (First time       4.2.6
after 3 years and then every year).
15. EP Valve i. Check the healthiness of EP valve coil resistance       --
Solenoid 1510±8% at 35ºC
Coil
16. Pressure i. Check the setting of pressure switch.       5.1.4
Switch
ii. Check the tightness of pneumatic connection       --
iii. Replace pressure switch with union bend       5.1.4

17. Contact i. Check contact spring       4.2.8
Spring
ii. Replace contact spring       4.2.8
18. Lubrication i. Lubricate driving plate assy.       --
ii. Lubricate shafting head bearing guides, vertical       4.2.9
spring, flexible braids, piston seal, piston rod and
EP valve
19. Torque i. Check rear flange -- 19.3Nm       --
Tightening
ii. Check shafting head -- 67Nm       --
iii. Check vertical insulator -- 67Nm       --
iv. Check tightness of nuts of base plate -- 15Nm       --
v. Check Bolts of cover for holding cylinder – 39.4Nm       --
vi. Check air tank mounting nuts -- 15Nm       --
20. Air Dryer i. Weight the air dryer. If increase in weight is more       5.1.1
than 0.8kg from new weight, regenerate molecular
sieves by heating and replace if required.
ii. Replace molecular sieves       5.1.1
21. RC Network i. Measure individual resistance and capacitance       5.1.2
value 4.7±10% and 25µF±10%. Replace
abnormal components.
To be done before each winter period strictly.

4.2.1 Visual Inspection
Carry out a visual inspection of the circuit breaker and specially the ceramic insulator (A) for
any cracks or damage to enamel and connections (B) for earthing terminals.
Figure - 4.1
Replacement Criteria
Parts Check
A No cracks or damage to enamel of the insulator ceramics and their sealing
B No damage to connections of contact spring of earthing switch
As required, using mild products and soft rags, clean any parts that are dirty. The insulators
can, depending on the user's preferences, have a silicone grease applied externally.
Attention: Do not use cleaning products based on fluorated or chlorated compounds or

sodium metasilicate.
4.2.2 Checking Tightening Torque
Check tightening torque on the following parts (Refer Figure 4.2) :
 High voltage connections (A)
 Earthing connections (B)
 Circuit breaker fixing screws (C)
Use a torque wrench for this and apply a tightening torque of 70Nm to each part.

Figure - 4.2
4.2.3 Inspection of Pneumatic Circuit (Refer Figure-4.3)
In order to guarantee correct operation of the pneumatic elements, it is necessary to

eliminate condensate from the vehicle pipe work. For this, it is necessary to drain the places
where condensate can accumulate, namely:
 In the regulator-filter case (A)
 In the bottom of the circuit breaker air tank (B)
Figure - 4.3

Draining the Regulator-Filter (F):
With the supply circuit is under pressure; unscrew the wing screw (A) sufficiently to
allow the condensate to escape.
When the flow stops, retighten the wing screw (A) and check that there is no
leakage.
Draining Circuit Breaker Air Tank (R):
 Close the circuit breaker isolating cock (in the main pipe) and release the
pressure in the reservoir.
 Once the pressure has fully dropped, completely unscrew the plug (B) located
under the reservoir.
 Gently open the isolating cock in the main pipe and allow air to blow out of the
open orifice until there is no longer any condensate in the air tank.
 Close the isolating cock and screw in the plug (B) again.
 Check that there is no leakage.
It is strongly recommended that the pneumatic circuit is drained before the

winter period in order to avoid condensate ice forming and causing faults in
the operation of the pneumatic elements.
Note: Care to be taken while draining; the condensate does not fall on other
electrical equipments.
Checking Sealing
After draining the pneumatic system of the circuit breaker, it is necessary to check the
sealing of connectors and check the condition of the flexible pipe, connected between the
main pipe of loco and the circuit breaker.
4.2.4 Checking of Vacuum in the Switch Tube (Refer Figure 4.4)
In order to define the state of the vacuum in the switch tube, it is necessary to carry out an
insulation test using vacuum tester. This device applies repetitive discharges of 40kV across
the terminals of the circuit breaker. For this reason, it is necessary to disconnect the
vehicle's high voltage (HT) connections to carry out the test.

Figure - 4.4
Test Procedure:
 Disconnect the vehicle high voltage connections and move them as far as
possible away from the circuit breaker terminals.
 Connect the crocodile clips on the high voltage cable (1) to the circuit breaker
terminals.
 Connect the earth (8) to nearby unearthed parts.

 Ensure that the main switch (11) on the device is at "0" and connect the mains
cable (220V AC).
 Check that the circuit breaker is in the "open" position (main contacts open) and
ensure that maintenance personnel are more than a meter away from the test
area.
 Set the main switch on the tester (11) to "1" and the green indicator (5) should
glow.
 Select the test voltage with the selector (9).
 Recommended tension Ue = 40 kV
Note: Disconnect the vehicle & remove high voltage connection to protect other
electrical equipments of locomotive.
 Carry out the insulation test by turning the rotary knob (6) for 10 seconds. The
red indicator (2) flashes and the yellow indicator (3) should not glow.
 If the yellow indicator (3) glows, the test must be performed again because the
test voltage supplied by the device is not sufficient.
 If the green << Acceptable >> indicator (4) stays ON (glows) during the test, the
test is positive and the vacuum in the switch tube is considered to be acceptable.
 If the red << Defective >> indicator (10) glows, then the vacuum in the switch
tube is not sufficient and the vacuum switch tube must be replaced.
Note: Depending on the state of the insulators (interior as well as exterior), it is

possible to have audible crackling during the insulation test.
 When the test has finished, it is necessary to wait 30 seconds after having
opened the main switch (11) on the test device to be able to take the crocodile
clips off the circuit breaker terminals. For safety, take off a single clip and touch it
against the other one to get rid of any possible charges on capacitors. Put the
cables away in the test case.
 Reconnect the vehicle high voltage connections, adhering to the 70 Nm

tightening torque.
4.2.5 Exchanging Filter Element of Pressure Regulator (Refer Figure 4.5)
(a) Unscrew the wing screw (A) sufficiently to allow the condensate to escape
(b) To open the regulator bowl (F), press the lever and rotate the bowl gently.
(c) Unscrew the conical nut (4) carefully.
(d) Change the filter element with new one (2).

(e) Tight the conical nut (4) carefully.
(f) Change o-ring ø30 (3) with new one.
(g) Apply grease syntheso Glep on o-ring.
(h) Fit the bowl (F).
Inspection to be done:
Retighten the wing screw (A) and check there is no leakage and adjust pressure, if required.
Figure - 4.5
4.2.6 Exchanging O-Ring for Side Cover (Refer Figure 4.6)
(a) Open the bolt M12×25 with washer (A).
(b) Open the anti breaking screw (B)
(c) Remove side cover (C).
(d) Remove O-ring from side cover.
(e) Clean the sides cover.
(f) Apply grease syntheso Glep on new O-ring. Fit O-ring in the side cover.

(g) Put side cover in proper place and tighten with new anti breaking screws & elastic
washers ø6.1 to a torque 8Nm (Apply grease molykote GN plus on screw threads).
(h) Re-fitted hex bolt M12×25 & elastic washer (A) along with cover right contact.
Tools used:
Open end spanner 19mm, Special Allen key (SG300121P0001), Torque wrench 8Nm.
Inspection & check:
Check sealing of high voltage part at 0.8 kg/cm² pressure and maximum air leakage is
permitted 0.05 kg/cm² in 30 minutes.
Figure 4.6
4.2.7 Exchanging Auxiliary Switch (Refer Figure 4.7)
– Take the auxiliary switch and check the contact movement. It should be smooth.
– Take 4nos. Allen head screw M6x20. Apply loctite 542.
– Place auxiliary switch on plate for auxiliary switch and tight with 4nos. screws, elastic
washer ø6.1 and hex nut M6.
– Apply loctite 542 on 4nos. Allen head screw M6x20 and 4nos. elastic washer ø6.1
and tight the auxiliary switch with main frame and apply 10Nm torque.
Tools used:
Allen key 5mm, Torque wrench 10Nm, Screw driver 828, Allen socket 10mm.

Inspection & check:
Check alignment of auxiliary switches with continuity of all contacts.
Figure 4.7
4.2.8 Exchanging Contact Spring
For cover right contact connection (Refer Figure 4.8)
– Open the hex head screw M6×16 (6) & M6×14 (7) and remove contact spring (4).
– Tighten new contact spring (4) with new above screws and elastic washer ø6.1 (9) to
a torque 8Nm
Figure 4.8
For rear support for tong (Refer Figure-4.9)
– Open the hex screw M12 & Allen head screw M8 (1 & 2 - Figure 4.6), both for fixing
of rear support for tongs.

– Open and remove 4nos. hex head screw M6×16 (10 - Figure 4.9).
– Remove contact spring (4 - Figure 4.9).
– Take 2nos. new contact springs (4 - Figure 4.9) and sleeve (5 – Figure 4.9), insert on
one of them & shrink.
– 2nos. contact springs (4 - Figure 4.9) tighten with new screws & elastic washers (10,
11 - Figure 4.9) on proper place to a torque 8Nm.
– Take complete rear support for tongs and tighten with bolt (1 - Figure 4.6) & Allen
head screw (2 - Figure 4.6) to a torque 19.3Nm. Apply molykote GN plus.
Figure 4.9
Tools used:
Open end spanner 10mm, Open end spanner 19mm, Torque wrench 8Nm, Hex socket
10mm, Allen key 6mm, Torque wrench 19.3Nm, Allen socket 6mm
Inspection & check:
Check alignment of contact springs.
4.2.9 Procedure for the Lubrication of Shafting Head Guide
– Open side covers
– Open conic head screw M6×16 - 4nos.

– Apply molykote 33 Light on main spring by brush.
– Apply grease molykote G-rapid plus on bearing guides.
– Clean braid face & shafting head face with emery paper (lightly).
– Apply syntheso Glep grease on the flexible connections.
– Tight conic head screw M6×16 - 4nos.
– Change o-ring and tighten side covers.
Tools used:
Torque wrench 8 & 10Nm, Allen head socket 4mm, Special Allen key 4mm etc.
Inspection & check:
Check sealing of high voltage part at 0.8 kg/cm² pressure.
4.3 Procedure for Fixing of Gasket of Driving Plate Assy. in Assembled VCB
-- Close the breaker by giving closing command.
-- Open the side cover of shafting head using special Allen key.
-- The special tool – ‘Safety strip' is to be fixed on shafting head so that VCB does not
open up in case of power failure.
-- Apply Loctite-480 on mounting surfaces of shock absorber plate and cylinder

mounting plate and then fix it properly.
Figure 4.10
-- Now remove the ‘Safety strip' and open the breaker.
-- The driving plate sits on the gasket. Allow it to set for 1/2 hr.

4.4 Dismantling of VCB
4.4.1 High Voltage Part Dismantling (Vacuum Switch Tube)
1. Mount the VCB on stand (Part No. HSBF100201) by tightening 6nos. Allen bolts with
base plate and stand frame.
2. Reverse the stand and unscrew the Allen head screws of protection cover and spring
washer with 5mm Allen key and remove the cover, refer figure 4.11
Figure 4.11
3. Keep the stand in upright position (high voltage part to be on the top).
4. Unscrew both HT terminal bolts, on rear flange, and other on shafting head with
open end spanner 19mm.
5. Dismantle rear flange by following technique:
i) Close the VCB.
II) Unscrew the rear support tong fitted on rear flange by 6mm Allen key.
Figure 4.12

6. Open the two socket head plug on the rear flange with Allen key 8mm. Unscrew and
take out the two Allen head screws from rear flange using Allen key 6 mm (long).
Figure 4.13 Figure 4.14
7. Remove the 7 Allen head screws and take out the rear flange by rotating gently it in
anti clock wise direction.
Figure 4.15
8. Now off the VCB (Open Condition)

Open the cover right contact connection assembly using a special Allen key
(SG300121P0001). Similarly open the other side cover using the same Allen key.

9. Open the flexible connections of vacuum switch tube on shafting head using Allen
key 4mm.
Figure 4.18
10. Hold the horizontal insulator with a rope using crane and open the socket button
head cap screws of horizontal insulator from shafting head. Remove the horizontal
insulator carefully.
11. Support the vacuum bottle till it is dismantled from shafting head.
Figure 4.21

12. Close the VCB and it should be ensure that the VCB should not open until the VST
removed.
13. Pull the cam rod away from shafting head by removing retaining ring.
14. Unscrew the one nyloc nut of the coupling rod with hex socket spanner 17mm by
holding the second nut from other side and remove the rod with bearings, washers
and distance pieces (care to see that vacuum bottle is firmly held on a support). It
should be ensuring that the thread of coupling rod should not be damage and
needles of bearing should not spread and fAllen down inside / outside the VCB.
Figure 4.22
15. Remove the air supply after switching off the VCB (Open condition)..
16. Remove the vacuum switch tube from the shafting head by using crane.
Figure 4.23
17. Remove the 4nos. socket button head cap screws from shafting head and vertical
insulator and remove the shafting head and compression spring.
18. Reverse the breaker.

4.4.2 Dismantling of Other Parts
A. Removing Assy. Cover for Holding Cylinder & EP Valve
1. Remove the plug connector from solenoid coil and unscrew the 2nos. hex nut M5 and
take out the connections of solenoid coil assembly.
2. Remove the 4nos. Allen head screws M10x110 with spring washer of cover for holding
cylinder using Allen key 8mm and remove the cover for holding cylinder plate with
gasket along with EP valve.
Assy. Cover for Holding

Cylinder & EP Valve
Figure 4.24
B. Air Tank
1. Remove the plug connector from pressure switch by loosening the screw.
2. Loosen the nuts of the air tank assembly using a tubular spanner of 13mm and remove
the air tank assembly. Remove the connecting pipe.
Note: Care to be taken that the same number of washers below the air tank to be
retained while assembling the air tank again for maintaining the alignment with
cover for holding cylinder.
Air Tank
Figure 4.25

C. Auxiliary Switch with Support Plate
1. Open all wiring connections from auxiliary switch contacts. Open 4nos. Allen head
screw M6x20 with elastic washer and hex nut M6.
2. Remove auxiliary switch assy.
3. Unscrew the 4nos. Allen head screw along with washers.
Figure 4.26
4. Remove the support plate for auxiliary switch.
D. Piston Assembly with Air Cylinder
1. Hold operating rod bush with special spanner 28mm.
2. Open central piston holding screw M10x120 along with packing washer, washer, air
damper and o-ring.
3. Remove piston cover with seal, guide pin, piston springs, air cylinder, piston rod and
spring shells.
4. Remove operating rod assy.

E. Driving Plate Assy.
1. Open 4nos. hex head screw M12x130 with elastic washer.
2. Remove driving plate assy.
F. Vertical Insulator
1. Reverse the stand in up right condition. Open the two Allen bolts and remove
the vertical insulator.
2. Remove the 6 mounting bolts of the base plate assembly from stand
(HSBF100201).
4.5 Sub-Assemblies of VCB
A. Air Tank Assembled (4300003900)

1. Take screwed socket (SG300066P0001) and apply loctite 542 use gasket KD
1/4'' (SG300071P0001) and tighten with air tank with hex nut G 1/4''
(SG300070P0001).
2. Take filter tube (4303153222). Apply loctite 542 and tightened.
3. Place o-ring (HSBA432095P0020) 2nos. into connecting block (4302253155) at
2 places.
4. Take Allen head screw M6×40 (9ADA 187-29) 2 nos. Apply loctite 542.
5. Tighten the screw with elastic washer M6 (9AVA330-11) into the air tank to fix
the connecting block. Apply tightening torque of 10Nm.
6. Take special connection (HSBA432714P0001), apply loctite 542 and place
packing ring (SG300073P0002).
7. Tighten the regulator with filter (HSBA433890P0001) on the connecting block
with o-ring (HSBA432095P0026), use silicon grease on o-ring.
8. Take the nipple for connecting pipe (SG300056P0001) with packing ring
(SG300073P0003) & o-ring (HSBA432095P0026).
9. Tighten the nipple on the connecting block.
10. Take the coupling and fix to the inlet side of regulator with filter.
11. Fit the o-ring (4306057377) into the groove of air tank by applying silicon
grease.
12. Assembled the tank top cover (4301153433) with Allen head screw M6x20
(9ADA187-25) and elastic washer M6 (9AVA330-11). Apply tightening torque of
10Nm.
13. Fix cap G3/8’’ (HSBA432531P0001), tight by hand only
14. Take pressure switch assy. and tightened to the reservoir.

B. Base Plate Assembly (430004900)

1. Clean base with an organic solvent like petrol.
2. Apply silicon spray on o-ring groove portion and on ring type joint. Insert ring
type joint in groove portion of assembled frame & welded base.
C. Driving Plate Assembly (430003700)

1. Apply loctite 480 on clean face of shock absorber plate and also on the cylinder
mounting plate.
2. Fix the shock absorber plate on cylinder mounting plate.
3. Apply Molykote G rapid on cam bracket pin (4301154199), driving plate pin
(4301154299) and corresponding fitment hole of cam bracket (4302255255),
auxiliary cam (4302254955), and driving plate (4302251555).
4. Tighten the cam bracket on cylinder mounting plate with Allen head screw
M6x20 (9ADA187-25) and elastic washer M6 (9AVA330-11) by applying loctite
270 on the screw thread portion and applying torque 10Nm.
5. Insert the driving plate pin and bracket pin into the cam bracket, auxiliary cam
and driving plate and lock with 2nos. circlip ø6mm, insert the spilt pin and
applying molykote G rapid on all moving parts.
D. Assy. Cover for Holding Cylinder (430005200)

1. Hold the NRV (Non return valve) ½’’ BSP (4303058022) A/F in bench vice.
2. Apply loctite 542 on connecting nipple (4301153577) and tighten in NRV with
39.4Nm torque both side of NRV.
3. Take the cover for holding cylinder (4302254555) and clean threads and bore
with loctite 7061.
4. Take NRV block (4302253655) 2nos. and clean with loctite 7061. Dry with
compressed air blow.
NRV
Figure 4.29
5. Apply silicon grease on o-ring (HSBA432095P0025) 2nos. and insert in NRV

block one in each.
6. Apply silicon grease on o-ring (HSBA432095P0024) 2nos. and place on cover
for holding cylinder.
7. Fit NRV block on both side of NRV assembled and place on cover for holding
cylinder. Check the arrow position on NRV; it should be towards fixed plug 3/4’’
side.

8. Insert spring lock washer M4 (NB335805P0507) in Allen head screw M4x40

(9ADA187-10). Apply loctite 542 on screw and tight the NRV block.
9. Insert elastic washer M6 (9AVA330-11) in Allen head screw M6x20 (9ADA187-
25). Apply loctite 270 on threads of screw and fix counter plate (4301354644)
with cover for holding cylinder.
10. Apply silicon grease on o-ring 26x2.5 (4306057577) and place on cover for
holding cylinder.
11. Insert elastic washer M6 (9AVA330-11) in Allen head screw M6x25 (9ADA187-
26). Apply loctite 542. Place valve assy. (4300005400) over cover for holding
cylinder and tight the assy. with 10Nm torque.
4.6 Main Assembly (VCB)
A. Base Plate Assembly
1. Mount the assembled base (4300004900) on the trolley, using six Allen bolt M12×50 &
washers.
2. Clean the top surface with loctite 7061.
3. Fix the stud small 2nos. near connector plate assy. and stud big 2nos. near air tank
assembled by applying loctite 638.
B. Vertical Insulator
1. Place the vertical insulator (4300050100) on the bench and clean with petrol and dry
with air.
2. Take the vertical sleeve (HSBA331677P0001) and apply silicon spray and fit the sleeve
at the upper flange end.
3. Apply Hylomar sealant on the collar of lower flange. Allow 10 min. for solvent to
evaporate.
4. Apply the same paste on two screws M6×25.
5. Place the vertical insulator over the assembled base.
6. Tighten two Screws and elastic washer ø6.1 from bottom side with 10Nm torque.

C. Driving Plate Assy.

1. Take 4 nos. hex head screw M12×130, elastic washer ø12.4 and apply Hylomar sealant
on thread of hex head screw.
2. Place driving plate assy. (4300003700) over the 4nos. of spacer.
3. Tighten with above screw (4nos.) with 67Nm torque.
D. Operating Rod Assembly
1. Reverse the VCB position (Vertical insulator upside).
2 Place operating rod (4300004800) in the bore of the insulator assy. with chamfer face to
horizontal direction (Bottle side).
E. Shafting Head Assembly
1. Apply silicon grease on o-ring (HSBA432580P0002) and put in shafting head.
2. Place the complete shafting head assy. over the vertical insulator.
3. Position the operating rod assy. with special mandrel.
4. Apply grease molykote Gn+ on the bolts M12×40 & M12×50.
5. Tighten the assy. with above bolts using 6 nos. elastic washer (9AVA 330-6) and hex
nuts (9ADA 271-6) with the help of Allen key 8mm and open end spanner 19mm. Apply
67Nm torque on nuts.

6. Apply grease Molykote 33 Light on compression spring and insert between spring guide
pin and compressed by operating rod in shafting head assembled.
7. Place the dummy tool in place of sub-assy., engage it with the Special Mandrel and
check the gap with Go-No-Go gauge.
Figure 4.36
8. Place wedge washer (HSBA433389) (0.2, 0.5 & 1.0 thick) on face of operating rod in
order to maintain the desired gap of 5mm between bearing & shafting head slot and
checked with Gauge.
F. Piston Assembled
1. Insert the spring shell (4301155033) 2nos. into the counter bore of driving plate assy.
2. Apply molykote 33 light grease on compression spring (4301556088) 2nos. and place in
spring shell.
3. Apply molykote 33 lights on piston rod (4301154777) and place centrally in driving plate
assy.
4. Apply molykote 33 light grease on piston spring guide pin (4301155877) 2nos. and fit
into piston rod side (4302155955).
5. Apply grease LUB-KB2 on piston seal (4306055677). Fit piston seal over piston cover
side (4302155555) properly.
6. Place piston rod side fitted with guide pin over spring.
7. Apply the Festo grease on air cylinder (4302255155. Place air cylinder over driving
plate.
Figure 4.37

8. Place piston cover side fitted with seal over piston rod side.
9. Insert screw M10x120 into packing washer (WASHR000008), air damper (4302154855)
and o-ring (4306057177) and tight the whole assy. with Operating Rod by applying
39.4Nm torque. Hold operating rod bush with special spanner 28mm for better
alignment.

G. VST Assembly
1. Fix air connection to cover for holding cylinder assy.
2. Close the exhaust port of the valve assy. with 1¼’’ male plug.
3. Remove the special mandrel from the operating rod. After giving air supply at cover for
holding cylinder to bring connecting rod in upward position.
4. Raise the vacuum switch tube assy. (4300004000) by crane and bring to the level of
housing of complete shafting head.
5. Insert the flexible cable inside the shafting head and two rollers of sub assy.
(4300004400) should slide in the slot of shafting head.

6. Take the coupling rod (4301151977) applies Molykote G-Rapid.
7. Insert cam spacer (4305151677) between the operating rod and operating cam.
Chamfering portion of spacer should be towards operating rod and plane portion should
be towards operating cam.

8. Insert the coupling rod into the operating cam.

9. Apply molykote G-rapid on the coupling rod.
10. Insert aluminum washer (HSBA432539P0001) at both ends of the coupling rod.
11. Apply molykote 33 lights on the needles of the bearing and place in to the coupling rod.
12. Insert aluminum washer (HSBA432539P0001) at both ends of coupling rod. Clean
the both sides thread of coupling rod with cleaner 7061.
13. Tighten with lock nut (9ADA299-6) 2nos. at both ends with torque wrench 27Nm
together.
14. Apply molykote G-rapid on the outer surface of cam rod (4301152277).
15. Insert the cam rod through shafting head, operating cam to shafting head other side.
16. Fix retaining ring (9ABA 135-10) on both side with circlip plier.
17. Release the air.
18. Apply the silicon grease on VST shaft and screwed the lock nut M36 (4303152177) on
it.
H. Horizontal Insulator Fixing
1. Take the complete horizontal insulator assy. (4300050200) and clean with petrol.
2. Apply silicon spray on the front horizontal sleeve (HSBA331594P0001) and insert on the
bigger flange of the insulator.
3. Take o-ring (HSBA432580P0001).
4. Apply silicon grease on the o-ring and fit into shafting head.
5. Lift horizontal insulator assy. with crane and tighten it with shafting head by using bolt
M12x50 (HSBA433467P0001), hex nut M12 (9ADA 271-6) 4nos, elastic washer M12
(9AVA 330-6) 8nos. and apply 67Nm torque.
Figure 4.42

6. Apply syntheso glep-1 grease on the braided contact plates.
7. Fasten both sides braided cable along with plate (HSBA432510P0001) & Screw (9AVA
194-616) (Don't tighten full) 2nos. each side tightened with 10Nm torque.
8. Fasten hex nut M12 (9ADA 271-6) (2 nos.) along with washers (9AVA 330-6) (2nos.) on
earthing studs of base plate using grease Molykote Gn+.
9. Take rear flange (HSBA331585P0001).
10. Take o-ring (HSBA432579P0002), apply syntheso glep-1 grease on it and fit into the
groove of flange.
11. Take rear horizontal sleeve (HSBA331593P0001).
12. Apply silicon spray on the rear horizontal sleeve and the horizontal insulator’s flange
OD.
13. Insert rear horizontal sleeve on the flange of horizontal insulator.
14. Screwed rear flange in clockwise direction, butting with lock nut already mounted on the
VST shaft.
15. Then take 1½ turn back and align with two holes of rear flange .
16. Take 2 bolts M8×80 (9ADA187-47) & apply Molykote Gn+ on thread portion put spring
washer (NB335805P0511) and tighten in lock nut (not fully tighten).
17. Give air pressure to the cylinder.
18. Screw clockwise the rear flange to maintain 4 mm gap between rear flange and insulator
flange face by mounting 2 nos. screws
19. After maintaining the 4mm gap, screwed all 7nos. bolt M8×35 with washer (9AVA 330-
12) by applying Molykote Gn+, on their threads.
20. Release the air.

21. Tighten all 7nos. bolts with torque 19.3Nm.

22. Tighten 2 screws fitted in lock nut with torque 19.3Nm.
23. Remove air connection from cover for holding cylinder.
24. Remove the male plug 1¼ from valve assy.
I. Auxiliary Switch Assembly

1. Take the auxiliary switch and check the contact movement. It should be smooth.
2. Take 4nos. Allen head screw M6x20. Apply loctite 542.
3. Place auxiliary switch on plate for auxiliary switch and tight with 4nos. screws, elastic
washer ø6.1 and hex nut M6.
4. Apply loctite 542 on 4nos. Allen head screw M6x20 and 4nos. elastic washer ø6.1 and
tight the auxiliary switch with main frame and apply 10Nm torque.
Figure 4.45
J. Cover for Holding Cylinder Assy.

1. Place the o-ring into cover for holding cylinder groove (4300005200).
2. Put the cover for holding cylinder over air cylinder properly.
3. Apply loctite 542 on threaded portion of Allen head screw M10x110 (SCREW000017)
and insert spring washer M10 (NB335805P0512) 4nos. and tight all 4nos. screw with
39.4Nm torque.
Figure 4.46

K. Air Tank Assembled
1. Take air tank assembled (4300003900) and engage connecting sleeve inlet air
(4301153377) with valve assy.
2. Tight the air tank assy. with hex nut M8 (9ADA 271-4) 4nos. with elastic washer ø8.2
(9AVA 330-4) 4nos and apply torque 15Nm.
Figure 4.47
L. Wiring for Pressure Switch, EP Valve Coil and Counter (If required)
1. Cut rubber sleeve (4306016700) 220mm long (one no.) and 400mm (one no.)
2. Apply silicon spray on sleeve I.D. and O.D. Place Rubber sleeve in slot of main frame of
base plate.
3. Insert three wires (coming out from counter, EP valve, pressure switch) in the rubber
sleeve 400mm from connector plate side and pull it out from the other side.
4. Insert connector wire 18nos. in rubber sleeve 220mm length.
5. Take the counter (SG300044P0003) and fix with spring clip supplied with counter to the
counter plate.
6. Insert the connection pin crimped with cable to counter input terminal. Clamp the cable
with drive plate assy. by cable tie and M4 hex bolt.
7. Fasten the solenoid wire with coil stud by hex nut M5 and plain washer and spring
washer. Tight the lug fully by hand force.
8. Cover the connection with dust covers of solenoid coil and tight the cover with M3
screw.
9. Insert the pressure switch wire in plug connector (HSBA433352P0001) and connect
wire on 1 and 3 number terminal. Tight the terminal screw fully.
10. Assembled the plug connector and fasten with pressure switch by M3 screw.
11. Tighten the cable and sleeve with cable tie at suitable location.

M. Wiring of Auxiliary Contact (If required)
1. Take the cable fix connector assy. (4300004100).
2. Separate the wire coming out from connectors and put number ferrule over the cable as
per the wiring diagram fitted on the cable fix connector assy.
3. Separate out the wire to be fixed in left side and right side of auxiliary switch.
4. Cut the proper length of wire according to connection.
5. Crimp the cable terminal (9ADA 220-10) 18nos. on 17 wires coming from connectors
and 1 wire from terminal.
6. Unscrew the terminal screw, terminal plate and washer of auxiliary switch and fasten
again with cable. Do the complete wiring of contacts 5NO and 4NC as per wiring
diagram (4302557766). Tighten the terminal screw with torque 1.7Nm.
7. Tie the wires of both sides of auxiliary contact with cable tie at appropriate places.
N. Side Cover Fixing
1. After completion of testing according to test procedure, fit side covers LHS
(4302252955) with o-ring (4306057477) and anti-breaking screw (SG300120P0001)
with elastic washer (9AVA330-11) with 8Nm torque.
2. Fix Cover right contact 25KV assy. (4300004700) with O-ring (4306057477), anti-
breaking screw and elastic washer with 8Nm torque.
3. Check sealing test at 0.8 kg/cm² of high tension assy.
4. Fit Rear support for Tong assy. (HSBA433496R0003) with Allen hd. screw M8×55
(9ADA187-43) with elastic washer (9AVA330-12) and apply torque 19.3Nm.
5. Fit cap 3/8’’ (HSBA432531P0001) 2nos. on rear flange & tight fully.

O. Protection Cover
1. Take protection cover assy. (4300004500).
2. Apply GN+ on protection cover screw threaded portion.
3. Place the protection covers over the VCB control portion and tight the Allen head screw
M6 (4nos.).
4. Take the Allen head screw M6x20 (9ADA 187-25) 2nos., spring washer M6 (2nos.)
(NB335805P0509) and apply GN+. Tight the screw with connector fully.
5. Fit the connector 1/2, 3/8 (4301210600) on air input supply.
6. Tight the hex head screw M12x25 (9ADA123-58) with elastic washer M12 (9AVA330-6)
on shafting head HT connections.
7. Tight the hex head screw M12x30 (9ADA123-59) with elastic washer M12 (9AVA330-6)
on rear flange HT connections.
4.7 Setting of Regulator with Filter
1. Fit the pressure gauge on the air tank of VCB.
2. Pull the adjusting knob of the pressure regulator (regulator unlocked).
3. Turn the knob and adjust the pressure regulator to maximum 4.5±0.1 kg/cm². Check the
value given on sticker.
4. Finally press the adjusting knob (regulator locked).
4.8 Setting of Pressure Switch
1. Fit the pressure gauge on the air tank of VCB.
2. Connect the air supply to air tank.
3. Open the rubber cap of pressure switch; keep the adjusting screw (big screw) to
minimum. Connect contact 1 & 3 of the pressure switch with continuity tester.
4. Increase the air pressure gradually and observe that continuity is within ±0.1 kg/cm² of
nominal pressure (i.e. PUpper).
5. Increase the pressure up to regulator setting and release air slowly, observe the
pressure at which the contact opens (discontinuity). This should be within ±0.1 kg/cm² of
nominal pressure (i.e. PLower).
6. Remove the air supply.
PNominal = PUpper & PLower limits (3.6±0.1 kg/cm² & 3.3±0.1 kg/cm²) values mentioned on sticker of
pressure switch housing.

4.9 Work Instruction EP Valve Maintenance (4300005400WI)
4.9.1 Assy. Details of EP Valve
Open the main valve assembly and separate out all components. Clean all metal
components except rubber part with patrol. Check that all components should be free from
surface defects such as surface finish, dents & scratches etc. Apply grease syntheso Gelp I
on all O-rings, PZ seal & Locating seats.
Note: (i) Use lubricants and consumable 4300005300 or 4300005400/22
(ii) Must apply grease on inner surface of cylinder where the seal move item no. 9.
(iii) Caution follow safety measures when using solvents to clean parts, take care
not to inhale the fumes: also ensure that smoking is not permitted, since some
solvents are flammable and others produce poisonous gases.
Assemble O-ring (4) & O-ring (5) in bottom seal seat (3) as per figure. Apply grease on
marked area.
Assemble Piston MV (7), O-ring (8) & Pz seal (9) as per figure. Apply grease on marked
area.
Assemble O-ring (17) in Inlet Flange. Apply grease in Inlet Flange Use brush for greasing.
Take O-ring (16) & assemble on Main Body. Take Allen hd. screw M5x30-4Nos, spring
washer M5 and apply loctite-542 on screw thread portion. Assemble Inlet Flange (15) on
main body (1) with spring washer M5 & Allen hd. screw M5x30 (19) & L.N. Socket 4mm with
Torque 5Nm.

Art 1 (Main valve assembly)
Take Main body MV (1) and assemble bottom seal seat (3) with bolt M8 MV (2) from bottom
side and spool (6) from top side. Take piston assembly (7) & cylinder MV (13) apply grease
on inside surface of cylinder (13) then insert in Main body (1), check that orientation of piston
(7) & cylinder (13) should be as per art 1. Use special tool 4302261955AF1 for locating the
inner assembly.
Place washer (10) and hex nut M8 A/F20 (11), apply loctite 542 on ID of hex nut M8 A/F20
(11), then tight hex nut M8 A/F20 (11) with nut tightening tool 4301262677 AF1 and hex
socket extended 13mm with torque wrench of 19.3Nm. Apply loctite 542 on hex nut M8 (12).
Make check nut between hex nut M8 (12) & hex nut M8 A/F20 (11) with nut tightening tool,
torque wrench with hex socket.
Take O-Ring 57x2.5 (14) Assemble in main body from bottom side. Take Compression
Spring (20), bottom plate assembly (21), socket head cap screw M8x25 04Nos & spring
washer M8. Apply Loctite 542 on threaded portion of screw M8x25 Tight with L.N. Socket
6mm & Torque wrench of 19.3Nm. Take O-Ring 57x2.5- (14) assembles in main body from
top side. After assembly check the movement of piston (7) in cylinder (13) by manually
pressing and releasing. It should move freely & smooth and should return completely.
Ensure that air hole passage should not block during assembly.
Open the Pilot valve assembly and separate out all components. Clean all metal
components except rubber part with patrol. Check that all components should be free from
surface defects such as surface finish, dents & scratches etc. Apply grease syntheso Gelp I
on all O-rings, PZ seal & Locating seats.
Note: (i) Use lubricants and consumable 4300005300 or 4300005400/22
(ii) Must apply grease on inner surface of cylinder where the seal move item no.
10.

Assemble O-ring (6) & O-ring (5) in bottom seal seat (4) as per figure. Apply grease on
marked area.
Assemble Piston MV (8), O-ring (9) & PZ seal (10) as per figure. Apply grease on marked
area.
Art 2 (Pilot valve assembly)
Take pilot valve body PV (1) and assemble bottom seal seat (4), Allen head screw M5x35
(2), Plain washer (3) apply loctite 542 on screw thread and assemble these from bottom
side and spool (7) from top side. Take piston assembly (8) & cylinder PV (11) apply grease
on inside surface of cylinder (11) then insert in pilot valve body (1), check that orientation of
piston (8) & cylinder (11) should be as per art 2. Tight the assembly by holding it with special
tool 4303260477AF and LN Socket 4mm & torque wrench 5Nm.
Insert the compression spring (14) in head of screw from bottom side, take O-Ring (12)
assemble in pilot valve body (1) from bottom side, take Allen hd screw M5x16 4nos. Apply
loctite 542 on threaded portion. Assemble bottom cover with Spring washer M5 towards

bottom side. Tight with L.N. Socket 4mm & Torque wrench 5Nm. Take O-Ring (12)
assembles in pilot valve body from top side. After assembly check the movement of piston
(8) in cylinder (11) by manually pressing and releasing. It should move freely & smooth and
should return completely.
Ensure that air hole passage should not block during assembly.
Art-3
Take all components & Sub Assembly. Clean & check all sub Assembly & Components
before assembly for any foreign particle or damages. Apply grease Kluber syntheso Gelp I
on O-ring wherever applicable. Take Pilot valve assembly (3), O-ring 5.28x1.78, O-ring
57x2.5, Spring Washer M8 & Allen head screw M8x25 (4, 5) 4Nos. Locate Pilot Valve Assy
(3) & O-ring 5.28x1.78 on Main Valve assembly (1). Apply loctite-542 on threaded portion of
screw M8x25 and assemble Main valve & Pilot Valve assembly. Apply Tightening torque of
19.3Nm by using LN Socket 6mm.

Take Rubber Washer (7), Coil Assembly (6), & Plastic Nut M14 (8), Assemble in upper
orifice manually & with spanner 19mm. Tight nut M14 with light hand pressure. Ensure that
orientation of Coil Assembly, check that coil assembly should not rotate after tighting of nut.
Take connecting sleeve (inlet Air) (12), sleeve coupling (11) & Allen hd. screw M4x16-2Nos
(13). Assemble manually in inlet flange of main valve assembly as per Art-3.
Do the air leakage & operation test in energized and un-energized condition. Do the
operation tests pick up & dropdown voltage test at 4.5kg/cm². Do the air leakages test in
energized and un energized condition at 10Kg/cm².
Art 4
Clean all metal components of Silencer assembly in patrol. To make the silencer block
assembly (4) take plate 2.5mm thk. & Skt hd. screw M4x45 4Nos. Insert screw in plate and
start stacking of hollow plate 0.5mm thk and Mesh each alternately 27 layer each part. Make
similar assembly 4Nos total. Apply loctite 542 on screw threading portion. Assemble silencer
block assembly on Base plate all 4nos. Ensure orientation of assembly should look like as
art 4. Make proof locking of silencer with Prevailing torque hex nut M4 on all 16 screws
applies torque 3Nm using hex socket 7mm & L N Key 3mm on Prevailing nut to lock it with
base plate.
Apply loctite-542 on screw thread of Allen head screw M6x35 2Nos (12) & Allen head screw
M6x25-2Nos (11). Assemble Silencer base (7) with EP valve Assembly by using Spring
washer M6-4Nos (10). Apply Tightening Torque of 10Nm using L N Socket 5mm on M6
Screw. Now Apply loctite-542 on screw thread of Allen head screw M5x16 (9) 6Nos.
Assemble Silencer (4) on silencer base (7) by using Spring washer M5-6Nos (8). Apply
Tightening Torque of 5Nm using L N Socket 4mm on M5 Screw. Ensure that orientation of
Silencer should be as per Art – 4

4.9.2 List of Assembly, Dis-assembly Tools and Testing Equipment of AAL EP Valve
(Mandatory) for each Maintenance Location.
Can be supplied by M/s AAL, Noida, on chargeable basis.
Special Tools
1. 4303260477AF Piston (P.V) tightening fixture. 1
2. 4301262677AF Nut (M.V) tightening tool. 1
3. 4302261955AF1 Bottom seal seat guide fixture 1
Standard Tools
1. -- Allen key size 3, 4, 5, 6mm 4
2. -- Allen socket 3, 4, 5, 6mm 4
3. -- Hex socket 7, 8, 10, 13 4
4. -- Torque Wrench 3, 5, 10, 19.3 4
5. -- Spanner set 10
Test Equipment (Assumed to be available in Shed for testing of AAL VCB)
Special Test Equipment
1. 4300033500 Speed control system (LVDT) 1
2. STOOL000029P0001 Simulator for VCB 1
3. STOOL000031P0001 Software for RT oscilloscope 1
4. 4300031800 Cable assy. (with connector) 1
5. HSBF100201 Trolley for VCB assy. Stand (optional) 1
6 STOOL000033P0001 Vacuum tester (optional)
Standard Test Equipment
1. -- Power supply 0-150V DC,15A 1
2. -- High voltage tester for coil dielectric 2kv 50Hz 1min 1
3. -- Digital Multimeter with probe 2
4. -- Digital RT oscilloscope & Cable 1
5. -- Digital Vernier caliper 150mm 1
6. -- RS-232 cable & computer 1
7. -- Air reservoir with pressure Gauge 16 kg/cm² 1

4.10 Tool List for VCB
4.10.1 Tools Required for Maintenance of VCB GENERAL TOOL KIT (4300009700/05)
S. No. Part No. Description Qty.

1. STOOL000001P0002 Double Ended Spanner 10x11 mm 1
11. STOOL000002P0002 Single Ended Spanner 55 mm 1
12. STOOL000002P0004 Single Ended Spanner 35 mm 1
13. STOOL000003P0002 Hex Socket Spanner 10mm x 3/8"Sq 1
17. STOOL000004P0001 Hex Soc Spanner(G) 7mm x 1/4"Sq 1
18. STOOL000004P0002 Hex Soc Spanner(G) 13mm x 1/4"Sq 1
19. STOOL000005P0001 Allen Key Long 2.5 mm 1
27. STOOL000005P0009 Allen key long 2.0 mm 1
28. STOOL000006P0001 Torque Wrench 67 Nm (Open End) 1
29. STOOL000006P0002 Torque Wrench 70 Nm 1
30. STOOL000007P0001 Torque Wrench 1.2 Nm Fixed 1

S. No. Part No. Description Qty.

33. STOOL000007P0004 Torque Wrench 15.0 Nm 1
38. STOOL000008P0001 Torque Wrench 1.7Nm Fixed 1
39. STOOL000009P0001 Allen Key 4.0mm x 3/8"Sq 1
43. STOOL000011P0001 Reducer 3/8"F To 1/4"M 1
44. STOOL000011P0002 Reducer 1/4" F To 3/8"M 1
45. STOOL000011P0003 Reducer 3/8"M To 1/2"F 1
46. STOOL000011P0004 Reducer 3/8" F To 1/2"M 1
47. STOOL000012P0001 Adjustable Wrench 8" 1
48. STOOL000014P0001 Screw Driver Set (General) 1
49. STOOL000015P0002 Soc. -Ve Screw Driver-1/4" Sq 1
50. STOOL000020P0001 Extension Rod 250mm x 3/8 "Sq. 1
51. STOOL000016P0001 Mallot 500gms. 1
52. STOOL000025P0004 Nose Plier 7" 1
53. STOOL000035P0001 Wire Cutter & Stripper (Multi) 1
54. STOOL000026P0001 Tublar Box Spanner 13mm 1
55. STOOL000026P0002 Box Spanner 7mm 1
58. STOOL000026P0005 Ring Spanner 1.0" 1
59. STOOL000027P0001 Try Square 6" 1
60. STOOL000023P0001 Heat Gun 1
61. STOOL000024P0001 Feeler Gauge 0.8 mm 2
64. PKG43000008 Packing Case (Tool Kit) 1
65. PKG43016013 Tool Box (For BVAC Kit) 1

4.10.2 Tools Required for Maintenance of VCB ASSY SPECIAL TOOL (4300009700/06)
S.No. Part No. Description Qty.

1. STOOL000022P0005 Crimping Tool (Knipex-975206) 1
2. STOOL000025P0002 Circlip Plier 7" External Crlp 1
3. STOOL000025P0003 Circlip Plier 7" Internal Crlp 1
4. 4300030400 Bearing Pressure Punch 2
5. 4300032600 Air Pressure Gauge 0.8 Bar 1
6. 4300031600 Coupling With Quick Change 1
7. 4300032700 Sealing Test-Pipe For Air Pres 1
8. SG300121P0001 Special Allen Key 1
9. 4300030100 Special Screw Driver 1
10. 4300033400 Special Screw Driver New Absor 1
11. SG300099P0001 Taper Wedge 1
12. 4300003100 Safety Strip + Gauge 1
13. 4300030600 Allen Screw Driver 1
14. 4300032300 Pin Removal Tool(M/F) 1
15. 4300032400 Pin Insertion Tool 12/0.75-1.0 1
16. 4300032500 Pin Insertion Tool 12/4.0-6.0 1
17. 4300033000 Pin Extracting Tool 1
18. 4300032800 Die 0.75-1.0mm² 1
19. 4300032900 Die 4.0-6.0mm² (G) 1
20. STOOL000022P0001 Hand Crimping Tool (M8ND) 1
21. STOOL000022P0004 Crimp Die WMPS GR12/1.5-2.5mm² 1
22. STOOL000021P0001 Crimping Tool 1
23. 4300032200 Pin Removal Tool (RM/RC16M 23K) 1
24. HHIM025020 Ph.Hd.Screw M3x16 W/P&S Washer 4
25. 4300032100 Open End Spanner 28mm 1
26. SG300024P0001 Wedge 2
27. DL98097 Fixture For Air Tank Assy. 1
28. SG300023 Centering Pin 1
29. 4300031200 Spring Insertion Tool 2
30. STOOL000010P0001 Allen Key 6.0mm(L) x 3/8"Sq 1
31. 4300031000 Feeler Gauge 4mm 1
32. HSBA433489 Positioning Mandrel 1
33. PKG43000008 Packing Case (Tool Kit) 1

S.No. Part No. Description Qty.

34. PKG43016013 Tool Box (For BVAC Kit) 1
35. 4301322633 C Clamp For VCB Assy. 1
36. 4303260477AF Piston (P.V) Tightening Fixture. 1
37. 4301262677AF Nut (M.V) Tightening Tool. 1
38. 4302261955AF1 Bottom Seal Seat Guide Fixture 1
 These special tools are supplied by M/s AAL, Noida on chargeable basis.
4.10.3 Tools for Installation & Commissioning of VCB
For requirement of the tools for installation & commissioning of VCB, please refer clause no.
3.6.

4.11 Tool Kit for VCB Assy. Test Equipment
S. No. Part No. Description

1. 4300033500 Speed control system (LVDT) 
2. STOOL000029P0001 Simulator for VCB
3. STOOL000031P0001 Software for RT oscilloscope
4. 4300031800 Cable assy. (with connector) 
5. -- Power supply 0-150V DC,15A
6. -- Digital RT oscilloscope
7. -- Digital vernier caliper 150mm
8. STOOL000033P0001 Vacuum tester (optional) 
9. -- Digital multimeter
10. -- Cable (RT oscilloscope tester)
11. -- RS-232 cable
12. -- Air reservoir with pressure gauge (16 kg/cm²)
13. HSBF100201 Trolley for VCB assy. – Stand (optional) 
 These special tools are supplied by M/s AAL, Noida on chargeable basis.

4.12 List for Torques and Required Tools
S. Torque Position as Description Tool Required for

No. Wrench per Drg. No. Torque Wrench
4300003600
1. 1.7Nm 12 On auxiliary switch connection Screw driver type socket
2. 8Nm 69 Anti breaking screw (Side cover) Specical Allen socket
4mm
3. 10Nm 10 Allen hd. screw M6x20 Allen socket 5mm
(Plate for auxiliary switch)
4. 10Nm 43 Conic hd. screw M6x16 Allen socket 4mm
(On VST flexible connection)
(Vertical insulator)
(Auxiliary switch)
7. 15Nm 63 Hex nut M8 Hex socket 13mm
(Air tank and base plate assy.)
8. 19.3Nm 84 Allen hd. screw M8x55 Allen socket 6mm
(Rear support for tong assy.)
9. 27Nm 46 Lock nut M10 (On VST) Hex socket 17mm
10. 39.4Nm 82 Allen hd. screw M10x120 Allen socket 8mm
(Cover for holding cylinder)
11. 39.4Nm 83 Allen hd. screw M10x110 (Piston assy.) Allen socket 8mm
12. 67Nm 58 Hex nut M12 Torque wrench with
(Shafting head) 19mm open end
arrangement
13. 67Nm 62 Hex hd. screw M12x130 Torque wrench with
(Driving plate assy.) 19mm open end
arrangement
14. 70Nm -- On VCB fixing bolt, HT connections and Torque wrench 70Nm
earthing of VCB at base plate (Used at open end
the time of installation and
commissioning)

[5]
TESTING

5.1 Test Procedures
5.1.1 Test Procedure of Air Dryer
– At the time of initial fitment, weight of the air dryers should be taken and a record
kept for future reference.
– Ensure that the air dryer is fitted vertically.
– Remove both air connections from the dryer.
– Remove air dryer assembly by unscrewing the 2nos. M12 mounting bolts.
– Check the weight of the air dryer, if it is more than 0.8kg from the new weight,
change molecular sieve by a new or regenerated one. Method of regenerating is
given in note (a).
– Unscrew one filter assembly from the body, empty sieve material and replenish with
new / regenerated material, leaving sufficient room for the filter only. Refit and
tighten the filter assembly.
– Dryer to be "blown-down" by giving compressed air from one end keeping the other
end open to remove any molecular sieve dust.
– Check air leakage by using a soap solution around the filter assembly. For this
purpose, blank off one air connection and connect the other with compressed air.
– Remount the air dryer assembly on the loco and reconnect the air supply
connections.
– Check the weight of molecular sieve to be regenerated.

Note: (a) Regenerate the used sieves by heating in an oven at 200ºC for 8 hours. Check the
weight again and compare with the earlier weight. It should be less by 15-20%.
There should be no visual indication of moisture contents.
(b) Refilling should be carried out as quickly as possible by scooping pellets into the air
dryer body in case of replacement. After filling, ensure the drum is properly closed
with the lid and stored in a dry covered area.
(c) Specification of molecular sieve
(i) Type : 4A
(ii) Size & form : ø3.0mm, Cylindrical pellets
(iii) Bulk density : 620 - 680 gms / lit.
(iv) Crushing strength : 6 - 12 kgs (Avg. of 10 values)
(v) Bed crushing strength : 80 - 90%
(vi) Loss on attrition : 0.2 - 0.5%
(vii) Equilibrium water absorption capacity –
– 75% RH : 21 - 23%
– 15% RH : 18 - 19%
(viii) Nominal pore diameter : 4ºA
5.1.2 Test Procedure of RC Damping Panel
(a) Test Equipment
Multimeter
(b) Check Resistance
– Connect the multimeter terminals to resistance terminals.
– Check resistance 4.7±5%.
– Replace resistor, if required.
(c) Check Capacitance
– Connect the multimeter terminals to capacitor terminals.
– Check capacitance 25µF±5%.
– Replace capacitor, if required.
Note: Check all RC Damping Panel.

5.1.3 Test Procedure for Main Contact Wear
Remove one of the side cover
Remove the two fixing screws of the corresponding flexible conductor
Close the breaker. Check that the needle bearing moved in the closed position.

Insert the safety strip in the guide to secure the closing position.
Insert the gauge of 2mm through the hole in the rod and push it home.
Stay the gauge in horizontal position.
If it is not possible to insert the gauge of 2mm, than replace the vacuum circuit breaker and
change the vacuum switch tube.
Retighten the two fixing screws of the flexible conductor to a torque of 10 Nm.

Take off the safety stirrup.
Fit the side cover with a new O-ring.
Retighten the screws of the side cover to a torque of 8 Nm.
Tools used:
Safety strip & Inspection gauge (4300003100), Special Allen key for side cover
(SG300121P0001), Torque wrench 8Nm, Torque wrench 10Nm, and Allen socket 4mm.
5.1.4 Procedure for the Checking of Pressure Switch (Refer Figure 4.3)
– Remove pressure switch connector (C).
– Open Plug (B). Fit 0-6 kg/cm² pressure gauge (G 3/8’’).
– Check pressure gauge reading, it should be same as written on sticker of pressure

switch.
– Connect continuity tester at pin nos. 1 & 3 of pressure switch. See air tank assy.
drawing (4300003900).
– Release air in the air tank up to upper limit of switch mentioned on sticker by
adjusting wing screw “A”.
– Open wing screw slightly to release air and check pressure in gauge at what point
beep sound comes and check pressure of gauge & lower limit of switch.
– If setting is disturb then adjust it by rotating the screw provided in pressure switch or
replace it with new switch.
Tools used:
Screw driver, Allen key 5 & 8mm, multimeter etc.
5.1.5 Sealing Test for Air Tank Assembly

– Connect Air Line at the inlet of air tank.
– Remove the air sealing plug of air tank & connect the pressure gauge (0 - 10kg/cm²)
there.
– Open the lock of pressure regulator and rotate its knob in anti clock wise direction
completely.
– Perform Air Tightness test of VCB & maximum loss of 10% is permitted.

5.2 Test Procedure for Closing and Opening Speeds
Dynamic Operating Conditions
Legend:
U : Total contact pressure mechanism stroke.
S : Distance between new contacts.
S' : Distance between worn contacts.
VC : Closing speed.
UVC : Measurement distance to determine the VC.
tVC : Duration to determine the VC.
VO : Opening speed.
UVO : Measurement distance to determine the VO.
tVO : Duration to determine the VO.
tb : Main contact (HV) bounce duration.
tbr : Contact pressure duration.
0 : Circuit breaker open.
0-1 : Acceleration of the piston.
2-3 : Speed measurement of the closing time (VC).
3 : Closing of the main contact.
3-4 : Wear compensation (S'-S) and establishment of the over contact pressure.
4-5 : Establishment of the minimum contact pressure after wear (U-S').
5-6 : Circuit breaker closed.
6-7 : Time of the magnetic and mechanical reaction.
7 : Opening of the main contact.
7-8 : Speed measurement of the opening time (VO).
9 : Pneumatic damping and circuit breaker open.

5.2.1 Closing Speed Measurement
– Keep the breaker in normal position i.e. H.T. section on top.
– Adjust the inlet pressure to about 8 kg/cm².
– Open the side cover by special Allen key (SG300121P0001).
– Open the flexible conductor by Allen key (4mm).
– Fit the test jig (L.V.D.T.) on the VCB, the moving plate along with the shaft is fitted on
the moving contact.
– Connect the L.V.D.T. to the simulator.
– Connect the main contact to the simulator by cable.
– Connect the CRO one channel to LT out of simulator test jig and other channel to HV
out of simulator test jig.
– Adjust the CRO settings according the equipment being used.
– Adjust the control supply to 110V DC and turn on the simulation unit in manual
mode.
– Turn ON the breaker and capture the wave forms on the CRO.
– Calculate closing speed (VC) by interpretation by captured data.
– Turn OFF the breaker.
5.2.2 Opening Speed Measurement
– One channel of CRO is connected to displacement transducer (L.V.D.T.) output from

simulator at LT out & other channel to main contact output on simulator at HT out.
Make adjustments in CRO.
– Turn the breaker ON then after a minimum delay of 5 sec turns it OFF. CRO will
trigger & capture the turn OFF event.
– Calculate opening speed (VO) by suitable interpretation of captured data.
5.2.3 Main Contact Closure Time
– Connect the CRO channel A to Iout of simulator test jig.
– Connect the CRO channel B to HV out of simulator test jig.
– Make adjustments in the CRO.

– Turn ON the breaker & the CRO will capture the turn ON event. Adjust the time
measuring cursors on the captured wave.
– Measure the time difference. This time is the main contact closing time.
5.2.4 Opening Time of Main Contacts
– Connect one channel of CRO to LT out of simulator test jig & other to HV out of
simulator test jig.
– Make suitable adjustments on CRO.
– Turn the breaker ON & after a minimum delay of 5 sec turn it OFF.
– CRO will capture the turn OFF event and measure opening time on the wave. This
time is the main contact opening time.
5.3 Sealing Test for High Voltage Section
Note: Before doing this test ensure air is fully dry and dust free.
– Keep the breaker in normal position (i.e. H. T. Section on top).
– Remove one of the sealing caps (G 3/8") on rear flange.
– Remove one of the screws seen after removing the cap & mount the pressure
coupling.
– Apply pressure of 0.8 kg/cm² for 30 min. (Ensure that the applied air is free of dust &
moisture. This is very much important).
– Observe that the pressure drop is less than 0.05 kg/cm² after 30 min. Reconnect the
bolt & apply 19.3Nm torque. Refit the sealing cap.
5.4 High Voltage Test
5.4.1 High Voltage Test for H.T. Section
(a) – Keep the breaker in normal position (i.e. H.T. Section on top).
– Connect the earthing terminal of the HV tester to the earthing bolts.
– Connect the shorting connector jig on the control connector and to the
earthing bolt.
– Short moving contact terminal to earth.
– Connect high voltage terminal of HV tester to the fixed contact terminal.

– Turn ON the HV tester & gradually increase the voltage to 40kV AC and
maintain it for 10sec. Observe no tripping of the HV tester.
– After 10 sec. turn OFF the HV tester & wait for 1 min. & then short the
earthing terminal with the HV terminal to discharge any residual charge.
(b) – Reconnect the earthing terminal of HV tester to the earthing bolt of the
breaker.
– Remove the connection between the moving contact & earthing bolt &
connect moving contact terminal to the fixed contact.
– Connect the high voltage terminal of HV tester to the fixed contact.
– Turn ON the HV tester & gradually increase the voltage to 40kV AC and
maintain it for 10sec. Observe no tripping of the HV tester.
– After 10 sec. turn OFF the HV tester & wait for 1 min. & then short the
earthing terminal with the HV terminal to discharge any residual charge.
– Remove the terminals connected to the moving & fixed contacts. Remove the
shorting between moving & fixed contacts.
– Remove the shorting connector jig to the earthing bolt.
5.4.2 High Voltage Test for L.T. Section
– Use 2kV HV tester.
– Connect the earthing terminal of the tester to the earthing bolt of the breaker.
– Connect high voltage terminals to the shorting connector jig.
– Turn ON the HV tester & adjust the voltage to 2kV AC. For 1 min. & observe no flash
over takes place resulting in tripping of HV tester.
– After one min, put OFF the HV tester & short the earthing terminal to the high voltage
terminal to discharge any residual charge.
– Remove the shorting connector jig on the control connector.

[6]
SPARE PARTS

NOTE: Change all Rubber Parts & Spring Washers each time when Assy. is dismantled.
6.1 AOH Kit -- 1 Year Maintenance (4300007100/10)
S. No. Part No. Description Where used Pos. Unit Qty.

Drawing No.
1 4300014000 Filter Element (40µm) 4300003900 13 Nos. 1
2 69.211.215 O-RING 4300003900 13 Nos. 1
3 HSBA432577P0001 Ring type joint 4300004900 4 Nos. 1
6.2 IOH Kit -- 3 Years Maintenance (4300007100/32)

Drawing No.
1 4300007100/10 AOH Kit (1 Year Maintenance) -- -- Nos. 1
2 4300007100/23 Kit For Side Cover LHS & RHS 4300003600 -- Nos. 1
3 4300007100/43 Pressure Switch Kit 4300003900 16 Nos. 1
4 4320010700 Molecular Sieves 4320001000 Kgs 4
5 WASHR000008 PL CU ø10 Washer 4300003600 81 Nos. 1
6 9AVA330-12 Elastic Washer M8 4300004200 17 Nos. 4
7 HSBA432095P0026 O-Ring 4300003600 14 Nos. 2
8 4306057177 O Ring 4300003600 77 Nos. 1
9 4306057277 O Ring 4300003600 78 Nos. 1
10 4306057577 O Ring 4300005200 11 Nos. 2
11 NB335805P0509 Spring Lock Washer M6 4300003600 72 Nos. 2
12 NB335805P0511 Spring Washer M8 (HT) 4300004200 15 Nos. 2
13 NB335805P0512 Spring Washer M10 4300003600 70 Nos. 4
14 HSBA432531P0001 Socket Head Plug 4300003600 52 Nos. 3
17 9AVA330-4 Elastic Washer Φ8.2 4300003600 67 Nos. 4
18 HSBA432095P0020 O-Ring 4300003900 8 Nos. 2
19 4300007100/35 KIT of EP Valve 4300005200 14 Nos. 1

6.3 POH Kit -- 6 Years Maintenance (4300007100/33)

Drawing No.
1 4300007100/32 VCB Kit IOH -- -- Nos. 1
2 4300018900 Valve Cone 4300003900 -- Nos. 1
3 4300019000 Diaphragm Assembly 4300003900 -- Nos. 1
4 HSBA432095P0026 O-Ring 4300003900 14 Nos. 2
8 HSBA432579P0002 O-Ring 4300004200 10 Nos. 1
9 HSBA432580P0001 O-Ring 4300004200 6 Nos. 1
10 HSBA432580P0002 O-Ring 4300003600 41 Nos. 1
11 NB335805P0507 Spring Lock Washer M4 4300005200 6 Nos. 8
12 NB335805P0511 Spring Washer M8 (HT) 4300004200 15 Nos. 2
13 4306055677 Piston Seal 4300003600 19 Nos. 1
14 HSBA432463P0001 Compression Spring 4300003900 - Nos. 1
15 4302254955 Auxiliary Cam 4300003700 4 Nos. 1
16 4305151677 Cam Spacer 4300003600 79 Nos. 2
17 4301151977 Coupling Rod 4300003600 54 Nos. 1
18 4301154199 Bracket Pin 4300003700 6 Nos. 1
19 4301154299 Driving Plate Pin 4300003700 7 Nos. 1
20 4306057377 O-Ring 4300003900 22 Nos. 1
21 4300004800 Operating Rod Assembled (25KV) 4300003600 8 Nos. 1
22 4301556088 Compression Spring 4300003600 14 Nos. 2
23 HSBA432539P0001 Washer 4300003600 44 Nos. 4
24 HSBA432623P0001 Needle Bearing NAO 4300003600 45 Nos. 4
25 HSBA433389P0001 Wedge Washer 30x10.5x0.2 4300003600 64 Nos. 2
28 HSBA432095P0024 O-Ring 4300005200 10 Nos. 2
29 HSBA432095P0025 O-Ring 4300005200 12 Nos. 2
30 9AVA330-4 Elastic Washer M8 4300003600 -- Nos. 4
31 9ABA135-10 Retaining Ring Dia 12 4300003600 40 Nos. 4


Drawing No.
32 PINSX000002 Split Pin 4300003700 11 Nos. 2
33 CRCLP000005 Retaining Ring Dia 6 4300003700 10 Nos. 2
34 SG300066P0001 Standpipe Assy 4300003900 -- Nos. 1
35 SG300070P0001 Hex Nut G 1/4" 4300003900 20 Nos. 1
36 9ADA299-6 Lock Nut M10 4300003600 46 Nos. 2
37 4306054477 Shock Absorber Plate 4300003700 2 Nos. 1
38 SG300073P0002 Packing Ring 4300003900 12 Nos. 1
39 SG300073P0003 Packing Ring 4300003900 10 Nos. 1
40 4301562877 Compression Spring 4300005500 - Nos. 1
41 4301560677 Compression Spring 4300005500 - Nos. 1
42 4300007100/26 Auxiliary Switch Maintenance 4300003600 - Nos. 1
Note: Lubricant and consumables (4300007100/29) required during overhauling may be procured
on need base separately.

6.4 Special Lubricants & Consumables (4300007100/29)
S. Part No. Description Unit Qty.

No.
1. SG300074P0001 Hylomer sealant Universal Blue ml 100
(For sealing purpose)
2. SG300181P0001 Molykote 33 light gms 1000
(For relatively high & very low temp.)
3. SG300180P0001 Molykote G-rapid plus gms 1000
(On moving parts)
4. HSBA433750P0005 Molykote Gn plus gms 1000
(To protect threads from corrosion)
5. HSBA432292P0015 Loctite 7061 ml 4*100
(Cleaning agent to be applied before applying
any loctite)
6. HSBA432893P0001 Silicon Spray gms 250
(Rubber parts lubrication)
7. 4300022800 Silicon liquid polish ml 300
8. SG300182P0001 Kluber syntheso Glep-1 [Lubrication & To gms 1000
protect electrical surfaces from oxidation]
9. 4300013100 Leak finder CRC ml 500
(To check air leakage)
10. 4300013200 Loctite 542 ml 50
(Thread locking)
11. HZN453265P0001 Loctite 638 ml 50
(Thread locking)
12. 4300013500 Loctite 480 gms 20
13. 4300013400 Loctite 270 gms 50
14. 4300022700 Loctite 567 ml 50
15. 4300022900 Special grease (Festo) LUB-KC1 ml 20
Note: Qty. contains minimum packing size.

[7]
OTHER SPARES

7.1 KIT of Pressure Switch Assy. (BVAC – SG300146R0001, AAL - 4300007100/43)
S. No. Part No. Description Unit Qty.

1 HSBA432553P0001 Pressure Switch Nos. 1
2 SG300067P0001 Male stud Elbow assy Nos. 1
7.2 KIT of Pressure Regulator Assy. (SG300147R0001)

1 HSBA433890P0001 Regulator With Filter Nos. 1
2 SG300073P0002 Packing Ring 17.28x23.08x2.03 Nos. 1
3 HSBA432095P0026 O-Ring Dia 17.86 X 2.62 Nos. 1
4 4301210200/01 Mail Stud Coupling G3/8” Nos. 1
5 4305510966 Sticker (Air Regulator) Nos. 1
7.3 Repair Kit Pressure Regulator (4300021000)

1 4300018900 Valve Cone Nos. 1
2 4300019000 Diaphragm Assembly Nos. 1
3 69.211.215 ‘O' Ring 30x2mm Nos. 1
7.4 KIT of Flexible Pipe Assy. 700mm for WAG-7 (4300001200)

1. 4301210300 Elbow Nos. 2
2. 4300019600/01 Hose Pipe 3/8"(F)-700mm Nos. 1
3. 4301221388 Connector 3/8"(M) x ø10.0 mm Nos. 1
4. 4301210200/01 Mail Stud Coupling Nos. 1
5. 4300021400 Male Adaptor G3/8EDxG1/2 Nos. 1
6. 4303220300 Copper Washer Nos. 4
7.5 KIT of Flexible Pipe Assy. 700mm for ABB Loco (4300001300)

1. 4300001200 Kit Of Flexible Pipe Assembly Nos. 1
2. 4301210200 Male Stud Coupling G3/8” Nos. 1

7.6 KIT of Flexible Pipe Assy. 2000mm for EMU (4300001900)

1. 4301210300 Elbow Nos. 1
2. 4300019600/02 Hose Pipe 3/8"(F)-(2000mm) Nos. 1
3. 4303220300 Copper Washer Nos. 4
4. 4301210200/01 Mail Stud Coupling G3/8” Nos. 1
5. 4301210200 Male Stud Coupling G3/8” Nos. 1
6. 4300021400 Connector G1/2xG3/8” Nos. 1
7. 4301221388 Connector 3/8"(M) x ø10.0 Mm Nos. 1
7.7 Kit of Male Contact (4300007300)

1. 3503118499/02 Contact Pin 12/1.0 mm² Nos. 21
2. 32.202.148/01A Heat Shrink Sleeve ID ø4.8 mm 630
7.8 Kit of Resistor for RC Damping Panel Assy. (4300007400)

1. 4310001100 Resistor Assembly Nos. 1
2. 8.1211.414/14 Csk Screw M5x20 Nos. 2
3. 62.115.210 Plain Washer Dia 5.3 Nos. 6
4. 63.215.005 Spring Washer Dia 5.1 Nos. 4
5. 60.215.211 Hex Hd Screw M5x10 Nos. 2
6. 64.115.008 Hex Nut M5 Nos. 4
7.9 Kit of Air Dryer Assy. (4300007500)

1. 4300021400 Connector G1/2xG3/8” Nos. 2
2. 4320010700 Molecular Sieves kgs 4
7.10 Kit for Side Covers LHS & RHS (430007100/23)

1. 4306057477 O-Ring Dia 4×130 Nos. 2
2. SG300120P0001 Anti Breaking Screw M6x20 Nos. 8
3. 9AVA330-11 Elastic Washer Dia 6 Nos. 8

7.11 Kit for Cover for Holding Cylinder Assy. (4300007100/25)

1. NB335805P0507 Spring Lock Washer Dia 4 Form A Curve Nos. 8
3. HSBA432095P0024 O-Ring ID12x2.0mm Nos. 2
4. 4306057577 O Ring Dia 2.5x26 Nos. 1
5. HSBA432095P0025 O-Ring ID13.95x2.62mm Nos. 2
6. NB335805P0512 Spring Washer Dia 10 Nos. 4
7. 4306057277 O Ring Dia 2.5x105 Nos. 1
7.12 KIT for Aux Switch Assy (4300007100/26)

1. 4309056199 Auxiliary Switch Nos. 1
3. 9ADA187-25 Allen Hd M6x20 Screw Nos. 8
4. 9ADA271-3 Hex Nut M6 Nos. 4
7.13 Kit of Piston Assy. (4300007100/27)

1. 4301556088 Compression Spring Nos. 2
2. 4302154855 Air Damper Nos. 1
3. 4306057177 O Ring Dia 3.5x10 Nos. 1
4. WASHR000008 Pl Cu ø10.2x2mm Thk Washer Nos. 1
5. 4306055677 Piston Seal Nos. 1
6. NB335805P0512 Spring Washer Dia 10 Nos. 4
7.14 Shafting Head for Spare Assy. (Replacing BVAC to AAL Shafting head)
(4300007100/28)

1. 4300003800 Complete Shafting Head Nos. 1
2. 4306057477 O-Ring Dia 4×130 Nos. 2
3. 4300004700 Side Cover Right Assembly Nos. 1
4. 4302252955 Side Cover (L.H.S) Nos. 1
5. SG300120P0001 Anti Breaking Screw M6x20 Nos. 8


7.15 KIT of VST (VITZRO) (4300007100/31)

1. 4300004000 Assembled Vacuum Switch Tube Nos. 1
2. 4303152177 Lock Nut M36 x 1.5 Nos. 1
3. HSBA432580P0001 O-Ring ID 189.87x5.34mm Nos. 1
4. HSBA432579P0002 O-Ring ID 110x4mm Nos. 1
5. 4306057477 O-Ring Dia 4×130 Nos. 2
6. HSBA432531P0001 Socket Hd Plug Ed, G3/8 Viton Nos. 2
7 9ADA299-6 Lock Nut M10 Nos. 2
8 SG300120P0001 Anti Breaking Screw M6x20 Nos. 8
9 HSBA432623P0001 Needle Bearing Nao 12x24x13 Nos. 2
10 HSBA432539P0001 Washer Nos. 4
11 4301151977 Coupling Rod Nos. 1
12 9AVA194-616 Conic Hd Screw M6x16 Nos. 4
13 9AVA330-6 Elastic Washer Dia 12 Nos. 10
14 4306057277 O Ring Dia 2.5x105 Nos. 1
15 NB335805P0511 Spring Washer Dia 8 (Ht) Nos. 2
16 NB335805P0512 Spring Washer Dia 10 Nos. 4
18 9ADA123-59 Hx Hd Screw M12x30 Nos. 1
19 9ADA123-58 Hx Hd Screw M12x25 Nos. 1
21 PKG43013010 EP Packing For VST Nos. 2
22 PKG43010011 Corrugated Box For VST Nos. 1
23 PKG43012012 Wooden Box For VST Nos. 1
24 4301152277 Cam Rod Nos. 1
25 HSBA432095P0026 O-Ring Dia 17.86 x 2.62 Nos. 1
26 4305151677 Cam Spacer Nos. 2
27 9ADA135-10 Retaining Ring Dia 12 Nos. 2

7.16 KIT of Rear Flange (4300007100/39)

1 NB335805P0511 Spring Washer Dia 8 (Ht) Nos. 2
3 HSBA432579P0002 O-Ring ID 110x4mm Nos. 1
4 HSBA432531P0001 Socket Hd Plug Ed, G3/8 Viton Nos. 2
6 HSBA331585P0001 Rear Flange Nos. 1
7 SG300182P0001 Grease Syntheso Glep-1 (1000gm) gm 10
7.17 KIT of AAL EP Valve VCB (4300007100/44)

1 4300005500 Ep Valve Assy. (110V DC) Rotex Nos. 1
2 4300005500 Ep Valve Assy. (110V DC) AAL Nos. 1
2 9ADA187-28 Allen Head Screw M6 x 35 Nos. 4
4 4306057577 O Ring Dia 2.5 x 26 Nos. 1
5 HSBA432095P0026 O-Ring Dia 17.86 x 2.62 Nos. 1
7.18 Kit of Capacitor Assy for RC Damping Panel (4300007100/41)

1. CAPST000134 Capacitor Nos. 1
2. 8.1211.414/14 C'sk Screw M5×20 Nos. 4
3. 62.115.210 Plain Washer ø5.3 Nos. 5
4. 63.215.005 Spring Washer ø5.1 Nos. 5
5. 64.115.008 Hex Nut M5 Nos. 5
6. 60.515.221 C'sk Screw M5 x 50 Nos. 1
7.19 Kit of RC Damping Panel Assy. (4300007100/42)

1. 4315310477 Sealing Board Nos. 1
2. 4315310177/01 Panel Board For Capacitor Nos. 1
3. 64.115.011 Hex. Nut M10 Nos. 4


4. 63.215.010 Spring Washer Dia 10.5 Nos. 4
5. 62.115.514 Plain Washer Dia 10.5 Nos. 8
6. 60.215.369 Hex Head Screw M10×40 Nos. 4
7. 8.1211.414/14 Csk Screw M5 x 20 Nos. 6
8. 62.115.210 Plain Washer Dia 5 Nos. 13
9. 63.215.005 Spring Washer Dia 5 Nos. 13
10. 64.115.008 Hex Nut M5 Nos. 13
11. 60.515.221 Csk Screw M5x50 Nos. 3
12. Y04405 Cable Tie Mini Base Nos. 4
13. 32.312.000/029 Cable Tie 100mm Nos. 4
7.20 KIT of Male Connector Assy. (4300007200)

1 3500003200/06 Connector Recp.Size 40/35 Nos. 1
2 9ADA123-3 Hex Hd. Screw M4x12 Nos. 4
3 9ADA271-1 Hex Nut M4 Nos. 4
7.21 Complete Shafting Head (4300003800)

1 4302250355 Shafting Head Finished Nos. 1
2 NBT300226P0107 Helicoil M12x30 Nos. 1
3 4301151777 Spring Guide Pin Nos. 1
4 HSBA431859P0105 Grub Screw M12x25 Nos. 1

Main Assembly – VCB (4300003600)

C-63, Sector-57, Noida-201 307, U.P. (India)
Ph.: 0120-2479200, 2583545, 2583546; Fax : 0120-2583542
E-mail : info@autometers.com; Web site : www.autometers.com
(Technical Modifications Reserved) [ March 2012 ]

[ OM-VCB-01 Rev.01 ]

Manual VCB PDF

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Autometers Alliance Ltd [ OM-VCB-01 Rev.

AC VACUUM CIRCUIT BREAKER

OPERATION & MAINTENANCE MANUAL

Edition – March 2012

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 1 ]

 If you observe the recommendations contained in this << Operation &

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 2 ]

1. General Description .......................................................................................................................................7

2. Part List ........................................................................................................................................... 31

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 3 ]

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 4 ]

4.10 Tool List for VCB ............................................................................................................................. 113

5. Testing .......................................................................................................................................... 119

6. Spare Parts .......................................................................................................................................... 129

7. Other Spares .......................................................................................................................................... 135

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 5 ]

Main Assembly – VCB

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 6 ]

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 7 ]

The distinguishing features of the circuit breaker are:

 Its vacuum switch tube (VST)

 Its electro-pneumatic control

 A high degree of insensitivity to climatic conditions

 High rupture capacity

The device complies with IEC-60077 recommendations.

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 8 ]

1. The upper part, which is the high voltage circuit (HT)

2. The intermediate part, which assures isolation from earth

1.2.1 Upper Part

It is outside the vehicle, on the roof, and comprises:

 A horizontal ceramic insulator (HI) which is fixed

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 9 ]

1.2.2 Intermediate Part

1.2.3 Lower Part

(a) The Pneumatic Circuit

 Air inlet connector (C)

 An air pressure regulator with filter (FR)

(b) The Drive Mechanism

 Pneumatic cylinder (PN)

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 10 ]

(c) The Auxiliary Circuit (LT)

 An electro-pneumatic valve assuring closing and opening function.

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 11 ]

1.3.1 Closing of VCB

(a) VCB Open (Figure-1.3)

 Status of VCB in open condition.

(b) Order (Pulse) to Close the VCB (Figure-1.3 & Figure-1.4)

 Energizing of the electro-pneumatic valve solenoid coil.

 Operating of the electro-pneumatic valve (EP).

 Air flows from air tank (AR) to the piston drive.

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 12 ]

(c) Mechanism Movement (Figure-1.3, Figure-1.4 & Figure-1.5)

 Closing of the main contacts inside the vacuum bottle.

(d) Holding of VCB in Close Position (Figure - 1.5)

 Holding of VCB in close position is achieved by the compressed air.

 VCB switched ON.

1.3.2 Opening of VCB

(a) VCB Closed (Figure-1.5)

 Status of VCB in close condition.

(b) Interruption of Current Supply of EP Valve Solenoid Coil

C:\Users\AAL\Documents\VCB\Manual-VCB (New) March 2012 - RND - Copy.doc [ Page 13 ]

 Exhaust of compressed air available in pneumatic cylinder (PN).

(c) Rapid Movement of Piston (Figure - 1.7)