I 750-310
Revision: July 2007
Supersedes: June 2007
VBM Fault Interrupter
Instructions
THREE PHASE
15kV/25kV Grounded 400A
15kV/25kV Grounded 600A
ONE POLE*
38kV 400A
38kV 600A
48.5kV 200A
THREE PHASE
25kV 200A
25kV 300A
25kV 400A
THREE PHASE
38kV 300A
ONE POLE*
48.5kV 300A
48.5kV 400A
(with longer insulators)
*Three poles required for a three phase installation.
Joslyn Hi-Voltage
4000 E. 116th St.
Cleveland, OH 44105
Ph (216) 271-6600 Fax (216) 341-3615
Email: info@joslynhv.com
www.joslynhivoltage.com
ONE POLE*
72.5kV 300A
VBM Instruction Manual
I 750-310
TABLE OF CONTENTS:
I. Safety ........................................................................................................... 4
Hazard Statement Definitions..................................................................................................................... 4
II. General ....................................................................................................... 5
Description ................................................................................................................................................. 5
III. Installation ................................................................................................ 7
Inspection and Uncrating............................................................................................................................ 7
Mounting .................................................................................................................................................... 8
Clearance Requirements............................................................................................................................. 9
Clearance Requirements - Continued ....................................................................................................... 10
Control Voltage ........................................................................................................................................ 11
Control Wiring ......................................................................................................................................... 12
High Voltage Connections ....................................................................................................................... 12
VACSTATTM Operational Information.................................................................................................... 13
Vacuum Interrupter Integrity Test............................................................................................................ 14
High Potential Withstand ......................................................................................................................... 14
Vacuum Contact Resistance Test ............................................................................................................. 15
IV. Servicing ................................................................................................. 16
Tools Required ......................................................................................................................................... 16
Replacement Parts .................................................................................................................................... 17
Removal and Replacement of the Housing Cover and Breather Bag....................................................... 17
Removal and Replacement of a Vacuum Module Assembly ................................................................... 20
Synchronization of Replacement Module Assembly ............................................................................... 25
Switch Operators ...................................................................................................................................... 28
The Solenoid Operator ......................................................................................................................... 28
The Motor Operator ............................................................................................................................. 30
Servicing – Electrical ............................................................................................................................... 32
Removal and Installation of Control Assembly - Brief ........................................................................ 32
Installation of Control Assembly - Detailed......................................................................................... 33
Servicing – Mechanical ............................................................................................................................ 35
Install Motor Mechanism ..................................................................................................................... 35
Install and Pre-adjust two Power springs into the assembly. ............................................................... 37
Setup tripping. ...................................................................................................................................... 39
Replacement of Motor.............................................................................................................................. 42
Auxiliary Switch Adjustment ................................................................................................................... 43
V. Switches Rated 1,000 Amperes and Higher ............................................ 45
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TABLE OF FIGURES:
Figure 1: Diagram VBM Switch .................................................................................................................... 5
Figure 2: Cutaway Drawing of a Single Vacuum Module on 15kV Line-to-Ground Insulator.................... 5
Figure 3: VBM Switch with VACSTATTM vacuum monitor ........................................................................ 6
Figure 4a: Motor Operator
Figure 4b: Solenoid Operator ...................................................................... 7
Figure 5: Typical Erecting Sling .................................................................................................................... 8
Figure 6a: 32” Clearance Around Interrupters – Front View (38 kV Single Phase shown) ......................... 9
Figure 6b: 32” Clearance Around Interrupters - Side View.......................................................................... 9
Figure 7: Terminal Pad Diagram.................................................................................................................. 12
Figure 8: VACSTATTM Operational Information ........................................................................................ 13
Figure 9: AC High Potential Test Set Connections...................................................................................... 14
Figure 10: Contact Resistance Test Connections ......................................................................................... 15
Figure 11: Replacement Module with Temporary Bolts .............................................................................. 22
Figure 12: Synchronization of Replacement Module Assembly .................................................................. 26
Figure 13: Description of Operation ............................................................................................................ 28
Figure 14: VBM Motor Operator Picture..................................................................................................... 30
Figure 15: VBM Motor Operator Diagram .................................................................................................. 31
Figure 16: Sequence of Motor Operation..................................................................................................... 31
Figure 17: Sequence of Motor Operation..................................................................................................... 31
Figure 18: Sequence of Motor Operation..................................................................................................... 31
Figure 19: Sequence of Motor Operation..................................................................................................... 32
Figure 23: Shim Placement .......................................................................................................................... 43
Figure 24: Auxiliary Switch Adjustment ..................................................................................................... 43
Figure 25: Auxiliary Switch Adjustment (Prior to 1997)............................................................................. 44
Figure 26: Wiring Harness and Auxiliary Contact Adjustment ................................................................... 45
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I. Safety
Hazard Statement Definitions
!
WARNING: Refers to hazards or unsafe practices which could result in
death, severe personal injury, or significant equipment damage.
!
CAUTION: Refers to hazards or unsafe practices which could result in
damage to equipment or in personal injury.
!
!
!
!
WARNING: Before installing, operating, maintaining, or testing this
equipment, carefully read and understand the contents of this manual.
Improper operation, handling, or maintenance can result in death, severe
personal injury, or equipment damage.
WARNING: This equipment is not intended to protect human life. Follow
all locally approved procedures and safety practices when installing or
operating this equipment. Failure to comply may result in death, severe
personal injury and/or equipment damage.
WARNING: Hazardous voltage. Do not rely on the contact position
indicator to determine that the line has been de-energized. Always
establish a visible disconnect and establish person grounds when
performing de-energized line work. Failure to follow proper safety
practices can result in contact with high voltage, which can cause death or
severe personal injury.
WARNING: Hazardous voltage. Contact with high voltage will cause
serious personal injury or death. Follow all locally approved safety
procedures when working around high voltage lines and equipment.
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II. General
Description
The VBM switch is manufactured in voltage ratings from 15kV to 69kV with continuous
current capabilities from 200 amperes. The mechanism may be operated manually, or
electrically by solenoid or motor operators.
LINE-TO-GROUND
INSULATOR
CONTROL CABLE
CONNECTOR
VACUUM
MODULE
PAIR
ASSEMBLY
SINGLE
VACUUM
MODULE
MECHANISM
HOUSING
UPPER
MODULE
LOWER
MODULE
POSITION
INDICATOR
OPERATING HANDLE
BREATHER
BAG COVER
MECHANISM COVER
Figure 1: Diagram VBM Switch
The assembly containing the vacuum interrupter is called a module (Figure 2). Each
module has a vacuum interrupter contact sealed in Joslyte, a solidified foam which
provides mechanical strength, high dielectric strength and complete moisture sealing. The
module housings are cycloalephetic or EPR rubber bonded to a fiberglass tube. One or
two modules are mounted on each insulator and connected to the mechanism by a high
strength pull rod.
Figure 2: Cutaway Drawing of a Single Vacuum Module
on 15kV Line-to-Ground Insulator
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Optional VACSTATTM feature
The VBM is also available with a new feature, the VACSTATTM vacuum interrupter
monitor. This feature will monitor the vacuum inside each interrupter assembly. If loss
of vacuum is detected, a flag type indicator will rotate to indicate the loss of vacuum. In
addition, a relay will be energized that will block all close and trip operations. A second
relay will also be energized and close its normally open contacts. The two wire output of
this dry contact status signal is available for remote signaling if a loss of vacuum occurs.
See Figure 8 on Page 13 for a more detailed description of VACSTATTM operation.
The cutaway drawing
shows the placement of
the vacuum sensor. It is
connected via fiberoptic cable to a control
board located in the
base of the unit.
Flag type indicator.
Normally dark.
Shows Orange on
loss of vacuum.
Figure 3: VBM Switch with VACSTATTM vacuum monitor
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The VBM is offered with two types of mechanisms: motor and solenoid.
Figure 4a: Motor Operator
Figure 4b: Solenoid Operator
(For single mechanism switches only)
The completely sealed operating mechanism housing supports line-to-ground insulators
and the modules. An expansion bag in the housing prevents “breathing-in” contaminants
or moisture and contains a desiccant package to maintain dry air.
All electrical control connections to the mechanisms are made through a single
environmental control cable connector.
An “Open-Closed” position indicator is directly coupled to the mechanism. A separate
operating crank enables manual operation of the switch. The entire assembly can
withstand several G’s without damage. Depending upon rating there may be one or more
mechanisms for a three-phase switch.
III. Installation
Inspection and Uncrating
Carefully inspect the equipment on arrival. Contact carrier and file a claim if damaged
during shipment. Remove crating or carton surrounding the VBM switch. Do not unbolt
switch from the wooden base to prevent accidental contact from knocking over switch.
Consult the factory if VBMs with multiple interrupters (Figures 6d thru 6h) are being
installed in a metal enclosure. An indoor RC network option can be supplied to reduce
the 32” requirement to standard clearances.
!
CAUTION: PERFORM A VACUUM INTERRUPTER INTEGRITY TEST
DESCRIBED IN THIS SECTION, PRIOR TO PUTTING EQUIPMENT INTO
SERVICE.
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Mounting
Attach an erecting sling to each mechanism as shown in Figure 5. Make certain the lift is
stabilized. Remove the three nuts holding VBM to wooden base. Hoist the switch to its
mounting location with the manual operating handle facing the desired direction. Fasten
the VBM to its mounting with three 5/8” bolts and remove the erecting sling.
CAUTION
The two boards shown are for
stabilization only. Be careful
that the sling exerts no forces
on the vacuum contacts or
insulators.
CAUTION
Do not lift from terminal pads
Figure 5: Typical Erecting Sling
!
CAUTION: THE STRUCTURE AND VBM MECHANISM HOUSING MUST
BE SOLIDLY GROUNDED.
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Clearance Requirements
NOTE: For switches with multiple vacuum interrupters in series, a 32 inch (81.3 mm)
clearance must be maintained from all switch line parts to adjacent equipment (bus,
reactors, CT’s, transformers, frames). This also includes the high voltage conductors,
which must run horizontally for at least 32 inches before bending upwards.
Failure to meet this clearance requirement will adversely affect the electrical voltage
distribution and electromagnetic field within the interrupters during opening and closing
operations. This insufficient clearance can prevent proper interruption within the vacuum
switch interrupters resulting in undesirable restrikes during opening operations for some
application parameters.
Incorrect!
Conductor
within 32 inch
area.
32”
32”
32”
Correct.
Conductor
outside 32 inch
area.
2 Interrupters in
series (with bus
bar)
32”
32”
Figure 6a: 32” Clearance Around Interrupters – Front View (38 kV Single Phase shown)
32”
32”
32”
Figure 6b: 32” Clearance Around Interrupters - Side View
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Clearance Requirements - Continued
The 32 inch requirement does NOT apply to switches with only 1 interrupter per phase,
as shown in Figure 6c below. All other configurations shown must maintain a 32 inch
clearance from adjacent objects, as previously stated.
NO Clearance
Requirement!
(Only 1 interrupter
per phase)
Figure 6c: 15kV/25kV 3 Phase Ungrounded
Figure 6d: 25kV 3 Phase
32 Inch Clearance
Requirement!
(2 or more
interrupters per
phase)
32 Inch Clearance
Requirement!
(2 or more
interrupters per
phase)
Figure 6e: 38kV 3 Phase
Figure 6f: 48.5 kV Single Phase
Figure 6g: 69kV Single Phase
Figure 6h: Double-Stack Interrupters
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Control Voltage
A variety of control voltage options are available. Refer to the table below.
Control
Voltage
48 VDC
125 VDC
120 VAC
250 VDC
Note 1:
Note 2:
Note 3:
Note 4:
Operating
Mechanism
Motor1
Solenoid4
Reclosing
Motor1
Solenoid
Reclosing
Motor1
Solenoid
Reclosing
Solenoid
Control Current
Per Switch
Mechanism
3 amps
60 amps3,4
7 amps
4 amps
60 amps2
7 amps
5 amps
60 amps3,4
7 amps
60 amps
Close Time
Trip Time
5 sec
6 cycles
6 cycles
3 sec
6 cycles
6 cycles
3 sec
6 cycles
5 cycles
6 cycles
2 cycles
6 cycles
3 cycles
2 cycles
6 cycles
3 cycles
2 cycles
6 cycles
3 cycles
6 cycles
Motor operating mechanisms are designed for single mechanism switches.
Current is 60 amperes peak for one, two, or three mechanism switch systems.
Current is 120 amperes for 34.5kV 300A VBM.
Current for three mechanism switch systems is approximately 180 amperes.
Control power must meet the requirements of the drawing supplied with the switch. Refer
to the appropriate power input tables for proper requirements.
Solenoid Operated Switches
Direct Energy DC Operated VBM Switch
Direct Energy AC Operated VBM Switch
3045A0176
3045A0169
Motor Operated Switches
5A max during operation
!
CAUTION: FAILURE TO COMPLY WITH THE CONTROL POWER AND
WIRING REQUIREMENTS MAY RESULT IN SWITCH MALFUNCTION
OR DAMAGE.
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Control Wiring
All control connections to the VBM switch are made through either of the following
methods:
a.
Environmental cable and connector. The cable may be shortened to
desired length if supplied with a connector on the switch end only.
NOTE: For multiple mechanism switches, all cable lengths should be
cut to the same length. Connection to the control enclosure must be in
accordance with the specific wiring diagram for the system supplied.
b.
A junction box mounted on the housing wired to the mechanism
through conduit.
High Voltage Connections
The terminal pads are aluminum alloy with standard NEMA two-hole drilling. The
electrical connection at the terminal pad must be treated with Alcoa No. 2 joint
compound or equivalent. Remove brown paper from terminal pad before making
electrical connections. Wire brushing through the compound will improve the
connection.
1 ¾”
[44mm]
½” [13mm]
Figure 7: Terminal Pad Diagram
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VACSTATTM Operational Information
For VBM’s that have the optional VACSTAT vacuum monitor, the PC board shown in Figure 8
is added inside the VBM. This PC board will send a signal via fiber optic lines to each vacuum
interrupter. If the interrupter has vacuum, the signal will be returned. In the event of a loss of
vacuum on any interrupter, the signal will not be returned, indicating that a loss of vacuum has
occurred. The 74 Relay (located next to the PC board inside the VBM) will then energize and
open the circuits to the Close and Trip solenoids. The Flag Indicator will rotate and the 74-1
Relay will close its contacts for remote indication. Note: The 74-1 Relay is not available for all
configurations.
There is a Test switch on the PC board that will simulate a vacuum loss to test all indicators and
relay operation. The Reset switch will clear the faulted condition.
There are 3 red LED’s on the board that will provide the vacuum status of each phase. A fault
will cause the LED to turn on. A blinking red LED indicates an intermittent or poor fiber optic
connection.
On power up, the Flag indicator will rotate to show a “Faulted” condition, and then back to
“Normal”. The 74 Relays will NOT change state during the initialization sequence.
In the event of a power loss to the board, the Flag Indicator will remain as it was prior to the
power loss. That is, if it was showing a Fault, the indication will remain. On power up, it will still
go through the initialization sequence but will change back to the “Faulted” state.
Green LED
Flashing = OK
Off or On Steady = Not OK
Flag Indicator. Faulted condition shown.
Shielded Cable
Test
Switch
Phase A
Vacuum
Module
74 Relay
Reset
Switch
Close and Trip
Blocking Contactor
(Located inside VBM)
Fiber Optic
Receive
Phase B
Vacuum
Module
*74-1 Relay Output
(+) AC/DC Input
74-1 Relay
(-) (Power supplied
by Control or VBM)
Phase C
Vacuum
Module
PN 3187A0000
3
*74-1 Relay Detail
N.O. Dry Contacts.
Will close on loss of vacuum.
Contacts rated 120 VAC, 10 A
1
Fiber Optic
Transmit
Red LED’s
On Steady = Loss of
vacuum in interrupter.
Blinking = Loose connection
3 phase or 1
phase selection
jumper.
Caution. Use care when working
around the fiber optic lines. They
are fragile. Do NOT bend them
sharply or they may break.
Figure 8: VACSTATTM Operational Information
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Vacuum Interrupter Integrity Test
Two tests, high potential withstand and contact resistance, may be performed to evaluate
the vacuum contacts. They should be performed across each module separately. Figure 6
indicates connection points for vacuum module assemblies.
High Potential Withstand
!
WARNING: DISCONNECT ANY HIGH VOLTAGE CONNECTIONS TO
THE SWITCH PRIOR TO HIGH POTENTIAL TESTING.
30kV
AC
30kV
AC
AC HighPotential Test Set
Test Performed with switch in OPEN position
Figure 9: AC High Potential Test Set Connections
NOTE: Test each module separately
Loss of vacuum results in complete breakdown across an open vacuum contact at
voltages below 30kV RMS. Only AC high potential testing is meaningful. DC testing
cannot be used. Apply 30kV RMS across each individual contact for 15 seconds with the
switch open. To avoid possible generation of X-rays, do not apply more than 30kV RMS.
During the high potential testing, self-extinguishing, momentary breakdowns lasting only
a few microseconds may occur. These “barnacles” are not significant but can result in
false indication of vacuum loss, if the test set utilizes a high speed overload relay or
breaker.
During normal operation with the switch in service, loss of vacuum or a defective switch
module may be indicated by excessive radio noise with the switch open or observation of
different surface temperatures of modules on the same switch. See Joslyn Engineering
Memo TD 750-918.
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Vacuum Contact Resistance Test
MicroOhm
Meter
MicroOhm
Meter
Test Performed with switch in Closed position
Figure 10: Contact Resistance Test Connections
NOTE: Test each module separately
With the switch closed, the resistance across each module should be less than 200 microohms. On switches with modules connected in parallel for higher current operation,
remove the connecting bus to perform this test. If higher resistance values are measured
contact Joslyn Hi-Voltage.
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IV. Servicing
Tools Required
Servicing of VBM switches is easily accomplished by referring to the appropriate section
of these instructions. The following tools are required:
3090X0014G1 VBM Adjustment and Repair Kit
The kit above includes the following items:
PART NUMBER
DESCRIPTION
3090X0014P1
Brightstar 1618CT Magnet Flashlight
3090X0014P3
Mounting Fixture 3090B0005G2
3090X0014P5
Starrett Indicator
3090X0014P7
Torque Wrench (10-200 in-lbs.) 3/8 drive
3090X0014P8
Torque Wrench Preset – 50 in. lbs.
3090X0014P11
1/2-3/8” Drive
3090X0014P12
5/16” Wrench
3090X0014P13
7/16-3/8” Socket
3090X0014P14
3/8” Wrench
3090X0014P15
Phillips No. 3 Screwdriver
3090X0014P16
Flat Tip 1/8” Screwdriver
3090X0014P17
7/16” Wrench
3090X0014P18
9/16” Wrench
3090X0014P19
3/4” Wrench
3090X0014P21
Tool Box
3090X0014P22
3/16” Allen Socket
3090X0014P23
Dow Corning
3090X0014P25
Adjustment Gauge 1 degree
3090X0014P26
Go-No-Go Gauge 3090A0012P1
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Micro ohm meter
30kV AC
High Potential Test Set
3070A0244P2
Replacement Parts
Replacement parts are available from our factory in Cleveland, Ohio. Furnish complete
nameplate data and the Joslyn Hi-Voltage GO order number applying to the original
purchase, along with description of the part and quantity required.
Removal and Replacement of the Housing Cover and Breather Bag
The parts necessary to replace the breather bag are as follows:
Breather Bag
Desiccant Bag
17
Clamping Plate
VBM Instruction Manual
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1. Place the switch on a table or use a stand to access the bottom of the switch.
Remove the ten (10) or twelve (12) screws that hold the mechanism cover to the
switch base.
2. Remove three (3) cover screws from breather bag cover.
¼”-20 x 5/8 plastic screw
¼” self tapping screw
Screws
3. Remove breather bag cover.
4. To remove breather bag, turn base over and remove 7/16” nut leaving the holes
exposed. Turn base back over to and remove breather bag.
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5. To install new breather bag, put desiccant bag inside breather bag.
6. Put clamping plate into breather bag with beveled side facing inside the bag. The
flange of the clamping plate and breather bag MUST be aligned properly otherwise it will
not seal.
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7. Place bolt back through the center hole and attach breather bag by screwing the 7/16”
bolt. Make sure the breather bag is sealed around clamping plate.
8. Replace breather bag cover by tightening the three screws.
9. Replace mechanism cover to the base of the switch by securing the ten or twelve cover
screws.
Removal and Replacement of a Vacuum Module Assembly
Removal
One or two modules are mounted on each insulator depending on switch rating. Module
pair assemblies should not be separated in the field because special tools are required for
assembly and adjustment. Furthermore, if a switch’s breather bag ruptures, all vacuum
modules on that switch must be replaced.
To remove a module assembly, disconnect all power from the VBM and remove the
mechanism cover.
1. Place the switch on a table or use a stand to access the bottom of the switch. Remove
the ten (10) or twelve (12) screws that hold the mechanism cover to the switch base and
remove the cover.
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Screws
2. Disconnect pull rod from the switch mechanism by removing two bolts and washer
plates.
Caution. For VBM’s with
VACSTATTM, Use care when
working around the fiber optic
lines. They are fragile. Do NOT
bend them sharply or they may
break.
3.Remove four bolts at top of insulator and lift module assembly complete with lower
terminal pad and pull rod from the insulator. Insulators may be removed by taking out
four cap screws holding them to switch base.
Preparation of the Replacement Module Assembly
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1. Remove the bolts temporarily holding the lower terminal plate to single replacement
modules.
Temporary
Bolts
Figure 11: Replacement Module with Temporary Bolts
2. Apply silicone grease (Dow Corning DC III or equivalent) to gasket channel and reuse
rubber gasket if in good condition.
!
CAUTION: WITH THE BOLTS REMOVED, EXTREME CARE
MUST BE USED NOT TO PUT ANY FORCE WHATSOEVER ON
THE LOOSE TERMINAL PAD SINCE THIS FORCE WOULD BE
DIRECTLY TRANSMITTED TO THE DELICATE BELLOWS OF
THE VACUUM MODULES. ANY TWISTING COULD RESULT IN
IMMEDIATE LOSS OF VACUUM.
3. Attach pullrod to the vacuum module. The double module assembly consists of two
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modules in series, an upper terminal plate and a lower terminal. It should not be
disassembled. The single module and module pair assemblies are mounted in the same
manner. An aluminum clevis link may be bolted in the mechanism end of replacement
pull rods. If so, remove the aluminum clevis link and discard it. DO NOT attempt to
replace the link already in the mechanism.
All single replacement modules are supplied with a separate “screw-on” pull rod. It is
installed by slowly screwing onto the bolt in base of the module. Stop as thread bottoms
to avoid putting any stress or strain on the vacuum contact. Back the rod off a maximum
of one turn as required to mate with the clevis link on mechanism.
NOTE: Do not overtighten pull rod to module.
Earlier modules utilized either a permanently attached pull rod or a “screw-in” design. To
replace a “screw-in” pull rod, slip the 1” nylon bushing supplied over the bolt end of the
rod and slowly screw into the threaded module base. Stop as thread bottoms and back rod
out approximately three full turns as required for proper orientation with the mechanism.
Double module assemblies of the present design utilize a pull rod which is bolted to a
draw bar in the lower module. All necessary hardware is supplied with replacement
double module assemblies. The former design utilized a “screw-on” pull rod system.
All module assemblies are interchangeable and may be used on the same mechanism,
regardless of type of pull rod, however using a present and former design double module
pair assembly on the same mechanism requires special considerations. If this situation is
required, contact Joslyn Hi-Voltage.
!
CAUTION: BUMPING OR TWISTING ANY PULL ROD WHEN
ATTACHED TO A MODULE CAN DAMAGE THE VACUUM
INTERRUPTER AND REDUCE ITS LIFE.
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Mounting the Replacement Module Assembly
Insert pull rod through insulator with module terminals in proper position. Fasten the
replacement module to insulator with the ¼-20 x 2 ½” bolts, nuts, and washers from the
original module. Tighten the bolts evenly.
In mounting insulators and vacuum switch modules,
particular attention should be paid to torque values. If
a bolt head or nut bears on porcelain it should be
torqued to 25 inch-pounds, otherwise torque to 50
inch-pounds.
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With switch mechanism closed, attach pull rod to the steel clevis link of the mechanism
with ¼-20 x 1” stainless steel bolts, nuts, and lockwashers placed outside the pull rod
side pieces. Do not tighten the nuts to facilitate adjustment/synchronization.
Synchronization of Replacement Module Assembly
Operation of a replacement module assembly must be synchronized with other module
assemblies on the mechanism. Module pair assemblies are synchronized using the lower
contacts only. Synchronization refers to the difference in over-travel of modules (or
lower contacts of module pair assemblies) on the same operating mechanism. Although
the actual over-travel measurement can vary depending upon the ambient temperature,
synchronization is not affected by the ambient temperature.
NOTE: Do not attempt to synchronize a lower module with an upper module on a
module pair assembly.
Caution. For VBM’s with
VACSTATTM, Use care when
working around the fiber optic
lines. They are fragile. Do NOT
bend them sharply or they may
break.
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Toggle Link
Toggle Link
Auxiliary Contact
Assembly
Dial Indicator
(Secure against bolt)
Toggle Link
Support Bar
Cable Connector
Screws
Open Stop
Bolts
Close Stop
Connecting Bolts
Figure 12: Synchronization of Replacement Module Assembly
1. Place the continuity lights across all modules connected to line-to-ground
insulators on the mechanism.
2. Attach a dial indicator to the mechanism to measure vertical movement of the
switch actuating bar. Joslyn recommends the dial gauge indicator be
positioned against the bolt head as indicated by the arrows in Figure 8. It is
shown out of position to enable photographing of other components.
3. Closed Position Initial Reference. Put switch in closed position. The close
stop should be positioned so that toggle links are toward the open position of
the switch.
If adjustment is necessary, loosen the clamping bolts, reposition, and retorque
to 120 inch-pounds. Adjust dial indicator to zero.
For VBMs with Standard Controls
The toggle links should be about 1 degree off vertical.
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For VBMs with Zero Voltage Closing Controls
The toggle links should be about 5 degrees off vertical.
1° [5° for ZVC applications]
4. Full Travel. Put switch in open position. Dial indicator should read 0.205”±
0.005”. If out of tolerance, adjust open stop. Refer to Figure 8. Retorque bolts
to 120 inch-pounds.
5. Over-travel. With switch in closed position, slowly move the mechanism
toward the open position with ¾” wrench on a toggle link. Observe the dial
gauge reading at which the continuity light(s) on the other module(s) goes out.
This movement measured is the “OVERTRAVEL”. At ambient temperatures
between 50°F and 80°F the lights should go out at 0.040” ± .004” travel.
Insert a spacer between the close stop and bumper to hold the mechanism at a
reading midpoint between opening readings of the two other module
assemblies, or at the same reading if there are only two module assemblies on
the mechanism. The spacer should be inserted on the opposite side from that
shown in Figure 4. Torque the connecting bolts on the replacement assembly
pull rod to 75 inch-pounds.
6. Synchronization. Remove the spacer and close the mechanism. Slowly open
the mechanism and observe the continuity lights. Note the dial readings at
which the replacement and adjacent modules open. The last light must go out
within .005” mechanism travel after the first light. If synchronization is not
achieved, loosen pull rod varying the “set” position in appropriate direction
until all single or lower contacts open within 0.005” of mechanism travel.
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7. After module pair assemblies have been synchronized using the lower
contacts only, the synchronization between upper and lower contacts should
be verified. The synchronization of upper and lower contacts is related to
ambient temperature. At temperatures between 50°F and 80°F the dial gauge
should measure a maximum of 0.010” travel of the actuating bar between the
opening of each lower contact and its corresponding upper contact.
Switch Operators
The Solenoid Operator
In the single solenoid operator, two solenoids, one for opening and one for closing are
used to move a toggle linkage over center releasing stored spring energy to open and
close the vacuum contacts. This operation is sequentially described in Figure 9.
VRL
IMPROPER
CONDITION
Toggle link is past
vertical away from
open position
PROPER
Closed position initial reference approximately 1° “toward” opening
“Toward OPEN”
SOLENOIDS
TOGGLE LINK – Rotates around A and is fastened to actuating bar at B.
CONTROL YOKE – Rotates around C.
ACTUATING BAR – Moves in arc around D and E.
DESCRIPTION OF OPERATION
1.Switch is open. Spring assembly connected between toggle link and control yoke holds open stop against bumper.
2. Control circuit energizes close solenoid. Actuating pin rotates control yoke clockwise until toggle link is over center.
3. Spring assembly pulls toggle link and actuating arm in counterclockwise arc until close stop and bumper engage. Vertical
movement of actuating bar raises pull rods and closes vacuum contacts.
4. When open solenoid is energized, the control yoke is rotated counterclockwise until the toggle link is over center and pulled
clockwise by the spring assembly. This returns the actuating bar to the original position, opening the vacuum contacts.
Figure 13: Description of Operation
Some solenoid operators use a double solenoid assembly which utilizes two solenoids
each for close and open operation. The operation and maintenance of the double
solenoid operator is similar to that described for the single solenoid operator. The
switch may be operated manually using a switch hook. An operating crank is located
on the switch housing. The crank ends are notched to receive a switch hook. To close
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the interrupter, place a switch hook in the notch above the words “push to close” and
push. This moves the toggle linkage over center, releasing spring energy to close the
contacts at high speed independent of speed at which the arm is pushed. To trip, or
open the interrupter, place the switch hook in the notch above the words “push to
open” and push.
a. Solenoid Assembly Replacement. Open splicing connectors on the yellow
solenoid wires. Leave wires as long as possible.
Nylon pin
Bolts
Remove four bolts (two visible in picture) and the solenoid assembly is released.
The following procedure is for Decco solenoids. Replacement solenoids are sold
as an assembly. Solenoid assembly can be replaced by removing the appropriate
bolts attaching the assembly to the mechanism. As the assembly is removed, the
nylon actuating pins will fall out. All bolts should be torqued to 70 inch-pounds.
In case of Namco solenoids, one or both solenoids can be replaced by removing
and replacing the appropriate bolts holding the assembly together, however
replacements solenoids are sold as an assembly. The nylon actuating pins will fall
out as the assembly is removed. All bolts should be torqued to 70 inch-pounds.
To remount the solenoid assembly, insert new nylon actuating pins and position
the assembly. Do not reuse old nylon pins. Torque four mounting bolts to 150
inch-pounds. Connect the four yellow solenoid coil leads to corresponding wires
using new insulated compression splices.
To insure operating components freedom of movement necessary to achieve
proper operation speed, use a feeler gauge to check pin gap of each actuating pin.
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The gap should be .070 and .090”. Manually change the switch position to check
opposite pins. Pin gap is adjusted by adding or removing flat washer shims under
nylon spacer sleeves.
The Motor Operator
A series motor drives a cam which loads a spring assembly. When the springs are fully
loaded, the cam releases a linkage closing the vacuum switch using one-half the energy in
the spring assembly. A low energy solenoid releases the remaining energy in the spring
assembly through the same linkage to open the interrupter. Operation is sequentially
described in the following figures. The design inherently prevents closing the switch,
unless sufficient energy to trip is stored in the spring assembly.
The motor consists of a mechanical energy storage assembly and a control assembly. The
control assembly is located in the base of the VBM switch. Connections to external
circuitry are made through a control cable with environmental connectors.
The VBM motor operator is designed to operate at 24VDC, 48VDC, 125VDC, or
120VAC depending upon application.
Figure 14: VBM Motor Operator Picture
(F) Environmental Connector
(G) Wiring Harness
(D) Auxiliary Switches (E) Screws (4)
Actuator Bar
(C) Cable Connector
(B3) Mounting Bolt
(B1) Mounting Bolt
Operating Lever Stops
(A) Relay Panel (Control Assembly)
Motor Operator
(B2) Mounting Bolt
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Figure 15: VBM Motor Operator Diagram
Description of Operation
The following figures illustrate the sequential operation of the assembly. The motor
operator lever is connected to the switch actuating bar at point M. The actuating bar
linkage is connected to the pull rods (not shown) of each module assembly.
1. Switch is open.
2. Toggle links P1 and P2 are in relaxed
position.
3. Spring assembly S1 is unloaded.
4. Cam is rotated counter-clockwise by motor or
manual pumping.
Figure 16: Sequence of Motor Operation
5. Lever is displaced in direction R1.
6. Spring assembly S1 is compressed storing
energy in springs.
7. Lever pulls toggle links P1 and P2 over center.
8. Toggle spring S2 brings toggle linkage in
extended position against stop.
9. The switch is open and the mechanism is ready to
close.
Figure 17: Sequence of Motor Operation
10. As spring assembly S1 is fully loaded the
cam releases lever and stops.
11. Lever pivots around fulcrum T. Pin R
moves in arc R2 and comes against motor
assembly chassis stop using ½ total
energy in spring assembly S1.
12. M is moved in arc M1. M’s displacement
moves the switch actuating bar and closes
the interrupter contacts.
Figure 18: Sequence of Motor Operation
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13. Switch is closed.
14. Solenoid exerts force U on lever V which
pivots on fulcrum W exerting force X on
toggle linkage P1 and P2.
15. Toggle link assembly is displaced. The
remaining ½ total energy S1 pulls lever
which pivots on fulcrum R.
16. M moves in arc M2 moving switch
actuating bar and opening contacts.
17. The switch is open.
Figure 19: Sequence of Motor Operation
Manual Operation
The switch may be operated manually using a switch hook. An operating crank is located
on the switch housing. The crank ends are notched to receive the switch hook. To close
the fault interrupter, place a switch hook in the notch above the words “Push to Close”
and pump. After approximately 25 strokes, the switch will close. A unique rotary clutch
allows strokes of any length to rotate the cam. A single swift push in the notch above the
words “Push to Open” will trip the switch.
NOTE: SLOWLY PUSHING THE HANDLE WILL NOT PROVIDE ENOUGH
ENERGY TO OPEN THE SWITCH.
Vacuum contact operating speed is independent of speed of manual activation.
Servicing – Electrical
Removal and Installation of Relay Panel - Brief
a. Relay panel (Figure 15):
Remove entire relay panel (A) by removing the mounting bolt (B1) and
disconnecting cable connector (C), trip coil leads, charging motor leads, and
install new relay panel.
b. Wiring harness (Figure 15):
Remove wiring harness by disconnecting cable connector (C) and remove
leads from terminals of auxiliary switch(es) (D). Remove four screws (E)
which hold the environmental connector (F) and pull wiring harness (G) out
of the housing.
To install wiring harness (G), clean surfaces of casting where connector
mounts. Apply a small amount of silicone grease to gasket of new connector.
Install new harness (G) and rewire.
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c. Auxiliary switch(es) (D) (Figure 15):
Refer to Auxiliary Switch Adjustment section.
Installation of Relay Panel - Detailed
Relay Panel Installation.
a.) Connect the motor wires to the Relay panel as shown in the picture below.
b.) Remove the bolt from the Motor mechanism assembly as shown in the picture
below.
Bolt
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Spacer
Shock absorber
Relay Panel
c.) Attach the assembly to the Motor mechanism assembly.
Torque bolt to
80 in-lb.
d.) Reinstall the bolt. Torque the bolt down to 80 in-lb.
e.) Tie the wire with Plastic Tie Rap as need to make it look neat in appearance.
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Plastic Tie Raps
Servicing – Mechanical
Install Motor Mechanism
a.) Attach the Motor Mechanism to the Linkage. Secure the assembly with two 3/816x3¼” bolts.
3/8-16x3¼" bolt
Motor mechanism
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b.) Attach the assembly to the actuating bars with a clevis pin. Secure the clevis pin
with three large nylon washers (two nylon washers on one side and one on the
other), and a cotter pin. Open the split end of the cotter pin.
Pin assembly
Close the cotter
pin as shown
c.) Using a hammer, pound the Roll pins, located on Mech. Plate, down until the Roll
pins is in the center of the mechanism.
Roll pin
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Punch
holder
Install and Pre-adjust two Power springs into the assembly.
d.) Install two power springs to the motor mechanism assembly. Secure the power
springs with ¼-20 jam nuts. Tighten the jam nut down until the end of the jam nut
is even with the end of the thread of the power spring.
¼-20 jam nut
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e.) Loosen up the ¼-20 nut of the power spring until there are 4 threads left between
the power spring and the nut.
f.) Torque the jam nut to 80-in-lb.
Torque to
80 in-lb.
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g.) Using a feeler gauge, adjust the gap on both of the stop bolts to 0.020”
Stop bolt
Setup tripping.
h.) Loosen Jam nut, located on the Trip Link, all the way.
Jam nut
Trip screw
i.) Turn the Trip Screw clockwise until it trips then back it off 2 full turns.
j.) Close the switch. Fine-tune the Trip screw until it trips. Turn the Trip Screw 5/8
to ¾ of a turn backward.
k.) Tighten the nut until no movement is allowed. Close the switch.
l.) Using Pin gauge, reset the Stop bolts at 0.020”
m.) Open the switch. Set the length of the Power Spring between 3” to 3 1/8”. Make
sure that both springs are set at the same length.
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Space washer
Set 3" to 3 1/8"
without the thickness
of the washers
Ruler
Torque the
jam nut to
80 in-lb.
n.) Check Cranks for number of strokes to manually close the switch.
o.) Turn the Shaft, at the bottom of the motor; to setup one Eccentric operated at a
time.
p.) Pull the crank to manually close the switch. It must be no more than 30 full
manual strokes before the switch is operated.
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q.) Set eccentrics by turning shaft of motor. Rotate shaft of motor to rotate eccentrics
180° using screwdriver. Reverse position and open switch. Close switch by
moving handle back and forth less than 30 times and set.
Cranks
Eccentrics
r.) Recheck the tightness of the setscrews on the motor mechanism assembly.
s.) Close the switch. Make sure that the Spring plates assembly is flat with the
Actuator bar.
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Spring Plates
assembly
Replacement of Motor
Not all motors are identical. When ordering replacement motors, the catalog number from
the VBM nameplate must be supplied. New control panel may be required for obsolete
motors.
1. Loosen bolts B1-B3. (Figure 15)
2. Remove three set screws (if present)
3. Disconnect push-on connectors of motor leads from relay.
4. Unbend locking straps and remove three set screws.
5. Remove motor.
6. Install motor using set screw.
7. Retighten bolts B1-B3. (Figure 15)
8. Install locking straps and nuts and set the set screws.
9. Bend corners of locking straps.
10. Connect push-on connectors of motor leads to relay.
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Auxiliary Switch Adjustment
Auxiliary Switch Adjustment (Switches Made After 1997)
While the switch is in the open position, place a shim with 0.100” thickness up
between the close bumper stop and casting. Close the switch using the manual
operating handle so shim is firmly held in place.
Shim (0.100” thickness)
Close Bumper Stop
Figure 20: Shim Placement
Move auxiliary switch contact bracket so the spring is completely depressing plungers of
auxiliary switch. Adjust the angle between spring and actuating bar to 88° to 90°.
Tighten bolts on contact bracket. Open switch with the manual operating handle and
remove the shim.
Auxiliary Contacts
Contact bracket
Spring
88° to 90° angle
Figure 21: Auxiliary Switch Adjustment
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Auxiliary Switch Adjustment (Switches Made Prior to 1997)
With mechanism in closed position, use a C-clamp to hold the operating crank to its
cover, so the crank cannot move from the closed position. Attach dial indicator and
set at zero. With a wrench on toggle link move the mechanism toward the open
position. The auxiliary switch should operate at or before 0.175” vertical movement
is indicated. Slowly return mechanism to closed position. The auxiliary switch should
operate before the mechanism has returned to within 0.025” of the fully closed
position. If adjustment is not correct, release bolts and reposition bracket in
appropriate direction. Retighten the bolts and recheck operation. Repeat until
auxiliary switch operations occur within the allowable range. Tighten bolts to 70
inch-pounds.
Switch Bracket
Gasket
Cable Connector
Auxiliary Switch
Toggle
Link
Dial Indicator
Figure 22: Auxiliary Switch Adjustment (Prior to 1997)
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Wiring Harness and Auxiliary Contact Replacement (Switches Made Prior to 1997)
The auxiliary switch (8) and cable connector (9) are integral parts of the wiring
harness assembly. The entire assembly must be removed as a unit. Open splicing
connectors on the four black solenoid wires. Remove the auxiliary switch bracket
(10) from the support bar (11). Remove four screws (12) which hold the
environmental control cable connector and pull wiring harness assembly out of
housing.
Figure 23: Wiring Harness and Auxiliary Contact Adjustment
To install wiring harness, clean surfaces of casting where connector mounts. Apply a
small amount of silicone grease (Dow Corning DC III or equivalent) to gasket (13) of
new connector. Install harness assembly, remount and adjust the auxiliary switch and
rewire.
See Auxiliary Switch Adjustment section to adjust properly.
V. Switches Rated 1,000 Amperes and Higher
These switches utilize modules connected in parallel. For some ratings, more than one
mechanism per pole is used. They are installed per instructions in Installation Section III
and connected per Joslyn Hi-Voltage drawings and control schematic for the particular
switch.
All servicing and testing is performed on separate mechanisms by removing the
connecting bus and referring to the appropriate section of these instructions.
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