I 750-310
Revision: February 2013
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.
8155 T&B Boulevard, Memphis, Tennessee 38125
Phone: 800.888.0211 Fax: 800.888.0690
T&B Utility: http://utility.tnb.com
JHV: www.joslynhivoltage.com
ONE POLE*
72.5kV 300A
VBM Instruction Manual
I 750-310
TABLE OF CONTENTS:
I. Safety ..............................................................................................................................6
A. Hazard Statement Definitions .........................................................................................................................................6
II. General ..........................................................................................................................7
A. Description .....................................................................................................................................................................7
B. Switches Rated 1,000 Amperes and Higher....................................................................................................................8
C. Operating Mechanisms ...................................................................................................................................................8
1. Solenoid Operator .......................................................................................................................................................9
a) Description of Operation..........................................................................................................................................9
b) Manual Operation...................................................................................................................................................10
2. Motor Operator .........................................................................................................................................................10
a) Description of Operation........................................................................................................................................10
b) Manual Operation...................................................................................................................................................12
D. Optional VACSTATTM feature .....................................................................................................................................12
1. Description of Operation...........................................................................................................................................12
III. Installation..................................................................................................................14
A.
B.
C.
D.
E.
F.
G.
Inspection and Uncrating ..............................................................................................................................................14
Mounting ......................................................................................................................................................................14
Clearance Requirements ...............................................................................................................................................15
Control Voltage ............................................................................................................................................................17
Control Wiring..............................................................................................................................................................17
High Voltage Connections............................................................................................................................................18
Vacuum Interrupter Integrity Test ................................................................................................................................18
1. High Potential Withstand ..........................................................................................................................................19
2. Vacuum Contact Resistance Test ..............................................................................................................................20
IV. Servicing ....................................................................................................................21
A. Tools Required .............................................................................................................................................................21
B. Replacement Parts ........................................................................................................................................................22
C. Servicing Housing Cover and Breather Bag .................................................................................................................23
1. Removal ....................................................................................................................................................................23
2. Installation.................................................................................................................................................................25
D. Servicing Vacuum Module Assembly...........................................................................................................................26
1. Removal.....................................................................................................................................................................27
2. Preparation.................................................................................................................................................................28
3. Mounting....................................................................................................................................................................29
E. Servicing Solenoid Switch Operator.............................................................................................................................31
1. Solenoid Assembly Replacement...............................................................................................................................31
a) Pin Gap Setting Procedure .....................................................................................................................................32
F. Servicing Motor Switch Operator .................................................................................................................................34
1. Servicing Motor Assembly - Mechanical...................................................................................................................34
a) Installation..............................................................................................................................................................34
b) Charging Springs Installation and Adjustment .......................................................................................................36
c) Tripping Setup........................................................................................................................................................38
2. Replacing Motor ........................................................................................................................................................41
3. Servicing Motor Assembly - Electrical ......................................................................................................................42
a) Removal and Installation of Relay Panel – Overview ............................................................................................42
b) Installation of Relay Panel – Detailed ....................................................................................................................43
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G. Synchronization of Replacement Module Assembly ....................................................................................................44
1. Toggle Link Setting Procedure ..................................................................................................................................45
a) Measuring Toggle Link Setting..............................................................................................................................45
b) Setting Toggle Link Requirements.........................................................................................................................45
2. Full Travel Setting Procedure ....................................................................................................................................48
a) Measuring Full Travel Setting................................................................................................................................48
b) Setting Full Travel Requirements...........................................................................................................................50
3. Overtravel Setting Procedure.....................................................................................................................................51
a) Measuring Overtravel Setting.................................................................................................................................51
b) Setting Overtravel Requirements............................................................................................................................52
4. Auxiliary Switch Adjustment.....................................................................................................................................55
a) Auxiliary Switch Adjustment (Switches Made After 1997) ...................................................................................55
b) Auxiliary Switch Adjustment (Switches Made Prior to 1997) ...............................................................................56
H. Wiring Harness and Auxiliary Contact Replacement (Switches Made Prior to 1997)..................................................57
V. Specifications ..............................................................................................................58
Appendix A ......................................................................................................................59
Manual Revision Notes .......................................................................................................................................................59
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VBM Instruction Manual
I 750-310
TABLE OF FIGURES:
Figure 1: Diagram VBM Switch............................................................................................................................................... 7
Figure 2: Cutaway of a Single Vacuum Module on 15kV Line-to-Ground Insulator ............................................................... 7
Figure 3: Solenoid Operator ..................................................................................................................................................... 8
Figure 4: Motor Operator ......................................................................................................................................................... 8
Figure 5: Solenoid Operated Mechanism Diagram................................................................................................................... 9
Figure 6: VBM Motor Operated Mechanism ......................................................................................................................... 10
Figure 7: Sequence of Motor Operations................................................................................................................................ 11
Figure 8: VBM Switch with VACSTATTM vacuum monitor.................................................................................................. 12
Figure 9: VACSTATTM Operational Information................................................................................................................... 13
Figure 10: Typical Erecting Sling........................................................................................................................................... 14
Figure 11: 32” Clearance Around Interrupters - Front View (38 kV Single Phase shown) .................................................... 15
Figure 12: 32” Clearance Around Interrupters - Side View ................................................................................................... 15
Figure 13: 15kV/25kV 3 Phase Ungrounded.......................................................................................................................... 16
Figure 14: 25kV 3 Phase ........................................................................................................................................................ 16
Figure 15: 38kV 3 Phase ........................................................................................................................................................ 16
Figure 16: 48.5kV Single Phase ............................................................................................................................................. 16
Figure 17: 69kV Single Phase ................................................................................................................................................ 16
Figure 18: Double-Stack Interrupters ..................................................................................................................................... 16
Figure 19: Terminal Pad Diagram .......................................................................................................................................... 18
Figure 20: VBM Test Equipment ........................................................................................................................................... 18
Figure 21: AC High Potential Test Set Connections .............................................................................................................. 19
Figure 22: Contact Resistance Test Connections.................................................................................................................... 20
Figure 23: 3090X0014G1 VBM Adjustment and Repair Kit................................................................................................. 21
Figure 24: Breather Bag Replacement Parts........................................................................................................................... 23
Figure 25: Breathe Bag Cover and Screws............................................................................................................................. 23
Figure 26: Removing Breather Bag Cover ............................................................................................................................. 24
Figure 27: Removing Breather Bag........................................................................................................................................ 24
Figure 28: Placing Desiccant Bag into Breather Bag ............................................................................................................. 25
Figure 29: Attaching Clamping Plate to Breather Bag ........................................................................................................... 25
Figure 30: Attaching Breather Bag to VBM Cover ................................................................................................................ 26
Figure 31: Mechanism Cover and Screws .............................................................................................................................. 27
Figure 32: Disconnecting Pull Rod......................................................................................................................................... 27
Figure 33: Temporary Bolts and Replacement Module.......................................................................................................... 28
Figure 34: Replacement Module Preparation ......................................................................................................................... 28
Figure 35: Mounting VBM Module ....................................................................................................................................... 30
Figure 36: Fastening Insulators and Modules......................................................................................................................... 30
Figure 37: Attaching Pull Rod to Clevis Link ........................................................................................................................ 31
Figure 38: Solenoid Assembly................................................................................................................................................ 31
Figure 39: Inserting Feeler Gauge .......................................................................................................................................... 32
Figure 40: Flat Brass Washer and Pin Gap Location.............................................................................................................. 33
Figure 41: Attaching Motor Mechanism to Linkage............................................................................................................... 34
Figure 42: Attaching Assembly to Actuating Bars ................................................................................................................. 35
Figure 43: Attaching Roll Pins ............................................................................................................................................... 36
Figure 44: Installing Charging Springs................................................................................................................................... 36
Figure 45: Pre-adjusting Charging Springs............................................................................................................................. 37
Figure 46: Charging Spring and Jam Nut ............................................................................................................................... 37
Figure 47: Adjusting Stop Bolts ............................................................................................................................................. 37
Figure 48: Trip Link and Jam Nut .......................................................................................................................................... 38
Figure 49: Setting Power Springs Lengths ............................................................................................................................. 38
Figure 50: Turning Motor Shaft ............................................................................................................................................. 39
Figure 51: Setting Eccentrics.................................................................................................................................................. 39
Figure 52: Setscrews on Motor Mechanism Assembly........................................................................................................... 40
Figure 53: Spring Plates Assembly......................................................................................................................................... 40
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Figure 54: VBM Motor Operator Diagram ............................................................................................................................ 41
Figure 55: Relay Panel Assembly Diagram............................................................................................................................ 42
Figure 56: Motor Wires and Relay Panel ............................................................................................................................... 43
Figure 57: Relay Panel Assembly........................................................................................................................................... 43
Figure 58: Attaching Relay Panel Assembly .......................................................................................................................... 43
Figure 59: Tie Raped Wires and Relay Panel Assembly ........................................................................................................ 44
Figure 60: Toggle Link Adjustment ....................................................................................................................................... 45
Figure 61: Switch Indicator in Close Position ........................................................................................................................ 45
Figure 62: Location of the Close Bumper Stops..................................................................................................................... 46
Figure 63: Degree Guide Position .......................................................................................................................................... 46
Figure 64: Adjusting the Close Stop....................................................................................................................................... 47
Figure 65: Adjusting Screw.................................................................................................................................................... 47
Figure 66: Tightening the Bumper Stop ................................................................................................................................. 47
Figure 67: Position of Dial Indicator Gauge........................................................................................................................... 48
Figure 68: Actuating Rod/Arm and Dial Indicator Gauge...................................................................................................... 49
Figure 69: Switch Indicator in Open Position ........................................................................................................................ 49
Figure 70: Full Travel Value on Dial Indicator Gauge........................................................................................................... 49
Figure 71: Open Bumper Stop Assembly ............................................................................................................................... 50
Figure 72: Solenoid Operated VBM Mechanism ................................................................................................................... 51
Figure 73: VBM Mechanism with Dial Indicator................................................................................................................... 52
Figure 74: Wedge and Dial Indicator ..................................................................................................................................... 53
Figure 75: Pull Rod and Clevis............................................................................................................................................... 53
Figure 76: VBMs First-to-Last Synchronization .................................................................................................................... 54
Figure 77: VBM Module Pair Synchronization...................................................................................................................... 54
Figure 78: Shim Placement..................................................................................................................................................... 55
Figure 79: Auxiliary Switch Adjustment ................................................................................................................................ 55
Figure 80: Auxiliary Switch Adjustment (Prior to 1997) ....................................................................................................... 56
Figure 81: Wiring Harness and Auxiliary Contact Replacement............................................................................................ 57
TABLE OF TABLES:
Table 1: VBM Control Voltage Options ................................................................................................................................ 17
Table 2: VBM Adjustment and Repair Kits ........................................................................................................................... 21
Table 3: VBM Tools in a Kit (3090X0014G1) ...................................................................................................................... 22
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VBM Instruction Manual
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I. Safety
A. 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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VBM Instruction Manual
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II. General
A. 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.
BUS BAR
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.
Vacuum Contacts
High Voltage
Terminals
Solid Dielectric
Joslyte Insulation
Dead Soft
Copper Shunts
Porcelain Insulator
Insulated
Fiberglass Pull
Figure 2: Cutaway of a Single Vacuum Module on 15kV Line-to-Ground Insulator
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VBM Instruction Manual
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B. 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.
C. Operating Mechanisms
The VBM is offered with two types of mechanisms: solenoid and motor.
A solenoid mechanism has an expected maintenance-free life of 100,000 operations on AC and
15,000 operations on DC. Controls for solenoid operators are mounted in a separate enclosure.
A motor operator is only used on single-mechanism three-phase Varmaster VBM switches,
such as 15kV, 400 Amp and 600 Amp models and 34.5kV, 300 Amp models. All controls are
located inside the VBM mechanism housing. Inspection after 10,000 operations is
recommended.
Figure 3: Solenoid Operator
Figure 4: Motor 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.
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VBM Instruction Manual
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1. 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 Description of Operation
section.
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.
VRL
IMPROPER CONDITION
Toggle link is past vertical away from open position
“Toward OPEN”
Bumpers
C
Toggle Link
B
Control Yoke
Close Stop
Open Stop
E
Actuating Bar
Spacer Sleeves
Actuating Pin
Actuating Pin End
Play “Pin Gap”
A
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.
Figure 5: Solenoid Operated Mechanism Diagram
a) 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.
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VBM Instruction Manual
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b) 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 a switch hook. To
close 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.
2. 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 Description of Operation section. 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 6: VBM Motor Operated Mechanism
a) Description of Operation
The following Figure 7 illustrates 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.
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VBM Instruction Manual
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1.)
2.)
3.)
4.)
Switch is open.
Toggle links P1 and P2 are in relaxed position.
Spring assembly S1 is unloaded.
Cam is rotated counter-clockwise by motor or manual
pumping.
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.
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.
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 7: Sequence of Motor Operations
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b) 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. Vacuum contact operating speed is
independent of speed of manual activation.
NOTE: Slowly pushing the handle will NOT provide enough energy to open the switch.
D. 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.
The cutaway of a VBM Switch in Figure 8 shows the placement of the vacuum sensor. It is
connected via fiber-optic cable to a control board located in the base of the unit.
Refer to Figure 9 on the next page for a more detailed description of VACSTATTM operation.
Vacuum
Interrupter
Vacuum
Interrupter
Monitor
Normal
Alarmed
Figure 8: VBM Switch with VACSTATTM vacuum monitor
1. Description of Operation
For VBM’s that have the optional VACSTAT vacuum monitor, the PC board shown in
Figure 9 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
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VBM Instruction Manual
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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.
!
CAUTION: USE CARE WHEN WORKING AROUND THE FIBER OPTIC LINES. DO
NOT BEND THEM SHARPLY TO AVOID DAMAGING GLASS FIBER.
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
74-1 Relay
(+) AC/DC Input
(-) (Power supplied
by Control or VBM)
Phase C
Vacuum
Module
PN 3187A0000
3
1
Fiber Optic
Transmit
Red LED’s
On Steady = Loss of vacuum in interrupter.
Blinking = Loose connection
3 phase or 1
phase selection
jumper.
Figure 9: VACSTATTM Operational Information
13
*74-1 Relay Detail
N.O. Dry Contacts.
Will close on loss of vacuum.
Contacts rated 120 VAC, 10 A
VBM Instruction Manual
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III. Installation
A. 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 14 through 18) 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.
B. Mounting
Attach an erecting sling to each mechanism as shown in Figure 10. 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 10: Typical Erecting Sling
!
CAUTION: THE STRUCTURE AND VBM MECHANISM HOUSING MUST BE
SOLIDLY GROUNDED.
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C. 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 11: 32” Clearance Around Interrupters - Front View (38 kV Single Phase shown)
32”
32”
32”
Figure 12: 32” Clearance Around Interrupters - Side View
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VBM Instruction Manual
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The 32 inch requirement does NOT apply to switches with only 1 interrupter per phase, as
shown in Figure 13 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)
32”
32”
32”
32”
Figure 13: 15kV/25kV 3 Phase Ungrounded
32”
Figure 14: 25kV 3 Phase
32”
32”
32”
32”
32”
32”
32”
32”
32”
32”
Figure 15: 38kV 3 Phase
Figure 16: 48.5kV Single Phase
32”
32”
32”
32”
32”
32”
32”
Figure 17: 69kV Single Phase
32”
Figure 18: Double-Stack Interrupters
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D. 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
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
Table 1: VBM Control Voltage Options
NOTE 1:
NOTE 2:
NOTE 3:
NOTE 4:
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.
E. 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.
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b. A junction box mounted on the housing wired to the mechanism through conduit.
F. 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 19: Terminal Pad Diagram
G. 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. The following test
equipment is required:
30kV AC High Potential Test Set
3070A0244P2
Micro Ohm Meter
Figure 20: VBM Test Equipment
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1. High Potential Withstand
Figure 21 indicates connection points for vacuum module assemblies.
!
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 21: 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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2. Vacuum Contact Resistance Test
MicroOhm
Meter
MicroOhm
Meter
Test Performed with switch in Closed position
Figure 22: 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
A. Tools Required
Servicing of VBM switches is easily accomplished by referring to the appropriate section of
these instructions. One of the following VBM Adjustment and Repair Kits is required when
performing maintenance/repair on appropriate switch type:
KIT NUMBER
3090X0014G1
3090X0014G2
3090X0014G3
3090X0014G4
DESCRIPTRION
VBM (Standard)
VBM (⅜ Gap - Straight)
VBM (⅜ Gap - 20 Degree Angle)
VBM (ZVC)
Table 2: VBM Adjustment and Repair Kits
Figure 23: 3090X0014G1 VBM Adjustment and Repair Kit
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The kit above (Figure 23) includes the following items:
PART NUMBER
3090X0014P1
3090X0014P3
3090X0014P5
3090X0014P7
3090X0014P8
3090X0014P11
3090X0014P12
3090X0014P13
3090X0014P14
3090X0014P15
3090X0014P16
3090X0014P17
3090X0014P18
3090X0014P19
3090X0014P21
3090X0014P22
3090X0014P23
3090X0014P24
3090X0014P25
3090X0014P26
DESCRIPTION
Snap-On Flashlight
Mounting Fixture 3090B0005G2
Starrett Indicator
Torque Wrench (10-200 in-lbs.) 3/8 drive
Torque Wrench Preset – 50 in. lbs.
1/2-3/8” Drive
5/16” Wrench
7/16-3/8” Socket
3/8” Wrench
Phillips No. 3 Screwdriver
Flat Tip 1/8” Screwdriver
7/16” Wrench
9/16” Wrench
3/4” Wrench
Tool Box
3/16” Allen Socket
Dow Corning
Torque Wrench Preset – 25 in. lbs.
Adjustment Gauge 1 degree
Go-No-Go Gauge 3090A0012P1
Table 3: VBM Tools in a Kit (3090X0014G1)
Tool required not in the kit:

Synchronization Lamps (Sync Lamps) – required for continuity test
B. Replacement Parts
Replacement parts are available from our factory in Hackettstown, New Jersey. 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.
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C. Servicing Housing Cover and Breather Bag
The parts necessary to replace the breather bag are as follows:
Breather Bag
Desiccant Bag
Clamping Plate
Figure 24: Breather Bag Replacement Parts
1. Removal
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
Figure 25: Breathe Bag Cover and Screws
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3.) Remove breather bag cover.
Figure 26: Removing 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.
Figure 27: Removing Breather Bag
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2. Installation
1.) To install new breather bag, put desiccant bag inside breather bag.
Figure 28: Placing Desiccant Bag into Breather Bag
2.) 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.
Figure 29: Attaching Clamping Plate to Breather Bag
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3.) 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.
Figure 30: Attaching Breather Bag to VBM Cover
4.) Replace breather bag cover by tightening the three screws.
5.) Replace mechanism cover to the base of the switch by securing the ten or twelve cover
screws.
D. Servicing Vacuum Module Assembly
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.
Prior to the removal of a module assembly, disconnect all power from the VBM and remove the
mechanism cover.
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1. Removal
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.
Screws
Figure 31: Mechanism Cover and Screws
2.) Disconnect pull rod from the switch mechanism by removing two bolts and washer
plates.
Figure 32: Disconnecting Pull Rod
!
CAUTION: FOR VBM’S WITH VACSTAT, USE CARE WHEN WORKING AROUND
THE FIBER OPTIC LINES. DO NOT BEND THEM SHARPLY TO AVOID DAMAGING
GLASS FIBER.
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3.) Remove four bolts on top of the insulator that connect module to 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.
2. Preparation
1.) Remove the bolts temporarily holding the lower terminal plate to single replacement
modules.
Temporary
Bolts
Figure 33: Temporary Bolts and Replacement Module
2.) Apply silicone grease (Dow Corning DC III or equivalent) to gasket channel and reuse
rubber gasket if in good condition.
Figure 34: Replacement Module Preparation
!
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.
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3.) Attach pullrod to the vacuum module. The double module assembly consists of two
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.
3. Mounting
In mounting insulators and vacuum switch modules, particular attention should be paid to
torque values. If a bolt head or nut bears on epoxy or porcelain housing should be torqued to
25 inch-pounds, otherwise torque to 50 inch-pounds. (See Figure 36)
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1.) 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.
Figure 35: Mounting VBM Module
2.) Tighten the bolts evenly to the specified torque.
Epoxy or
Porcelain
Housing
Torque to
50-in-lb.
Torque to
25-in-lb.
VBM Base
Figure 36: Fastening Insulators and Modules
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3.) With switch mechanism closed, attach pull rod to the aluminum 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.
Figure 37: Attaching Pull Rod to Clevis Link
4.) Refer to Synchronization of Replacement Module Assembly section on Page 44 to
sync modules.
E. Servicing Solenoid Switch Operator
1. Solenoid Assembly Replacement
Refer to Servicing Housing Cover and Breather Bag section on Page 23 for instructions
regarding removal of housing cover. Once the cover is removed, refer to Figure 38 below
and follow the instructions on next page for removal and installation of Solenoid Assembly.
Splicing
Connectors
Nylon Pin
Bolts Torque to
70 in-lbs
Figure 38: Solenoid Assembly
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1.) Open splicing connectors on the yellow solenoid wires. Leave wires as long as possible.
2.) Remove four bolts (two visible in Figure 38) and the solenoid assembly is released.
Decco Solenoids
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.
Nemco Solenoids
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.
3.) To remount the solenoid assembly, insert new nylon actuating pins and position the
assembly. Do not reuse old nylon pins.
NOTE: To insure operating components freedom of movement necessary to achieve
proper operation speed, refer to next section on setting pin gap of each actuating pin.
4.) Connect the four yellow solenoid coil leads to corresponding wires using new insulated
compression splices.
NOTE: Refer to wiring diagram on switch nameplate for wiring details.
a) Pin Gap Setting Procedure
Solenoid Pin Gap Requirements = 0.070” – 0.090”
1.) Insert the Feeler Gauge (Part # 3090A0011) between the Solenoid actuating plunger
and the Nylon pin. The gauge will slide to a preset position on the device which will
represent the actual gap setting. The gap must be between 0.070” and 0.090”.
Feeler Gauge
Feeler Gauge: 0.070” and 0.090”
Figure 39: Inserting Feeler Gauge
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2.) Manually change switch position to check opposite pins.
3.) Pin gap is adjusted by adding or removing flat washer shims (Part # 9991542) under
nylon spacer sleeves.
4.) To add or remove washers the solenoid assemblies’ four (4) mounting bolts must be
removed.
If the gap is less than 0.070”, add brass flat washer into the assembly as needed.
If the gap is greater than 0.090”, take brass flat washers out of the assembly as
needed.
Location to add or
remove washers
Nylon Pin
Bolts
Torque to
70 in-lbs
Flat Brass Washer:
.620” OD x .255” ID x .010”
Figure 40: Flat Brass Washer and Pin Gap Location
5.) Tighten the bolts to 70 in-lbs.
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F. Servicing Motor Switch Operator
1. Servicing Motor Assembly - Mechanical
a) Installation
NOTE: Insure Switch is in Closed position.
1.) Attach the Motor Mechanism to the Linkage. Secure the assembly with two 3/816x3¼” bolts to temporarily hold mechanism in place.
3/8-16x3¼" bolt
Motor Mechanism
Figure 41: Attaching Motor Mechanism to Linkage
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2.) 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
Figure 42: Attaching Assembly to Actuating Bars
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3.) Remove the bolts and replace with Roll pins. 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
Punch Holder
Figure 43: Attaching Roll Pins
b) Charging Springs Installation and Adjustment
1.) 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
Figure 44: Installing Charging Springs
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2.) Loosen up the ¼-20 nut of the power spring until there are four (4) threads left
between the power spring and the nut.
Figure 45: Pre-adjusting Charging Springs
3.) Torque the jam nut to 80-in-lb.
Torque to
80 in-lb.
Figure 46: Charging Spring and Jam Nut
4.) Using a feeler gauge, adjust the gap on both of the stop bolts to 0.020”
Stop Bolt
Figure 47: Adjusting Stop Bolts
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c) Tripping Setup
1.) Loosen Jam nut, located on the Trip Link, all the way.
Jam Nut
Trip Screw
Figure 48: Trip Link and Jam Nut
2.) Turn the Trip Screw clockwise until the switch trips then back it off 2 full turns.
3.) Close the switch. Fine-tune the Trip screw exerting minimum upward pressure on
the screw until the switch trips. Turn the Trip Screw 5/8 to ¾ of a turn backward.
4.) Tighten the nut until no movement is allowed. Close the switch.
5.) Using Pin gauge, reset the Stop bolts at 0.020”
6.) 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.
Space Washer
Set 3" to 3 1/8"
without the thickness
of the washers
Torque the
Jam Nut to
80 in-lb.
Figure 49: Setting Power Springs Lengths
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7.) Check Cranks for number of strokes to manually close the switch.
8.) Turn the Shaft, at the bottom of the motor; to setup one Eccentric operated at a time.
Figure 50: Turning Motor Shaft
9.) Pull the crank to manually close the switch. It must be no more than 30 full manual
strokes before the switch is operated.
10.) 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
Figure 51: Setting Eccentrics
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11.) Recheck the tightness of the setscrews on the motor mechanism assembly.
Torque to
70 in-lb.
Figure 52: Setscrews on Motor Mechanism Assembly
12.) Close the switch. Make sure that the Spring Plates Assembly is flat with the
Actuator Bar.
Spring Plates
Assembly
Figure 53: Spring Plates Assembly
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2. Replacing 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.
(G) Wiring Harness
(D) Auxiliary Switches
(F) Environmental Connector
(E) Screws (4)
Actuator Bar
(C) Cable Connector
(B3) Mounting Bolt
(B1) Mounting Bolt
Operating Lever Stops
(A) Relay Panel (Control Assembly)
(B2) Mounting Bolt
Motor Operator
Figure 54: VBM Motor Operator Diagram
Refer to Figure 54 and follow steps below to replace motor assembly.
1.) Loosen bolts B1-B3. (Figure 54)
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 54)
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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3. Servicing Motor Assembly - Electrical
a) Removal and Installation of Relay Panel – Overview
Refer to Figure 55 and follow steps below for removal and installation of Relay Panel.
(G) Wiring Harness
(D) Auxiliary Switches
(F) Environmental Connector
(E) Screws (4)
(C) Cable Connector
Motor Operator
(B1) Mounting Bolt
(A) Relay Panel (Control Assembly)
Figure 55: Relay Panel Assembly Diagram
1.) 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.
2.) 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.
3.) 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.
NOTE: Refer to specific wiring diagram supplied with the switch. Check switch
nameplate for wiring diagram number.
4.) To adjust auxiliary switch(es) (D), see the Auxiliary Switch Adjustment section on
Page 55.
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b) Installation of Relay Panel – Detailed
1.) Connect the motor wires to the Relay panel as shown in the figure below.
Figure 56: Motor Wires and Relay Panel
2.) Remove the bolt from the Motor mechanism assembly as shown in the figure below.
Spacer
Bolt
Shock
Absorber
Relay Panel
Figure 57: Relay Panel Assembly
3.) Attach the assembly to the Motor mechanism assembly.
Torque Bolt to
80 in-lb.
Figure 58: Attaching Relay Panel Assembly
4.) Reinstall the bolt. Torque the bolt down to 80 in-lb.
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5.) Tie the wire with Plastic Tie Rap as need to make it look neat in appearance.
Plastic Tie Raps
Figure 59: Tie Raped Wires and Relay Panel Assembly
G. 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.
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. DO NOT BEND THEM SHARPLY TO AVOID
DAMAGING GLASS FIBER.
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1. Toggle Link Setting Procedure
Toggle Link Requirements
Standard Controls = 1 degree off vertical
ZVC Application = 5 – 6 degrees off vertical
a) Measuring Toggle Link Setting
5.) Place the VBM in the close position.
6.) Position the 1 (Standard) or 5-6 (ZVC) degree guide on linkage to confirm the guide
lines up tight against the linkage. If a gap is present, adjust the toggle per steps
below.
1 [5-6 for ZVC applications]
Figure 60: Toggle Link Adjustment
b) Setting Toggle Link Requirements
1.) Place the VBM in the close position.
Figure 61: Switch Indicator in Close Position
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2.) Loosen the close bumper stop.
Close Bumper
Stop
Toggle Link
Toggle Link
Auxiliary Contact
Assembly
Bolts
Toggle Link
Support
Bar
Cable Connector
Connecting Bolts
Open Stop
Close Stop
Figure 62: Location of the Close Bumper Stops
3.) Position degree guide on linkage under the position indicator.
Figure 63: Degree Guide Position
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4.) Adjust the close stop to align the linkage against the degree guide. Use the ¾”
wrench to help slowly move the linkage required.
Figure 64: Adjusting the Close Stop
5.) Use the “adjusting screw” to hold the linkage in place after positioning the degree
guide.
Figure 65: Adjusting Screw
6.) Reposition the close bumper tight against the mechanism housing and tighten the
bumper stop to 120 inch-lbs.
Torque the Bumper
Stop Bolts to
120 in-lb.
Figure 66: Tightening the Bumper Stop
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2. Full Travel Setting Procedure
Full Travel Requirements (Revised December 2010)
Solenoid/Motor = 0.220” – 0.230”
Motor (⅜” Gap) = 0.405” – 0.425”
Operating Notes: Full Travel setting was revised from 0.200” – 0.210” on December 2010.
It is recommended that this new setting be used if maintenance is performed on the VBM.
There is no need to make this change unless maintenance/repair is being performed.
a) Measuring Full Travel Setting
1.) Place the VBM in the close position.
2.) Position the Dial Indicator gauge under the position indicator and then set the dial to
the zero point.
Set to the Zero
Position
Figure 67: Position of Dial Indicator Gauge
!
CAUTION: AN OPEN OPERATION WITH THE DIAL GAUGE ATTACHED COULD
DAMAGE THE GAUGE.
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3.) Pull out and hold the actuating rod/arm on the dial indicator gauge.
CAUTION:
If arm is not held down
during the open
operation, damage to dial
gauge could occur.
Figure 68: Actuating Rod/Arm and Dial Indicator Gauge
4.) Manually operate the VBM to the open position.
Figure 69: Switch Indicator in Open Position
5.) Release the arm dial indicator gauge when the VBM is in the open position. The dial
should read a full travel value between acceptable range. If out of tolerance, refer to
next section to adjust full travel.
Figure 70: Full Travel Value on Dial Indicator Gauge
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b) Setting Full Travel Requirements
1.) Place the VBM in the close position.
2.) Position the Dial Indicator gauge under the position indicator and then set the dial to
the zero point.
3.) Loosen the Open Bumper stop and slide the bumper against the cast housing stop.
Slide Assembly towards
Housing Stop
Loosen Bolts to Open Bumper Stop
Note: Holes are actually slotted behind
bracket to allow assembly to slide
Figure 71: Open Bumper Stop Assembly
4.) Manually start to operate the VBM towards the open position with the ¾” wrench
while holding the manual handle to prevent a complete open operation. Manually
move the wrench towards the open position until 2 full rotations are observed on the
dial.
!
CAUTION: AN OPEN OPERATION WITH THE DIAL GAUGE ATTACHED COULD
DAMAGE THE GAUGE.
5.) After the 2 full rotations, allow the mechanism to return back to the close position.
6.) Torque the open stop to 120 in-lbs. Be sure the auxiliary contact striker bracket is
aligned before tightening.
7.) The setting can be confirmed by performing the test done previously by pull out and
hold the actuating rod/arm on the dial indicator gauge.
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!
CAUTION: IF ARM IS NOT HELD DOWN DURING THE OPEN OPERATION,
DAMAGE TO THE DIAL GAUGE COULD OCCUR.
8.) Manually operate the VBM to the open position.
9.) Release the arm when the VBM is in the open position; dial should read the full
travel requirement value.
3. Overtravel Setting Procedure
Overtravel Requirements
Solenoid/Motor = 0.038” – 0.048”
ZVC Application = 0.043” – 0.048”
a) Measuring Overtravel Setting
1.) Place the VBM in the close position.
2.) Position the Dial Indicator gauge under the position indicator and then set the dial to
the zero point.
Toggle Link
Toggle Link
Auxiliary Contact
Assembly
Dial Indicator
(Secure against bolt)
Toggle Link
Support Bar
Cable Connector
Open Stop
Bolts
Connecting Bolts
Close Stop
Figure 72: Solenoid Operated VBM Mechanism
3.) Attach the sync lamps clamps to the high voltage contacts; the lamp should be
illuminated.
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4.) Using the 3/4" wrench, manually start to operate the mechanism towards the open
position until the connected sync lamps turn off. An overtravel reading should be
observed on the dial gauge.
Figure 73: VBM Mechanism with Dial Indicator
!
CAUTION: USE CAUTION TO PREVENT A COMPLETE OPERATION DUE TO
POTENTIALLY DAMAGING THE DIAL GAUGE.
b) Setting Overtravel Requirements
1.) Place the VBM in the close position.
2.) Position the Dial Indicator gauge under the position indicator and then set the dial to
the zero point.
3.) Attach the sync lamps clamps to the high voltage contacts; the lamp should be
illuminated.
4.) Using the ¾” wrench, manually start to operate the mechanism towards the open
position.
5.) Observe the dial gauge reading at which the sync lamps on the other module(s) turn
off. At ambient temperatures between 50ºF and 80ºF the lights should turn off when
appropriate overtravel value is observed on the dial gauge.
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6.) Insert the triangle wedge between close bumper stop and mechanism housing to hold
the linkage at a position that the dial indicator reads overtravel spec value.
Wedge
Close Bumper Stop
Figure 74: Wedge and Dial Indicator
7.) With the mechanism held in place, loosen and then re-tighten the pull rod to the
clevis at 70 in-lbs.
Clevis
Pull Rod
¼-20x1" bolts, split
lockwashers & ¼-20 nuts
Torque to 70 in-lbs.
Figure 75: Pull Rod and Clevis
8.) Remove the triangle wedge and close the mechanism.
9.) Slowly open the mechanism using the ¾” wrench, observe the sync lamps turn off as
the mechanism travels to the open position. Note the dial readings at which the
replacement and adjacent modules open. The last light must go out within 0.005”
mechanism travel after the first light (see Figure 76).
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Max sync 0.005”
Max sync 0.005”
L
L
L
L
Sync
Lamps
L
One Pole
34.5kV Switch
Three Phase
15kV/25kV Switch
Figure 76: VBMs First-to-Last Synchronization
!
CAUTION: USE CAUTION TO PREVENT A COMPLETE OPERATION DUE TO
POTENTIALLY DAMAGING THE DIAL GAUGE.
10.) If desired sync requirement 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.
11.) 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 50ºF and 80ºF 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 (see Figure 77).
L
Max contact sync
on each pole
0.005”
Sync
Lamps
Max contact sync
on each pole
0.005”
L
L
L
Three Phase
34.5kV Switch
Three Phase
25kV Switch
Figure 77: VBM Module Pair Synchronization
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VBM Instruction Manual
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4. Auxiliary Switch Adjustment
a) 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 78: 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 – 90.
Tighten bolts on contact bracket to 20 in-lbs. torque. Open switch with the manual
operating handle and remove the shim.
Auxiliary Contacts
Contact Bracket
Spring
Torque to 20 in-lbs
88° to 90° angle
Actuating Bar
Figure 79: Auxiliary Switch Adjustment
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VBM Instruction Manual
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b) 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
Torque to
70 in-lbs.
Dial Indicator
Figure 80: Auxiliary Switch Adjustment (Prior to 1997)
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VBM Instruction Manual
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H. 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 81: Wiring Harness and Auxiliary Contact Replacement
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 on Page 56 to adjust properly.
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VBM Instruction Manual
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V. Specifications
Description
Requirements
Manual
Reference
Torque:
Through Epoxy or Porcelain
Metal to Metal
Pull Rod Bolts
Auxiliary Contacts (Switches Made After 1997)
Auxiliary Contacts (Switches Made Prior to 1997)
Solenoid Bracket - 4 Bolts
Allen Head Screw (Motor Mech. Assembly)
Bumper Stop
Bus Bar
25 in-lb
50 in-lb
70 in-lb
20 in-lb
70 in-lb
70 in-lb
70 in-lb
120 in-lb
315 in-lb
Toggle Link:
Solenoid/Motor
Angle 1°
Angle 5-6° (ZVC Application)
Page 48
Full Travel:
Solenoid/Motor
Motor, ⅜” Gap
Page 29, 30
Page 29, 30
Page 53
Page 54
Page 55
Page 33
Page 40
Page 47, 50
n/a
Page 45
0.220” – 0.230”
0.405” – 0.425”
Overtravel:
Solenoid
0.038” – 0.048”
0.043” – 0.048” (ZVC Application)
Max sync. First-to-last ≤ 0.005”
Max sync. Module Pair pole ≤ 0.005”
Page 51
Page 51
Page 54
Page 54
Motor
0.038” – 0.048”
Max sync. First-to-last ≤ 0.005”
Max sync. Module Pair pole ≤ 0.005”
Page 51
Page 54
Page 54
0.070” – 0.090”
Page 32
200 µΩ Max
Page 20
Pin-Gap:
Solenoid
Resistance:
All VBMs
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VBM Instruction Manual
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Description
Torque:
Handle Force
Requirements
25 lb max
Timing:
Solenoids
Open Timing
26-37 ms @ 120VAC
Open Sync
2 ms max between Phases
2 ms max between Module Pair (Double Stack)
Open Bounce
1 ms max
Close Timing
29-37 ms @ 120VAC
25.8-37.8 ms @ 120VAC, timing repeatability must
be < 0.5ms between all shots (ZVC Application)
Close Bounce
2 ms max between Single Contacts
4 ms max between Module Pair (Double Stack)
Motor
Open Timing
50 ms max @ 24/48/125VDC, 120VAC, 220/240VAC
Open Sync Time
1 ms max between Phases @ 24VDC, 120VAC/125VDC, or 220/240VAC
1 ms max between Module Pair (Double Stack) @ 24VDC, 120VAC/
125VDC, or 220/240VAC
Open Bounce
1 ms max
Close Timing
4 sec max @ 125VDC/120VAC
6 sec max @ 24/48VDC
Close Current
2 A max running current @ 220/240VAC
3 A max running current @ 48/125VDC
4 A max running current @ 24VDC
Appendix A
Manual Revision Notes
Date:
Scope:
January xx, 2011
Added Detailed Sections for Toggle Link Setting, Full Travel Setting, Overtravel Setting,
and Pin Gap Setting
Added Specifications Section
Revised Section Organization
September 25, 2012
Changed 1 ms to 2 ms on page 59, under Open Sync
February, 2013
Re-numbers index
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VBM Instruction Manual
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Thomas & Betts Corp.
8155 T&B Blvd.
Memphis, TN 38125
Phone: 800.326.5282
T&B Utility Products: http://utility.tnb.com
Joslyn Hi-Voltage: www.joslynhivoltage.com
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