Handbook On Motorised Isolator PDF

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(For Official Use Only)

CAMTECH/E/10-11/MI/1.0 1
Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky; MINISTRY OF RAILWAYS
eksVjkbZTM vkbZlksysVj ij gLriqfLrdk

Handbook on Motorised Isolator
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TARGET GROUP: TRD Maintenance Staff
dSeVsd@bZ@10-11@,evkbZ@1-
1-0
CAMTECH/E/10-11/MI/1.0
vizsy] 2011
April, 2011
egkjktiqj, Xokfy;j & 474 005

Maharajpur, GWALIOR - 474 005
Handbook on Motorised Isolator April, 2011
2 CAMTECH/E/10-11/MI/1.0
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xq.koRrk uhfr
jsyksa esa ;k=h vkSj eky ;krk;kr dh c<+rh ek¡x dks
iwjk djus ds fy, xq.koRrk Áca/k Á.kkyh esa vuqla/kku]
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djrs gq, lqjf{kr] vk/kqfud vkSj fdQk;rh jsy
ÁkS|ksfxdh dk fodkl djuk A
QUALITY POLICY
“To develop safe, modern and cost
effective Railway Technology complying
with Statutory and Regulatory
requirements, through excellence in
Research, Designs and Standards and
Continual improvements in Quality
Management System to cater to growing
demand of passenger and freight traffic
on the railways”.
April, 2011 Handbook on Motorised Isolator

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2011 dk;Zdkjh funs’kd

FOREWORD
At present isolators are being opened and closed

manually for feeding or isolating the OHE. This manual
operation consumes man-power as well as valuable time which
is counted in power block duration.
To save this valuable power block time, the concept of

doing the operation of isolator by means of a motor from a
convenient location is developed and is being used by DMRC,
New Delhi and also by some Railways. RDSO has also issued a
specification on the subject.
This handbook contains comprehensive information on

motorized isolator containing specification & constructional
details
I am sure this document will be informative as well as

useful for our field personnel working in Traction Installations.
CAMTECH, Gwalior S.C. Singhal

Date:28th April, 2011 Executive Director

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dSeVsd] Xokfy;j ih;w"k xqIrk

fnukad% 28] vizsy] 2011 la;qä funs’kd ¼fo|qr½

PREFACE
The operation of conventional isolators is carried out
manually and solely depends on applied manual energy. When
this operation is performed by means of a motor, it is called
Motorised Isolator.
This handbook on motorized isolator has been prepared

by CAMTECH with the objective of disseminate basic
information on the subject. It contains comprehensive
information from RDSO specification on motorized isolator,
constructional details, installation and their applications at
various places etc.
It is clarified that this handbook does not supersede any

existing provisions laid down by RDSO or Railway Board. The
handbook is for guidance only and it is not a statutory
document.
I am sincerely thankful to all field personnel who have

helped us in preparing this handbook.
Technological up-gradation & learning is a continuous

process. Hence feel free to write to us for any addition or
modification in this handbook. We shall highly appreciate your
contribution in this direction.
CAMTECH, Gwalior Peeyoosh Gupta

Date:28th April 2011 Jt. Director Electrical
e - mail: direlcamtech@gmail.com

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la’kks/ku ifpZ;ksa dk izdk’ku xi
1-0 ÁLrkouk 01
2-0 eksVjkbZTM vkbZlksyVj ds ykHk 02
3-0 ifjHkkf"kd 'kCnkoyh 02
3-1 vkbZlksysVj 02
3-2 vfFkZax fLop 02
3-3 eq[; ifjiFk 02
3-4 iksy 02
3-5 can fLFkfr 03
3-6 [kqyh fLFkfr 03
3-7 fLFkfr lwpd ;qfä 03
3-8 b.VjykWfdax ;qfä 03
3-9 ifjos’kh rkieku 03
3-10 ifjpkyu pØ 03
3-11 fMisUMsaV esuqvy ifjpkyu 04
3-12 jsVsM eku 04
3-13 lkekU; djsUV 04
3-14 'kkWVZ Vkbe fonLVs.M djsUV 04
3-15 'kkWVZ lfdZV djsUV dh vuqKs; vof/k 04

CONTENTS
Sr.No. Description Page No.
Foreword iv
Preface vi
Contents viii
Correction Slip xiv
1.0 INTRODUCTION 1
2.0 ADVANTAGES OF MOTORISED
ISOLATOR 2
3.0 TERMINOLOGY 2
3.1 Isolator 2
3.2 Earthing Switch 2
3.3 Main Circuit 2
3.4 Pole 2
3.5 Closed Position 3
3.6 Open Position 3
3.7 Position Indicating Device 3
3.8 Interlocking Device 3
3.9 Ambient Temperature 3
3.10 Operation Cycle 3
3.11 Dependent Manual Operation 4
3.12 Rated Value 4
3.13 Normal Current 4
3.14 Short-Time Withstand Current 4
3.15 Permissible Duration of Short Circuit Current 4

3-16 vuqKs; ihd fonLVs.M djsUV 04

3-17 jsVsM 1 fefuV ikoj ÝhDosalh fonLVs.M oksYVst 05
3-18 jsVsM bEiYl fonLVs.M oksYVst 05
3-19 fDy;jsUl 05
3-20 iksyksa ds chp fDy;jsUl 05
3-21 vFkZ ls fDy;jsUl 05
3-22 vksiu dkUVsDV ds chp fDy;jsUl 05
3-23 vkbZlksysfVax nwjh 06
3-24 jsfVax 06
3-25 'kkWVZ Vkbe jsfVax 06
3-26 vksoj yksM 06
4 -0 fof’k"Vrk;sa 07
4-1 tyok;q ifjfLFkfr;k¡ 09
4-2 okrkoj.kh; ifjfLFkfr;k¡ 09
5 -0 vfHkdYi vkSj lajpukRed fo’ks"krk;sa 10

5-1 lIykbZ oksYVst 10
5-2 eksVj MªkbZo ;wfuV 10
5-3 daVªksy lfdZV 11
5-4 ifjpkyu ra= 11
5-5 iksy@CysM 12
5-6 yphyh czSM 12
5-7 fQDLM dkWUVsDV 12
5-8 cksYV] uV ,oa ykWd uV 13
5-9 vfFkZax 13
5-10 ifjpkyu ikbZi 13
5-11 esfy,sfoy dkLV vk;ju ,oa Qsjl Hkkx 14
5-12 LVhy LVªDpj 14

3.16 Permissible Peak Withstand Current 4

3.17 Rated 1 min Power Frequency
Withstand Voltage 5
3.18 Rated Impulse Withstand Voltage 5
3.19 Clearance 5
3.20 Clearance between Poles 5
3.21 Clearance to Earth 5
2.22 Clearance between Open Contacts (Gap) 5
3.23 Isolating Distance 6
3.24 Rating 6
3.25 Short Time Rating 6
3.26 Over Load 6
4.0 SPECIFICATION 7
4.1 Climatic Conditions 9
4.2 Environmental Conditions 9
5.0 DESIGN AND CONSTRUCTIONAL
FEATURES 10
5.1 Supply Voltage 10
5.2 Motor Drive Unit 10
5.3 Control Circuit 11
5.4 Operating Mechanism 11
5.5 Pole/Blade 12
5.6 Flexible Braid 12
5.7 Fixed Contact 12
5.8 Bolts, Nuts and Lock Nuts 13
5.9 Earthing 13
5.10 Operating Pipe 13
5.11 Malleable Cast Iron and Ferrous Part 14
5.12 Steel Structure 14

5-13 balqysVj ,oa VfeZuy dusDVj 14

5-14 ykWfdax 15
5-15 vFkZ dkUVsDV vlsEcyh 15
5-16 vkfdZax gkWuZ 16
6-0 Mh,evkjlh] ubZ fnYyh esa yxs eksVjkbZTM

vkbZlksysVj dk fooj.k 16
6-1 eksVjkbZTM vkbZlksysVj 16
7-0 vuqj{k.k 'ksM~;wy 26

7-1 f=ekfld 'ksM~;wy 26
7-2 v)Zokf"kZd 'ksM~;wy 27
7-3 okf"kZd 'ksM~;wy 27
8-0 nf{k.k e/; jsyos ¼fr#ifr½ esa yxs eksVjkbZTM

vkbZlksysVj dk fooj.k 28
8-1 Mhlh eksVj dk rduhdh fooj.k 31
8-2 dUoVZj dk rduhdh fooj.k 32
Ikfjf’k"V&1 33
vFkZ dkWUVsDV vlsEcyh lfgr 25 dsoh flaxy iksy
eksVjkbZTM vkbZlksysVj
Ikfjf’k"V&2 41
lEcaf/kr fof’k"Vrkvksa dh lwph
lanHkZ 45

5.13 Insulators and Terminal Connectors 14

5.14 Locking 15
5.15 Earth Contact Assembly 15
5.16 Arcing Horn 16
6.0 DETAILS OF MOTORISED ISOLATORS

PROVIDED AT DMRC, NEW DELHI 16
6.1 Motorised Isolator 16
7.0 MAINTENANCE SCHEDULE 26

7.1 Quarterly Schedule 26
7.2 Half Yearly Schedule 27
7.3 Yearly Schedule 27
8.0 DETAILS OF MOTORISED ISOLATORS

PROVIDED AT SOUTH CENTRAL
RAILWAY (TIRUPATI) 28
8.1 Technical Data of DC Motor 31
8.2 Technical Data of Converter 32
ANNEXURE-1 33
25 KV Single Pole Motorised Isolator With
Earth Contact Assembly As Discussed
During Seminar
ANNEXURE-2 41
List of Related Specifications
REFERENCES 46

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la’kks/ku ifpZ;ksa dks fuEukuqlkj la[;kafdr fd;k tk;sxkA
dSeVsd@bZ@10-11@,evkbZ@1-0 lh,l # XX fnukad---

tgk¡ “XX” lEcfU/kr la’kks/ku iphZ dh dze la[;k gS ¼ 01 ls
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izdkf’kr la’kks/ku ifpZ;kW¡

dz-la- izdk’ku dh la’kksf/kr Ik`"B la[;k fVIi.kh
rkjh[k rFkk en la[;k

ISSUE OF CORRECTION SLIP
The correction slips to be issued in future for this

handbook will be numbered as follows:
CAMTECH/E/10-11/MI/1.0/ C.S. # XX date---
Where “XX” is the serial number of the concerned

correction slip (starting from 01 onwards).
CORRECTION SLIPS ISSUED
Sr. No. Date of Page no. and Item Remarks

issue no. modified

1.0 ifjp; INTRODUCTION
Isolator is a mechanical switching device

which provides, in the open position, an isolating
distance between the two contacts in accordance with
specified requirements.
The Isolator is capable of opening and closing

a circuit when either negligible current is broken or
made. It is also capable of carrying currents under
normal circuit conditions and carrying, for a specified
time, currents under abnormal conditions such as
those of short circuit.
The operation of conventional isolators is

carried out manually and solely depends on applied
manual energy. When this operation is performed by
means of a motor, it is called Motorised Isolator.
Single pole as well as double pole motorised

isolators are used in 25kV AC, Over Head Equipment
(OHE), Traction Substations (TSS) and Switching
Stations (SSP) for OHE maintenance, equipment
maintenance and segregation.
These isolators are mounted on a mast/ structure
as required. The operation of isolators is performed by
means of a DC motor and DC voltage supply to this
motor is given through a multi core insulated copper
cable. The operation of isolator is possible from a
remote location at more than 500 m .The status of
isolator i.e. whether close or open can be made
available at the station master chamber/ cabin or
desired location.

2.0 eksVjkbZTM vkbZlksyVj ds ykHk

ADVANTAGES OF MOTORISED ISOLATOR
• Man power saving.
• Increase power block time due to quick operation
of isolator.
• Quick segregation in faulty section resulting time
saving.
3.0 ifjHkkf"kd 'kCnkoyh TERMINOLOGY
The following terms are commonly used in
isolator system:
3.1 vkbZlksyVj
sVj Isolator
It is a mechanical switching device which
provides in the open position an isolating distance
between the two contacts.
3.2 vfFk
vfFkZax fLop Earthing Switch
A mechanical switching device for earthing
part of a circuit, capable of withstanding for a
specified time currents under abnormal conditions
such as those due to short circuit, but is not required
to carry current under normal conditions of the circuit.
3.3 eq[; ifjiFk Main Circuit
All the conducting parts of an isolator or
earthing switch included in the circuit which is
designed to close or open.
3.4 iksy Pole
The portion of an isolator or earthing switch
associated exclusively with one electrically separated
conducting path of its main circuit and excluding
those portions which provide means of mounting and
operating all poles together.
3.5 can fLFkfr Closed Position

The position in which the predetermined,
continuity of the main circuit is secured.
3.6 [kqyh fLFkfr Open Position
The position in which the predetermined,
clearances between open contacts in the main circuit,
is secured.
3.7 fLFkfr lwpd ;qfä Position Indicating Device
A device, which indicates, at the location of
the isolator or earthing switch, whether the contacts of
the main circuit are in open or closed position.
3.8 b.VjykWfdax ;qfä Interlocking Device
A device, which makes the operation of the
isolator or earthing switch dependent upon the
position or operation of one or more other pieces of
equipment.
3.9 ifjos’kh rkieku Ambient Temperature
The temperature determined under prescribed
conditions, of the air surrounding the complete
switching device (e.g. for enclosed switching device,
it is the air outside the enclosure).
3.10 ifjpkyu pØ
pØ Operation Cycle
Operation cycle is a succession of operations
from one position to another and back to the first
position through all other operations if any.

3.11 fMisUMsaV esuqvy ifjpkyu

Dependent Manual Operation
An operation solely by means of directly
applied manual energy, such that the speed and force
of the operation are dependent upon the action of the
operator.
3.12 jsVsVM
s eku Rated Value
A stated value of any one of the characteristic
values that serve to define the working condition for
which, the isolator or earthing switch, is designed.
3.13 lkekU; djsUV Normal Current
The current of the main circuit of the isolator
is capable of carrying continuously under specified
conditions of the use and behavior.
3.14 'kkWVZ Vkbe fonLVs.M djsUV
Short-time Withstand Current
The current of the isolator or the earthing
switch can carry in the closed position during a short
specified time period under prescribed conditions of
the use and behavior.
3.15 'kkWVZ lfdZV djsUV dh vuqKs; vof/k
Permissible Duration of Short Circuit Current
The time during which an isolator or earthing
switch is in the closed position can carry a short
circuit current of specified value.
3.16 vuqKs; ihd fonLVs.M djsUV
Permissible Peak Withstand Current
The value of peak current that an isolator or
earthing switch can withstand in the closed position
under prescribed conditions of use and behavior.
3.17 jsVsM 1 fefuV ikoj ÝhDosalh fonLVs

fonLVs.M oksYVst
Rated 1 min Power Frequency Withstand Voltage
The r.m.s value of sinusoidal alternating
voltage at power frequency which is the insulation of
the isolator or earthing switch withstands under
specified test conditions.
3.18 jsVsM bEiYl fonLVs

fonLVs.M oksYVst
Rated Impulse Withstand Voltage
The peak value of the standard (1.2/50µs)
impulse voltage wave which are the insulation of the
isolator or earthing switch can withstand under
specified test conditions.
3.19 fDy;jsUl Clearance

The distance between the conducting parts
along a string stretched the shortest way between
these conducting parts.
3.20 iksyksa ds chp fDy;jsUl Clearance between Poles

The clearance between any conducting parts
of the adjacent poles.
3.21 vFkZ ls fDy;jsUl Clearance to Earth

The clearance between any conducting parts,
any parts which are earthed or intended to be earthed.
3.22 vksiu dkUVsDV ds chp fDy;jsUl

Clearance between Open Contacts (gap)
The total clearance between the contacts or
any conducting parts thereto of a pole of an isolator or
earthing switch in the open position.

3.23 vkbZlksysfVax nwjh Isolating Distance

The clearance between open contacts or any
conducting parts connected thereto in a pole of an
isolator meeting safety requirements.
3.24 jsfVax Rating

A statement of operating limits assigned to the
machine by the manufacturer.
3.25 'kkWVZ Vkbe jsfVax Short Time Rating

A rating which specifies the load at which the
motor, starting at the ambient temperature, may be
operated for the period and under the conditions
specified on the rating plate.
3.26 vksoj yksM Over Load

Any condition of load in excess of the rated
load, usually the amount of the excess is expressed as
a percentage excess torque for motor.

4.0 fof’k"Vrk;s
fof’k"Vrk;sa SPECIFICATION (As per RDSO’s
Specification No.TI/SPC/PSI/ISOLTR/1060)
Type Motor operated, horizontally
mounted on pole, vertical break
type and suitable for outdoor.
Number of One
phases
Number of poles One or Two
Isolating distance 500 mm (min.)
(In air)
Rated current Type-I - 1250 A
( used in OHE at SP,SSP)
Type-II - 1600 A
(used at feeding post & traction
substation)
Type-III - 3150 A
(used in OHE during transition
in DC- AC conversion and in
30MVA traction substation on
Mumbai suburban section)
Operating Type-I isolator shall employ 24
Mechanism V DC motors with battery
charger for charging 24 Volt 40
Ah battery. Battery shall be
capable of performing 10 CO
operations with stored energy in
fully charged condition. Power
supply shall be 240 Volt AC
with variation from 170 to
270Volts.
Type-II and III isolators shall
employ 110 V DC motors
without charger.
Rated frequency 50 Hz +/-3 %
Rated short time withstand 20 kA (rms) for 3s for Type I & II

current (both isolators.
for main & earthing 50 kA (rms) for 3s for Type III
switch) isolator.
Rated peak withstand 50 kA for Type I & II isolators.
current both for main &
earthing switch) 125 kA for Type III isolator.
Temperature rise The temperature rise of any part of
an isolator shall not exceed the
maximum temperature rise.
Nature of parts Temperature in Temperature rise in
degree Celsius degree Celsius
1. Copper contacts in air: 90 75
50
2. Bare copper or tinned The temperature shall not reach a
aluminium Alloy value where the elasticity of the
3. Terminals of isolators materials is impaired. For pure
to be connected to copper the temperature limit is 75
deg. C
external conductors by
screws or bolts – bare
4. Metal parts acting as
springs.
Rated impulse (1.2/50
micro second)
withstand voltage
i) To earth and between 250 kV (peak)
the poles.
ii) Across the isolating 290 kV (peak)
distance
Wet power frequency 1
min. withstand voltage
i) To earth 95 kV ( rms)
ii) Across isolating 110 kVrms
4.1 tyok;q ifjfLFkfr;k¡ Climatic Conditions
The motorized isolator is intended to be used

as outdoor line sectioning switches. The isolator may
be used in normally polluted atmosphere, subject to
dust, smoke and effluents from chemical plants. It
may also be used in coastal areas.
4.2 okrkoj.kh; ifjfLFkfr;k¡ Environmental Conditions
S. Parameters Value
No.
1. Maximum ambient air 55°C
temperature
2. Minimum temperature -5°C
of air in shade
3. Maximum relative 100%
humidity
4. Annual rainfall Ranging between
1750 mm & 6250
mm
5. Number of thunderstorm 85 (Max)
days per annum
6. Number of dust storm 35 (Max)
days per annum
7. Number of rainy days 120 (Max)
per annum
8. Maximum basic wind 200 kgf/m2
pressure
9. Altitude Not exceeding
1000 m
10. Pollution level Very heavy as per
IEC 815-1986 & IS
13134-1992
5.0 vfHkdYi vkSj lajpukRed fo’ks"krk;sa

DESIGN AND CONSTRUCTIONAL FEATURES
5.1 lIykbZ oksYVst Supply voltage
The isolator motor shall be suitable for

operation with 24 V dc for type I and 110V dc for
type II & III. The voltage at the battery terminals may
vary between 110% and 85% of the normal value.
The voltage at the isolator motor terminals is likely to
be less than 85% of the normal value of 24 V or 110V
due to voltage drop in control cable. The isolator shall
be able to operate manually in case of failure of motor
circuit. Once the closing /opening operation has been
initiated it must be completed automatically (snap
action) even if there is a failure of 24 V or 110 V dc
supply.
5.2 eksVj MªkbZo ;wfuV Motor Drive Unit
The motor drive unit shall be installed in a

weather and corrosion proof, adequately ventilated
cubicle made of sheet steel not less than 2 mm thick
with adequate stiffeners to prevent deformation. The
cubicle shall have a sloping roof. To prevent
condensation of moisture in the cubicle, metal clad
space heater shall be provided which shall be
controlled by associated thermostat and switches.
The top of the cubicle shall be at a height of

about 1.5 m from the rail level. The cubicle shall be
so positioned that the hinge of the operating handle
for manual operation is at a height of about 1.1 m
from the rail level.
5.3 dVª
aVkª sy lfdZV Control Circuit
The isolator and its control circuit shall be
operated from the remote control centre (RCC) by the
traction power controller (TPC) as well as from the
isolator cubicle. A local/remote spring-loaded switch
as well as necessary terminations for tele-signals and
tele-commands from and to the isolator for operation
from the RCC shall be provided in the isolator
cubicle. The isolator cubicle shall be provided with
motor protection relays.
5.4 ifjpkyu ra= Operating Mechanism
The operating mechanism shall be fasten the
base to which the operating handle is attached, to
either of the two mutually perpendicular vertical faces
of the supporting structure on which the isolator is
mounted. The operating handle of the isolator shall be
work in the vertical plane. The isolator shall close
when the handle is moved upwards. The free end of
moving contact shall be fully housed in the fixed
contact. When the handle is moved fully upward in
which position the isolator can be locked. The single
pole isolator shall be such as to permit coupling of
isolators for gang operation from a single operating
handle. Not more than two single pole isolators are
required to be coupled. Suitable “OFF” and “ON”
plates shall be provided on the operating handle to
indicate when the isolator is open and closed
respectively. The mounting arrangement and the
operating mechanism shall be such that with the
isolators mounted in the working position, the hinge
pin of the operating handle is at a height of 1.1m from
ground level.

5.5 iksy@CysM Pole/Blade

All poles of the isolator shall operate
simultaneously. Provision shall be made for
adjustments, if required, for the proper alignment of
the pole after mounting. All movable joints shall be
provided with brass bushes/ bearings, which shall be
entirely maintenance free. The blades of the isolator
shall be of electrolytic high conductivity copper tubes
of adequate strength and cross section to IS: 191 (Part
V) – 1980 to withstand thermal and bending stresses
particularly under short circuit fault conditions.
5.6 yphyh czSM Flexible Braid
Flexible braided copper, where used, shall
have corrosion resistant coating such as tinning or
silvering. The connection between the flexible braid
and rotating and fixed parts shall be by means of not
less than two bolts to prevent any tendency of
rotation. The leakage current can not pass from the
terminals of one side to any of the terminals of the
other side of the isolator. During installation of the
isolator, it shall be able to bear on terminals the total
forces (including wind load and electrodynamics
forces on the attached conductors) related to the
application and rating without impairing their
reliability or current carrying capacity.
5.7 fQDL
fQDLM dkWUVsDV Fixed Contact
The fixed contacts of isolator shall be of
extruded, rolled or drawn copper strips. The contacts
shall be spring-loaded. Only non-ferrous or stainless
steel components shall be used in the contact
assembly. The springs used in the contact assembly of
the isolator shall be of phosphor bronze conforming to

IS: 7608-1975. To avoid current passing through the
springs, nylon strip of suitable size shall be provided
for insulation. The characteristics of the springs shall
conform to IS: 7906 (Pt. II)-1976 and their
mechanical properties shall not be affected in any
manner on account of rise in temperature during
operation.
5.8 cksYV] uV ,oa ykWd uV Bolts, Nuts and Lock Nuts
Bolts, nuts locknuts and other fasteners shall

be stainless steel of 12 mm dia. Fasteners of higher
size may be made of hot dip galvanized steel. The
fasteners shall confirm to RDSO specification no.
ETI/OHE/18.
5.9 vfFkZax Earthing

The frame (isolator mounting channel) of each
isolator shall be provided with an earthing terminal
for connecting to an earthing conductor having
clamping screws, suitable for earth fault conditions.
The diameter of the clamping screws shall be not less
than 12 mm. The connecting point shall be marked
with “Earth” symbol.
5.10 ifjpkyu ikbZi Operating Pipe
The operating pipe shall not have any joint

and provide minimum four guides. The operating pipe
shall be obtained only from approved manufacturers.
The isolator’s operating pipe shall be supplied with in
exact length for the particular mast/ structures.

5.11 esfy,sfoy
foy dkLV vk;ju ,oa Qsjl Hkkx
Malleable Cast Iron and Ferrous Part
All malleable cast iron parts shall be of black
heart malleable cast iron grade BM- 340 conforming
to IS: 2108-1977.All ferrous parts shall be hot dip
galvanized in accordance with specification no.
ETI/OHE/13(4/84).
5.12 LVhy LVªDpj Steel Structure
The support and framework shall be
withstanding a wind pressure of 200 kgf/m2 acting on
150 % of the projected area in addition to all other
loads. During the opening and operations of the
isolator there shall be no shock. There shall also not
be a backlash tending to open the isolator after
closing, due to the jerk, if any. The height of base of
the rigid frame shall be depending on the type of
mast/ or structure on which the isolator is mounted.
5.13 balqys
yVs j ,oa VfeZuy dusDVj
Insulators and Terminal Connectors
The support and operating rod insulators shall
be of solid core/composite type in accordance with
the latest RDSO specification No.ETI/OHE/15. All
wiring in the cubicle shall be clearly identified by
lettered/ figured ferrules of the interlock type,
preferably of yellow color with black letters/ figures.
The various circuits shall be clearly distinguished and
well separated from each other.
Suitable legend and schematic diagram plates

made of anodized aluminium with black lettering and
lines shall be fixed on the inside surface of the cubicle
door.
5.14 ykWfdax Locking

The isolator shall be provided with suitable
interlocking arrangement with associated CB/
Interrupters to prevent its mal-operation (including
manual operation).
A bolt type integral lock and /or interlock
shall be fitted on the isolator to enable the operating
handle of the isolator to be locked effectively in the
open as well as in the close position. It shall not be
possible to withdraw the key from the integral lock
except when the isolator is locked either in the open
or in the closed position.
The operating mechanism shall be so designed
as to permit padlocking, in addition to the integral
lock or interlock, for locking the operating handle of
the isolator both in the open as well as in the closed
positions.
The internal mechanism of integral lock and
inter lock shall be of stainless steel or non-ferrous
material. It shall be of robust construction. The outer
housing of the interlock and integral lock shall be
chrome plated steel and the construction shall be such
that it is not prone to theft. Electrical/mechanical
interlocking shall be provided for manual/motorized
operation. Each lock shall be supplied with two keys.
Key/lock number shall be inscribed on the keys
/locks.
5.15 vFkZ dkUVsDV vlsEcyh Earth Contact Assembly

The design of the isolator shall be such that it
is possible to incorporate an additional pair of
contacts so as to effectively earth the fixed contact of

the isolator in open position even at a later date. The

design of the isolator frame shall permit the provision
of the earth contact assembly without calling for
modification to the frame itself. Two holes of
15.5+0.5 mm dia shall be provided on the mounting
channel for connecting earth contact assembly.
5.16 vkfdZax gkWuZ Arcing Horn

The single pole isolator shall be provided with
arcing horns which shall be of bright steel to Gr. 20-c-
8 of IS: 1570 (Pt. II) - 1979. The arcing horns shall
make contact before the main contacts close and
break contact after the main contacts break.
6.0 Mh,evkjlh] ubZ fnYyh esa yxs eksVjkbZTM

vkbZlksysVj dk fooj.k
DETAILS OF MOTORISED ISOLATORS
PROVIDED AT DMRC, NEW DELHI
Motorised isolators are provided at Delhi Metro
Rail Corporation, New Delhi. The schematic diagram
of electrical circuit, operating mechanism, etc. is
given below for reference.
6.1 eksVjkbZTM vkbZlksyVj

sVj Motorised Isolator
25 kV Single pole motorized isolator with
Monitoring box is provided at DMRC New Delhi. It
operates at 110V DC by three position switch
(Remote/local/manual). The isolator has following
accessories -
a. 110 V DC Supply for Motor
b. 240 V AC Supply
c. Control Supply 110V DC

d. Terminal Block for DC & AC

e. Monitoring Box
a. eksVj ds fy;s 110 oksYV Mhlh lIykbZ

110 V DC Supply for Motor
110 V DC supply for Motor is taken

from terminal block-2 (51-52) through wire
no.H11 & H18 and feed to 2 pole MCB (S1).
From MCB S1 supply goes to motor through over
load relay (OLR) and contacts of open/ close
contactor (OC & CC) as shown in figure-1.

110V DC SUPPLY
TB2-51 TB2-52
H11 H18
SI
H12 H17
K8 L1
TB1-53
OLR MOTOR ANNUATIATION

TRIP
H13 TB1-54
H16
K28 H15
L2
OC CC CC OC
H15
H14 H14 H15
Fig: 1 - Schematic diagram of 110V DC supply for motor

b. 240 oksYV ,lh lIykbZ 240 V AC Supply

240 V AC supply is taken from terminal
block-2 (55-56) through wire no. H30A & H40
terminated to single pole with neutral MCB (S3).
From MCB-S3 supply tapped for cubical heater,
thermostat, power socket etc. as shown in figure- 2
240V, SINGLE AC SUPPLY
TB2-55 TB2-56
P N
H30A H40
S3
H41
H35
HS DLS PSS
H36 H37 H38

PS
TH
L
H39
H41 H41
CH
H41
Fig: 2 - Schematic diagram of 240V AC supply

c. 110 oksYV Mhlh dUVªksy lIykbZ

Control Supply 110V DC
110 V DC Control supply to solenoid coil of

open/ close contactor (OC/ CC) is given from
terminal block-1 (1-2) through wire no. J1 & J2, 2 pole
MCB (CS) etc. as shown in figure- 3
Description Abbreviation
Key interlock switch KINC
Local/Remot/Mannual selector S2
switch
Power socket PS
Motor M
Mannual push button for handle PB3
1 Pole + neutral MCB for AC S3
supply
Overload relay OLR
Thermostat TH
Open push button PB2
Close posh button PB1
Lamp switch DLS
Solenoid coil SC
Limit switch LS1/LS2
1 Pole MCB for power socket PSS
1 Pole MCB for Heater HS
2 Pole MCB for motor S1
2 Pole MCB for DC supply CS
Cubical heater CH
Cubical lamp holder L
Close & Open Contactor(110 V CC & OC
DC)

CS KIMC OLR PB4 (OFF)
+Ve J1 K3 K4 K4
K1
TB1-1
S2 KS
L
R
TB1-3
K7
RPB1
K9 PB3
CLOSE (MANUAL)
CAMTECH/E/10-11/MI/1.0
RPB2 OC PB1
(CLOSE) PB2
(OPEN)

OPEN TB1-4 K17
CONTROL K11
SUPPLY a
CONTROL PANEL
SOLENOID COIL
(FOR REMOTE OPERATION) TB1-5 FOR MANUAL SC
OPERATION
K13
CC OC
K11 K2
CC
K11a K13a
LS2
LS1
K13b
CC K11b
K2
Fig: 3 - Schematic diagram of control supply 110V DC

-Ve J2 K2
April, 2011
21
TB1-2 CS
d. Mhlh ,oa ,lh ds fy;s VfeZuy CykWd

Terminal Block for DC & AC
In coming 110 V DC & 240 V AC supply is

terminated on TB (Terminal Block), in which
control supply110V DC is given to motor through
J1 & J2, remote operation, inter locking etc.
In coming 240V AC supply is terminated on
TB (Terminal Block), in which 240V supply is
given to thermostat, cubical heater, socket etc. as
shown figure-4 REM O TE CAB LE SIDE
1 10 V DC
31 1
C ON TRO L SU PPL Y
32 2
k7 3
FO R R EM O TE
k1 1 4 O PE RATIO N
K1 3 5
K1 6 FOR
IN TER L OC KING
K3 7
L1 8 S PAR E CO N TACT O F
L O CA L PO SITION
L2 9
R1 10 S PAR E CO N TACT O F
RE M OTE PO SITIO N
R2 11
12
S PAR E
13
TB2
H 11 1 10 V DC SUP PL Y
51 FO R M O TOR
H 18 52
L1 53
M O TOR AN NU ATIATIO N TR IP
L2 54
H 30A
55 1 2 40 V AC
SUP PLY 5 0 Hz
H40 56
57
S PAR ES
58
Fig: 4 - Schematic diagram of Terminal Block

e. ekWuhVfj
hVfjax ckWDl Monitoring Box
Monitoring Box is mounted on the mast at

hand level (1.2 m). It is made of steel sheets,
totally enclosed, dust proof and water tight type.
It is equipped with following parts and figure as
shown in figure- 5,5a.
Fig: 5a - Monitoring Box front view

Fig: 5a - Monitoring Box side view

iqtkZ lwph Part List
1 Door
2 Rubber gasket
3 Thermostat
4 Pad lock provision
5 Lamp holder
6 Panel board hinges
7 Power socket
8 MCBs
9 Light, heater & socket switches
10 Overload relay cum single phase preventer
11 Open & close contactors
12 Local/Remote selector switch
13 Hole flange
14 ‘ON’ & ‘Off’ indicator
15 Motor
16 Knob for manual operation
17 Cam
18 Limit Switch
19 Aux. Switch
20 Emergency Switch
21 Push button
22 Earthing bolt
23 Box fixing cleat
24 Enclosure
25 Heater
26 Terminal block
27 Detector type cable glands fixing plate
28 Upper panel
29 Lower panel
30 Gear unit

7.0 vuqj{k.k 'ks

'ksM~;wy MAINTENANCE SCHEDULE
7.1 f=ekfld 'ksM~;wy Quarterly Schedule

i. Open the cover of control box. Check the interior
& remove the accumulated dust by using dry
cloth or vacuum cleaner.
ii. If any part of the panel found rusted indicating
entry of moisture, find out the cause, plug the
holes and repaint the rusted part.
iii. Check weather proof gasket for their good
condition.
iv. Check the connection tightness and corrosion of
terminal connector nut, bolt and washer.
v. Check clearance between blades in open
condition it should be minimum 500 mm. and
adjust, if required. Check the correct alignment of
isolator for its firm grip while isolator in closed
condition.
vi. Check the operation manually as well as
electrically in local and remote, keeping the
control door open, observe whether the
mechanism and operating rod functions smoothly
without any rubbing or obstruction.
vii. Check wiring connection tightly secured.
viii. Check healthiness of relays and contactors.
ix. Check the working of heater.
x. Check the earthing connections for proper
tightness.
xi. Check locking arrangement.
xii. Grease and lubricate all moving parts.
7.2 v)Zokf"kZd 'ksM~;wy Half Yearly Schedule

In addition to 7.1 above, carry out following
activities:
i. Clean the male/female blade/Jaw of isolator with
kerosene oil, and then clean with dry cloth and
apply Vaseline lightly. Wipe off the jelly to avoid
accumulation of dust.
ii. Check limit switches, auxiliary switches &
contacts.
iii. Check correct setting and alignment of arcing
horn.
7.3 okf"kZd 'ksM~;wy Yearly Schedule
In addition to 7.1 & 7.2 above, carry out following

activities
i. Check the winding resistance of the 110V DC
motor.
ii. Clean the commutator with muslin cloth.
iii. Check carbon brushes and replace if necessary.
iv. Lubricate the operating mechanism and main
contacts.

8.0 nf{k.k e/; jsyos ¼fr#ifr½ esa yxs eksVjkbZTM

vkbZlksysVj dk fooj.k
DETAILS OF MOTORISED ISOLATORS
PROVIDED AT SOUTH CENTRAL RAILWAY
(TIRUPATI)
25 kV/240V AC supply is
taken from auxiliary
transformer for cabin or
ASM room.
240V AC Auxiliary
transformer supply is
converted into 110V DC
supply by AC-DC
converter.
110 V DC supply to
electric point machine is
given through junction
box, multi core copper
cable is used for this
purpose.
In junction box spring type
rotary switch is provided for
giving command to isolator
for opening or closing. The
indication of ‘OPEN’ or
‘CLOSE’ condition of
isolator is provided at the
junction box.
143 mm throw Electric

Point Machine of signaling
department with internal
locking is being used for
motorised isolator.
110V DC power supply is

given to motor through
rotary switch. The motor
drives the point mechanisms
through friction clutch,
reduction gears and throw
bar.
The rotary motion of the motor is converted into a

rectilinear movement of the toothed driving bar with
the help of transmission assembly.

The detector slide is

attached to the lever and
operating rod of isolator.
When open command is given, the detector slide comes

outside, moves lever and opens the isolator and the
open indication comes in junction box through
contactor.
When close command is given, the detector slide comes

inside, lever moves and closes the isolator and the close
indication comes in junction box through contactor.

During the failure of motor or power supply,

facility is provided for operating the isolator manually.
For this crank handle is provided. It is inserted in the
point machine and by rotating it, drive is imparted to
the point.
8.1 Mhlh eksVj dk rduhdh fooj.k

Technical Data of DC Motor
• DC split field series Motor

• Rated voltage 110 V DC capable of working at
+/- 25% of rated voltage.
• RPM 1700+/- 15%
• Rated current 5.3A and maximum 8.5A.
• Operating time 4 to 5 seconds.
• Power 440 Watts.
• Gear oil SAE 30.

8.2 dUoVZj dk rduhdh fooj.k

Technical Data of Converter
• Type - Single phase, air cooled AC-DC Converter

for indoor installation.
• Input Voltage - 240 V AC
• Output Voltage - 110 V DC
• Current - 10 A
• Rated Frequency - 50 Hz.
• Power - 1.1 Kw
• Type of cooling - AN

Ikfjf’k"V&1
Ikfjf’k"V&1 ANNEXURE-1
vFkZ dkWUVsDV vlsEcyh lfgr 25 dsoh flaxy iksy eksVjkbZTM

vkbZlksyVj
s Vj
25 kV SINGLE POLE MOTORISED ISOLATOR WITH
EARTH CONTACT ASSEMBLY
A seminar was held on 11.03.2011 on 25 kV

motorised isolator. The participant from different Zonal
Railways have participated in seminar and discussed on
motorized isolators (Type-1, Type-2 and Type-3) along with
earth contact assembly.
The general arrangement diagram of single pole

motorized isolator with earth contact assembly and sub
assemblies are shown in figures – 7, 8, 8a, 9, 10. These
details are provided by M/s S. B. Industries, Kolkata.

Moving blade arcing horn

Moving blade body silver plated end
Fixed contact based hinge side Fixed spring contact silver plated
Fixed blade arcing horn Moving blade op. clevis
Moving plate hinge pin
Terminal pad silver plated
Terminal pad (Hinge side)
Fixed
contact Moving blade op. clevis pin
Solid core insulator base
Isolator mounting channel (Right & Left)
Moving earthing
contact Operating rod insulator
Isolator base plate
Flexible electrolatic blading Channel hinge support
Operating down road clamp
Operating rod insulator shaft link
Operating pipe
Guide ring
Motor operating Mechanism
Fig:7- Schematic diagram of 25 kV Single pole motorised

isolator with earth contact assembly

Fig: 8 - Schematic diagram of Motor Drive Mechanism front

view

Fig: 8a – Schematic diagram of Motor Drive Mechanism side

view

S No Description
1 Enclosure 12 S.W.G. MS sheet
2 Output flange 160 dia x 15 holes, at 127 PCD
3 On & Off indicators
4 Rain guard
5 Side entrance for manual operating lever
6 Gear Assembly
7 Interlock for manual operation
8 Limit switch (close/open)
9 Aux. switch 4NO +4NC
10 Light button switch
11 Space heater switch
12 HRC switch
13 Power switch socket
14 Overload bimetelic relay
15 Push button (open/close)
16 Cable entry plate (without cable glands)
17 Local/ Remote selector switch
18 Control supply switch (On/Off)
9 Motor supply switch (On/Off)
20 Mechanical interlock with solenoid
21 Push button - solenoid
22 Contactors – close, open (110 V DC coil)
23 Electric motor (110V DC)
25 Mechanical stopper
26 Screw clamp

Specification of motor
1 Motor - ¼ & ½ HP
2 Supply Voltage – 220 V & 110 V AC/DC
3 Mounting - Foot
4 Bearing - Ball
5 Lubrication - Grease/ Oil mixture
6 Rating - Intermittent
7 Gear Ratio - 1170:1
8 R.P.M of driving
shaft - 4.5 approx
9 Maximum torque - 3750 Kg. Cm
Manual operation shaft
Shaft for Driving shaft

auxiliary
switch
Gear box
Motor
Fig: 9- Diagram of motor fitted with gearbox

P(+VE)
110V, DCSUPPLY
N(-VE)
1 2
J2 J1
FP FN FN1 FP1
M1 J4 J3
M2
K1 CS
M3 14 15
M4
K3
K3
1 5 K2 LK K3
LR
19 ILS
2 6
M K4
M5 ML 96
CLOSE OPEN
TR/a
K15
4 95
M7 REMOTE LR
K5
L R
3 PSL REMOTE
K16
20 21 K7 K7
25
M7 16
M6 K14 LKS
L1 L2 31
M6 26
38 39 K6
KC/a KC/a KO/a KO/a 1 PC PO
KC KO
M8 LC/b LO/b
M8 K8
SL 17
M9 K2
4 K8
M9 K9 K9
40 18
M8 32 KO KC
KC/a KO/a
4 M12 K10 K11
6 K2 a a
K2
KC KO
A1 F1
b b
M11
MA MF M12
36 37
A2 F2 K2 K12 K13
5 7
M12 LC/a LO/a
M11
KC/a KO/a
M10 K2
K2 40
Fig: 10 – DC motor, DC control & AC heater schematic

diagram of motor drive for 25kV single pole isolator

Abbreviation Description
FP,FN Motor HRC fuse, 16Amp
FP1,FN1 Control HRC fuse, 2A
FP2,FN2 Control HRC fuse& Neutral
link(HRC fuse - 2A)
MS Motor supply switch
TR Overload Relay
KC,KO Close/ Open contactor
CS Control Supply Switch
LK Link fir introducing any out side
interlocking
ILS Interlocking switch for blocking
motor operation in manual mode
ML Mechanical interlocking for manual
operation
SL Solenoid interlocking for manual
operation
PSL Push button for solenoid interlock
LR Local/Remote/Manual switch
PC,PO Close, Open push button
LC,LO Close, Open limit switch
PSS Power Switch Socket
LB Light Bulb Socket
SH Space Heater
LBS Light Bulb Switch
SHS Space Heater Switch
M Motor – 110 V DC

Ikfjf’k"V&2
Ikfjf’k"V&2 ANNEXURE-2
lEcaf/kr fof’k"Vrkvksa dh lwph List of related specifications
The isolator and earthing switch shall, unless otherwise

specified herein, conform to the latest version of the Indian
Standards, Specifications/IEC recommendations/Research designs
and Standards Organization (RDSO) specifications as indicated
below and the Indian Electricity Rules, wherever applicable.
S.No. Standard no. Description

1 IS:1248 Electrical indicating instruments
2 IS: 1570 Carbon steels (unalloyed steels)
(Pt.II)
3 IS:1651 Specification for stationary cell &
batteries, leadacid type (with tubular +ve
plates)
4 IS:1652 Specification for stationary cells &
batteries, .lead – acid type (with plante
+ve plates)
5 IS: 2071 General definitions and test requirements
(Pt.I & II) and test procedures
6 IS: 2108 Black heart malleable iron castings
7 IS: 2419 Electrical indicating instruments
8 IS: 2544 Porcelain post insulators for systems
with nominal voltage greater than 1000
volts
9 IS: 4540 Rectifier assemblies & equipments
10 IS: 5561 Electric power connectors
11 IS: 6619 Rectifier assemblies & equipments
12 IS: 7608 Phosphor bronze wires (for general
engineering purposes)

S.No. Standard no. Description

13 IS: 7906 Helical compression springs
14 IS: 8828 Miniature circuit breaker
15 IS: 9921(Pt.I, II, Alternating disconnectors
III&IV) (Isolators) and earthing switches
for voltage above 1000V
16 IEC: 129 Alternating current
disconnectors (Isolators) and
earthing switches
17 ETI/OHE/13(4/84) Specification for hot dip zinc
coating on steel masts (rolled
and fabricated) tubes and fittings
used on 25 kV ac OHE
18 ETI/OHE/18(4/84) Specification for steel and
stainless steel bolts, nuts and
washers.
29 ETI/OHE/64 Specification for Solid Core
Cylindrical post insulators for
system with nominal voltages of
220kV, 132kV, 110kV & 66kV.

NOTE 

lanHkZ
1- 25 dsoh ,lh] flaxy iksy ,oa Mcy iksy

eksVjkbZTM vkbZlksysVj ds fy;s vkjMh,lvks dh
fof’k"Vrk la[;k TI/ SPC/ PSI/ ISOL/ TR/ 1060 A
2- Mh,evkjlh] ubZ fnYyh ls feyh tkudkjh A
3- fofHkUu jsyos dk;Z{ks=ksa dk v/;;u ,oa ogk¡ ls

,d= lkexzh A
4- dSeVsd Xokfy;j esa fnukad 11 ekpZ 2011 dks

vk;ksftr lsehukj esa vk;s gq;s fofHkUu {ks=h; jsyos
,oa fuekZrkvksa ds izfrfuf/k;ksa }kjk fn;s x;s lq>koA

REFERENCES
1. RDSO Specification for 25 kV AC single pole and

double pole motorized isolators no.
TI/SPC/PSI/ISOL/TR/1060.
2. Details received from DMRC, New Delhi.
3. Field study and Literature collected from various

Railways.
4. Presentations given by participants from various Zonal

Railways and manufacturer during seminar conducted on
11th March 2011 at IRCAMTECH/ Gwalior.
*****

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djuk rFkk mRikndrk vkSj jsyos dh ifjlEifRr
,oa tu’kfDr ds fu"iknu esa lq/kkj djuk
ftlls vUrfoZ"k;ksa esa fo’oluh;rk] miyC/krk]
mi;ksfxrk vkSj n{krk izkIr dh tk ldsA
;fn vki bl lanHkZ esa dksbZ fopkj vkSj fo’ks"k lq>ko nsuk
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lEidZ lw= % funs’kd ( fo|qr )
Ik=kpkj dk irk % Hkkjrh; jsy

mPp vuqj{k.k izkS|ksfxdh dsUnz]
egkjktiqj] Xokfy;j e- iz-
fiudksM 474 005
Qksu % 0751&2470803
0751&2470740
QSDl % 0751&2470841
bZ&esy : direlcamtech@gmail.com

OUR OBJECTIVE
To upgrade maintenance technologies and

methodologies and achieve improvement
in productivity and performance of all
Railway assets and manpower which inter-
alia would cover reliability, availability,
utilisation and efficiency.
If you have any suggestions and specific comments

please write to us.
Contact person Director Electrical
Postal address Indian Railways

Centre for Advanced
Maintenance Technology,
Maharajpur, Gwalior,
Pin Code - 474 005
Phone 0751 – 2470740

0751 – 2470803
Fax 0751 – 2470841
Email direlcamtech@gmail.com

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y{; lewg % VhvkjMh vuqj{k.k deZpkjh

egkjktiqj, Xokfy;j & 474 005

April, 2011 Handbook on Motorised Isolator

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Handbook on Motorised Isolator April, 2011

At present isolators are being opened and closed

To save this valuable power block time, the concept of

This handbook contains comprehensive information on

I am sure this document will be informative as well as

CAMTECH, Gwalior S.C. Singhal

April, 2011 Handbook on Motorised Isolator

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Handbook on Motorised Isolator April, 2011

This handbook on motorized isolator has been prepared

It is clarified that this handbook does not supersede any

I am sincerely thankful to all field personnel who have

Technological up-gradation & learning is a continuous

CAMTECH, Gwalior Peeyoosh Gupta

April, 2011 Handbook on Motorised Isolator

Handbook on Motorised Isolator April, 2011

April, 2011 Handbook on Motorised Isolator

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Handbook on Motorised Isolator April, 2011

Sr.No. Description Page No.

3.16 Permissible Peak Withstand Current 4

April, 2011 Handbook on Motorised Isolator

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Handbook on Motorised Isolator April, 2011

Sr.No. Description Page No.

5.13 Insulators and Terminal Connectors 14

6.0 DETAILS OF MOTORISED ISOLATORS

7.0 MAINTENANCE SCHEDULE 26

8.0 DETAILS OF MOTORISED ISOLATORS

April, 2011 Handbook on Motorised Isolator

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Handbook on Motorised Isolator April, 2011

ISSUE OF CORRECTION SLIP

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CORRECTION SLIPS ISSUED

Sr. No. Date of Page no. and Item Remarks

April, 2011 Handbook on Motorised Isolator

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