PR-05 mechanisms are intended for manual operation of disconnectors and earthing switches. The mechanisms are manufactured in accordance with GOST 689-90, climatic design UHL, placement category 1 per GOST 15150-69 and GOST 15543-89 (with environmental categories aligned to EN/IEC 60721-3-4 / EN/IEC 60721-3-3).
The PR-05 mechanism is intended to operate the contact blades or earthing switches of the new series of disconnectors RDZ, RG, RLK, etc., for medium-voltage ratings up to 35 kV.
PR-05 is manufactured with one main shaft and two earthing-switch drive shafts.
Normal operation is ensured under the following conditions:
– altitude above sea level not more than 1000 m;
– upper operating ambient temperature +40 °C;
– lower operating ambient temperature -60 °C.
The mechanism consists of a housing, output shaft, an interlocking mechanism based on the electromagnetic key lock ZB-1M UHL1, a switching mechanism, an operating handle and cable glands.
Access to the internal mechanisms (during installation and adjustment) is provided after unlocking with a special key and lowering the cover.
For connection to the disconnector or earthing-switch shaft, a clamping adapter is fixed on the output shaft, allowing adjustment during switching ON/OFF of the disconnector or earthing switch.
The operating handle can be pinned in the horizontal position during operation and, upon completion, set vertically and locked with a padlock.

Technical data

Purpose and application

The PR-05 manual operating mechanism is a mechanical drive unit for local operation of three-pole and single-pole switchgear apparatus rated up to 35 kV, including outdoor disconnector series RDZ, RG, RLK and their earthing blades. The mechanism transmits rotary motion to the disconnector’s main shaft with the required torque and precise latching of the end positions “Open/Closed” and “Earthed/Released”, which is essential for operational switching in 6–10–35 kV substation switchgear, distribution points, KRUN, KSO and RP at industrial facilities.

The application scope includes:
- operating the main blades of air disconnectors and earthing-switch drives with an output-shaft rotation angle of 90 deg;
- equipping new-build and refurbished substations with outdoor and indoor switchgear;
- upgrading existing apparatus of domestic and foreign manufacture provided the coupling and connection dimensions of shafts and linkages are coordinated;
- implementing mechanical and electromagnetic interlocks in schemes that must exclude mal-operations (e.g. “closing a disconnector with the circuit breaker not open” or “opening under load”).

PR-05 is aimed for use in distribution networks of industrial and municipal power systems, at small and medium generation facilities, on railway substations, and in the oil & gas and mining sectors where simple, fail-safe, non-energized control of switching devices and reliable position latching are required.

Service conditions

The UHL1 climatic design ensures operation outdoors and in unheated rooms in temperate and cold climates. The operating temperature range corresponds to outdoor equipment requirements: from -60 °C to +40 °C (short-time up to +45 °C). Permissible relative humidity up to 98 % at +25 °C without internal condensation, subject to proper storage and commissioning. Atmospheric pressure corresponds to altitudes up to 1000 m above sea level.

Resistance to vibration and shock corresponds to industrial installation (no permanent impact loads). Operation is permitted at sites with moderately polluted atmosphere (dust, fine sand, salt) provided a protective cover is installed and routine maintenance is carried out. Placement category 1 guarantees resistance to UV and precipitation with correct housing orientation and a weather hood (for outdoor installation). For indoor switchgear (sealed-housing versions), protection against draughts and dripping water is provided.

Requirements for installation and operation:
- mount on a rigid base with accurate alignment of axes “mechanism - transmission linkages - disconnector shaft”;
- eliminate skew and jamming in kinematics; adjust the end-position stops;
- protect cable entries from water ingress; use seals and cable glands per design;
- maintenance interval per manual: fastener check, interlock verification, lubrication of friction pairs (if applicable).

Layout and design solutions

The PR-05 mechanism is built as a standardized cabinet with a drive module. It comprises: a metal housing with anti-corrosion coating; the main output shaft (for disconnector blade operation); two earthing-switch output shafts (for single-pole or grouped blades); a cam/roller-lever switching mechanism; an end-position latching system; an electromagnetic interlock based on the ZB-1M UHL1 lock; an operating handle with optional extension up to 1.5 m; cable glands; and a set of auxiliary signalling contacts (KSA).

Force transfer from the handle to the shafts is implemented via a reduction and lever mechanism that ensures stable torque and high repeatability of the 90 deg rotation. The handle force is limited by ergonomic and operator-safety requirements; optional damping elements and counterweights can be supplied to ease the start and final positioning.

To interface with various disconnector series, interchangeable clamps and adapters are provided on the output shafts, enabling PR-05 to couple with the drive shafts of leading poles of RDZ/RG/RLK and their modifications. The system of adjustable stops and slotted (elliptical) holes on the clamps simplifies fine tuning of pole synchronism and accuracy of end positions on the specific site. The two earthing-switch shafts (independent) allow separate or synchronous operation of earthing blades, including mechanical interlocking of the operation sequence.

The housing provides:
- a hinged drop-down cover with latching for convenient adjustment access;
- a hasp plate for padlocking in the mode “handle vertical, mechanism locked”;
- a mounting panel for terminals, limit switches and cable entries; an optional window for position indication;
- a post/bracket for mounting on steel structures or on a foundation plate.

Position signalling is provided by KSA contact groups (up to 12 contacts for the main shaft and up to 4 for the earthing-switch shaft). The contacts are intended for low-power protection and automation circuits; for auxiliary circuits with higher load, use intermediate relays.

Safety and interlocks

The PR-05 implements a set of measures to prevent mal-operations and ensure personnel safety:

• Electromagnetic interlock based on the ZB-1M UHL1 lock (with KEZ-1M electromagnetic key and KM-1M emergency magnetic key) prevents handle movement without a permissive signal from adjacent apparatus/protection relays. The electric key enables applying/releasing the interlock only when the scheme logic is satisfied.
• Mechanical handle latching in the horizontal position during operation and padlock locking in the vertical position - to support LOTO procedures.
• Adjustable end stops prevent over-rotation of the shaft and consequent mechanical damage to linkages and blades.
• Position signalling via KSA contacts enables interlocks between circuit breaker - disconnector - earthing switch in switchgear schemes, including blocking closure when an earthing blade is engaged.

All interlock components are arranged for easy service; wiring is performed with screened cable through sealed cable glands. For electrical safety, the housing and all exposed conductive parts have a grounding stud for connection of the PE conductor per project.

Versions and options

The basic PR-05 line can be adapted to a specific disconnector and site conditions. On request:

• arrangement variants of output shafts (right/left, one or two earthing-switch shafts);
• handle extensions up to 1.5 m with quick-release coupling;
• extended KSA set (additional “dry” contacts for telemechanics);
• housing with enhanced anti-corrosion coating for coastal areas;
• space heater with thermostat to prevent condensation (version for indoor switchgear);
• position indicators (mechanical plates/flags) on the shaft and on the front panel;
• adaptor flanges/clamps for specific RDZ, RG, RLK series and analogues;
• cable glands for the required cable diameter and type (metal/plastic);
• inter-apparatus interlock kit (electrical and mechanical) per customer’s scheme.

Standards compliance

The design and manufacture of PR-05 are oriented to the requirements of the following standards (or their current versions/equivalents):

• GOST 689-90 “AC disconnectors and earthing switches above 1000 V. General specifications” (as applied to operating mechanisms);
• GOST 15150-69 “Machines, instruments and other technical products. Versions for different climatic regions” (UHL1 climatic design; environmental categories aligned with EN/IEC 60721-3-4 / EN/IEC 60721-3-3);
• GOST 15543.1-89 “Electrical products. General requirements for resistance to climatic factors” (reference to IEC 60068 series);
• IEC 62271-102 “High-voltage switchgear and controlgear - Part 102: AC disconnectors and earthing switches” (applicable to medium-voltage disconnectors and earthing switches);
• IEC 62271-1 “High-voltage switchgear and controlgear - Common specifications”;
• ISO 12100 / IEC 60204-1 - general machinery safety and electrical equipment of machines (as applicable).

Engaging partners and manufacturers

We invite manufacturers and investors interested in producing manual mechanisms for medium-voltage disconnectors. We provide a full set of working documentation, manufacturing routings, material and purchased-part specifications, and support in selecting cooperation for machined parts, welded assemblies, protective coatings and assembly. Partners gain access to an up-to-date database of interface dimensions for popular disconnector series and to commissioning/adjustment methods.

System integrators and electrical contractors can include PR-05 in retrofit projects for switchgear and KRUN, receiving from us inquiry sheets, kinematic calculations, adjustment charts and typical interlock schemes using electromagnetic keys.

Documentation and support offered

To accelerate start of production and ensure confident supervision/commissioning, a complete documentation package is provided:

• general-arrangement and assembly drawings, BOMs and purchased-parts lists;
• 3D models (STEP/Parasolid), AutoCAD files (DWG), DXF, SolidWorks models;
• lists of fasteners and interface dimensions, lubrication and adjustment charts;
• installation and operating manuals, test program & procedures, trial assembly protocols;
• typical wiring diagrams for KSA and interlock logic (ZB-1M/KEZ-1M);
• recommendations on materials and coatings for UHL climatic regions.

Scope of supply

The standard scope of supply includes: PR-05 mechanism in the selected version; a set of clamps/adapters for the output shaft; operating handle (with provision for an extension); product passport and operating manual; spare parts per list; installation kit (bolts, washers, cotter pins); terminal markers; optionally - the KEZ-1M electromagnetic key and KM-1M emergency magnetic key.

Why work with us

- No need to maintain highly qualified engineering staff: you receive a documentation package for the product that can be handled by a mid-level engineer.
- No need to build prototypes: our experience allows direct ramp-up of serial production.
- Working to our documentation, your specialists will receive consulting on all nuances of manufacturing the PR-05 manual mechanism.

Cooperation

We are open to cooperation with machine-building plants, machining shops, galvanic and powder-coating facilities, as well as RP/KRUN integrators. We will provide manufacturing routings, control cards, equipment and tooling lists, recommendations on materials and coatings, and we will help to arrange supplies of purchased items (“ZB-1M/KEZ-1M”, KSA, cable glands, fasteners). For investors we will prepare a business plan for setting up production, cost calculations and quality plans.

For additional information on the PR-05 mechanism please contact: inbox@proekt-energo.com

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