How to Safely install an Isolator on a Double-Pole Structure

Step-by-Step Installation Guide for Electrical Isolators on a Double Pole Structure

• Step 1: Preparing the Site and Checking the Structure

1. Site Preparation :

Clear the installation area of any debris or obstacles.

Ensure a stable foundation for the double pole structure.

Verify that environmental conditions (e.g., wind and weather) are suitable for work.

2. Inspection of the Structure :

Confirm that the double pole structure is securely erected and aligned.

Check for structural integrity (no cracks or rust if metallic).

Ensure the structure complies with load and safety standards for the isolator being installed.

Must coloured with Red oxide and Silver paint before installation .

Proper Fabrication for Isolator is designed and installed on Poles .

3. Safety Measures :

Turn off power to the circuit where the isolator will be installed.

Ensure proper grounding of the structure and tools.

Equip personnel with appropriate PPE (helmets, gloves, insulated boots).

• Step 2 : Mounting the Isolator on the Double Pole Structure

1. Positioning the Isolator :

Identify the designated mounting location on the structure.

Use a level to ensure proper alignment of the isolator.

Isolator should handle carefully for its Insulator , Fixed Contact and Moving Contact assembly .

Extra care to be taken for Porcelain type Insulator .

2. Securing the Mounting Base :

Attach the isolator’s mounting brackets to the double pole structure using bolts or clamps. Base channels of 3200 to 3500 mm used for mounting of Isolator as per site and DP dimensions .

Tighten fasteners to the manufacturer's torque specifications to prevent slippage. SS hardware are preferably used for copper conductor path nut bolting and for fabrication Hot dip galvanized nut bolts are used .

3. Assembling the Isolator :

Follow the manufacturer’s instructions to attach isolator components like arms, blades, or rotating mechanisms. Isolator Manufacturers like Balaji Engineers Isolators Private limited are provided Pre factory aligned Isolators , where Isolator links to be erected on structure and nut bolting of manual operation mechanism . Advantage of Balaji Isolator is Isolator come with alignment of Fixed contact and Moving Contact of Row , Also in case of Earth blade it is totally came duly alignment of Earth blade.

• Step 3 : Connecting Electrical Cables and Terminals

1. Cable Or Conductor Preparation:

Strip the insulation from cables to the appropriate length without damaging the core.

Verify that cable sizes match the isolator's specifications as per its ampre capacity .

2. Terminal Connections :

Connect the input and output cables to the isolator terminals as per the circuit diagram.

Ensure proper polarity and secure connections with appropriate torque to avoid loose joints.

Termincal connector are palys very Important role in Isolator assembly on double pole . Connectors should be as per correct ampere rating with proper hole design .

3. Earthing Connections :

Attach the grounding wire to the designated terminal on the isolator.

Verify that the grounding path complies with safety standards

• Step 4 : Testing and Ensuring Proper Functionality

1. Visual Inspection

Check all connections for tightness and proper insulation.

Verify that all moving parts (e.g., blades, switches) operate without obstruction.

Confirm all Assembly , Insulators are in good condition after installation of total Isolator on Pole

Alignment Fixed Contact and Moving Contact of Isolator to checked once .

2. Functional Testing :

Operate the isolator manually or via the control mechanism to confirm smooth opening and closing.

Use a multimeter to check for continuity and ensure the circuit is completely isolated when switched off.

Manual 4 No 4 NC box is provided by Isolator Manufacturer , Rotary mechanical handle also provided some times . Operation system should be checked properly before its charging .

Mechanical endurance Isolator ON OFF test is very important before charging of system.

3. System Integration :

Reconnect power and perform load testing under controlled conditions.

Verify that the isolator handles the rated current and voltage without any abnormalities.

4. Final Safety Checks :

Test the isolator under fault conditions (if applicable) to ensure fail-safe operation.

• Step 5 : Common Mistakes to Avoid During Isolator Installation

1. Misalignment During Installation

Issue : Improper alignment of the isolator's components (such as blades, terminals, or the operating mechanism) can lead to uneven operation or failure to establish a proper electrical connection

Impact : Misaligned isolators may fail to isolate circuits effectively, increasing the risk of faults or accidents. They can also cause excessive wear on moving parts, shortening the lifespan of the equipment.

Solution :
Use a level and alignment tools during installation.
Double-check that blades and contacts align correctly in both open and closed positions.
Follow manufacturer-recommended alignment procedures. Visit –

2. Loose Connections or Improper Wiring

Issue :Loose terminals, incorrect cable sizing, or improper wiring practices can result in poor electrical contact, arcing, or overheating.

Impact :These issues can cause equipment failure, energy losses, or fire hazards. In high-voltage setups, they may lead to catastrophic failures.

Solution :
Ensure all terminals are tightened to the recommended torque specifications.
Use the correct cable size as specified in the isolator's technical documentation.
Conduct a thorough inspection of all wiring before energizing the system.
Use crimping tools or appropriate connectors to avoid damaged or loose cable ends.

3. Ignoring Safety Protocols

Issue : Skipping essential safety measures, such as not de-energizing the circuit, failing to wear personal protective equipment (PPE), or neglecting proper grounding, poses serious risks to personnel and equipment.

Impact : Ignoring safety protocols can result in electric shocks, severe injuries, or equipment damage. Additionally, it may lead to non-compliance with local electrical codes.

Solution :
Always de-energize the circuit and verify it with a voltage tester before starting work.
Wear PPE, including insulated gloves, boots, and helmets with visors.
Ensure proper grounding of the isolator and nearby structures to prevent stray voltage risks.
Follow lockout-tagout (LOTO) procedures to prevent accidental re-energization.

4. Final Safety Checks :

Test the isolator under fault conditions (if applicable) to ensure fail-safe operation.