Instruction Booklet IB01900002E Effective June 2011 Instructions … · 2020. 6. 6. · 2 Instruction Booklet IB01900002E Effective June 2011 Instructions for Magnum DS Metal-Enclosed

ContentsDescription Page

1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . 22. Receiving,Handling,andStorage. . . . . . . . . . 43. EquipmentDescription. . . . . . . . . . . . . . . . . . 54. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 115. Inspection,Testing,andMaintenance. . . . . . 146. DocumentReferences. . . . . . . . . . . . . . . . . . 14

Effective June 2011Instruction Booklet IB01900002E

Instructions for Magnum DS® Metal-EnclosedLow-Voltage NEMA 3R Assemblies

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InstructionBookletIB01900002EEffective June 2011

Instructions for Magnum DS Metal-EnclosedLow-Voltage NEMA 3R Assemblies

EATON CORPORATION www.eaton.com

Readandunderstandtheseinstructionsbeforeattemptingtounpack,assemble,operateormaintainthistypeequipment.

NOTICEALL POSSIBLE CONTINGENCIES WHICH MAY ARISE DURING INSTALLATION, OPERATION OR MAINTENANCE, AND ALL DETAILS AND VARIATIONS OF THIS EQUIPMENT DO NOT PURPORT TO BE COVERED BY THESE INSTRUCTIONS.

Iffurtherinformationisdesiredbypurchaserregardingtheparticularinstallation,operationormaintenanceofparticularequipment,con-tactthelocalEatonrepresentative.

WARNINGMETAL-ENCLOSED LOW-VOLTAGE NEMA 3R ASSEMBLIES COVERED BY THESE INSTRUCTIONS ARE DESIGNED AND TESTED TO OPERATE WITHIN THEIR NAMEPLATE RATINGS. OPERATION OUTSIDE OF THESE RATINGS MAY CAUSE THE EQUIPMENT TO FAIL RESULTING IN DEATH, SERIOUS INJURY AND/OR PROPERTY DAMAGE. ALL RESPONSIBLE PERSONNEL SHOULD LOCATE THE EQUIPMENT RATING NAMEPLATE AND BE FAMILIAR WITH THE INFORMATION PROVIDED THEREON.

Purpose

Thisinstructionmanualisexpresslyintendedtocovertheinstalla-tion,operationandmaintenanceofMagnumDS®Metal-EnclosedLow-VoltageNEMA3RAssembliesusedwithMagnumDS®PowerCircuitBreakersorCM52NetworkProtectors.

NOTICETHIS INSTRUCTION MANUAL IS INTENDED TO EMPHASIZE THE FEATURES AND ENHANCEMENTS UNIQUE TO MAGNUM DS NEMA 3R SWITCHGEAR AND SWITCHBOARDS. IT IS NOT INTENDED TO BE A COMPLETE MANUAL FOR THE INSTALLATION, OPERATION AND MAINTENANCE OF MAGNUM DS METAL-ENCLOSED LOW-VOLTAGE ASSEMBLIES, BUT IS SUPPLEMENTAL IN NATURE; AND APPENDS THE ORIGINAL ONLY AS DESCRIBED HEREIN. FOR COMPLETE INSTRUCTIONS CONCERNING MAGNUM DS METAL-ENCLOSED LOW-VOLTAGE ASSEMBLIES, SEE IB01901001E.

Forapplicationinformationconsultapplicabledescriptivebulletins,applicationpublicationsand/ortheapplicableindustrystandards.Forinstallation,operationandmaintenanceofLow-VoltagePowerCircuitBreakersseeseparateinstructionbooklistedinSection6.

Safety

Allsafetycodes,safetystandardsand/orregulationsMUSTbestrictlyobservedintheinstallation,operationandmaintenanceofthisequipment.

DANGERTHE DANGER, WARNING AND CAUTION MESSAGES INCLUDED AS PART OF THE PROCEDURAL STEPS IN THIS MANUAL ARE FOR PERSONNEL SAFETY AND PROTECTION OF EQUIPMENT FROM DAMAGE. AN EXAMPLE OF A TYPICAL WARNING LABEL HEADING IS SHOWN ABOVE THIS PARAGRAPH TO FAMILIARIZE PERSONNEL WITH THE TYPE OF PRESENTATION. THIS WILL HELP TO ASSURE THAT PERSONNEL ARE ALERT TO THESE MESSAGES. IN ADDITION, THESE MESSAGES ARE ALL UPPER CASE AND BOLDFACE.

Section 1: Introduction1.1GeneralInformation

MagnumDSMetal-EnclosedLow-VoltageNEMA3RSwitchgearandSwitchboardAssembliesareuniquelydesignedforuseinoutdoorenvironmentsorotherharshconditions.TheNEMA3REnclosureisa"skin"or"shell"thatcontainsandprotectsthestandardindoorassemblyfromtheelementsassociatedwithoutdoorinstallations,suchasfallingrain,sleetorsnow.Therefore,mostfeaturesandoptionsinherenttothestandardindoorenclosureareavailableintheNEMA3Rversion,aswell.Theseassembliesaretestedtotherig-orsofUL50EandcertifiedasaNEMAType3Renclosure.

TheseassembliescontainthesamedistributionoptionsasstandardindoorassembliesandmayuseMagnumDS,MagnumSBand/orSeriesNRX®PowerCircuitBreakerstocontrolandprotectpowercircuitsuptoandincluding600voltsACandinterruptingcapacitiesuptoandincluding200kA.

Theswitchgearorswitchboardassemblyiscomposedofverticalsectionsthatarearrangedtosuitthecustomer’slayoutrequire-ments.MagnumDSswitchgearandswitchboardsutilizeafour-cellhighstructuredesignconsistingofvariouscombinationsofMagnumDS,MagnumSBand/orSeriesNRXPowerCircuitBreakersandauxiliarycompartments(SeeIB01901001EreferencedinSection6).Busandcablecompartmentsprovidespaceforconnections,mainte-nanceandinspection.Powercableconnectionsarerear-accessibleasastandard,ormaybefront-accessibleasanoption.

Accesstothecircuitbreakersisavailableviaawalk-indesign(42"aisle-way)asastandard,oranon-walk-indesign(aisle-less)asanoption.

Thisinstructionmanualcontainsimportantproceduresandinforma-tionpertinenttothereceiving,handling,storage,installation,opera-tionandmaintenanceofMagnumDSLow-VoltageMetal-EnclosedNEMA3RAssemblies.

NOTICEINFORMATION PROVIDED IN THIS INSTRUCTION MANUAL AND BY OTHER SUPPLIED DOCUMENTATION AND/OR DRAWINGS SHOULD BE READ AND UNDERSTOOD BY ALL PERSONNEL RESPONSIBLE FOR SUPERVISION, OPERATION OR MAINTENANCE. FAMILIARIZATION SHOULD ALWAYS INCLUDE THE CHARACTERISTICS OF EACH PIECE OF EQUIPMENT CONTAINED IN OR MOUNTED ON THE ASSEMBLY. PROPER INSTALLATION, OPERATION AND MAINTENANCE ARE ESSENTIAL TO ASSURE CONTINUED SATISFACTORY SERVICE FROM THE EQUIPMENT. IT SHOULD NOT BE INSTALLED IN PLACES WHERE IT WILL BE REQUIRED TO OPERATE AT VOLTAGE, CURRENTS OR FAULT CAPACITIES GREATER THAN THOSE FOR WHICH IT WAS DESIGNED, OR WHERE THE ENVIRONMENTAL CONDITIONS ARE DIRTY, CORROSIVE, HUMID OR OTHERWISE HARSH OR UNSUITABLE. (REF. ANSI C37.20.1 FOR ABNORMAL OPERATION CONDITIONS). THE INFORMATION GIVEN IN THIS MANUAL APPLIES TO NEMA 3R LOW-VOLTAGE ASSEMBLIES UTILIZING THE MAGNUM DS FAMILY OF DRAWOUT POWER CIRCUIT BREAKERS UNLESS OTHERWISE NOTED. FOR OTHER OPTIONS, SEE THE DOCUMENTS LISTED IN SECTION 6.

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1.2SafetyFeatures

EachMagnumDSAssemblyismanufacturedwithbuilt-ininterlocksandsafety-relatedfeatures.Theyareprovidedtoreducehazardstooperatingpersonnelandprovideproperoperatingsequences.

DANGERMETAL-ENCLOSED LOW-VOLTAGE ASSEMBLIES ARE PROVIDED WITH MANY SAFETY FEATURES. NEVERTHELESS, WHEN CONNECTED THEY CONTAIN POWER CIRCUITS WITH HIGH FAULT CAPACITY. THE VOLTAGES AND POWER LEVELS AVAILABLE IN THIS EQUIPMENT MAKE CONTACT WITH BARE CONDUCTORS OR TERMINALS EXTREMELY DANGEROUS, AND IS LIKELY TO BE FATAL. ALL POWER SHOULD BE TURNED OFF OR APPROPRIATE PROTECTIVE EQUIPMENT USED WHEN WORKING ON SUCH EQUIPMENT. IN ADDITION TO THE HAZARDS INHERENT TO THE LOW-VOLTAGE ASSEMBLY ITSELF, OPERATION BY UNQUALIFIED PERSONS MAY CAUSE INDIRECT DAMAGE TO CONNECTED EQUIPMENT AND INJURY TO OPERATORS OF CONNECTED EQUIPMENT UNDER NO CIRCUMSTANCE SHOULD THE INTERLOCKS OR OTHER SAFETY FEATURES BE MADE INOPERATIVE OR DISABLED, AS THIS MAY RESULT IN DEATH, BODILY INJURY OR PROPERTY DAMAGE. TO PROTECT PERSONNEL DURING THE INSTALLATION, OPERATION AND MAINTENANCE OF THIS, THE FOLLOWING PRACTICES MUST BE

FOLLOWED:

1.3SafetyPractices

WARNINGMAGNUM DS LOW-VOLTAGE SWITCHGEAR AND SWITCHBOARD ASSEMBLIES ARE COMPLEX, HIGH CURRENT ELECTRICAL EQUIPMENT DESIGNED TO OPERATE WITHIN THE VOLTAGE AND CURRENT LIMITATIONS SHOWN ON THEIR RESPECTIVE NAMEPLATES. DO NOT APPLY THIS EQUIPMENT TO SYSTEMS WITH VOLTAGES AND/OR CURRENTS IN EXCESS OF THESE LIMITS.

1. Onlyqualifiedelectricalpersonnelfamiliarwiththeconstructionandoperationofthisequipmentandtheassociatedhazardsshouldbepermittedtoworkonsuchequipment.Additionally,onlyqualifiedpersonnelshouldbepermittedtoinstalloroperatesuchequipment.

2. Alwaysbecertainthattheprimaryandsecondarycircuitsarede-energizedbeforeattemptinganymaintenance

3. Formaximumsafety,onlyinsertacompletelyassembledbreakerintoanenergizedcell.Frontcoversaresafetyfeaturesandmustbeinplacewhenenergized.

4. Whileintheassembly,alwaysensurethatdrawoutcircuitbea-kersareinoneofthreeintendedpositions:“Connect”,“Test”or“Disconnect”.Acircuitbreakerpermittedtoremaininaninter-mediatepositioncouldresultincontrolcircuitsbeingimproperlyconnectedcausingotherequipmenttomalfunction

5. Donotremoveaccesscoversunlessthecircuitstobeexposedarede-energized.

6. Usecalibratedtestequipmentofknownreliabilitytoconfirmthatallcircuitsarede-energizedbeforeservicing

7. Aftermaintenance,becertaineverycurrenttransformersecond-arycircuitiscompletelyconnectedorshorted.

DANGERIF THE SECONDARY CIRCUIT OF ANY CURRENT TRANSFORMER IS LEFT OPEN WITHOUT LOAD, AND ITS PRIMARY CIRCUIT IS ENERGIZED, A DANGEROUSLY HIGH VOLTAGE IS DEVELOPED ACROSS TRANSFORMER SECONDARY TERMINALS. TO PREVENT DEATH, BODILY INJURY OR ELECTRICAL SHOCK, EITHER DE-ENERGIZE THE CIRCUIT BY OPENING THE BREAKER, OR SHORT CIRCUIT CURRENT TRANSFORMER SECONDARY TERMINALS, BEFORE ENERGIZING THE CIRCUIT AND PROCEEDING WITH MAINTENANCE.

8. Alwaysbecertainthatallassemblyhardwareisinplaceandboltedtightlybeforeinsertingadrawoutcircuitbreakerintoitscompartment.

WARNINGFAILURE TO FOLLOW THESE DIRECTIONS MAY RESULT IN DEATH, SERIOUS BODILY INJURY OR PROPERTY DAMAGE.

1.4QualifiedPersonnel

Forthepurposeofoperatingswitchgearandswitchboardassem-blies,apersonwhohasbeenthoroughlytrainedintheoperationofcircuitbreakersandanyincludedinstrumentationandwhohascom-pleteknowledgeoftheloadsconnectedtotheassemblymaybeconsideredtobeaqualifiedperson.

Forthepurposeofinstalling,inspectingandmaintainingswitchgearandswitchboardassemblies,aqualifiedpersonMUSTalsobeaqualifiedelectrician,whoisthoroughlytrainedinregardtorecogniz-ingandavoidingthehazardsinherenttoworkingwithelectricityandintheproperwaytoperformsuchwork.Theindividualmustbeabletode-energize,clearandlockout/tagoutcircuitsinaccordancewithestablishedsafetypractices.Inaddition,theindividualmustbeequippedwith,andtrainedintheuseof,PersonalProtectiveEquipment(PPE)(rubbergloves,arc-flashclothes,etc.)forthoseoccasionswhenitisnotpossibletode-energizeallcircuitsbeforedoingmaintenanceworkinthearea.

1.5Precautions

1. Ifrelaysareincluded,removeallblocking.Checkcontrolcircuits(exceptvoltageandcurrenttransformercircuits)forgroundsandshortcircuitsbeforeapplyingcontrolpower.

2. Connecttheassemblytothestationgroundbeforeapplyinganypower

3. Incaseoffire,donotuseliquidfireextinguisheruntilallcircuitshavebeendisconnected.

4. Ifanassemblyistobestoredforanextendedperiodpriortoinstallation,provisionsmustbemadeforenergizingthespaceheaterstopreventcondensationofmoistureinsidetheassem-bly.

1.6OtherPublicationsandDocumentation

Inadditiontothisinstructionmanual,otherprintedinformationanddocumentationissuppliedwitheachassembly.Thisadditionalinfor-mationwillinclude,butnotnecessarilybelimitedto,aMagnumDSLow-VoltagePowerCircuitBreakerinstructionmanual,arrangementdrawings,andconnectiondiagrams.ForadditionalreferencesseeSection6.

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Section 2: Receiving, Handling & Storage

NOTICEFOR COMPLETE RECEIVING, HANDLING AND STORAGE INSTRUCTIONS, SEE SECTION 2 OF THE PRIMARY INSTRUCTION BOOK IB01901001E, REFERENCED ELSEWHERE IN THIS PUBLICATION. INSTRUCTIONS WHICH FOLLOW EMPHASIZE THE UNIQUE FEATURES ASSOCIATED WITH MAGNUM DS LOW-VOLTAGE NEMA 3R ASSEMBLIES.

2.1GeneralInformation

MagnumDSMetal-EnclosedLow-Voltageassembliesareshippedinoneormoreshippinggroups,dependingonthenumberofverti-calsections,orthelimitationsofhandlingfacilitiesattheinstalla-tionsite.Thiscouldtypicallyresultinthreeorfoursectionsforacompleteassembly.MaximumlengthofapreassembledNEMA3Rshippingsectionis108”(2743mm)includingatransformerconnec-tionthroat,ifapplicable.

Allshippingsectionsareshippedsoastobeprotectedfromtheweatherduringshipmentbutarenotsuitableforstorageoutdoorsasshipped.NEMA3Rassembliesarenotweatherproofuntilcom-pletelyassembled.Treatthemthesameasindoorequipmentuntilfullyassembled.

2.2Receiving

WhenaMagnumDSLow-Voltageassemblyreachesitsdestination,thepurchasershouldcheckthematerialreceivedagainsttheship-pinglisttobecertainthatallitemshavearrived.Noteaccuratelyanydiscrepancies.Eachshippinggroupisplainlymarkedwithoraccom-paniedbyanidentifyingshopordernumber,generalordernumberandshippingweight.Eachshipmentincludesacontentslistwhichisapartoftheoverallpackageofshippingpapers.Toavoidthelossofanyparts,thecontentsofeachcontainershouldbecarefullycheckedagainstthepackinglist.Donotdiscardanypackingmate-rialuntilitiscertainthateveryitemhasbeenreceivedintheproperconditionandthatcertainpackingmaterialwillnotberequiredlaterforequipmentstorage.Largeritems,suchasportabletravelinglift-ers,areshippedinseparatecartons.Otherlooseandunmounteditemsmaybepackedinadditionalcartons.Theseitems,suchasshippingsplithardware,shouldbeloggedinandsetasideinasafelocationuntiltheassemblyhasbeensetinitsfinalposition.

Equipmentshippedfromthefactoryiscarefullypackedandinspect-edpriortoitsdeparture.Onoccasion,however,equipmentdamageisincurredduringtransportation.Ifanydamageisfound,fileadam-ageclaimimmediatelywiththetransportationcarrierandnotifyanEatonrepresentative.Allclaimsshouldbefiledassoonaspossibleandincludeapplicablepartnumbers,shopordernumbersand/orgeneralordernumbers

2.3Precautions

Itispreferabletouseanoverheadcranewhenmovingtheassem-bly.Circumstancesattheinstallationlocationmaypreventtheuseofanoverheadcraneforallmovement.Insuchinstances,thecarefuluseofrollerscanbeemployed.AlthoughthemethodsformovingNEMA1andNEMA3Rassembliesaresimilar,thetechniquesvaryslightly.Thedifferencesarehighlightedinthissection.

2.3.1 Overhead Lifting

WARNINGFAILURE TO FOLLOW LIFTING INSTRUCTIONS MAY RESULT IN DEATH OR SERIOUS BODILY INJURY. READ INSTRUCTIONS FOR LIFTING SWITCHGEAR PRIOR TO ATTACHING CABLES, CHAINS OR SPREADER BARS.

Liftingplatesareattachedalongtheassemblybaseatthefrontandrearforcranecableattachment.Suitablysizedspreaderbars(notprovided)mustbeplacedbetweenliftcablestopreventequipmentdamage(Figure1).Ifitappearsthatthecableswilltouchtheassem-blyduringtheliftingprocess,placeappropriatelysizedlumberalongthesideswherecontactcouldbemadebetweenthecableandtheequipment.Thiswillpreventdamagecausedbytheliftingcables.

Figure1.NEMA3RAssemblyLiftingMethod.

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2.3.2 Rolling

Ifduringthemovingandpositioningprocessitisnotfeasibletouseanoverheadcrane,theequipmentcanbemovedonconstructionrollers.TheheavysteelbaseonanNEMA3Rassemblyissuitableforusedirectlywhenrolling.Usenolessthanfourevenlyspacedrollersforassemblymovement.Sinceequipmentlengthcanvary,each1.5to2.0feet(457to610mm)ofequipmentlengthrequiresaroller.Astheequipmentiscarefullymoved,therollersthatbecomefreeattheendoppositethemovementdirectionshouldonceagainbeplacedatthefrontforcontinuedmovement.

2.3.3 Lifting Plate Removal

Theliftingplatesattachedatthebaseperformthedualpurposeofprovidingaconvenientandrobustmethodofsecuringtheunittothefoundation.Aseparatechannelbaseisnotrequired.Onceanassemblyisinitspermanentlocationremovetheliftingeyesfromtheangles(Figure2).Rotatetheangles180degreesandreinstall.Usetheholesintheanglestobolttheassemblytothefoundation.

Figure2.Figure2LiftingAngleinPlaceAsReceivedPriortoReversingforSecuringtoFoundation.

2.4Storage

Afullyassembledassemblyrequiresaminimumofcareduringoutdoorstorage.Theareashouldbereasonablyfreeofdirtandcorrosivegases.Thespaceheaters,whicharestandardwithweath-erproofassemblies,mustbeenergizedtopreventcondensation.NEMA3Rassemblieswhicharenotfullyassembledmustbetreat-edinthesamemannerasindoorequipment.

CAUTIONWHEN SPACE HEATERS ARE ENENERGIZED, CARE MUST BE TAKEN THAT INTEGRAL CONTROL POWER TRANSFORMERS ARE NOT BACK-FED. DISCONNECT PRIMARY AND SECONDARY FUSES.

Duringstorage,allassemblies,whetherindoorsoroutdoors,shouldbeplacedonafirm,levelsurface.Thiswillpreventanyunneces-sarystrainorpossibledistortion.Storeallotherseparatelypackagedaccessoryequipmentinaclean,drylocation.Itisrecommendedthatawaterproofcoverbeplacedovercircuitbreakercartonsandthecartonskeptinanindoorstoragelocationwhenthecircuitbreak-ersarestoredseparatelyfromtheassembly.

Section 3: Equipment Description3.1GeneralDescription

Thefollowingdescriptionsapplytostandardmetal-enclosedcon-structionandwiring.Specialfeaturesandcontrolschemesareoftenincorporatedpercustomerspecifications.Thesespecialfeaturesareevidentandportrayedonthedrawingsanddiagramsforthespecificassembly.Instructionsonincludedapparatussuchasrelays,instru-ments,controlswitchesandcircuitbreakersareincludedelsewhereinseparateinstructionbooksorsheets.

Eachlow-voltage(600voltsandbelow)indoorandoutdoormetal-enclosedassemblyisfactoryassembledandtested.Itisdesignedtorequireaminimumamountoflaborforinstallation.

Eachmetal-enclosedassemblyconsistsofastationarystructurethatincludesoneormorefree-standingverticalsectionsmechanicallyandelectricallyjoinedtomakeasinglecoordinatedinstallation.

Inenclosuresidentifiedasrear-accessible,averticalsectionconsistsofthreemajordivisions:thefrontcompartment(breakers),buscompartment,andcablecompartment,whereinthepowercablesareaccessedthroughdoorslocatedintherearoftheenclosure.Inaddition,personnelingress(andaccesstothecircuitbreakers)isaffectedeitherthroughawalk-inaisleway(Figure3)ordirectlythroughthefrontoftheenclosure(Figure4).

Inenclosuresidentifiedasfront-accessible,thethreedivisionsareredistributedbetweenapairofverticalsections:frontcompartment/buscompartmentinonehalf;cablecompartment/buscompart-mentintheremaininghalf,whereinthepowercablesareaccessedthroughdoorslocatedinthefrontoftheenclosure.Inaddition,per-sonnelingress(andaccesstothecircuitbreakers)isaffectedeitherthroughawalk-inaisleway(Figure5)ordirectlythroughthefrontoftheenclosure(Figure6).

AllMagnumDSMetal-EnclosedLow-VoltageNEMA3RAssembliesareapredetermineddepthbasedononeofthefourconfigurationschosen.Directtransformerconnectionsareeasilymanagedwithrear-accessibleunits.However,duetotheforeshorteneddesignoffront-accessibleassemblies,directtransformerconnectionisnotpossiblewithouttheaidofaspecialtransitionenclosure.Ifthisisanessentialpartofaninstallation,contactanEatonsalesandser-vicerepresentativeforassistance.

NOTICEFOR SPECIFIC INFORMATION REGARDING THE INTERNAL CONSTRUCTION OF MAGNUM DS METAL-ENCLOSED LOW-VOLTAGE ASSEMBLIES, INCLUDING BUT NOT LIMITED TO CIRCUIT BREAKER INSTALLATION, BUS CONSTRUCTION AND CABLE/CONDUIT SPACES, REFER TO SECTION 3 OF IB01901001E, REFERENCED IN SECTION 6 OF THIS MANUAL.

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3.2NEMA3REnclosureConstructionOptions(Figures3-6)

MagnumDSMetal-EnclosedLow-VoltageNEMA3RAssembliesareofferedinfourvarietiestomeetthelimitationsofspaceandcustomerpreferences.Theoptionsincludelocationofpowercableconnectionsaswellaspresenceorabsenceofapersonnelingressaisle-way.

3.2.1 Rear-Access with Aisle-way

Powercableconnectionsareaccessiblefromtherearoftheassem-bly.Therearaccessdoorsarehingedandprovidedwithdoorstops.Thesebraceskeepthedoorsopenata90degreeangle.Powercablesandconduitscanexitthroughthefloororthroughtheroofiftheproperroof-exitflangeisinstalled(bycustomerorderrequest).Connectiontolineand/orloadbreakerconnectionsisthesameasdescribedinIB01901001E,theindoorassemblyliteratureforrear-accessibleenclosures.

Afrontoperatingandmaintenanceaisleextendsthroughallunitsoftheassembly.Alargereinforceddoorwithpanichardwareisstan-dardateachendoftheaisle.Thesedoorscanbeopenedfromtheinside,evenwhenpadlockedfromtheoutside.

Thestructurealsoincludes,asstandard,filteredventilationopen-ings(filterscanbechangedwithoutopeningaisleorrearcompart-mentdoors),aislelighting,GFIprotectedconveniencereceptaclesandspaceheaters.Whenspecified,athermostatismountedinthecablecompartment.Spaceheatersarelocatedinthe“D”positionbreakercell,buscompartmentandcablecompartmentofeachverti-calsection

3.2.2 Rear-Access without Aisle-way (Non walk-in)

Powercableconnectionsarethesameasdescribedabove.Connectiontolineand/orloadbreakerconnectionsisthesameasdescribedinIB01901001E,theindoorassemblyliteratureforrear-accessibleenclosures.

Thefrontaisle-wayisabsentinthenon-walk-indesign,permittinganassemblydepthreductionofapproximately32inches(812mm)overthestandardrear-accesswalk-inassembly.Accesstothebreakercompartmentisaffectedthroughfull-heightdoorsonthefrontoftheenclosure.Thesedoorscontainthesamebracingfeaturespresentonthereardoorsdescribedabove.Ventilatedfilters,lighting,recep-taclesandheatersarestandardasdescribedabove.

Theworkspacebetweentheexternalshellandtheinternalbreakerenclosureisapproximately7.5inches(190mm),thereforetheneedforameansofemergencyexitisnotprovided.

otee:N Auniquefeatureofthenon-walk-inassemblyistheinternalbreakerdoorshingeontheright-handsideasnormalconvention,ratherthantheleft.

3.2.3 Front-Access with Aisle-way

Frontaccessibleassembliesprovidefurtherfootprintreductionswhenrequiredbycustomerinstallations.

Powercableconnectionsareaccessiblefromthefrontoftheassem-blythroughthemaintenanceaisle-wayasdescribedbelow.Powercablesandconduitscanexitthroughthefloororthroughtheroofiftheproperroof-exitflangeisinstalled(bycustomerorderrequest).Connectiontolineand/orloadbreakerconnectionsisthesameasdescribedinIB01901001E,theindoorassemblyliteratureforfront-accessibleenclosures.

Afrontoperatingandmaintenanceaisleextendsthroughallunitsoftheassembly.Alargereinforceddoorwithpanichardwareisstan-dardateachendoftheaisle.Thesedoorscanbeopenedfromtheinside,evenwhenpadlockedfromtheoutside.

Thestructurealsoincludes,asstandard,filteredventilationopen-ings(filterscanbechangedwithoutopeningaisleorrearcompart-mentdoors),aislelighting,GFIprotectedconveniencereceptaclesandspaceheaters.Whenspecified,athermostatismountedinthecablecompartment.Spaceheatersarelocatedinthe“D”positionbreakercell,buscompartmentandcablecompartmentofeachverti-calsection.

3.2.4 Front-Acess without Aisle-way (Non walk-in)

Powercableconnectionsarethesameasdescribedabove.Connectiontolineand/orloadbreakerconnectionsisthesameasdescribedinIB01901001E,theindoorassemblyliteratureforfront-accessibleenclosures.

Thefrontaisle-wayisabsentinthenon-walk-indesign,permittinganassemblydepthreductionofapproximately31inches(784mm)overthestandardfront-accesswalk-inassembly.Accesstothebreakercompartmentandpowercableconnectionsisaffectedthroughfull-heightdoorsonthefrontoftheenclosure.Thesedoorscontainthesamebracingfeaturespresentonthereardoorsdescribedabove.Ventilatedfilters,lighting,receptaclesandheatersarestandardasdescribedabove.

Theworkspacebetweentheexternalshellandtheinternalbreakerenclosureisapproximately7.5inches(190mm),thereforetheneedforameansofemergencyexitisnotprovided.

otee:N Auniquefeatureofthenon-walk-inassemblyistheinternalbreakerdoorshingeontheright-handsideasnormalconvention,ratherthantheleft.

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C

C

9255C35

120.0[3047]

OVERALL DEPTH

18.4[468]

BUS OPENING(FROM BASE)

109.1[2772]

105.1[2668]

51.2[1301]

2.0[51]

4.0[102]

3.9[99]

2.3[58]

28.6[726]

(FROMBASE)

26.0[660]

43.4[1102]

AISLE WIDTH117.1[2974](BASE)

30.2[767]

(OPENINGWIDTH)

0.6[15]

33.5[850]

(DOORWIDTH)

5.8[146]

5.8[146]

111.5[2832]

OVERALLHEIGHT

Figure3.SideElevationNEMA3RAssemblyRear-AccessiblewithWalk-inAisleWay.

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Figure4.SideElevationNEMA3RAssemblyRear-AccessiblewithoutWalk-inAisleWay.

C

C

9259C06

86.0[2185]

(BASE)

26.0[660]

28.6[726]

(FROMBASE)

51.2[1301]

2.0[51]

4.0[102]

109.8[2789]

OVERALLHEIGHT

105.1[2669]

109.1[2770]

4.2[107]

18.4[468]

88.0[2236]

OVERALL DEPTH


9




Figure5.SideElevationNEMA3RAssemblyFront-AccessiblewithWalk-InAisleWay.

8652C19

87.1[2211]

OVERALL DEPTH

29.1[740]

111.4[2830]

107.9[2740]

2.0[51]

3.9[99]

111.5[2832]

OVERALLHEIGHT

4.0[102]

30.2[767]

(OPENINGWIDTH)33.5

[850](DOORWIDTH) 5.8

[146]

43.4[1102]

AISLE WIDTH85.3

[2166](BASE)


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Figure6.SideElevationNEMA3RAssemblyFront-AccessiblewithoutWalk-InAisleWay.

8652C25

54.2[1378](BASE)

105.1[2669]

110.3[2800]

109.8[2789]

OVERALLHEIGHT

2.0[51]

4.0[102]

3.9[99]

30[766]

56.2[1428]

OVERALL DEPTHBUS OPENING(FROM BASE)

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Section 4: Installation

WARNINGBEFORE PROCEEDING WITH ANY INSTALLATION, TESTING, START-UP OR MAINTENANCE, REVIEW ALL OF SECTION 1 FOR SAFETY PRACTICES AND RECOMMENDATIONS. FAILURE TO DO SO MAY RESULT IN DEATH, SERIOUS BODILY INJURY OR PROPERTY DAMAGE.

4.1GeneralInformation

ThissectioncontainsinstructionsforinstallingMagnumDSMetal-EnclosedLow-VoltageAssemblies.ProperinstallationofMagnumDSMetal-EnclosedLow-VoltageAssembliesisofprimeimportance.Toomuchemphasiscannotbeplacedonthisphaseofthework.Studytheassociatedinstructionmanualsanddrawingscarefully.

CAUTIONPERSONNEL INSTALLING THIS EQUIPMENT MUST BE THOROUGHLY FAMILIAR WITH ALL ASSOCIATED INSTRUCTION MANUALS AND APPLICABLE GOVERNING CODES. ADDITIONALLY, ALL DRAWINGS, WHETHER MECHANICAL OR ELECTRICAL, MUST BE UNDERSTOOD AND STRICTLY FOLLOWED TO PREVENT POSSIBLE DAMAGE TO THE SWITCHGEAR OR EQUIPMENT BEING PROTECTED.

4.2LocationandFoundation

MagnumDSMetal-EnclosedLow-Voltageassembliesarecon-structedatthefactoryonsmoothlevelsurfacestoassurecorrectalignmentofallparts.Extracarebythepurchaserinselectingthelocationandpreparingthefoundationwillresultinreducedinstalla-tioncosts,aswellasgoodequipmentperformance.

4.2.1 Location

Ingeneral,thelocationwillhavebeendeterminedduringthespeci-ficationand/orprocurementphases.Certainlocationsmayimposerequirementswhichmustbemetsothattheswitchgearassemblymayoperateefficientlywiththeleastamountofmaintenance.Considerationmustbegiventotheopenspacerequiredatthefrontandrearoftheequipment,spaceattheendsofthelineup,andthecharacteristicsoftheenvironment.

Thespaceatthefrontmustbesufficienttomeetapplicablecodes,permittheopeningofdoors,theinsertionandwithdrawalofcircuitbreakers,andthetransferofcircuitbreakerstoothercompartmentsbymeansofanoverheadlifterorportableliftingdevice.Inrear-accessibleenclosures,thespaceattherearmustbesufficienttomeetlocalcodes,permitventilation,openreardoors,installcables,inspectequipmentandperformmaintenance.

4.2.2 Foundation

Thesitefoundationshouldbesmoothandlevel(within1/8inchperthreefeet[3.5mm/meter]inanydirection)toavoiddistortionofthestructure.Theliftingplatesattachedatthebaseperformthedualpurposeofprovidingaconvenientandrobustmethodofsecuringtheunittothefoundation.Aseparatechannelbaseisnotrequired.Oncetheassemblyisinitspermanentlocationremovetheliftingeyesfromtheangles(Figure2).Rotatetheangles180degreesandreinstall.Usetheholesintheanglestobolttheassemblytothefoundation.Forfurtherdetailsseethefoundationplansprovidedwiththeequipment.

4.2.3 Conduits

Provisionsmustbemadeinthesitefoundationforallconduitsenteringfrombelow.Specificfloorplandetailsprovidedwiththeequipmentmustbeusedtodeterminethefinalconduitlayoutandfootprintrequiredforeachlineup(SeeBasePlanreferencedrawing4A37896).

Powerconduitsshouldprojectabovethefinishedfloornotmorethanteninches(254mm)foroneoftheseassemblies.Controlwireconduitsshouldnotextendhigherthannineinches(228mm).Itwillsimplifymovingtheshippingsectiongroupsintoplaceifthecon-duitsareflushwiththeconcretesurfaceandappropriateextensionsleevesaddedaftertheunitsareintheirfinallocation.SeeBasePlanreferencedrawing4A37896suppliedwiththeassemblyforbot-tomentryconduitspaceandlocation.

4.3ShippingSectionGroupAssembly

Beforeconnectingtheseparateshippingsectionsoftheassembly,allcomponentsshouldbeavailableatthesitelocation.Thepreparedfoundationshouldbereadyandallembeddedconduitsinstalledandcapped.

CAUTIONPRIOR TO INSTALLATION AND ASSEMBLY, BE CERTAIN THE FOUNDATION IS LEVEL AND FREE OF ANY DEBRIS TO PREVENT EQUIPMENT DAMAGE.

4.3.1 Preparation of the Unit for Assembly

MagnumDSNEMA3RAssembliesareshippedwithexternalship-pingbracesattachedtopreventdistortionoftheunitduringtrans-port.Thesebracesmaybealengthofaluminumangle,asteelsupportasshowninFigure7,orbothdependingupontheenclosuretype.Anysuchbraceattachedistemporaryandshouldberemovedanddiscardedpriortoconnectingtheshippingsections.

Roofseamsarecoveredbyaweldedseamcover.Theseareshippedattachedtotheenclosureroofforconvenience.Priortojoiningshippingsections,removetheseamcoverfromanyshippingsectionwhereitoverhangs,similartoasshowninFigure8.Removethesecuringhardwareandretainforreinstallationaftertheunitsareconnectedandsecuredpertheinstructionsbelow.

Alsoremoveanypackingcardboard,includingcardboardonaisle-wayfloors,priortoinstallation.

Figure7.TemporaryShippingBraceonWalk-inAisleway.

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Figure8.RoofSeamCover.

4.3.2 Assembly Procedures

Whencorrectlyinstalled,bothrearandfront-accessibleassembliesshouldconformtothefollowingrequirements:

1. Frontpanelsshouldformastraightline.Whentransformersand/orothergearareincluded,equipmentshouldbelocatedinkeep-ingwiththeplandrawingssuppliedwiththeequipment.

2. Verticalsectionsmustbecorrectlyspacedfromcentertocenterandplumb.Asuggestionforlininguptheshippinggroupsistoestablishabaselineafewinchesinfrontoftheassemblyandparalleltothefinallocation.Equalizethedistancesfromthefrontoftheshippinggroupstothebaseline,thusmakingthefaceoftheassemblyparalleltothebaseline.Checkeachverticalsec-tionbydroppingaplumblinefromthetopcornerofeachverticalsection.Itshouldalignwiththebottomcorner.

3. Theentireassemblyofverticalsectionsshouldbesecurelyfas-tenedtofloorchannelsorbasepad.

4. Shippinggroupsmustbesecurelyboltedtogetherandallbusandcontrolwiringconnectionsproperlymade.

Afterthefirstshippinggrouphasbeenlocated,thesecondship-pinggroupshouldbemovedintopositionandsimilarlychecked.Theshippinggroupsarefastenedtogetherinaccordancewiththeinstructionsgivenindrawing9253C18.Thisdrawingisincludedintheinformationpacketattachedtothesideoftheswitchgearassem-bly.Shouldadditionalcopiesofthisdrawingbeneeded,contactyourEatonsalesoffice.

4.4Bus,CableandControlConnections

RefertoSection4.4.1thru4.4.6ofreferenceIB01901001Eforcom-pleteinstructionsandguidelinesonvariousbusconnections,installa-tionofpowercables,andconnectionofcontrolwiring.

4.5TravelingCircuitBreakerLifter

Thetravelingoverheadcircuitbreakerlifterisastandarddeviceinstalledontheseassemblieswhereanaisle-wayispresent.Forconveniencethehoistassemblyisshippedcontainedwithinoneoftheendshippingsectionsofanymulti-sectionshippinggroup.Removetheretainingstrapssecuringthebreakerlifterhoistpriortouse.Aready-touseoverheadlifterisshowninFigure9.

Figure9.OverheadCircuitBreakerLifter.

DANGERDO NOT STAND UNDER THE CIRCUIT BREAKER DURING HOISTING OPERATIONS. THE CIRCUIT BREAKER MIGHT SLIP AND CAUSE PERSONAL INJURY. KEEP HANDS AND TOOLS AWAY FROM SPREADER BAR, LIFTING HOOKS AND BREAKER. SEVERE INJURY MAY RESULT. SUDDEN MOTIONS ARE COMMON IN A CABLE UNDER TENSION AS IT WINDS AROUND A WINCH DRUM.

Spreaderbarsthatattachtothetravelinghoistforpurposesofattachingtothecircuitbreakerwillbeshippedseparately.

Inassemblieswhereanaisle-wayisnotpresent(non-walk-in),orbycustomerrequest,aseparateportablebreakerliftermaybespeci-fied.Portableliftingdevicesarerecommendedtoonlybeutilizedonsmoothlevelsurfaces.SeeFigure10below.

4.6MovingParts

TherearefewmovingpartsinthestationarystructuresofMagnumDSLow-VoltageAssemblies.Itisrecommendedthatallmov-ingpartsbecarefullyoperatedbyhand.Thiswillensurethatnobindingordamagehasoccurredduringshipmentorhandling.Insomecases,accessoriesmaybeblockedorbracedforshipment.Thoroughlycheckapparatus,suchasmetersandrelays,forformsofblockingorbracingwhichmustberemoved.

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Section 5: Inspection, Testing and MaintenanceForcompleteinstructionsregardinginspectionandtestingofMagnumDSswitchgearandswitchboardspriortostart-upandoper-ation,seeSection5ofIB01901001E.Readandfollowallinstructionsregardingsafetypracticesdescribedtherein.

DANGERENERGIZING THE SWITCHGEAR FOR THE FIRST TIME IS POTENTIALLY DANGEROUS. THEREFORE, ONLY QUALIFIED PERSONNEL SHOULD BE PRESENT WHEN THE EQUIPMENT IS ENERGIZED. IF PROBLEMS CAUSED BY DAMAGE OR POOR INSTALLATION PRACTICES HAVE NOT BEEN DETECTED IN THE CHECKOUT PROCEDURE (PREVIOUSLY DESCRIBED), DEATH, PERSONAL INJURY OR SERIOUS DAMAGE MAY RESULT WHEN POWER IS APPLIED.

Forinstructionsregardingperiodicmaintenanceofswitchgear/switchboarddevices,busandconnections,aswellasreplacementparts,seeSection6ofIB01901001E.Readandfollowallinstructionsregardingsafetypracticesdescribedtherein.

DANGERWHEN ENERGIZED, A CIRCUIT BREAKER IS PART OF A HIGH POWER SYSTEM. BEFORE ATTEMPTING ANY INSPECTION OR MAINTENANCE, BE SURE THAT ALL PRIMARY AND CONTROL CIRCUITS HAVE BEEN DE-ENERGIZED AND GROUNDED AS REQUIRED. ALSO MAKE CERTAIN THAT PROPER STEPS HAVE BEEN TAKEN TO BE SURE THAT THEY WILL REMAIN DE-ENERGIZED UNTIL ALL WORK IS COMPLETED. FAILURE TO DO SO MAY RESULT IN DEATH, BODILY INJURY OR ELECTRICAL SHOCK.

Section 6: Document ReferencesInadditiontothisInstructionBook,thefollowingInstructionBooksanddrawingsarecommonlyincludedinanylow-voltageassemblyshipment.Pleaseinspectthepacketattachedtotheoutside,orwithinanemptycell,forallpertinentdocumentationbeforecontact-inganEatonservicerepresentativeforreplacements.

2A97855 MagnumDSStructureSectionViewTypeDS Low-VoltageMetal-EnclosedSwitchgear

4A37896 MagnumDSStructureBasePlan

9253C18 ShippingSplitBusInformation

9253C21 InstallationSpaceRequirements

Inaddition,thefollowingdocumentsmaybeincludeddependinguponoptionalequipmentcontainedwithintheassembly:

4A37898 InstallationGuidelinesforUsersofMagnumDS Low-VoltageRear/FrontAccessSwitchgear AssembliesforSeismicApplications

IB2C12060H08 InstructionsforInstallation,Operationand MaintenanceofMagnumDS,DSXandDSLLow VoltagePowerCircuitBreakers

IB2C12063H02 InstructionsforInstallation,Operationand MaintenanceofMagnumSBInsulatedCaseLow VoltagePowerCircuitBreakers

IB32-693A InstructionsforFieldTestingofGroundFault SystemsUtilizingEatonMagnumDSCircuit Breakers

IB32-698C InstructionsforC-HRG“Safe-Ground”Low- VoltageHighResistancePulsingGroundSystem

IB52-01-TE InstructionsforEatonTypeCM52Network Protectors800to4500Amperes

MN01301001E InstructionsforInstallation,Operationand MaintenanceofSeriesNRXLowVoltagePower (Air)CircuitBreakers

Also,supportingdocumentationandinstructionsforauxiliarycompo-nentsanddevicescontainedwithintheassemblywillbeforwardedwithanyshipment.TheaccuracyofclaimsmadewithindocumentsbyothermanufacturersisnottheresponsibilityofEatonbutthedevicemanufacturer.

Therearenumeroussupportingdocumentswhicharenotlistedhereduetothewidevarietyofcomponentscontainedwithinanygivenassembly.Forafullselectionofavailabledocuments,seetheTechnicalDocumentssectionofwww.Eaton.com.

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Notese:

EatonCorporationElectricalSector1111SuperiorAve.Cleveland,OH44114UnitedStates877-ETN-CARE(877-386-2273)Eaton.com

©2011EatonCorporationAllRightsReservedPrintedinUSAPublicationNo.IB01900002E/TBG000585June2011

EatonisaregisteredtrademarkofEatonCorporation.

Allothertrademarksarepropertyoftheirrespectiveowners.



ThisInstructionBookletispublishedsolelyforinformationpurposesandshouldnotbeconsideredall-inclusive.Iffurtherinformationisrequired,youshouldconsultanauthorizedEatonsalesrepresenta-tive.

ThesaleoftheproductshowninthisliteratureissubjecttothetermsandconditionsoutlinedinappropriateEatonsellingpoliciesorothercontractualagreementbetweentheparties.Thisliteratureisnotintendedtoanddoesnotenlargeoraddtoanysuchcontract.ThesolesourcegoverningtherightsandremediesofanypurchaserofthisequipmentisthecontractbetweenthepurchaserandEaton.

NOWARRANTIES,EXPRESSEDORIMPLIED,INCLUDINGWARRANTIESOFFITNESSFORAPARTICULARPURPOSEORMERCHANTABILITY,ORWARRANTIESARISINGFROMCOURSEOFDEALINGORUSAGEOFTRADE,AREMADEREGARDINGTHEINFORMATION,RECOMMENDATIONS,ANDDESCRIPTIONSCONTAINEDHEREIN.

InnoeventwillEatonberesponsibletothepurchaseroruserincontract,intort(includingnegligence),strictliabilityorotherwiseforanyspecial,indirect,incidentalorconsequentialdamageorlosswhatsoever,includingbutnotlimitedtodamageorlossofuseofequipment,plantorpowersystem,costofcapital,lossofpower,additionalexpensesintheuseofexistingpowerfacilities,orclaimsagainstthepurchaseroruserbyitscustomersresultingfromtheuseoftheinformation,recommendationsanddescriptioncontainedherein.