SafeGear Maintenancee Manual

7/31/2019 SafeGear Maintenancee Manual

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Installation andMaintenance Manua

Bulletin No. IB3.2.5-7C

Medium Voltage

Arc-resistant

Switchgear

ABB Power T&D Company Inc.


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ABB Power T& D Company

655 C entury Point

Lake Mary, Florida, 32746

Phone 407/323-8220 Fax 407/732-2132

No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any

form or by any means (electronic, mechanical photocopy, recording, or otherwise) without prior

permission from ABB Power T &D Com pany Inc.

November 1998


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Introduction .............................1General Instructions .......................1

Scope of Instructions ......................1

Important Safety Notes

and Warnings ..........................3Safety Notations .............................3

Receiving and Handling .........5Receiving ........................................5Storage ..........................................6

Site Preparation ......................7General ...........................................7Location ..........................................7Foundation ......................................8

Indoor/Outdoor Installation ...9General ...........................................9Towing ..........................................13Lifting With Slings ........................13Removal of the Shipping Base .....14

Unit Substations ...........................16Connections ...............................16Connection to Ground Bus ...........17Connection to Control source .......17Secondary and ControlConnections ................................18

Installation of Bus Bar ConnectionsBetween Groups ..........................18

Setting the 2000A and 3000ACircuit Breaker ModuleVanes and Damper .....................19

Outdoor Installation: General ........20

Testing & Final

Inspection ............................. 21

Testing ..........................................21Control Circuit Checkout ...............23Final Inspection .............................26

Placing Switchgear Into

Service .................................. 27Safety Precautions ........................27Installing the Rear Inner andExterior Panels on SafeGear....... 29

Energizing the Main Bus ...............35

Standard Construction ........ 37Standard Color ..............................37Galvalume .....................................37Bus Support Insulation ..................37Primary Disconnect Device ...........37Secondary Disconnects ................38Ground and Bus Contacts ............38Control Wires ................................38Circuit Breakers: Insertingand Removing ..............................39

Inserting and RemovingAuxiliary Modules .........................45

Maintenance ......................... 49General .........................................49Semi-Annual Inspection ................50Annual Inspection .........................5024 Month Inspection .....................5110 Year Maximum Inspection .......52Suspect Joint Maintenance ...........53

Care of Finish ...............................54Renewal Parts ..............................54Disclaimer of Warranties andLimitation of Liability ....................55


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Read these instructions carefully before installation and use as a guide

during installation and initial operation.

File these instructions with other instruction books, drawings and

descriptive data of th e switchgear. Keep this book available for the

installation, operation , and maintenance of th is equipm ent . Use of

these instructions will facilitate proper maintenance of the equipment,

and p rolong its useful life.

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T he instructions are general in natu re. T hey cover requirements for

installation, setup, checkout and maintenance as applied to ABB

SafeGear, medium -voltage, arc-resitan t, switchgear. T hese instru c-tions do not attempt to cover all variations and combinations of equip-

ment and installations.

Inform ation on particular installation s appears in t he following:

Bills of Materials that list electrical devices and equipment.

Single line drawings showing power connections.

Floor plan, representing available space for power and controlconduits.

Special construction details.

Elementary and schem atic diagrams.

C onn ection d iagram s.

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Equipment operation depends on proper handling, installation, and

maintenance. N eglecting fund amental requirement s may lead to per-

sonal injury, failure of the equipm ent an d p roperty dam age.

Safety as described in th is instru ction book involves two cond itions: Personal injury.

Product or property damage.

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Personnel installing, operating, or maintaining this equipment musthave thorough knowledge of all applicable local, regional, industry,

governm ental, and O SH A safety procedures as well as commonly

accepted safe working practices. Personnel working in, or around this

equipment must also exhibit common sense and good judgement

regarding the potential hazards for themselves and other personnel in

the area. T hese instructions are in tended for use by fully qualified per-

sonnel and are not a substitute for adequate training, experience, and

supervision.

Should clarification or additional information be required, refer the

matter to your ABB Power T & D Company sales office. W hen com-

municating with ABB regarding the product covered by this Instruc-

tion book, always reference th e ABB assigned Shop O rder (S.O .)

num ber or Serial Num ber.


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Before shipment, the equipment is inspected and marked with its

nu m ber and position . T he factory ships circuit breakers separately.

Upon receipt of the equipment, examine the shipment for damage orloss. C heck the content s against the packing list before discarding any

packing material. N otify ABB and the carrier at once of any discrepan-

cies. If there is dam age from imp roper han dling, file a claim for dam-

ages at once with the carrier and notify ABB.

Note: ABB standard shipments are FOB Factory. ABB is not responsible for

damage, after delivery of the equipment to the carrier.

+$1'/,1*For structural integrity, all doors and panels must be inplace and securely fastened before moving the equipment.

Do not move or transport the frames with circuit breakersor other drawout equipment installed in the modules.

Before energizing the heaters, remove all the packingmaterials from the switchgear. Open the breaker or cutoutdevice that controls the heaters when using a separatepower source.

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6725$*(Leave the equipment on the shipping base.

Store all equipment indoors in a well-ventilated area.

T he storage bu ilding shou ld have a well-drained paved floor. T he tem-

perature should be above 60F. T he air should be dry (approximately

50% maximum hum idity).

The sections ship wrapped in plastic for protection during shipment

only. Remove th e plastic wrap after placing in to storage. C over with

heavy wrapp ing paper or oth er moisture barrier. Use materials that willnot t rap moisture inside the un it. D o not cover louvered openings.

For long term storage, or in high-humidity, use heaters (optional) to

keep th e int erior dry. Bring power for the heaters to th e load term inals

of the device th at cont rols th e heater circuits. See Figure 1.

NOTE: The device must remain open when using a separate power source.

Store circuit breakers upright in their original shipp ing carton . D o not

stack. D o no t store circuit b reakers in th e switchgear.

Figure 1: H eater load term inals. Rem ove before bolting section s together.


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Before installing, consult all drawings furnished for the particular order.

T he drawings show top an d front views of the lineup, prim ary and sec-

ond ary connection diagrams, and Bills of Materials. Study these draw-

ings and the following recom mendation s before preparing the site plandrawings.

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Locate th e lineup in accordance with local regulations. C learances at

the front should allow installation and removal of the drawout equip-

ment. Provide rear access for making conn ections before start-up and

for periodic inspections and m aint enance. T he recommended mini-

mum clearances appear on the drawings.

* Try to maintain approximately 4 feet from the top

of the equipm ent to an y obstruction.

Table 1

Recommended Minimum Ceiling Height*

RATING FEET

25 kA 12

36 kA 14

50 kA 16

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)281'$7,21T he factory supplies floor plan d rawings for each installation . T he floor

must be straight and level with in inch over the full length and depth

of the switchgear. T he finished floor und er th e line-up and in fron t of

the line-up should be smooth .

Install power and second ary (cont rol) conduits before moving the un its

to th e site. Available space for the cond uits appears on the floor plans

supp lied with the units. C onduits shou ld not extend m ore than one

inch above th e station floor level. Plug condu it openin gs before pou r-ing concrete.


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Metal-enclosed and metal-clad switchgear ships in sections. Indoor sec-

tions ship on throw away steel bases.

Un load the units as close to the installation site as possible. Secure alldoors and panels. Raise the units with jacks and move on rollers with

the shipping bases attached or with an overhead h oist and spreader bar.

Do not move the shipping splits with drawout units installed. See Fig-

ures 2 th rough 7.

In many locations the best way of moving the equipment is with jacks

and rollers.

Use of fork lift trucks for jacking or placing the jacks otherthan as described may result in stress distortions and irrep-arable damage to the equipment.

Do not remove the shipping bases until the units are set inplace. Moving the units without the shipping base willcause irreparable damage and a hazardous condition.

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1. Do not remove the shipping base. Make sure that all doorsand panels are secure. Move the unit near the site. Raise theunit by jacks placed under the front and rear corners, inside theshipping bases. See Figure 2.

Figure 2: Position jacks under the front and rear corners.


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2. Raise the unit enough to position a roller under the shippingbase. Repeat the operation at the other end. See Figure 3.

3. Push the unit toward its final position, while another personputs a third roller under the forward end. Move a roller from therear to the front until the unit is in place. See Figure 4.

Figure 3 : Position rollers und er shipping base.

Figure 4: Move a roller from the rear to the front.


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4. For lateral moving, raise the units by jacks as described in step1. Place the rollers laterally with steel channels (not furnished)on the rollers. See Figures 5 and 6. Carefully push the unitonto a third roller and move a roller from the rear to the frontuntil the unit is in place.

Figure 5: Position rails on rollers as shown for lateral moving.

Figure 6: Carefully push the unit onto a third roller.


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5. Locate the units in their final position. Raise the units to clearthe rollers and channels. Remove the rollers and channels,and lower onto wood blocks.

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Use chains rated for safe handling of the shipp ing splits. C onsult the

chain m anufacturer or local code requirements for prop er safety factors.

Attach the chains to the holes at each end of the base (See Figure 7).

Secure to the towing equipment. M ake sure that the truck bed height

and dock height are even, or provide heavy duty steel sheets to bridgebetween the truck and t he dock. Protect the lower edge of the switch-

gear from d amage by the chains.

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1. Attach the shackles to the base or use the optional extensionplates to the 4 holes provided in the shipping bases. They pro-vide a large hole at each end for attaching a sling and spreaderbar assembly.

2. Use a spreader bar to keep the legs of the sling vertical.

Figure 7 : Towin g


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3. When using wire rope slings, place a 4 4 between theequipment and the sling.

4. Lift and move the equipment to its final place. Once the unit isset in place, remove the shipping base.

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O nce th e un its are in th eir final place, remove the shipping base.

1. Open the equipment doors. Remove the bolts holding the ship-

ping base to the equipment. See Figure 8.

NOTE: Secure all doors and panels before going to the next step.

2. Raise the units to a height that allows removal of the base. Usefour jacks for this operation to keep the units uniformly leveland prevent distortion.

Figure 8: Un bolting the shippin g base.


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81,768%67$7,216In multi-unit substations, physically identical transformers may have

disconnect switches that are key interlocked with secondary breakers.

Group the disconnects, switches, transformers, switchgear, and motor

control sections by their key.

The interlock sequence depends upon having the locks on the switch

and breaker op erated b y the same key.

NOTE: Avoid unnecessary rework by checking the key numbers before movingeach piece of equipment into its final position.

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Un it substations ship in separate sections. Each tran sform er is a sepa-rate section. T he factory splits the buses for shipment. Secondary and

control wiring end at t he shipping split.

Bolt the separate units together. Reconnect the bus and con trol wiring

at the shipping splits. Follow the connection d iagram when replacing

secondary and cont rol wiring. Bolted joints must be tight.

C om plete all intern al conn ection s. Make the external conn ections to

control p ower sources and circuits, to second ary and potential circuits,to feeders, power sources, and to ground.

NOTE: After completing all connections to secondary (control) circuits, followthese circuits and remove temporary connections from current trans-

former secondaries.

Before making primary source connections, verify that the primarycables are de-energized and the equipment is properly grounded.


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Temporary jumpers protect against voltages that may occur if the cur-rent transformer primaries carry currents while the secondary circuits

are still no t complete. W ith the secondary circuits conn ected, remove

the jum pers.

NOTE: Failure to remove the jumpers will interfere with meters, relays, or other

devices in these circuits.

If shorting Terminal Blocks are used, review the Connection Diagram

that was shipped with th e un it, for position of shorting screws. See

Step 16 on page 25.

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T he factory bolts the ground bus bars to each frame. C onn ect the

ground bus bars to th e station ground with a cable or bus of larger gage

than t he housing ground bus.

D o not ru n cable or bus in cond uit. T he cable or bus should take the

most direct path t o groun d.

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The control source wiring should be of larger gage than the rest of the

control wiring. Conn ect the cont rol source leads to the terminal

blocks.

NOTE: CHECK THE ELECTRICAL PHASING BEFORE CONNECTING.


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Set the Ventilation Vanes (see Figure 11) and D amper (see Figure 12)

in the open or operating position before bolting the vertical sections

together.

Failure to set the Vanes and Damper in the open or operat-ing position can cause the circuit breaker to overheat.

Figure 1 1: M odule Ventilation Vanes


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O utdoor installations are in m odified enclosures called Power D istribu-

tion Centers (PDC s). Due to ceiling height limitations, PDC s have

top m oun ted plenum s that exhaust to th e end of the enclosure.

O utdoor installations are shipped in pre-assembled modu les. Installa-

tion is cont racted through ABB Services. It is recom mended that

PD C s be installed by experienced personnel.

Figure 12: Location of the 20 00 / 30 00 A D amper

Open the damper beforeputting the circuit breakerinto service.


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W ith the system erected, assembled and con nected, perform the follow-

ing 16 step process.

1. Remove packing and shipping materials.

2. Make sure that all internal parts are clean and dry. If moistureis present, blow dry with warm air.

3. Remove any shipping blocks from relays.

4. Check for damaged insulation by applying potential tests to theprimary bus. Conduct potential tests phase-to-phase andphase to ground in accordance with Field Test values.

Test continued on next page.

Disconnect the primary power source

Do not exceed the listed voltages for the voltage class of the equip-ment under test.

Disconnect the shunt connected coils such as potential transformers.

Do not test solid state sensors or relays with high voltage. Disconnectsolid state sensors and relays before applying voltage.

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* The column headed D C Field Test is a reference for tho se using dc t ests to verify the

int egrity of conn ected switchgear. It represents values believed to be appropriat e and

approximately equivalent to the corresponding power frequency withstand test values

specified for each voltage class of switchgear. T he presence of this colum n in no way

imp lies any requirem ents for a dc withstan d test on ac equipm ent . Also, it does not

imp ly th at a dc withstand t est is an acceptable alternative to AN SI C37 .20 for design,

prod uction , or conform ance tests. W hen m aking dc tests, raise th e voltage to th e test

value in discrete steps and hold for one (1) minute.

5. With the main circuit de-energized and grounded, check thecontinuity of all circuits after installing the circuit breakers.Energize the control source and operate the equipment. Indi-cating instruments verify the continuity of current transformercircuits and energizing of the main circuit.


Table 1

60 HZ, RMS, WITHSTAND VOLTAGES (1 minute)

Rated Factory Test Field Test DC*Field Test

up to 250 volts 1500 1125 none

4160 volts 19,000 14,250 20,000

7200 volts 36,000 27,000 38,000

13,800 volts 36,000 27,000 38,000


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The preferred method to check the control circuit is to furnish a sepa-

rate temporary source of control power of the required control voltage

rating. T he temporary source must have a properly coordinated backup

protective device in th e circuit. Set th e device to clear any faults th at

might occur. Initially all circuit b reakers should be in t he DISCON-NECT position and the main circuit de-energized and grounded.

When ac control power is from control power transformers in the

switchgear, rem ove all fuses in th e transformer circuits. O n electrically

operated circuit b reakers, discharge the springs and place the motor-dis-

connect-switch in t he OFF position.

6. Rack drawout circuit breakers to the DISCONNECT position.

7. Open all normal control power source disconnects, if supplied.

8. Check each control switch or push-button. Make sure that it isin the OPEN position.

9. Connect a temporary control power source to the circuit loadterminals in the switchgear. Energize the control circuit from

the temporary control power source.

10. Rack one circuit breaker into the TEST position. When the on-off switch is in the ON position, the charging of the closingsprings of an electrically operated circuit breaker indicates con-nection to the control power.

11. Rack the remaining circuit breakers into the TEST position, oneat a time.

The breaker or cutout device of the local control power circuit mustremain open when using a separate control power source.

OPEN the circuit breaker before racking.


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12. Test all electrically and manually operated breakers for closingand tripping, while they are in the TEST position. Use theoptional test set available with the trip unit for testing solid statetripping.

13. De-energize the control circuit. If ac control power is fromtransformers in the switchgear, remove the temporary separatesource of control power. Reinstall all fuses in the transformercircuit.

14. Set all relays, regulators, and other devices for proper opera-

tion of loads. The factory does not set the relays.

15. Remove shorting screws from the terminal blocks in the currenttransformer circuits. See Step 16. Store screws in the tappedholes in the corners of the blocks.

NOTE: Verify the proper phasing of all main circuits according to diagram.



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16. To open the short circuiting device:

a. Single Ratio - Remove and store the shorting screw 1.

b. Multi Ratio - Remove the shorting screw 1. Insert short-ing screw according to connection dia-gram. Do not remove the ground screw 2.

1

2 2

1

Multi-RatioSingle-Ratio

1

2 2

1

Multi-RatioSingle-Ratio


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O nce installed an d all conn ections made, perform a final check and t est

on th e equipm ent and its cont rols. C heck for correct equipm ent instal-

lation and t hat all conn ections are com plete.

Use extreme care to prevent the controlled equipment from being con-

nected to th e system while perform ing preliminary tests.

There are hazards of electrical shocks and/or burns whenever work-ing in or around electrical equipment. Turn off power ahead of theswitchgear before performing any inspection or maintenance opera-tions. Check incoming line terminals to verify that the equipment isde-energized and grounded. Check out-going terminals to ensurethat no back-feed condition exists.


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T he contact surfaces of the bus at bolted joints are plated. C lean con-tact surfaces with a clean cloth and an O SH A approved solvent. Bolt

the bus together. C onductivity of a bolted joint depend s on th e pres-

sure or torque applied.


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INTERNAL PANELS

Upper Lower

Step 1

Position the panel so the 3 holes with

weld nuts are at the top.

Position the panel so the 3 holes

with weld nuts are at the bottom.

Step 2

Angle the lower end of the panel into

the rear of the frame, sliding the lower

flange behind the mid-frame channelsupport. Let the panel slide down until

it rests on the mid-frame support

Angle the upper end of the panel

into the rear of the frame, sliding the

upper flange behind the mid-framesupport.

Step 3

Swing the top of the panel in towardthe frame until the side flanges are

against the frame.

Slide the panel upward and swingthe bottom in toward the frame until

the side flanges are against the

frame.

Step 4

Move the panel upward, sliding the topflange inside the frame, until the 3

holes along the top align with the 3

mating holes in the frame.

Move the panel down, sliding thebottom flange inside the frame, until

the 3 holes along the bottom align

with the 3 mating holes in the frame.

Step 5Bolt the panel in place using 5 bolts oneach side. Do not place bolts in the 3

top holes at this time.

Bolt the panel in place using 5 boltson each side. Do not place bolts in

the 3 bottom holes at this t ime.

EXTERIOR PANELS

Step 6 Bolt the exterior panels (upper and lower) in place using 18 bolts in each panel.


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Figure 13 : Step 1 and 2, U pper Inner Panel.

Figure 1 4: Step 1 and 2 , Lower Inner Panel.

Holes with three weld

nuts at the top.

Holes with three weldnuts at the bottom.


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Figure 15 : Step 3 , U pper Inner Panel.

Figure 1 6: Step 3, Lower Inner Panel.


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Figure 17 : Step 4 , U pper Inner Panel

Figure 1 8: Step 4 , Lower Inner Panel

Align the upperholes before securingthe sides. Do not

Align the lower

the sides. Do not

put bolts in thesethree holes at this time

holes before securing

put bolts in thesethree holes at this tim


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Figure 19 : Step 5 , U pper Inner Panel

Figure 20 : Step 5 , Lower Inner Panel

Do not put bolts in thesethree holes at this time.

Do not put bolts in thethree bottom holesat this time.


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Figure 2 1: Step 6 , U pper Exterior Panel

Figure 2 2: Step 6 , Lower Exterior Panel


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(1(5*,=,1*7+(0$,1%86After completing the control circuit checkout, energize the equipment

main bu s.

1. Verify that all door and panel hardware is secure.

2 Energize the incoming bus to the equipments main circuitbreaker. Observe if operation of instruments and relays arecorrect.

3. Energize the separate control power source, if furnished.

4. Energize the switchgear main bus by closing the main circuitbreaker. Observe if operation of instruments and relays arecorrect.

5. Rack the circuit breakers to the CONNECTED position.

6. Close the desired feeder and tie-breaker circuit breakers.


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T he stand ard paint color is AN SI #61 . T his finish is electro-static

powder paint app lied over an iron phosphate coating. T his process

achieves a smooth, uniform paint finish that conforms to all UL

requirements.

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Unpainted parts are made of Galvalume. Galvalume is a cold rolled

sheet steel with a hot dipped coating of aluminum, zinc and silicon.

Galvalume greatly exceeds the p aint qualifications of AN SI C 37.20.2-

5.2.8.

%866833257,168/$7,21T he bu s suppor ts are glass filled polyester laminate or porcelain. T he

supports ensure safe operational clearances of bus under normal and

abnormal (short circuit) conditions.

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Circuit breakers ship separately. T he factory installs blocks in the mov-

able parts of breakers with un der-voltage release.

All circuit breakers of like rating are interchangeable unless the second-

ary (control) circuit requires otherwise.

C ircuit b reakers have th ree positions in th e housing.

1. The DISCONNECT position disengages the main disconnect-ing devices, and the control contacts on the breaker. They area safe distance from the stationary part of the devices locatedon the housings.

2. The TEST position disengages the main disconnectingdevices, and engages the control contacts. This positionallows operation of the circuit breaker for testing.

3. The CONNECTED position engages the main and control dis-connecting devices on the breaker.

Mechanical interlocks prevent moving a circuit breaker from one posi-

tion to anoth er unless th e circuit breaker is open . T he interlocks also

prevent closing the breaker between positions.


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INSERTION

Insertion from the WITHDRAWN to the DISCONNECTED posi-

tion.

Figure 24: Interlock slots. Right hand shown .

The module interlock tabs must engage the slots in the lifttruck platform before releasing the foot-brake and movingthe lift-truck. Lower the lift-truck platform before transport-ing drawout modules with the lift-truck.

Interlock

Module

Lift truckInterlock

Slot

Slot


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1. Align the locking tabs of the lift-truck with the slots in the front ofthe frame (see Figure 25). Push the lift-truck to the frame toengage the locking tabs with the module. Lower the truck plat-form slightly to lock in place. The truck platform should be hori-zontal and aligned with the rails in the module. Set the lift truckbrake. Try pulling the lift truck away from the frame. The lock-ing tabs should be set firmly in place and the brake set.

2. Release the circuit breaker from the lift truck by pulling the han-dles toward the center of the unit.

3. Push the drawout unit straight into the module.Keep the unit level as possible.Do not raise or lift the circuit breaker.

4. Align the Module Interlock Tabs (Figure 25) with the moduleslots (Figure 24)

5. Engage the Module Interlock Tabs by returning the handles totheir outward position.

a. Verify that the handles are fully outward and the ModuleInterlock Tabs are in the module slots.

Figure 25 : Modu le Interlock Tabs and H andles.

ModuleInterlockTab

RackingRelease

Module

Interlock

Handle

RackingScrew


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The unit will not rack into the TEST position if the ModuleInterlock Tabs are not properly engaged with the frame.

a. Push against both sides of the unit to verify that the tabs arelocked into position.

a. The circuit breaker is in the DISCONNECTED position.

6. Disengage the lift-truck and move it away from the frame

7. Close the door and secure all door bolts and latching devices.

To rack from the DISCONNECTED position to the TEST Position:

8. Press down on the Racking Release Handle.

Engage the racking screw with the Racking Tool and turnclockwise (CW).Release the handle and continue to rack the unit clockwise intothe TEST position.

Figure 26: Racking release handle.


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To rack from the TEST position to the DISCONNECTED position:

3. Press down on the Racking Release Handle.Engage the Racking Screw with the Racking Tool.Release the handle and continue racking counterclockwise(CCW), from the TEST position into the DISCONNECTED posi-tion.

4. Unlatch and/or remove all bolts from the module door. Openthe module door.

5. Align the locking tabs of the lift truck with the slots in the front ofthe frame. Push the lift truck to the frame to engage the lockingtabs with the module. Lower the truck platform slightly to lockin place. The truck platform should be horizontal and alignedwith the rails in the module. Set the lift truck brake. Try pullingthe lift truck away from the frame. The locking tabs should beset firmly in place and the brake set.

6. Release the circuit breaker from the module by pulling the han-dles toward the center of the unit.

7. Pull the drawout unit straight onto the lift truck platform.Keep the unit level as possible.Do not raise or lift the circuit breaker.

8. Align the Module Interlock Tabs with the lift truck slots.


a. Verify that the handles are fully outward and the ModuleInterlock Tabs are in the lift truck slots.



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,16(57,1*$1'5(029,1*$8;,/,$5


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1. Align the locking tabs of the lift truck with the slots in the front ofthe frame (see Figure 29). Push the lift truck to the frame toengage the locking tabs with the module. Lower the truck plat-form slightly to lock into place. The truck platform should behorizontal and aligned with the rails in the module. Set the lifttruck brake. Try pulling the lift truck away from the frame. Thelocking tabs should be set firmly in place and the brake set.

2. Release the module from the lift truck by pulling the handlestoward the center of the unit.

3. Push the drawout unit straight into the module.Keep the unit as level as possible.Do not raise or lift the unit.


Figure 29 : Modu le Interlock Tabs and H andles.

Module

InterlockTab

Handle


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4. Align the module interlock tabs (Figure 29) with the moduleslots (Figure 28).

5. Engage the module Interlock tabs by returning the handles totheir outward position.

a. Verify that the handles are fully outward and the moduleinterlock tabs are in the module slots.

The unit will not rack into the CONNECTED Position if themodule interlock tabs are not properly engaged with the

frame.

a. Push against both sides of the unit to verify that the tabs arelocked into position.

a. The unit is now in the DISCONNECTED position.

6. Disengage the lift truck and move it away from the frame.

7. Close the door and secure all door bolts and latching devices.

To rack from the DISCONNECTED to the CONNECTED position:

8. Press down on the Racking Release Handle before racking.For auxiliary units without a racking release handle, push theRacking Screw with the Racking Tool and rack clockwise (CW)into the CONNECTED position.

REMOVAL

1. Do not open the module door.

2. Press down on the Racking Release Handle before racking.Engage the racking screw with the Racking Tool. Rack coun-terclockwise (CCW), into the DISCONNECTED position.

3. Open the module door.


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4. Align the locking tabs of the lift truck with the slots in the front ofthe frame (see Figure 27 and 28). Push the lift truck to theframe to engage the locking tabs with the module. Lower thetruck platform slightly to lock into place. The truck platformshould be horizontal and aligned with the rails in the module.Set the lift truck brake. Try pulling the lift truck away from theframe. The locking tabs should be set firmly in place and thebrake set.

5. Release the unit from the module by pulling the handles towardthe center of the unit.

6. Pull the drawout unit straight onto the lift truck platform.Keep the unit level as possible.Do not raise or lift the circuit breaker.

7. Align the Module Interlock Tabs (Figure 29) with the lift truckslots.


9. Verify that the handles are fully outward and the Module Inter-lock Tabs are in the lift truck slots.



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0DLQWHQDQFH

*(1(5$/

Inspect all switchgear installations at frequent intervals. Perform a

visual inspection, front and rear, to see that there is no evidence of loose

parts, warping, or un due vibration. Take steps to remedy any deficien-

cies of th is nature that may appear. Keep the assembly dry. C over toprevent moisture from dripping on equipm ent. D o not block vents or

flaps.

There are hazards of electrical shocks and/or burns whenever work-ing in or around electrical equipment. Turn off power ahead of theswitchgear before performing any inspection or maintenance opera-tions. Check incoming line terminals to verify that the equipment isde-energized and grounded. Check out-going terminals to ensure

that no back-feed condition exists.

Limit the use of solvents to removing grease and contamination fromprimary conductors, insulation, and from unpainted metallic sur-faces. Do not use alcohols or freons. Use OSHA approved sol-vents in accordance with local regulations. Use a non-flammablesolvent with a threshold limit of 300 PPM or higher. Use solvents inwell-ventilated areas.

&KDSWHU


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6(0,$118$/,163(&7,21At least twice yearly, perform a through inspection of the switchgear.

Emphasize the following checks:

1. Perform an overall visual inspection.

2. Check all indicators, meters and instruments for proper opera-tion.

3. Make sure all bolted connections are secure.

4. Verify operation of heaters and thermostats, if used.

5. Check for undue noise and vibration that might loosen boltedconnections.

6. Look for evidence of moisture in the switchgear.

7. Note presence of abnormal ozone odor.

$118$/,163(&7,21In addition to the semi-annual inspection, perform the following rec-

ommended inspection and maintenance once a year, or sooner, if

required by local condition s or regulations.

1. Bolted connections should be tight. Discoloration, excessivecorrosion, embrittled or discolored insulation may indicate anoverheated connection. If found, follow the proceduredescribed under section Suspect Joint Maintenance.

2. Inspect all cables for tight connections and ample support.3. Inspect control wiring for signs of wear and damage.

Replace wire wherever doubtful.

4. Examine resistors and other devices prone to over heating.

5. Open all hinged doors and remove bolted panels.

6. Clean insulation thoroughly.


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7. Withdraw and clean all drawout components. (Refer to CircuitBreaker Instruction Booklets before cleaning contacts.)

8. Clean the stationary portion of the switchgear by wiping with aclean cloth. Use dry, compressed air in inaccessible areas.

9. Remove the covers of all panel devices where possible. Checkwiring for secure connections. Clean contacts on relays andswitches wherever necessary. Replace covers.

10. Remove air filters when used. Flush with clean water if neces-sary. Coat filters with Randolf Products, Super Coat Adhesiveor equivalent.

11. Inspect the gearing of lift devices, if used. For normal operationuse a heavy gear lubricant. In very dirty or gritty conditions,use a dry lubricant.

12. Follow the recommendations of any individual device instruc-tions furnished for maintenance of the device.

0217+,163(&7,21

In addition to the annual inspection, perform the following recom-

mended inspection and maint enance at 24 m onth intervals, or sooner,if required by local conditions or regulations.

1. Clean the circuit breaker stationary primary contacts. See themaintenance instructions shipped with each unit for detailedinstructions.

2. Inspect secondary wiring bundles for signs of discolorationbecause of heat or chafing. Check for cracked or embrittledinsulation. Replace wire whenever doubtful.

3. Inspect primary insulation system for accumulated contamina-tion. Clean insulation with a dry cloth, dry-air, vacuum, or ifnecessary with an OSHA approved solvent.

4. Check the calibration of protective relays approximately everytwo years.

5. Follow the recommendations of any individual device instruc-tions furnished for maintenance of the device.


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6863(&7-2,170$,17(1$1&(1. Open joint and inspect connection surfaces.

2. Clean surfaces with an OSHA approved solvent. Dress contactsurfaces that show minor corrosion or pitting by lightly rubbingwith a polishing cloth such as 3M Scotch Brite. Take care tominimize the removal of plating.

3. Replace parts that signs of heavy corrosion, arcing or melting.

4. Replace contact fingers springs after exposure to excess heat-ing at the breaker disconnect.

5. Before assembly, protect contact surfaces with No-Ox-Id Spe-cial A Compound, a product of Sanchem Chemical Co., orequivalent.

6. Use proper torque in tightening bolted connections. See Table2.

Table 2

Torque Values forEquipment Hardware

Bolt Size(Inches)

Foot-Pounds(Dry Threads)

3/8 15-35

1/2 30-45


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&$5(2)),1,6+T he finish is strong and durab le. Always keep the switchgear clean.

W iping with a clean dry cloth will usually suffice. To remove oil and

grease marks, use warm water and soap, and wipe dry with a clean, dry,

soft cloth.

Because the color and finish may vary, consult the front sheet of the Bill

of M aterials before using tou ch-up paint. T he stand ard paint color is

ANSI 61, light gray. A 12 ounce aerosol can of AN SI 61 touch-up

paint is available from ABB under part number 88787A00.

5(1(:$/3$576

Previous experience and the number of vertical sections in service are

the best guidelines for determining the stocking of replacement parts.

Order factory original replacement parts from ABB Power T&D Com-

pany Inc., D istribution Systems D ivision, Sanford, Florida. Specify

quantity, part numbers, description, and nameplate data of the device

requiring the replacement parts.

For replacement parts, call toll free: 1-800-929-SWGR.

O utside of U SA call: 1-4 07 -32 3-8 22 0, extension 0.


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',6&/$,0(52):$55$17,(6$1'/,0,7$7,212)/,$%,/,7


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,QGH[

AAUXILIARY DRAWOUT MODULES

Insertion ........................................45Removal ........................................47

BBILLOF MATERIALS ................................7BUSS SUPPORTS ..................................37

CCAREOF FINISH ...................................54CHAINS ................................................13

CIRCUIT BREAKERS ..............................39Insertion ........................................40Removal ........................................43

CONNECTION DIAGRAM ....................7, 17CONNECTIONS .....................................16

Bus Bar .........................................18Control Source ..............................17Ground Bus ...................................17Secondary .....................................18

CONTROL CIRCUITCheckout .......................................23

CONTROL WIRES ..................................38

DDAMPER ..............................................19

EEXTERNAL CONNECTIONS .....................16

FFINAL INSPECTION ................................26

FLOOR PLAN ..........................................8

GGALVALUME .........................................37

HHANDLING ............................................. 5

HEATERS .............................................. 6

IINSPECTION

10 Year ......................................... 5224 Month ...................................... 51Annual .......................................... 50Semi-Annual ................................. 50

J

JACKS ................................................... 9

KKEY INTERLOCKS ................................. 16

LLIFTING ............................................... 13

MMAIN BUS

Energizing .................................... 35MAINTENANCE

General ........................................ 49

OOUTDOOR INSTALLATIONS

PDC .............................................. 20

PPAINT

Color ............................................. 37Touch-up ...................................... 54

PANELSRear, Installation .......................... 29

PRIMARY DISCONNECT ........................ 37


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RREAR PANELS

Installation .....................................29RECEIVING .............................................5ROLLERS ...............................................9

SSAFETY NOTATIONS ...............................3SECONDARY DISCONNECT ....................38SHIPPING BASE ....................................10

Removal ........................................14SHORTING TERMINAL BLOCKS ..............17SITE PREPARATION ................................7

Ceiling Height .................................7Foundation ......................................8Location ..........................................7

SLINGS ................................................13

SPREADER BAR ................................... 13STEEL CHANNELS ................................ 12

STORAGE .............................................. 6SUSPECT JOINT ................................... 53

TTEMPORARY JUMPERS ......................... 17TESTING .............................................. 21TOLL FREE NUMBER ............................ 54TOWING .............................................. 13

U

UNIT SUBSTATIONS .............................. 16

VVENTILATION VANES ............................ 19

WWITHSTAND VOLTAGES ........................ 22


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ABB Power T&D Company Inc.North America Distribution Switchgear Grouphttp://www.abb.com/usae-mail: [email protected]

HeadquartersSwitchgear SystemsMotor Control CentersPower Distribution CentersIEC Products & SystemsAfter-market Components

655 Century PointLake Mary, FL 32746+1 (407) 732-2000+1 (407) 732-2132 (FAX)

Circuit Breaker OperationsOEM ComponentsKirk Interlock Systems

2300 Mechanicsville HighwayFlorence, SC 29501+1 (843) 665-4144+1 (843) 667-5109 (FAX)

Documents

SafeGear Maintenancee Manual