ABB K-Line Plus Page 1 Installation And Maintenance Instructions Manual Download

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ABB Power T&D Company Inc.

North America Distribution Systems Group

Installation and Maintenance Instructions

K-Line

Plus

™

Low Voltage Switchgear

IB3.1.4.7B

07-31-98

Summary of Contents for K-Line Plus

Page 1: ...ABB Power T D Company Inc North America Distribution Systems Group Installation and Maintenance Instructions K Line Plus Low Voltage Switchgear IB3 1 4 7B 07 31 98 ...

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Page 3: ...I N S T R U C T I O N A L B O O K L E T K Line Plus Low Voltage Switchgear ABB Power T D Company Inc 201 Hickman Drive Sanford Florida 32771 8201 Phone 407 323 8220 Fax 407 322 8934 ...

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Page 6: ...TROL CONNECTIONS 24 INSTALLATION OF BUS BAR CONNECTIONS BETWEEN GROUPS 24 OUTDOOR INSTALLATION 26 GENERAL 26 BUS DUCT FLANGE 26 JOINING THE SHIPPING SPLITS 28 TRANSFORMER TRANSITION UNIT 33 TESTING AND FINAL INSPECTION 35 TESTING 35 CONTROL CIRCUIT CHECKOUT 37 FINAL INSPECTION 40 PLACING SWITCHGEAR INTO SERVICE 45 SAFETY PRECAUTIONS 45 ENERGIZING THE MAIN BUS 46 STANDARD CONSTRUCTION 47 STANDARD C...

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Page 8: ...UCTIONS The instructions are general in nature They cover requirements for installation setup checkout and maintenance as applied to ABB K Line Plus Metal Enclosed Low Voltage Power Circuit Breaker Switchgear These instructions do not attempt to cover all variations and combinations of equipment and installations Information on particular installations appears in the following Bills of Materials t...

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Page 10: ...onnel to possible death injury or property damage situations The safety notations appear before the step in which the condition applies The four hazard levels are DANGER Danger indicates a hazardous situation that has a high probability of death or severe injury and substantial property damage WARNING WARNING indicates a hazardous situation that has some probability of death or severe injury and s...

Page 11: ...d good judgment regarding the potential hazards for themselves and other personnel in the area These instructions are intended for use by fully qualified personnel 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 When communicating with ABB regarding the p...

Page 12: ...ge from improper handling file a claim for damages 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 HANDLING For structural integrity all doors and panels must be in place and securely fastened before moving the equipment Do not move or transport the switchgear with the circuit break...

Page 13: ...acing into storage Cover with heavy wrapping paper or other moisture barrier Do not use materials that would trap moisture inside the unit Do not cover louvered or filtered openings When storing for a long period of time or in high humidity use heaters to keep the interior dry Bring the power for the heaters to the load terminals of the device that controls the heater circuits The device must rema...

Page 14: ...nd for periodic inspections The recommended minimum clearances appear on the drawings FOUNDATION The factory supplies floor plan drawings for each installation The concrete floor must be straight and level within inch over the entire length of the line up The design of the floor may include iron sills in the concrete The sills must be straight and level within inch over their full length and corre...

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Page 16: ...th jacks and move on rollers with the shipping bases in place or with an overhead hoist and spreader bar See pages 15 and 16 MOVING BY JACKS AND ROLLERS Use of forklift trucks for jacking or placing the jacks other than as described may result in stress distortions and irreparable damage to the switchgear Do not remove the shipping bases until the units are set in place Moving the units without th...

Page 17: ...jacks and rollers 1 Do not remove the shipping base Move the unit near the site Raise the unit by jacks placed under the front and rear corners See Figure 1 Note Some sections are on throw away steel bases Figure 1 Position jacks under the front and rear corners inside the shipping base ...

Page 18: ...osition while another person puts a third roller under the forward end Keep moving a roller from the rear to the front until the unit is in place 4 For lateral moving raise the units by jacks as described in step 1 Place the rollers laterally with steel channels not furnished on the rollers See Figure 3 and Error Reference source not found Carefully push the unit onto a third roller and move a rol...

Page 19: ...u s 12 Figure 3 Position rails on rollers as shown for lateral moving Figure 4 Carefully push the unit onto a third roller 5 Locate the units in their final position Raise the units to clear the rollers and channels ...

Page 20: ...ey provide a large hole at each end for attaching a sling and spreader bar assembly Figure 5 End view showing extended lifting eye with optional Drip Proof Roof 2 Use a spreader bar to keep the legs of the sling vertical 3 Lift and move the switchgear to it s final place Once the unit is set in place remove the shipping base as described on page16 ...

Page 21: ...formly level and prevent distortion 3 Remove and discard the shipping bases 4 Select four pieces of wood thick enough to permit removal of the jack after lowering Place one at each corner Slowly lower one side of the switchgear until it rests on the wood Repeat this process on the other side The switchgear should now be sitting on the four pieces of wood 5 Use a crowbar to lift each corner and rem...

Page 22: ...cuit breaker cradle with a lifting yoke A worm driven mechanism and wire rope operated by a removable hand crank provide lifting power Although the driving mechanism allows for easy hand operation the weight of the circuit breaker cannot accidentally move the mechanism See ABB drawing 962141 for detailed operating instructions Installation 1 Remove the lifting eye Drip Proof Roof side panel and Ca...

Page 23: ...ith holes in the rails Adjust the rails as required to loosely secure the locator plates in place with the 8 bosses in their mating holes After mating all Locator Plates in place with the rails secure the locator plates and the rails Figure 8 Mount Location Plate behind the rail Figure 9 Secure plates and rails for a smooth and continuous transition between sections ...

Page 24: ...lift Figure 10 Position Overhead Lift Device on tines of fork lift 3 Align the rollers on the Overhead lift device with the rails on the frame Figure 11 Align wheels on the front rail and behind the rear rail as shown Adjust the upper rear wheel to minimize vertical movement ...

Page 25: ...he Overhead lift device off the fork lift onto the rails Figure 12 Push the Overhead Lift Device onto the rails 5 Re install the carriage stop bracket the end plate and the lifting eye Figure 13 Install the items removed in Step 1 ...

Page 26: ... Do not leave a circuit breaker suspended on the wire rope UNIT SUBSTATIONS Unit substations are power transformers with primary and secondary switchgear They are field assembled to make a complete unit Install the transformers and switches next to the switchgear as shown on coordination drawings In multi unit substations physically identical transformers may have disconnect switches that are key ...

Page 27: ...ondary and control wiring end at terminal blocks located at the shipping split Wire markings match the markings on the terminal blocks Bolt the separate units together Reconnect the bus and control wiring at the shipping splits Follow the connection diagram when replacing secondary and control wiring Bolted joints must be tight See Table 1 Table 1 Torque Values for Low Voltage Equipment Hardware B...

Page 28: ...s If shorting Terminal Blocks are used review Connection Diagram for position of shorting screws See Figure 22 on page 39 Make incoming power connections after all other connections are complete A note on the connection diagram indicates devices that are phase sensitive Verify the phase sequence of the incoming power source before making connections CONNECTION TO GROUND BUS The factory bolts the g...

Page 29: ...ROUPS The factory assembles the main bus bar in each section The splices at the shipping splits are unbolted for shipment Refer to the Connection Diagram Do not use alcohols or freons Limit the use of solvents to removing grease and contamination from primary conductors insulation and unpainted metallic surfaces Use an OSHA approved non flammable solvent with a threshold limit of 300 PPM or higher...

Page 30: ...K L i n e P l u s 23 Torque the inch bus hardware to 30 45 foot pounds ...

Page 31: ...t tops Before assembling Walk In units see the Erection Procedure drawings For weatherproofing instructions see the Gasket Application drawings For anchoring the units to the concrete base see the Erection Procedure drawings BUS DUCT FLANGE Mount the bus duct flange when installing the switchgear 1 Place the gasket between the roof and the flange Use the adhesive as a binder between each of the pa...

Page 32: ...fter bolting the units together Allow space to install gasket material supplied with the unit if not already installed 1 Apply gasket material as shown on the Gasket application drawings See Figure 14 and Figure 17 2 Loosely bolt the sides of the unit together SeeFigure 15 3 Install the angle supplied to the roof seam and secure SeeFigure 17 and Figure 18 4 Tighten the bolts in the sides of the un...

Page 33: ...K L i n e P l u s 26 Figure 14 Install gasket material between shipping splits before bolting together Figure 15 Bolt shipping splits together ...

Page 34: ...K L i n e P l u s 27 Figure 16 Install gasket material between shipping splits Figure 17 Loosely install the shipping split angle as shown ...

Page 35: ...K L i n e P l u s 28 Figure 18 Tighten the shipping split angle evenly Figure 19 Install roof end caps as shown Apply sealant all around ...

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Page 37: ...K L i n e P l u s 30 Figure 20 Lifting eyes with anchor plates Lifting eye Anchor Plate ...

Page 38: ...ne up The unit completely disassembles allowing the transformer to be moved into position and aligned with the bus Once positioned make the connections and loosely re assemble the slotted panels Adjust the panels for best fit and secure the hardware Figure 21 Outdoor K Line Plus with transformer transition unit ...

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Page 40: ...r relays with high voltage Disconnect solid state sensors and relays before applying voltage With the switchgear erected assembled and connected do the following 1 Remove packing and shipping materials 2 Make sure that all internal parts are clean and dry If moisture is present dry with moving air and heat 3 Remove shipping blocks from relays 4 To check for damaged insulation apply potential tests...

Page 41: ...0 volts 1 The Column headed DC WITHSTAND is a reference for those using dc tests to verify the integrity of connected switchgear It represents values believed to be appropriate and approximately equivalent to the corresponding power frequency withstand test values specified for each voltage class of switchgear The presence of this column in no way implies any requirements for a dc withstand test o...

Page 42: ...formers in the switchgear remove all fuses in the transformer circuits On electrically operated circuit breakers discharge the springs and the motor disconnect switch should be in the OFF position DANGER OPEN the circuit breaker before racking 6 Rack drawout breakers to the DISCONNECT position 7 Open all normal control power source disconnects if supplied 8 Check each control switch or push button...

Page 43: ...trol circuit If ac control power is from transformers in the switchgear remove the temporary separate source of control power Reinstall all fuses in the transformer circuit 14 Set all relays regulators and other devices for proper operation of loads The factory does not set the relays 15 Remove shorting screws from the terminal blocks in the current transformer circuits See Figure 22on page 39 Sto...

Page 44: ...te Do not open circuit the secondary of an energized breaker 2 a Single Ratio Remove and store the shorting screw Do not remove the ground screw b Multi Ratio Remove the shorting screw Insert shorting screw according to connection diagram Do not remove the ground screw Figure 22 Short Circuiting Device Single Ratio Multi Ratio ...

Page 45: ...ing terminals to ensure that no back feed condition exists Once installed and all interconnections made perform a final check and test on the switchgear and its controls Check for correct equipment installation and that all connections are complete Use extreme care to prevent the controlled equipment from being connected to the system while the preliminary tests are being conducted Disconnect the ...

Page 46: ...ding an alarm switch undervoltage trip device LET LEC and spare auxiliary switch contacts 2 Secondary disconnect numbers begin with a letter that indicates in which plug the disconnect resides The A plug is the right hand plug when viewed from the rear of the breaker 3 The spare contacts in secondary disconnect A are standard on EO breakers Those routed through plug B are optional ...

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Page 48: ...tion exists The circuit breakers should be in the TEST position When working on switchgear de energize and ground the main bus Before energizing any part of the switchgear make a complete check of mechanical operation of all devices Remove blocking wedges from relays circuit breakers meters etc Manually operate all circuit breakers and relays Moving parts should not bind Verify that there are no f...

Page 49: ...eration of instruments and relays are correct 2 Energize the separate control power source if furnished 3 Energize the switchgear main bus by closing the main circuit breaker Observe if operation of relays and instruments is correct 4 Close the desired feeder and tie breaker circuit breakers 5 Verify that all door panel screws are tight 6 Rack all drawout type circuit breakers to the CONNECTED pos...

Page 50: ...s the paint qualifications of ANSI C37 20 2 5 2 8 BUS SUPPORT INSULATION The switchgear bus supports are glass filled polyester laminate The supports ensure safe operational clearances of bus under normal and abnormal short circuit conditions PRIMARY DISCONNECT DEVICE Each circuit breaker primary contact consists of a circle of fingers compressed by a garter spring or a set of inline fingers compr...

Page 51: ...he need for a test jumper Figure 23 Self aligning Secondary Disconnects GROUND BUS AND CONTACTS The ground bus contacts are on the rear of the circuit breaker The circuit breaker is grounded in all positions CONTROL WIRES The main control leads are in the rear of the bus compartment All electrically operated equipment connects to these control wires through a control circuit protective device ...

Page 52: ... distance from the stationary part of the devices located on the housings 2 The TEST position disengages the main disconnecting devices and engages the control contacts This position allows operation of the circuit breaker for testing 3 The CONNECTED position engages the main and control disconnecting devices on the breaker Mechanical interlocks prevent moving a circuit breaker from one position t...

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Page 54: ...s whenever working in or around electrical equipment Turn off power ahead of the switchgear before performing any maintenance operations Check incoming line terminals to verify that the equipment is de energized Check the out going terminals to make sure that no feedback conditions exist CAUTION Limit the use of solvents to removing grease and contamination from primary conductors insulation and f...

Page 55: ...ing checks 1 Perform an overall visual inspection 2 Check all indicators meters and instruments for proper operation 3 Make sure all bolted panels are secure 4 Verify operation of heaters and thermostats if used 5 Check for undue noise or vibration that might loosen bolted connections 6 Look for evidence of moisture in the switchgear ...

Page 56: ...n Refer to Circuit Breaker Instruction Booklet before cleaning circuit breakers 8 Clean the stationary portion of the switchgear by wiping with a clean cloth Compressed dry air is useful in the inaccessible areas 9 Remove the covers of all panel devices where possible Check wiring for secure connections Clean contacts on relays and switches wherever necessary Replace covers 10 Remove air filters w...

Page 57: ...ing bundles for signs of discoloration because of heat or chafing Check for cracked or embrittled insulation Replace wire whenever doubtful 3 Inspect primary insulation system for accumulated contamination Clean insulation with a dry cloth dry air vacuum or if necessary with an OSHA approved solvent 4 Check the calibration of protective relays approximately every two years 10 YEAR MAXIMUM INSPECTI...

Page 58: ...finger springs after exposure to excess heating at the breaker disconnect 5 Before assembly protect contact surfaces with No Ox Id Special A Compound a product of Sanchem Chemical Co or equivalent 6 Use proper torque in tightening bolted connections CARE OF FINISH The finish on the switchgear is strong and durable Always keep the switchgear clean Wiping with a clean dry cloth will usually suffice ...

Page 59: ...00 RENEWAL PARTS 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 Company Inc Distribution Systems Division Sanford FL Specify quantity part numbers description and nameplate data of the device requiring the replacement parts Obtain standard hardwa...

Page 60: ...o be all inclusive or covering all contingencies No warranties expressed or implied including warranties of fitness for a particular purpose or merchantability or warranties of fitness for a particular purpose or merchantability or warranties arising from course of dealing or usage of trade are made regarding the information recommendations descriptions and safety notations contained herein In no ...

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Page 62: ...ion procedure 24 footprint 7 lifting device 15 site plan 7 G GALVALUME 43 H HEATERS 6 I INSPECTIONS semi annual 48 INSTALLATION 1 3 clearances 7 conduits 7 foundation 7 J JACKS 9 JUMPERS 21 L LIFTING DEVICE drawings 15 lubricant 49 operation 19 overhead 15 M MAINTENANCE 1 3 suspect joint 51 MOVING 10 P PAINT care of 51 color 43 touch up 52 PHASE 21 PRIMARY DISCONNECTS 43 R RECEIVING 5 claims 5 REP...

Page 63: ...U S S SAFETY 3 4 SECONDARY DISCONNECTS 44 SETUP 1 SHIPPING BASES removal 14 steel 9 wood 9 SITE PLAN drawings 7 SLINGS 13 STORAGE 6 T TESTING 33 TORQUE VALUES 20 51 TRANSFORMER TRANSITION UNIT 31 W WEATHERPROOFING 24 ...

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Page 65: ...K L I N E P L U S ABB Power T D Company Inc North American Distribution Systems Group 201 Hickman Drive Sanford FL 32771 8201 Phone 407 323 8220 Fax 407 322 4434 ...

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