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Instruction Bulletin - 01.4IB.26264A

FlexGear™ Low Voltage Arc Resistant

Switchgear

Equipped with GE EntelliGuard, Siemens WL, or Eaton Magnum DS

Circuit Breakers

Up to and including 635V

Powered by Safety

Summary of Contents for FlexGear

Page 1: ...Instruction Bulletin 01 4IB 26264A FlexGear Low Voltage Arc Resistant Switchgear Equipped with GE EntelliGuard Siemens WL or Eaton Magnum DS Circuit Breakers Up to and including 635V Powered by Safety ...

Page 2: ...ar Low Voltage Arc Resistant Switchgear 01 4IB 26264A Contact Information Powell Electrical Systems Inc powellind com info powellind com Service Division PO Box 12818 Houston Texas 77217 2818 Tel 713 944 6900 Fax 713 948 4569 ...

Page 3: ...ut the safety alert symbol is used to address practices not related to personal injury CAUTION NOTICE NOTICE is used to address practices not related to personal injury Qualified Person For the purposes of this manual a qualified person as stated in NFPA 70E is one who has skills and knowledge related to the construction and operation of the electrical equipment and installations and has received ...

Page 4: ...Powered by Safety FlexGear Low Voltage Arc Resistant Switchgear 01 4IB 26264A This page is intentionally left blank ...

Page 5: ...1 Lifting the Switchgear 11 D Storage 13 E Positioning the FlexGear 14 1 Drawings and Diagrams 14 F Preparation of Floor Anchoring for Indoor FlexGear 14 G Grounding 18 H Connections 18 I Main Bus Assembly Insulation 20 1 Applying PVC Boots 20 2 Cleaning Bus Insulation 20 J Power Cables 21 K Control Cables 21 L Field Wiring Precautions for Arc Resistant Equipment 21 1 Adding Control Cable 22 2 Rem...

Page 6: ...1 Equipment 26 2 Bus Insulation 26 3 Mechanisms 26 4 Primary Disconnect Device Contacts 26 5 Control Contacts 26 6 Secondary Wiring 27 7 Mechanical Parts 27 8 Ventilation 27 9 Battery and Charging Equipment 27 10 Hardware 27 11 Heaters 27 12 Records 28 C Abnormal Conditions 28 Ch 6 Replacement Parts 29 A Ordering Instructions 29 B Recommended Renewal Parts 29 ...

Page 7: ...oving the Circuit Breaker from the Switchgear 9 Figure 3 Switchgear on Lifting Crane 11 Figure 4 Chain Cable Sling Installation 12 Figure 5 Base View 15 Figure 6 Side View 16 Figure 7 Ground Bus Splice Bolt Assembly 19 Figure 8 Typical Channel Type Main Bus Splice Connection 19 Figure 9 Plenum Vent 23 Figure 10 Arc Flash Preventers 24 ...

Page 8: ...iv General Information 01 4IB 26264A FlexGear Low Voltage Arc Resistant Switchgear Tables Table A FlexGear Ratings 7 Table B FlexGear Dimensions 16 Table C Bolt Torque Values for Powell FlexGear 20 Table D Accessories 30 ...

Page 9: ... servicing maintenance or any act requiring the operator to make physical contact with the equipment the power source must be disconnected and the equipment grounded Failure to do so may result in death or serious injury NOTICE The information in this instruction bulletin is not intended to explain all details or variations of the Powell equipment nor to provide for every possible contingency or h...

Page 10: ...or installation of the switchgear 4 Information for ordering renewal parts 5 Illustrations photographs and description of the switchgear Refer to the instruction manual provided with the circuit breaker for details on the circuit breaker operation The illustrations contained in this document may not represent the exact construction details of each particular type of switchgear section The illustra...

Page 11: ...d test instruments intended for use on electrical systems 1000 V and below 6 Where the possibility of induced voltages or stored electrical energy exists ground the phase conductors or circuit parts before touching them Where it could be reasonably anticipated that the conductors or circuit parts being deenergized could contact other exposed energized conductors or circuit parts apply ground conne...

Page 12: ...ash corrosive atmosphere vermin and insect infestations D Specific 1 DO NOT WORK ON ENERGIZED SWITCHGEAR If work must be performed on the switchgear remove it from service and place it in an electrically safe condition 2 DO NOT WORK ON THE SWITCHGEAR WITH THE CONTROL CIRCUIT ENERGIZED 3 EXTREME CARE MUST BE EXERCISED TO KEEP ALL PERSONNEL TOOLS AND OTHER OBJECTS CLEAR OF MECHANISMS WHICH ARE TO BE...

Page 13: ...AUTION and instruction labels attached to various locations All equipment DANGER WARNING CAUTION and instruction labels shall be observed when the circuit breaker is handled operated or maintained Warning and Caution labels are located in various places Do NOT remove or deface any of these warning caution labels NOTICE ...

Page 14: ...openings lower unit cable penetrations and view windows The switchgear sections consist of full depth structural frames and components providing separate compartments for circuit breakers buses cable and auxiliary components Powell FlexGear consists of multiple sections fastened together as a single group Figure 1 It is completely operational when installed and connected directly to the customers ...

Page 15: ...Current Rating Amperes Arc Fault Current kA Short Time Current Short Circuit Current Main Bus kA Riser Bus kA Main Bus kA Riser Bus kA 635 800 5000 85 5s 85 85 100 85 Notes 1 For specific circuit breaker ratings refer to the appropriate manufacturer s application guide 2 Eaton Magnum DS up to 4000A Continuous Current Rating ...

Page 16: ...Powered by Safety 8 Equipment Description 01 4IB 26264A FlexGear Low Voltage Arc Resistant Switchgear Figure 1 Typical Powell FlexGear Low Voltage Arc Resistant Switchgear Lineup ...

Page 17: ... Circuit Breaker Compartment a d f b c e g The arc resistant rating is only valid when all doors are closed and properly latched or bolted and components are installed and working properly In addition removal of any breaker from its compartment without reinstalling a circuit breaker maintenance cover will void the arc resistant rating DANGER Note Circuit breaker maintenance covers for compartments...

Page 18: ...d self supporting steel vertical sections The switchgear vertical sections are shipped in an upright position and when received should be kept upright When the switchgear is received check for signs of damage If damage is found or suspected file claims as soon as possible with the transportation company and notify the nearest Powell representative Refer to the instruction bulletin furnished with t...

Page 19: ...h section Four lift points shall always be used when lifting the switchgear Figure 3 If lifting a single section then three lift points are available It is important to note that when a spreader bar is not being used that each lift chain cable when loaded maintain at least a 45 angle from the horizontal plane Figure 4 Note At 45 the force on each lifting chain cable is equal to the total load divi...

Page 20: ...Powered by Safety 12 Installation 01 4IB 26264A FlexGear Low Voltage Arc Resistant Switchgear Figure 4 Chain Cable Sling Installation 45 45 1 45 45 1 2 45 45 1 2 3 Minimum Minimum Minimum ...

Page 21: ...d be stored in such a manner as to leave all doors and panels accessible for inspection The equipment must be inspected on a routine basis to assure operational integrity 2 Equipment stored in outdoor storage locations must be protected from airborne external contaminates Outdoor storage will also require additional care to maintain temporary covers over the openings and shipping splits The equipm...

Page 22: ...switchgear line up should first be lined up and set in position in accordance with the dimensions on the base plan drawing for the installation The additional sections should then be installed Establish a base line located a few inches in front of the sections and parallel with the desired front of the structure Equalize the distances from the front of the sections to the base line to make the fac...

Page 23: ...tingent on the frame size It has no bearing on the equipment depth and will be one of two dimensions shown in Table B FlexGear Dimensions C Cable Space Width 6 00 6 00 6 00 6 00 2 67 1 00 D 1 00 Front Compartment E B A C Width C Depth 0 75 x 0 56 OBR Available Customer Cable Space 4 Holes for Anchor Bolts ...

Page 24: ... Width in mm E Front Compartment Depth in mm Width Depth 74 1880 26 25 666 75 21 96 557 78 or 31 96 811 78 24 34 618 24 24 609 6 or 34 863 6 47 75 1212 85 80 2032 32 25 819 30 34 770 64 24 609 6 or 34 863 6 47 75 1212 85 86 2184 38 25 971 5 36 34 923 04 24 609 6 or 34 863 6 47 75 1212 85 92 2337 44 25 1124 42 34 1075 44 24 609 6 or 34 863 6 47 75 1212 85 Front Compartment E Cable Compartment B 94 ...

Page 25: ... spacing of the floor channels including the center channel must be as shown on the drawings Even though the switchgear is not anchored to the center channel its location is important to the proper support and alignment of the switchgear units The floor channels must be level and straight with respect to each other Brass shims should be placed under floor channels when leveling is needed Care shou...

Page 26: ...s 240mm2 or greater if the soil in which it is buried is of such character as to cause appreciable corrosion This is especially true where electrolysis from stray currents or contact with dissimilar metals exists The resistance of the soil surrounding a station ground depends on the condition of the soil as well as its chemical content Dry loose sandy or frozen soils will have a high resistance as...

Page 27: ...nclosed switchgear bars are normally silver plated Unplated bars either copper or aluminum should not be used to connect to plated bars 4 All field assembled primary conductor joints and terminations must be insulated before the operating voltage is applied Note All hardware must be tightened to the torque values listed in Table C Bolt Torque Values for Powell FlexGear Refer to Figure 8 for a typi...

Page 28: ...th joint c Secure the boot with the furnished nylon wire ties The joint insulation is now complete Note The PVC insulation boots are furnished for standard configurations d Replace all covers previously removed 2 Cleaning Bus Insulation The main bus bar is insulated with a high temperature thermoplastic or thermoset material that provides dielectric and mechanical properties Clean the insulation t...

Page 29: ...reconnected The wires will be cut to length and formed before being folded back so that a minimum time will be required for reconnecting them All entries should be sealed with duct seal to prevent gas transmission in case of a fault Any connections to the power bus that will enter the instrument compartment must follow the guidelines found in Ch 4 Installation L Field Wiring for Arc Resistant Equi...

Page 30: ...pening in the rear wall that is shrouded by a special cover ii All cables entering the compartment with connections to the power bus must be fuse protected iii The unprotected line side of the fuse must be shrouded by an insulated cover that prevents faults on these terminals from escalating and entering the compartment 2 Removing Control Cable Removing control cables from an arc resistant switchg...

Page 31: ...info powellservice com After the equipment has been installed and all connections made it shall be tested and inspected before putting in service Although the equipment and devices have been completely tested at the factory a final field test should be made to ensure the equipment has been properly installed The primary equipment should be completely deenergized while the tests are in progress The...

Page 32: ...uipment is energized 2 Testing The following tests shall be completed before placing the switchgear into operation a A megger test shall be made to ensure all connections made in the field are free of undesirable grounds b A dielectric test shall be made on the high voltage circuit for one minute at the appropriate test voltage Voltage transformers CPT s and surge arresters must be disconnected du...

Page 33: ...equipment repairs and any adjustments that were made Test data from successive maintenance interval should be compared to note any significant changes in the condition of the switchgear When performing maintenance the power source must be disconnected and the equipment grounded Failure to do so may result in death or serious injury WARNING B Overall Maintenance Procedures The switchgear lineup and...

Page 34: ...or isopropyl alcohol to clean the insulation Wear protective gloves and goggles and clean the main bus bar in a well ventilated area Wipe dirt or other foreign matter from the insulation with a clean cloth saturated with only denatured or isopropyl alcohol Inhalation of vapor could result in minor or moderate injury CAUTION Use only the cleaners recommended in this document Failure to do so could ...

Page 35: ... accumulations of dirt The air space around the switchgear which is necessary for the entrance of ventilating air should be cleaned of possible debris 9 Battery and Charging Equipment The control battery is such an important accessory to the switchgear operation that it must be given special periodic attention if it is to have a long life of reliable service Periodic inspections and tests are reco...

Page 36: ...ulation resistance readings This variation in insulation resistance between different switchgear assemblies emphasizes the value of a series of readings which can be charted to establish a normal insulation level so that progressive weakening of the insulation can be recognized C Abnormal Conditions Local atmospheric conditions such as high humidity salty atmosphere corrosive gases heavy dust extr...

Page 37: ...5 or better to ensure proper clamping torque and to prevent the joints from overheating The hardware should be plated to deter corrosion B Recommended Renewal Parts A sufficient amount of renewal parts should be stored to enable the prompt replacement of any worn broken or damaged part A sufficient amount of stocked parts minimizes service interruptions caused by breakdowns and saves time and expe...

Page 38: ...with Padlock Hasp H3 50 220 050 Linear Actuator H3 51 40 Cam for 1 06 Grip Range E5 6110 Rod Adaptor A5 92 201 31 Rod for 2 High Door 16 125 Long 26264P00000003 Rod for 1 High Door 4 5 Long 26264P00000022 Breaker Maintenance Cover 800A 3200A Circuit Breaker 26263G00000052 4000A Circuit Breaker 26263P00001217 Notes 1 The numbers in the indicate the number of pieces or the length of cable included 2...

Page 39: ...4569 powellind com info powellind com Equipped with GE EntelliGuard Siemens WL or Eaton Magnum DS Circuit Breakers Up To And Including 635V 01 4IB 26264A FlexGear Low Voltage Arc Resistant Switchgear October 2017 Powell Electrical Systems Inc Service Division Houston PO Box 12818 Houston TX 77217 ...

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