instructions for magnum ds metal-enclosed low …

Read and understand these instructions before attempt-ing to unpack, assemble, operate or maintain this typeequipment.

All possible contingencies which may arise during instal-lation, operation or maintenance, and all details andvariations of this equipment do not purport to be coveredby these instructions. If further information is desired bypurchaser regarding his particular installation, operationor maintenance of particular equipment, contact the localCutler-Hammer representative.

installation, operation and maintenance of Magnum DSMetal-Enclosed Low-Voltage Switchgear used withMagnum DS Power Circuit Breakers.

For application information consult applicable descriptivebulletins, application publications and/or the applicableindustry standards.

For installation, operation and maintenance of Low-Voltage Power Circuit Breakers see separate instructionbooks.

SAFETY

All safety codes, safety standards and/or regulations mustbe strictly observed in the installation, operation andmaintenance of this equipment.

INSTRUCTIONS FOR MAGNUM DS METAL-ENCLOSED LOW-VOLTAGESWITCHGEAR ASSEMBLIES WITH MAGNUM DS BREAKERS

METAL-ENCLOSED LOW-VOLTAGE SWITCHGEARASSEMBLIES COVERED BY THESE INSTRUCTIONSARE DESIGNED AND TESTED TO OPERATE WITHINTHEIR NAMEPLATE RATINGS. OPERATION OUTSIDEOF THESE RATINGS MAY CAUSE THE EQUIPMENTTO FAIL RESULTING IN DEATH, SERIOUS INJURYAND/OR PROPERTY DAMAGE. ALL RESPONSIBLEPERSONNEL SHOULD LOCATE THE EQUIPMENTNAMEPLATE AND BE FAMILIAR WITH THEINFORMATION PROVIDED ON THE NAMEPLATE. THEMAGNUM DS NAMEPLATE IS SHOWN IN FIGURE 1.

PURPOSE

This instruction manual is expressly intended to cover the

Figure 1 Blank Magnum DS Rating Nameplate

DANGER

Effective January 2003, Supersedes I.B. 32-697B dated July 1999

IB01901001ECutler-Hammer

DANGER

THE DANGER, WARNING AND CAUTION MESSAGESINCLUDED AS PART OF THE PROCEDURAL STEPS INTHIS MANUAL ARE FOR PERSONNEL SAFETY ANDPROTECTION OF EQUIPMENT FROM DAMAGE. ANEXAMPLE OF A TYPICAL WARNING LABEL HEADINGIS SHOWN ABOVE THIS PARAGRAPH TOFAMILIARIZE PERSONNEL WITH THE TYPE OFPRESENTATION. THIS WILL HELP TO ASSURE THATPERSONNEL ARE ALERT TO THESE MESSAGES. INADDITION, THESE MESSAGES ARE ALL UPPERCASE AND BOLDFACE.

IB01901001E

Effective January 2003

SECTION 1 INTRODUCTION

1.1 General Information 41.2 Safety Features 41.3 Safety Practices 51.4 Qualified Personnel 51.5 Precautions 51.6 Other Publications and Documentation 5

SECTION 2 RECEIVING, HANDLING AND STORAGE

2.1 General Information 62.2 Receiving 62.3 Precautions 62.3.1 Overhead Lifting 62.3.2 Rolling 72.3.3 Shipping Skid and Lifting Plate Removal 72.4 Storage 8

SECTION 3 EQUIPMENT DESCRIPTION

3.1 General Description 103.2 Front Compartment 103.2.1 Breaker Cells (Draw-out) 113.2.1.1 Breaker Cells (Fixed) 113.2.1.2 Breaker Cassette (Draw-out) 163.2.1.2.1 Extension Rails (Draw-out) 163.2.1.2.2 Breaker Interference Interlocks (Draw-out) 173.2.1.3 Key Interlocks 173.2.1.4 Metering Current Transformers 183.2.1.5 Cell Switch (Draw-out) 183.2.1.6 Space Heaters 183.2.1.7 Shutters (Draw-out) 183.2.2 Secondary Terminal Compartment 183.2.3 Control Wiring 183.2.4 Auxiliary Compartment 213.2.5 Auxiliary/Transition Section 213.3 Bus Compartment 223.4 Cable Compartment 223.5 Ground Bus 223.6 Outdoor Enclosure Type 3R 223.7 Type Magnum DS Circuit Breakers 23

SECTION 4 INSTALLATION

4.1 General Information 244.2 Location and Foundation 244.2.1 Location 254.2.2 Foundation 254.2.3 Indoor Equipment 254.2.4 Outdoor Equipment 264.2.5 Conduits 26

TABLE OF CONTENTS

IB01901001E


TABLE OF CONTENTS

4.3 Shipping Group Assembly 264.3.1 Assembly Procedures 264.3.1.1 Drip /Sprinkler Resistant Assembly 264.4 Bus, Cable and Control Connections 304.4.1 Bus Connections 304.4.2 Bus Joint Preparation 304.4.3 Bolt Tightness 304.4.4 Ground Bus 304.4.5 Power Cable Lashing 304.4.5.1 Lug Landing Boots 324.4.6 Control Connections 324.5 Traveling Circuit Breaker Lifter 334.6 Moving Parts 33

SECTION 5 INSPECTION AND TESTING PRIOR TO OPERATION

5.1 General Information 365.2 Test Equipment 365.3 Connections 365.4 Auxiliary Equipment 365.5 Ground Fault Systems 365.6 Electric and Arc Flash Hazard 375.7 Circuit Breakers and Trip Units 375.8 Baseline Test Data 375.9 Final Steps 37

SECTION 6 PERIODIC INSPECTION AND TESTING

6.1 General Information 386.2 Access to Switchgear Assembly Parts 386.2.1 Main Bus and Cable Compartment 386.2.2 Drawout Main Disconnecting Contacts and Current Transformers 386.2.3 Control Equipment 386.3 Inspection and Maintenance Schedule 396.3.1 Individual Devices 396.3.2 Overall Assembly Maintenance 396.3.3 Buses and Connections 396.3.4 Drawout, Main Disconnecting Contacts and Supports 396.3.5 Instruments, Relays and Other Panel Devices 396.3.6 Secondary Wiring, Blocks and Connections 406.3.7 Mechanical Parts 406.3.8 Ventilation 406.3.9 Records 406.3.10 Abnormal Conditions 406.3.11 Lubrication 406.3.12 Renewal Parts 40

IB01901001E


SECTION 1: INTRODUCTION

1.1 GENERAL INFORMATION

Magnum DS Switchgear assemblies with Magnum DSLow-Voltage ac Power Circuit Breakers control and protectpower circuits through 600 volts ac and interruptingcapacities through 100 kA at 600 volts. The switchgearassembly is composed of vertical sections that are ar-ranged to suit the customer’s requirements. Magnum DSswitchgear utilizes a four high structure design consistingof various combinations of Magnum DS Low-Voltage acPower Circuit Breakers and auxiliary compartments (Figure1-1). Rear accessible bus and cable compartments providespace for connections, maintenance and inspection.

This instruction manual contains important proceduresand information pertinent to the receiving, handling,storage, installation, operation and maintenance ofMagnum DS Low-Voltage Switchgear. Informationprovided in this instruction manual and by other supplieddocumentation and/or drawings should be read andunderstood by all personnel responsible for supervision,operation or maintenance. Familiarization should alwaysinclude the characteristics of each piece of equipmentcontained in or mounted on the switchgear assembly.

Figure 1-1 Type Magnum DS Low-Voltage IndoorSwitchgear (Front View)

Proper installation, operation and maintenance areessential to assure continued satisfactory service fromthe equipment. It should not be installed in places whereit will be required to operate at voltage, currents or faultcapacities greater than those for which it was designed,or where the environmental conditions are dirty, corro-sive, humid or otherwise harsh or unsuitable.(Ref. ANSI C37.20.1 for abnormal operation conditions).

The information given in this manual applies to bothdraw-out and fixed Magnum DS switchgear assembliesunless otherwise noted.

1.2 SAFETY FEATURES

Each Magnum DS Assembly is manufactured with built-ininterlocks and safety-related features. They are providedto reduce hazards to operating personnel and provideproper operating sequences.

METAL-ENCLOSED LOW-VOLTAGE SWITCHGEARASSEMBLIES ARE PROVIDED WITH MANY SAFETYFEATURES. NEVERTHELESS, THEY CONTAIN POWERCIRCUITS WITH HIGH FAULT CAPACITY. THEVOLTAGES AND POWER LEVELS AVAILABLE IN THISEQUIPMENT MAKE CONTACT WITH BARECONDUCTORS OR TERMINALS EXTREMELYDANGEROUS, AND IS LIKELY TO BE FATAL. ALLPOWER SHOULD BE TURNED OFF OR ADEQUATEPROTECTIVE EQUIPMENT USED WHEN WORKINGINSIDE SUCH EQUIPMENT. IN ADDITION TO THEHAZARDS INHERENT TO THE SWITCHGEARASSEMBLY ITSELF, OPERATION BY UNQUALIFIEDPERSONS MAY CAUSE DAMAGE TO CONNECTEDEQUIPMENT AND INJURY TO OPERATORS OFCONNECTED EQUIPMENT.

UNDER NO CIRCUMSTANCE SHOULD THEINTERLOCKS OR OTHER SAFETY FEATURES BEMADE INOPERATIVE, AS THIS MAY RESULT IN DEATH,BODILY INJURY OR PROPERTY DAMAGE.

TO PROTECT PERSONNEL DURING THEINSTALLATION, OPERATION AND MAINTENANCE OFTHIS EQUIPMENT, THE FOLLOWING PRACTICESMUST BE FOLLOWED:

DANGER

IB01901001E


1.3 SAFETY PRACTICES

Type Magnum DS Low-Voltage Switchgear is complexhigh current electrical equipment. It is designed to operatewithin the voltage and current limitations shown on thenameplate (Figure 1). Do not apply this equipment tosystems with voltages and/or currents in excess of theselimits.

1. Only qualified electrical personnel familiar with theconstruction and operation of this equipment and theassociated hazards should be permitted to work onsuch equipment. Additionally, only qualified personnelshould be permitted to install or operate such equip-ment.

2. Always be certain that the primary and secondarycircuits are de-energized before attempting anymaintenance.

3. For maximum safety, only insert a completely as-sembled breaker into an energized cell. Front coversand inter-pole barriers are safety features and mustbe in place when energized.

4. Always ensure that drawout circuit beakers are in oneof four designed positions: “Connect”, “Test”, “Discon-nect” or “Withdrawn”. A circuit breaker permitted toremain in an intermediate position could result incontrol circuits being improperly connected causingother equipment to malfunction.

5. Do not remove access covers unless the circuits tobe exposed are de-energized.

6. Use calibrated test equipment of known reliability toconfirm that all circuits are de-energized beforeservicing.

7. After maintenance, be certain every current trans-former secondary circuit is completely connected orshorted.

FAILURE TO FOLLOW THESE DIRECTIONS COULDRESULT IN DEATH, SERIOUS BODILY INJURY ORPROPERTY DAMAGE.

1.4 QUALIFIED PERSONNEL

For the purpose of operating switchgear assemblies, aperson who has been thoroughly trained in the operationof the circuit breakers and any included instrumentationand who has complete knowledge of the loads connectedto the assembly may be considered to be a qualifiedperson.

For the purpose of installing, inspecting and maintainingswitchgear assemblies, a qualified person must ALSO bethoroughly trained in regard to the hazards inherent toworking with electricity and in the proper way to performsuch work. The individual should be able to de-energize,clear and tag circuits in accordance with establishedsafety practices. In addition, the individual should beequipped with, and trained in the use of, protectiveequipment (rubber gloves, flash clothes, etc.) for thoseoccasions when it is not possible to de-energize allcircuits before doing maintenance work in the area.

1.5 PRECAUTIONS

1. If relays are included, remove all blocking. Checkcontrol circuits (except voltage and current trans-former circuits) for grounds and short circuitsbefore applying control power.

2. Connect the assembly to the station ground beforeapplying any power.

3. In case of fire, do not use liquid fire extinguisher untilall circuits have been disconnected.

4. If an indoor assembly is to be stored prior to installa-tion, it must be protected from the weather and keptfree of condensation.

5. If an outdoor assembly is to be stored prior toinstallation, provisions must be made for energizingthe space heaters to prevent condensation ofmoisture inside the assembly.

1.6 OTHER PUBLICATIONS AND DOCUMENTATION

In addition to this instruction manual, other printedinformation and documentation is supplied with eachassembly. This additional information will include, but notnecessarily be limited to, a Magnum DS Low-VoltagePower Circuit Breaker instruction manual, arrangementdrawings, and connection diagrams.

WARNING

IF THE SECONDARY CIRCUIT OF ANY CURRENTTRANSFORMER IS LEFT OPEN WITHOUT LOAD, ANDITS PRIMARY CIRCUIT IS ENERGIZED, ADANGEROUSLY HIGH VOLTAGE IS DEVELOPEDACROSS TRANSFORMER SECONDARY TERMINALS.TO PREVENT DEATH, BODILY INJURY OR ELECTRICALSHOCK, EITHER DE-ENERGIZE THE CIRCUIT BYOPENING THE BREAKER, OR SHORT CIRCUITCURRENT TRANSFORMER SECONDARY TERMINALS,BEFORE PROCEEDING WITH MAINTENANCE.

8. Always be certain that all assembly hardware is inplace and bolted tightly before inserting a drawoutcircuit breaker into its compartment.

DANGER

IB01901001E


SECTION 2: RECEIVING, HANDLING AND STORAGE


Magnum DS Metal-Enclosed Low-Voltage Switchgearassemblies are shipped in one or more shipping groups,depending on the number of vertical sections, or thelimitations of handling facilities at the installation site. Thiswould usually be up to five vertical sections for an indoorassembly, or up to three or four sections for an outdoorassembly.

Indoor shipping groups are secured by lag bolts towooden skids that extend beyond all sides of theswitchgear. All shipping sections are shipped so as to beprotected from the weather during shipment but are notsuitable for storage outdoors as shipped. Outdoorassemblies are not weatherproof until completelyassembled. Treat them the same as indoor equipmentuntil fully assembled.

2.2 RECEIVING

When a switchgear assembly reaches its destination, thepurchaser should check the material received against theshipping list to be certain that all items have arrived. Noteaccurately any discrepancies. Each shipping group isplainly marked with or accompanied by an identifyingshop order number, general order number and shippingweight. Each shipment includes a contents list which is apart of the overall package of shipping papers. To avoidthe loss of any parts, the contents of each containershould be carefully checked against the packing list. Donot discard any packing material until it is certain thatevery item has been received in the proper condition andthat certain packing material will not be required later forequipment storage. Larger items, such as indoor travelinglifters, are shipped in separate cartons. Other loose andunmounted items may be packed in the same box as thelifter (Figure 2-1). These items, such as shipping splithardware, should be logged in and set aside in a safelocation until the assembly has been set in its finalposition.

Equipment shipped from the factory is carefully packedand inspected prior to its departure. On occasion, how-ever, equipment damage is incurred during transportation.If any damage is found, file a damage claim immediatelywith the transportation carrier and notify a Cutler-Hammerrepresentative. All claims should be filed as soon aspossible and include applicable part numbers, shop ordernumbers and/or general order numbers.

2.3 PRECAUTIONS

It is preferable to use an overhead crane when movingthe assembly. Circumstances at the installation location

Figure 2-1 Carton Containing Indoor Lifter Assembly

may prevent the use of an overhead crane for allmovement. In such instances, the careful use of rollerscan be employed. Although the methods for movingindoor and outdoor assemblies are similar, thetechniques vary slightly. The differences are highlightedin this section.

2.3.1 OVERHEAD LIFTING

FAILURE TO FOLLOW LIFTING INSTRUCTIONSCOULD RESULT IN DEATH OR SERIOUS BODILYINJURY. READ INSTRUCTIONS FOR LIFTINGSWITCHGEAR PRIOR TO ATTACHING CABLES,CHAINS OR SPREADER BARS.

Indoor Assemblies: For ease of handling by crane, eachindoor shipping group is equipped with a lifting plate thatextends the length of the shipping group. The lifting plateis designed and placed such that a spreader bar is notrequired between the lifting cables (Figure 2-2). Spreaderbars can, however, be used if the overhead space islimited for crane use. In addition to the built in lifting angle,bolt on lift plates are attached to the front of eachSwitchgear shipping section to provide stability whilelifting. These lift plates are not provided as the primarylifting means and should only be utilized as a means ofproviding stability. The primary lifting means should beachieved by use of the built in lifting angles located overthe bus compartment. After installation, the bolt on liftplates can be removed and discarded.

DANGER

IB01901001E


Outdoor Assembly: Lifting plates are attached along theassembly base at the front and rear for crane cableattachment. The methods used for lifting an outdoorassembly are similar to those used with an indoorassembly, except that spreader bars, not provided, mustbe placed between lift cables to prevent equipmentdamage (Figure 2-3). If it appears that the cables willtouch the assembly during the lifting process, placeappropriately sized lumber along the sides where contactcould be made between the cable and the equipment.This will prevent damage caused by the lifting cables.

2.3.2 ROLLING

If during the moving and positioning process it is notfeasible to use an overhead crane, the equipment canbe moved on construction rollers. The shipping skids onindoor assemblies or the heavy steel base on outdoorassemblies are used directly when rolling. If conditions

Figure 2-3 Outdoor Assembly Lifting Method

Figure 2-2 Indoor Assembly Lifting Method

are such that the indoor assemblies cannot be rolled intoposition with the shipping skids in place, they may beremoved before rolling the assemblies. For best results,however, the shipping skids should be used. Use no lessthan four evenly spaced rollers for assembly movement.Since equipment length can vary, each 1.5 to 2.0 feet(457 to 610 mm) of equipment length requires a roller. Asthe equipment is carefully moved, the rollers thatbecome free at the end opposite the movement directionshould once again be placed at the front for continuedmovement (Figure 2-4).

2.3.3 SHIPPING SKID AND LIFTING PLATEREMOVAL

The wooden shipping skid bolted to the bottom of anindoor assembly should be removed once the indoorassembly is in its permanent location. Lag bolts attachthe shipping skids to the assembly from the inside. Theholes that remain after the skids and lag bolts are re-moved are used in securing the indoor assembly perma-nently in position (Figure 2-5).

Once an outdoor assembly is in its permanent locationremove the lifting eyes from the angles (Figure 2-6).Rotate the angles 180 degrees and reinstall. Use theangles to bolt the assembly to the foundation.

IB01901001E


recommended and should be avoided. The coveringprovided during shipment for indoor assemblies is NOTadequate for outdoor storage. Covering must be ad-equate to protect the assembly from dust and fallingdebris, but loose enough to permit adequate ventilation.Place blocking on the roof of the equipment to keepcovering material from restricting the air flow.

A fully assembled outdoor assembly requires a minimumof care during outdoor storage. The area should bereasonably free of dirt and corrosive gases. The spaceheaters, which are standard with weatherproof assem-blies, must be energized to prevent condensation.

Outdoor assemblies which are not fully assembled mustbe treated in the same manner as indoor equipment.

2.4 STORAGE

An indoor switchgear assembly which cannot beinstalled and put into service immediately should bestored in a dry and clean place, preferably indoors in aheated building. Conditions such as dampness, changesin temperature, dirty or corrosive atmospheres should becarefully avoided. Special precautions are required if theindoor assembly is to be stored outdoors. The assemblymust be kept clean, well ventilated, and warm enough toprevent condensation. It will be necessary to cover theassembly and install temporary heating equipment.Approximately 250 watts per vertical section arerequired for average conditions. Outdoor storage ofindoor equipment, even for a brief period, is not

Figure 2-4 Assembly Rolling Procedure

FRONT VIEW

REAR FRAME

PLYWOOD ATEACH BOLTLOCATION.

ACCESSRECT.HOLE

CENTER BOARDS ANDLAG BOLTS ARE FORSUPPORT ONLY.

(NOT BOLTED TO STRUCTURE)

REAR SILLFRONTSILL

REMOVE FROM ALL UNITS(.375 X 3.50 LAG BOLTS)

FRONT TOREAR SILL

Figure 2-6 Lifting Angle in Place on Outdoor Assembly

Figure 2-5 Shipping Skid

CARE MUST BE TAKEN THAT INTEGRAL CONTROLPOWER TRANSFORMERS ARE NOT BACK-FED.DISCONNECT PRIMARY AND SECONDARY FUSES.

During storage , all assemblies, whether indoor or out-door, should be placed on a firm, level surface. This willprevent any unnecessary strain or possible distortion.

Store all other separately packaged accessory equipmentin a clean, dry location. It is recommended that a water-proof cover be placed over circuit breaker cartons and thecartons kept in an indoor storage location when the circuitbreakers are stored separately from the assembly.

CAUTION

IB01901001E


Figure 3-1 Four High Vertical Section (Side View)

2A97855

IB01901001E


SECTION 3: EQUIPMENT DESCRIPTION

3.1 GENERAL DESCRIPTION

The following descriptions apply to standard metal-enclosedconstruction and wiring. Special features and controlschemes are often incorporated. These special features areevident on the drawings and diagrams for the specificswitchgear assembly. Instructions on standard apparatussuch as relays, instruments, control switches and circuitbreakers are included elsewhere in separate instructionbooks or sheets.

Each low-voltage (600 volts and below) indoor and outdoormetal-enclosed switchgear assembly is factory assembledand tested. It is designed to require a minimum amount oflabor for installation.

The switchgear assembly consists of a stationary structurethat includes one or more free-standing vertical sectionsmechanically and electrically joined to make a singlecoordinated installation. Each vertical section consists ofthree major parts: front compartment, bus compartment,and cable compartment (Figure 3-1).

Type Magnum DS metal-enclosed switchgear assembliesare available for both indoor (NEMA Type 1) and outdoor(NEMA Type 3R) applications. The circuit breakers anddesign features are similar whether the installation beindoor or outdoor. An outdoor metal-enclosed switchgearassembly is constructed by assembling an outdoor enclo-sure around a standard indoor switchgear assembly.

Modifications can be made to the NEMA 1 enclosure foruse in drip resistant or sprinkler resistant environments.When this is the case, these parts are shipped separately toreduce the risk of damage during shipping and handling.Installation instructions are given in drawings included in theinformation packet attached to the side of the switchgearassembly. Should additional copies of this drawing beneeded, contact your nearest Cutler-Hammer sales office.Refer to Section 4.3.1.1 for further information.

3.2 FRONT COMPARTMENT

The front compartment is a bolted steel structure. Thisstructure may be an auxiliary unit used to house instru-ments, relays, switches and their associated auxiliaryequipment or it may be divided into a maximum of fourindividual cells used to house circuit breakers (Figure 3-2).These individual cells may also be used as instrumentcells by omitting the circuit breaker and its associatedstationary parts. The hinged door then becomes availablefor mounting instruments, relays, etc. Either draw-out orfixed breakers can be mounted in this compartment.

Figure 3-2 Magnum DS Breaker in Connected Position

Figure 3-3 Magnum DS Breaker on Extension Rails

IB01901001E


A molded glass polyester plate at the rear of the breakercell provides mounting for the instrument class currenttransformers.

The breaker cell provides three positions for the circuitbreaker identified as “connect”, “test” and “disconnect”.Each specific position is indicated by the position indica-tor on the circuit breaker as it moves into and out of thecell. The “withdrawn” position is attained when the circuitbreaker is removed from the cell with the extension railsfully extended.

In the “connect” position, both the primary and secondarycontacts are engaged and the circuit breaker is ready foroperation. In the “test” position, only the secondarycontrol contacts are engaged and the circuit breaker canbe operated electrically without energizing the powercircuit. In the “disconnect” position, both the primary andsecondary control contacts are disengaged and theentire circuit breaker is isolated. Unlike the “connect” and“test” positions, the circuit breaker is not held captive inthe cell in the “disconnect” position.

The door can be closed with the breaker located in the“connect”, “test” and “disconnect” positions.

When the levering device, located on the circuit breaker,is moved to the “disconnect” position, the circuit breakercan then be freely withdrawn out of the cell.

3.2.1.1 BREAKER CELLS (FIXED)

In fixed mounted breaker applications, the breaker isrigidly supported via side plates anchored securely to thefront and rear of the cell. Many similarities exist betweendraw-out and fixed mounted cells. These similarities aredetailed in applicable sections of 3.2.

For removal of a fixed mounted breaker located in theA, B or C cell position proceed as follows.

Step 1. Remove the ground wire by disconnecting theground screw from the front post as shown in Figure 3-5.1.

Step 2. To remove the left hand breaker stop, remove thescrew as shown in Figure 3-5.2L and pull the metal plateforward. Then remove the two screws as shown in Figure3-5.2R and pull the metal plate to the left and forward.

Figure 3-4 Magnum DS Breaker Cell

Above each breaker cell exists a compartment thatcontains terminal blocks and control wiring for connec-tions to circuit breaker’s secondary terminals and otherdevices. Breaker control devices and instrumentationmay be mounted on the door defining this compartment.

3.2.1 BREAKER CELLS (DRAW-OUT)

FAILURE TO HAVE THE BREAKER COMPLETELY INTHE DISCONNECT POSITION BEFORE LEVERINGCAN CAUSE SERIOUS EQUIPMENT DAMAGE.ENSURE THAT THE BREAKER REACHES APOSITIVE STOP WHEN INSERTING INTO THE CELLPRIOR TO LEVERING.

In draw-out cells equipped for circuit breakers, a bolted-incassette with extension rails supports the breaker (Figure3-3). The cassette provides the mounting for the station-ary secondary control disconnecting contacts and islocated in the top/front region of the breaker cell (Figure3-4). These provide the control circuit interface to thecircuit breaker. In addition, the cassette provides thestationary ground contact for the circuit breaker, the truckoperated switch (cell switch), and shorting terminalblocks for cell mounted instrument current transformers.

DANGER

IB01901001E


Step 3. Remove the secondary terminal block mountingbracket above the breaker by removing the three screwsas shown in Figure 3-5.3. The bracket can then be tiltedand removed from the cell.

Figure 3-5.2L

Figure 3-5.1

Figure 3-5.2R

One Screw

One Screw

Two Screws

Step 4. Remove arc barrier above the breaker by remov-ing the four screws as shown in Figure 3-5.4 that attachthe arc barrier to the cell divider pan. Slide the arc barrierforward and remove it from the cell.

Figure 3-5.3

Three Screws

Figure 3-5.4

Two Screws

IB01901001E


Figure 3-5.5L

Figure 3-5.5R

Figure 3-5.6

Two Screws

Two Screws

Two Screws

Step 6. The line side barrier is removed by disconnectingthe two screws from the rear cell back pan (Figure 3-5.6).Then slide the line side barrier forward.

Step 5. Remove the main bracket assembly by com-pressing the spring-loaded terminal mounting channel byturning the screws shown in Figure 3-5.5B to the rightuntil the breaker secondary terminals are completelydisconnected. Then remove the four screws at the top ofthe breaker as shown in Figures 3-5.5L and 3-5.5R.

Figure 3-5.5B

Step 7. Remove the bottom half of the cell divider framelocated above the breaker. This is accomplished by firstremoving the remaining screw on the left side of the cell(Figure 3-5.7L), then removing the three screws on theright side of the cell (Figure 3-5.7R) and removing thetwo screws attaching the cell divider frame to the post(Figure 3-5.7B).

IB01901001E


Figure 3-5.7L

Figure 3-5.7R

One Screw

Figure 3-5.7B

Two Screws

Step 8. Remove the bolts from each phase of the lineside connections (Figure 3-5.8).

Figure 3-5.8

Step 9. Repeat steps 3 and 4 for the cell located belowthe breaker being removed.

IB01901001E


Step 10. Remove the top half of the divider frame locatedbelow the breaker cell by removing the two remainingscrews holding the left side of the top divider frame(Figure 3-5.10L). Then remove the two screws holdingthe right side (Figure 3-5.10R). Remove the three screwsholding the lower door hinge and the two screws attach-ing the frame to the bottom of the post (Figure 3-5.10T).Remove the seven screws holding the post (Figure 3-5.10P). Then the divider pan can be slid out of the cellgiving access to the load side connections (Figure 3-5.10).

Figure 3-5.10L

Figure 3-5.10R

Figure 3-5.10T

Figure 3-5.10P

CAUTION

Figure 3-5.10

CARE SHOULD BE TAKEN WHEN THE BREAKER ISREMOVED FROM THE CELL. FAILURE TO TAKEPROPER PRECAUTIONS IN HANDLING THEBREAKER CAN RESULT IN PERSONNEL INJURY.

Step 11. At this point the entire breaker weight is beingcarried by the side plates. Care should be taken whenthe breaker is slid out of the cell. It is recommended thatthere be a platform equal to the height at the bottom ofthe breaker to be removed that will hold the weight of thebreaker. Slide the breaker out onto this platform.

IB01901001E


3.2.1.2 BREAKER CASSETTE (DRAW-OUT)

The breaker cassette supports the breaker in the cell andon the movable extension rails as the breaker is placedinto the cell.

3.2.1.2.1 EXTENSION RAILS (DRAW-OUT)

The extension rails are withdrawn from the breakercassette by pulling the black handles located on the endof the extension rails. Once extended, the breaker isplaced onto the draw-out rails by aligning the hookfeatures located on each side of the circuit breaker

Figure 3-5.13

Step 12.With the breaker out of the cell, access is gainedto the cell connectors (Figure 3-5.11) and breakerconnectors (Figure 3-5.12).

Figure 3-5.14

Breaker Connectors

Load Side Runbacks

Figure 3-5.11

Cell Connectors

Figure 3-5.12

Breaker Connectors

For removal of a fixed mounted breaker located in the Dcell position follow the above steps 1 through 8. Thenfrom the bus compartment disconnect the load siderunbacks as shown in Figure 3-5.13. With these connec-tions removed, the breaker can be slid out of its cell.

Note that most of the loadside copper runbacks will stillbe attached to the breaker and will be withdrawn as thebreaker is removed from the cell (Figure 3-5.14).

IB01901001E


housing with the slotted features in the draw-out rails.The breaker is then pushed into the cell until it reaches apositive stop.

3.2.1.2.2 BREAKER INTERFERENCE INTERLOCKS (DRAW-OUT)

800, 1600, 2000 and 3200 Ampere circuit breakers havethe same dimensions. Additionally, 4000 and 5000Ampere breakers have the same dimensions. To preventinsertion of circuit breakers with mismatching features,insufficient interrupting ratings, or incorrect frame sizeinto cells, interference interlocks are provided.

DO NOT DISABLE AN INTERFERENCE INTERLOCK.IF A FAULT OCCURS THE USE OF A LOWERCAPACITY BREAKER COULD RESULT IN DEATH,BODILY INJURY AND SEVERE EQUIPMENTDAMAGE.

These interference interlocks are steel pins located onthe floor of the breaker cassette. As the breaker ispushed into the cell, the mating pins on the breakerbottom moves past a set of corresponding pins on thebreaker cassette. If the breaker is not matched correctlyfor the cell, the pins will not clear each other and thebreaker will not travel to the disconnect position. SeeTable 3-1 for emergency use of breakers.

3.2.1.3 KEY INTERLOCKS

Key interlocks are supplied when it is necessary toensure the proper sequence of operation between two ormore circuit breakers or between a circuit breaker, fusetruck or transformer high voltage disconnect switch. Theinterlock mechanism provided in a circuit breaker cellfunctions by keeping the breaker cell trip-free. The keyinterlock mechanism is located on the wire way side ofthe circuit breaker. The breaker can be removed, in-serted, or a different breaker installed and the cell willremain trip-free. The key interlock operates by pulling theslide forward, rotating the key, and removing it from thelock. The slide mechanism actuates a lever located onthe circuit breaker, which prevents the breaker from beingclosed. The key can then be used in another location.The cell will remain trip-free until the key is put back intothe lock, rotated, and the slide retracted.

BREAKERS WHICH WILL FIT CELL INEMERGENCIES

BREAKER CELL EMERGENCY SITUATION

MDS-408 MDS-608, MDS-616, MDS-620,MDS-808, MDS-816, MDS-820,MDS-C08, MDS-C16, MDS-C20

MDS-608 MDS-608, MDS-616, MDS-620,MDS-616 MDS-808, MDS-816, MDS-820,MDS-620 MDS-C08, MDS-C16, MDS-C20

MDS-808 MDS-808, MDS-816, MDS-820,MDS-816 MDS-C08, MDS-C16, MDS -C20MDS-820

MDS-C08 MDS-C08, MDS-C16, MDS-C20MDS-C16MDS-C20

MDS-632 MDS-832, MDS-C32

MDS-832 MDS-C32

MDS-C32 NONE

MDS-840 MDS-C40

MDS-C40 NONE

MDS-850 MDS-C50, MDS-860, MDS-C60

MDS-C50 MDS-C60

MDS-860 MDS-C60

MDS-C60 NONE

Table 3-1 Emergency Usage of Breakers

CAUTION

IN EMERGENCY SITUATIONS THE BREAKERLISTED ON THE RIGHT WILL FIT THE CELLLISTED ON THE LEFT. HOWEVER, DO SOONLY IF TRIP UNIT CAN BE ADJUSTED TOPROTECT THE COMPLETE CIRCUIT.

DANGER

IB01901001E


TO FACILITATE MANUFACTURE AND INSTALLATIONPROCEDURES, A KEY IS SUPPLIED WITH EACHLOCK. BEFORE PLACING A SWITCHGEARASSEMBLY WITH KEY INTERLOCKS IN OPERATION,THE KEY SCHEME MUST BE CAREFULLY CHECKED,AND ONLY THE PROPER KEYS LEFT IN THE LOCKS.ALL EXTRA KEYS MUST BE REMOVED ANDDESTROYED OR STORED WHERE NOT AVAILABLETO OPERATING PERSONNEL. THIS PROCEDURE ISNECESSARY SINCE THE IMPROPER USE OF SPAREKEYS WILL DEFEAT THE INTERLOCKING SCHEME.

3.2.1.4 METERING CURRENT TRANSFORMERS

When required for metering, current transformers arenormally positioned around the stationary main contacts(Figure 3-4) for draw-out breakers and around thebreaker conductors for fixed mounted breakers. Holesare provided in the main contact support insulation formounting front accessible current transformers. SeeTable 3-2 for metering accuracies.

Short circuiting terminal blocks are provided as standardfor each set of current transformers.

3.2.1.5 CELL SWITCH (DRAW-OUT)

An optional cell switch is operated by movement of thecircuit breaker between the “connect” and “test” positions.It is mounted on the side of the cassette at the rear of thewireway. A plunger connected to the switch is actuated bythe frame of the breaker as it moves into or out of the“connect” position. As a result, the cell switch can beused to electrically indicate whether or not the breaker isin the “CONNECT” position.

Its most common uses are for disconnecting remotecontrol circuits to electrically operated breakers, and forbypassing “b” interlocking auxiliary contacts when abreaker is withdrawn from the connected position.

For applications with four (4) Form C contacts, the cellswitch contacts are wired to C1-C12 (stationary secondaryterminal blocks). When the second module of four (4) FormC contacts are required, they are connected with a mateand lock type plug located in the vertical wireway.

3.2.1.6 SPACE HEATERS

Space heaters are furnished as standard equipment inoutdoor switchgear assemblies to reducecondensation. Heaters are placed at the rear of the “D”

position breaker cell, the bottom of bus compartment andthe bottom of the cable compartment. As an option, spaceheaters can be installed in indoor equipment.

3.2.1.7 SHUTTERS (DRAW-OUT)

CAUTION

Shutters covering the primary contacts are supplied on anoptional basis. The shutter is operated as a circuit breakeris moved into and out of the cell. These are provided toprevent accidental contact with live bus.

DO NOT ATTEMPT TO ACTIVATE SHUTTERSMANUALLY! SHUTTERS ARE ONLY INTENDED TO BEOPERATED BY THE CIRCUIT BREAKER. ALL POWERSHOULD BE TURNED OFF PRIOR TO INSPECTINGSHUTTERS. FAILURE TO DO SO COULD RESULT INDEATH, SERIOUS BODILY INJURY OR PROPERTYDAMAGE.

3.2.2 SECONDARY TERMINAL COMPARTMENT

Above each breaker cell is a narrow door (Figure 3-6).Control wiring entering or leaving the cell is connected toterminal blocks in the area behind this door. This areaprovides mounting for up to 72 termination points.Factory connections are made on the rear side of theseterminal blocks. Field connections are made along thefront surface of these terminal blocks by hinging theterminal block cover down. A screw type terminal landingis provided. See Figure 3-7 for secondary disconnectterminal arrangement.

3.2.3 CONTROL WIRING

The standard wire used in Switchgear Assemblies isType SIS stranded copper, No.14 AWG. For communica-tion wire, No.18 AWG shielded with 600 volt insulation isused.

Field installed control wiring is to enter the enclosure inthe area above the bus compartment for top entry and inthe breaker compartment base for bottom entry as shownin Figure 3-9. The right side of the front compartment hasbeen reserved for field wiring to run from top to bottom.For top entry field control wiring, an enclosed wiringtrough is provided to run wiring forward. When the wiringexits the wiring trough it can then be transitioned verti-cally to the appropriate breaker cell by tying to thevertical plane provided. Lances punched into this planeprovide placement of wire ties for securing wire bundles.

The control conduit cover plates for top (Figure 3-8) andbottom entry are removable. Once removed, these platescan then be punched for the appropriate conduit size.

DANGER

IB01901001E


Current Transformer Metering AccuracyMetering Type Current Transformers for

Mounting in Circuit Breaker Cells

Ratio Ratio B-0.1 B-0.2 B-0.5 B-0.9 B-1.8

800, 1600, 2000 100/5 100/1 2.4 — — — —

150/5 150/1 1.2 2.4 — — —

200/5 200/1 1.2 2.4 2.4 — —

250/5 250/1 0.6 1.2 2.4 — —

300/5 300/1 0.6 0.6 1.2 2.4 —

400/5 400/1 0.3 0.6 1.2 1.2 —

500/5 500/1 0.3 0.3 0.6 1.2 2.4

600/5 600/1 0.3 0.3 0.6 1.2 1.2

750/5 750/1 0.3 0.3 0.3 0.6 1.2

800/5 800/1 0.3 0.3 0.3 0.6 1.2

1000/5 1000/1 0.3 0.3 0.3 0.6 0.6

1200/5 1200/1 0.3 0.3 0.3 0.6 0.6

1500/5 1500/1 0.3 0.3 0.3 0.6 0.6

1600/5 1600/1 0.3 0.3 0.3 0.6 0.6

2000/5 2000/1 0.3 0.3 0.3 0.6 0.3

3200 1600/5 1600/1 0.3 0.3 0.6 0.6 1.2

2000/5 2000/1 0.3 0.3 0.3 0.6 0.6

2400/5 2400/1 0.3 0.3 0.3 0.3 0.6

2500/5 2500/1 0.3 0.3 0.3 0.3 0.3

3000/5 3000/1 0.3 0.3 0.3 0.3 0.3

3200/5 3200/1 0.3 0.3 0.3 0.3 0.3

3500/5 3500/1 0.3 0.3 0.3 0.3 0.3

4000/5 4000/1 0.3 0.3 0.3 0.3 0.3

4000 4000/5 4000/1 0.3 0.3 0.3 0.3 0.3

5000 5000/5 5000/1 0.3 0.3 0.3 0.3 0.3

6000 6000/5 6000/1 0.3 0.3 0.3 0.3 0.3

Table 3-2 Current Transformer Metering Accuracy

IF THE SECONDARY CIRCUIT OF ANY CURRENT TRANSFORMER IS LEFT OPEN WITHOUT LOAD, ANDITS PRIMARY CIRCUIT IS ENERGIZED, A DANGEROUSLY HIGH VOLTAGE IS DEVELOPED ACROSSTRANSFORMER SECONDARY TERMINALS. TO PREVENT DEATH, BODILY INJURY OR ELECTRICALSHOCK, EITHER DE-ENERGIZE THE CIRCUIT BY OPENING THE BREAKER, OR SHORT CIRCUITCURRENT TRANSFORMER SECONDARY TERMINALS, BEFORE PROCEEDING WITH MAINTENANCE.

DANGER

Breaker Frame Rating

IB01901001E


Figure 3-7 Secondary Disconnect Terminal Arrangement

Figure 3-8 Top Conduit Cover PlateFigure 3-6 Secondary Disconnect Terminal Compartment

Secondary Disconnect

Terminal Compartment

2A97870

IB01901001E


3.2.4 AUXILIARY COMPARTMENT

Auxiliary compartments are normally the same physicalsize as a circuit breaker cell. They are used to house andmount instruments, control components and other auxiliarydevices . The compartment has a hinged front door that isused for mounting a variety of devices (Figure 3-10).

3.2.5 AUXILIARY/TRANSITION SECTION

Full height auxiliary sections with hinged front doors ortransition sections with bolted covers are provided for avariety of reasons; (1) additional bus space needed formatching up to different equipment assemblies; (2) closecoupling to transformer; (3) mounting and wiring ofadditional control equipment. These vertical sections are22 inches (559 mm) wide.

Figure 3-9 Field Installed Control Wiring

9253C21C

Figure 3-10 Auxiliary Compartment Door

IB01901001E


3.3 BUS COMPARTMENT

The bus compartment provides space for vertical andhorizontal bus. The compartment is located just behindthe front compartment and is fully isolated from breakerand auxiliary cells. (See Figure 3-1) In addition, optionalgrounded steel barriers may be placed between the busand rear cable connections, providing an additionaldegree of safety. This helps prevents accidental contactwith the main bus during maintenance procedures.

The horizontal main bus ties the vertical sections to-gether electrically; the vertical bus feeds the individualbreaker compartments. Bus sizing is based on ANSIstandard temperature rise criteria of 65 Degrees C over40Degrees C ambient. All bus meets industry standardphase-to-phase clearance without utilizing insulated bus.Standard main and section bus is silver-plated copperwith tin-plated copper optional.

3.4 CABLE COMPARTMENT

The cable compartment is located behind the buscompartment and provides sufficient room for easy cableinstallation. Bus bars extend the line or load side of thestationary disconnecting contacts into the cable compart-ment. Lug landings will accept compression or mechani-cal lugs. They are mounted on a 45 degree angle (Figure 3-11), up or down, to facilitate cable termination with mini-mum bending. On four-wire systems, an isolated neutralbus extends the length of the line-up and includes a tap foroutgoing neutral cable for each feeder breaker.

Figure 3-11 Lug Adapters

Figure 3-12 Ground Bus in Cable Compartment

3.5 GROUND BUS

A permanent, low-resistance ground connection is essen-tial for safe operation. A terminal for the connection to thestation ground is provided in the service entrance section.

The ground bus is located at the bottom rear of the cablesection and includes terminals for customer’s connec-tions (Figure 3-12).

3.6 OUTDOOR ENCLOSURE TYPE 3R

The Magnum DS outdoor design is the indoor designenclosed in a separate outdoor enclosure (Figure 3-13).The rigid structure foundation base is easily anchored toa pad using the supplied lifting/tie down angles. A sepa-rate channel base is not required.

A front operating and maintenance aisle extends throughall units of the assembly. A large reinforced door withpanic hardware is standard at each end of the aisle.These doors can be opened from the inside, even whenpadlocked from the outside. The rear access doors arehinged and provided with door stops. These braces keepthe doors open at a 90 degree angle.

The outdoor structure also includes, as standard, filteredventilation openings (filters can be changed withoutopening aisle or rear compartment doors), aisle lighting,GFI protected convenience receptacles and spaceheaters. When specified, a thermostat is mounted in thecable compartment. Space heaters are located in the “D”position breaker cell, bus compartment and cable com-partment of each vertical section.

IB01901001E


Figure 3-13 Outdoor Enclosure

3.7 TYPE MAGNUM DS CIRCUIT BREAKERS

Refer to the latest revision of Instruction Book 2C12060for receiving, handling and storing, description and opera-tion, installation, adjustments, and maintenance instruc-tions. Circuit breaker data, and renewal parts informationis also included.

IB01901001E


4: INSTALLATION

Figure 4-1 Typical Installation Space Requirements

9253C21A

PERSONNEL INSTALLING THIS EQUIPMENT MUSTBE THOROUGHLY FAMILIAR WITH ALLASSOCIATED INSTRUCTION MANUALS ANDAPPLICABLE GOVERNING CODES. ADDITIONALLY,ALL DRAWINGS, WHETHER MECHANICAL ORELECTRICAL, MUST BE UNDERSTOOD ANDSTRICTLY FOLLOWED TO PREVENT POSSIBLEDAMAGE TO THE SWITCHGEAR OR EQUIPMENTBEING PROTECTED.

4.2 LOCATION AND FOUNDATION

Magnum DS Metal-Enclosed Low-Voltage Switchgear isassembled at the factory on smooth level surfaces toassure correct alignment of all parts. Extra care by thepurchaser in selecting the location and preparing thefoundation will result in reduced installation costs, as wellas good equipment performance.

DANGER

BEFORE PROCEEDING WITH ANY INSTALLATION,TESTING, START-UP OR MAINTENANCE, REVIEWALL OF SECTION 1 FOR SAFETY PRACTICES ANDRECOMMENDATIONS. FAILURE TO DO SO COULDRESULT IN DEATH, SERIOUS BODILY INJURY ORPROPERTY DAMAGE.


This section contains instructions for installing MagnumDS Metal-Enclosed Low-Voltage Switchgear Assemblies.Proper installation of Magnum DS Metal-Enclosed Low-Voltage Switchgear is of prime importance. Too muchemphasis cannot be placed on this phase of the work.Study the associated instruction manuals and drawingscarefully.

CAUTION

IB01901001E


4.2.1 LOCATION

In general, the location will have been determined duringthe specification and/or procurement phases. Indoorlocations impose certain requirements which must be metso that the switchgear assembly may operate efficientlywith the least amount of maintenance. Consideration mustbe given to the aisle space required at the front and rearof the equipment, space at the ends of the lineup, andequipment ventilation (Figure 4-1). In addition to Figure4-1, refer to floor plan drawings supplied as part of theequipment drawing package.

The space at the front must be sufficient to permit theopening of doors, the insertion and withdrawal of circuitbreakers, and the transfer of circuit breakers to othercompartments by means of an overhead lifter or portablelifting device. The space at the rear must be sufficient tomeet local codes, open rear doors, install cables, inspectequipment and perform maintenance.

Switchgear equipment should be placed in a clean, dryarea, allowing air to freely circulate. The bus and cablecompartments are ventilated by means of air entering theventilation openings in the rear of the enclosure andleaving through a ventilator in the bus compartment roof.

4.2.2 FOUNDATION

The floor or foundation must be smooth, level (within 1/8inch per three feet [3.5 mm./meter] in any direction) andstrong enough to support the weight of the equipmentwithout sagging. Table 4-1 outlines the approximateweights for various ratings of indoor switchgear assem-blies.

Actual weights will depend upon the amount of equip-ment in the individual sections. Adequate safety factorsmustbe included in any weight calculation. If the foundation issubject to vibration and/or impact loads, special mountingconsiderations must take place to prevent the transmis-sion of vibration or shock to the equipment.

4.2.3 INDOOR EQUIPMENT

The preferred method of anchoring an indoor assembly isby fastening it to level steel channels which are embed-ded in the concrete floor. Holes that remain after thewooded skids are removed from indoor assemblies areused for securing the assembly permanently in position.Four inch (5.4 lb./ft) structural channels are recommendedas a minimum size for the average lineup of indoorequipment.

Table 4-1 Switchgear Weights

Magnum DS Switchgear Structure Weights

Weights in Lbs. (Kg) Approximate

Dimension in inches (mm) Approximate

Indoor Switchgear Assemblies Less Breakers

Width Depth Weights

BREAKER STRUCTURES

22 (558.8) 60-66 (1524-1676) 1300 (590)

22 (558.8) 72-78 (1829-1981) 1400 (635)

22 (558.8) 84-90 (2133-2286) 1500 (680)

44 (1117.6) 60-66 (1524-1676) 1500 (680)

44 (1117.6) 72-78 (1829-1981) 1600 (726)

44 (1117.6) 84-90 (2133-2286) 1700 (771)

AUXILIARY STRUCTURES

22 (558.8) 60-66 (1524-1676) 1000 (454)

22 (558.8) 72-78 (1829-1981) 1100 (499)

22 (558.8) 84-90 (2133-2286) 1200 (544)

44 (1117.6) 60-66 (1524-1676) 1100 (499)

44 (1117.6) 72-78 (1829-1981) 1200 (544)

44 (1117.6) 84-90 (2133-2286) 1300 (590)

TRANSFORMER TRANSITION STRUCTURES

22 (558.8) 60-90 (1524-2286) 1000 (454)

BUSSED TRANSITION STRUCTURES

12 (305) 60-66 (1524-1676) 500 (318)

Breaker Element ➀

Fixed Draw-out

MDS-408 110 (50) 130 (59)

MDS-608 110 (50) 130 (59)

MDS-808 120 (54) 145 (66)

MDS-C08 120 (54) 145 (66)

MDS-616 110 (50) 130 (59)

MDS-816 120 (54) 145 (66)

MDS-C16 120 (54) 145 (66)

MDS-620 120 (54) 145 (66)

MDS-820 120 (54) 145 (66)

MDS-C20 120 (54) 145 (66)

MDS-632 135 (61) 175 (80)

MDS-832 135 (61) 175 (80)

MDS-C32 135 (61) 175 (80)

MDS-840 215 (98) 310 (141)

MDS-C40 215 (98) 310 (141)

MDS-850 250 (113) 310 (141)

MDS-C50 250 (113) 310 (141)

MDS-860 310 (141)

MDS-C60 310 (141)

➀ Impact weight equals 1.5 times breaker static weight.

IB01901001E


THE FRONT AND REAR CHANNELS MUST BE SETAND ALIGNED WITH EACH OTHER AND MUST BELEVEL (0.125" PER THREE FEET [3.5 MM/METER])OVER THEIR ENTIRE LENGTH TO AVOIDDISTORTION OF THE STRUCTURE. THE FINISHEDFLOOR MAY HAVE A SLIGHT PITCH AWAY FROMTHE CHANNELS BUT IN NO CASE SHOULD THEFINISHED FLOOR BE HIGHER THAN THECHANNELS.

Each unit is fastened to the floor channels by eitherbolting or welding. Welding is a quick and easy method ofsecuring the switchgear assembly in place, while elimi-nating the layout of the mounting holes in the channels.

4.2.4 OUTDOOR EQUIPMENT

Outdoor assemblies do not require floor channels. Holddown plates are provided by rotating the lifting angles180 degrees and then permanently bolted to the founda-tion. As was the case with the indoor foundation, theoutdoor foundation should also be level from front to rearand side to side to prevent distortion. For further detailssee the foundation plans provided with the equipment.

4.2.5 CONDUITS

Provisions must be made in the foundation for all con-duits entering from below. Specific floor plan detailsprovided with the equipment must be used to determinethe final conduit layout, spacing of floor channels, andfloor space required for each lineup (Figure 4-2).

Power conduits should project above the finished floornot more than two inches (51 mm) for an indoor assem-bly. Control wire conduits should not extend higher than 1inch (25 mm). It will simplify moving the groups into placeif the conduits are flush with the concrete surface andappropriate extension sleeves added after the units arein their final location. See the floor plan informationsupplied with the assembly for conduit space and loca-tion.

4.3 SHIPPING GROUP ASSEMBLY

Before assembling the switchgear equipment, all compo-nents should be available at the site location. Theprepared foundation should be ready and all embeddedconduits installed and capped.

4.3.1 ASSEMBLY PROCEDURES

When correctly installed, both indoor and outdoor assem-blies should conform to the following requirements:

CAUTION DANGER

PRIOR TO INSTALLATION AND ASSEMBLY, BECERTAIN THE FOUNDATION IS LEVEL AND FREE OFANY DEBRIS TO PREVENT EQUIPMENT DAMAGE.

1. Front panels should form a straight line. Whentransformers and/or other gear are included,equipment should be located in keeping with the plandrawings supplied with the equipment.

2. Vertical sections must be correctly spaced fromcenter to center and plumb. A suggestion for lining upthe shipping groups is to establish a base line a fewinches in front of the switchboard and parallel to thefinal location. Equalize the distances from the front ofthe shipping groups to the base line, thus making theface of the assembly parallel to the base line. Checkeach vertical section by dropping a plumb line fromthe top corner of each vertical section. It should alignwith the bottom corner.

3. The entire assembly of vertical sections should besecurely fastened to floor channels or base pad.

4. Shipping groups must be securely bolted togetherand all bus and control wiring connections properlymade.

After the first shipping group has been located, thesecond shipping group should be moved into position andsimilarly checked. The shipping groups are fastenedtogether in accordance with the instructions given indrawing 9253C18. This drawing is included in the infor-mation packet attached to the side of the switchgearassembly. Should additional copies of this drawing beneeded, contact your nearest Cutler-Hammer sales office.

4.3.1.1 DRIP/SPRINKLER RESISTANT ASSEMBLY

As an option, drip shields are provided for mounting alongthe front and rear of the switchgear to protect doorsagainst entry of water. In addition, a drip shield is suppliedfor mounting over the ventilation opening located abovethe bus compartment. These components are shippedloose to avoid damage during shipment and to facilitatelifting of the equipment without removal of the dripshields. Drip shields are provided for a shipping unit andmust be bolted in place during installation of the equip-ment. See Figure 4-3 for installation instructions.

IB01901001E


Figure 4-2 Indoor Equipment Location of Anchor Points and Conduit Location (see next page for continuation)

Drawing 4A337896

F C W D A C C

36 22 54 (1372) 18 (457) 7.3 (338)

(914) (559) 60 (1524) 24 (611) 13.3 (338)

66 (1676) 30 (674) 19.3 (490)

72 (1829) 36 (916) 25.3 (643)

78 (1981) 42 (1069) 31.3 (795)

84 (2134) 48 (1221) 37.3 (948)

90 (2286) 54 (1373) 43.3 (1100)

36 30 54 (1372) 18 (457) 7.3 (338)

(914) (762) 60 (1524) 24 (611) 13.3 (338)

66 (1676) 30 (674) 19.3 (490)

72 (1829) 36 (916) 25.3 (643)

78 (1981) 42 (1069) 31.3 (795)

84 (2134) 48 (1221) 37.3 (948)

90 (2286) 54 (1373) 43.3 (1100)

36 44 54 (1372) 18 (457) 7.3 (338)

(914) (1118) 60 (1524) 24 (611) 13.3 (338)

66 (1676) 30 (674) 19.3 (490)

72 (1829) 36 (916) 25.3 (643)

78 (1981) 42 (1069) 31.3 (795)

84 (2134) 48 (1221) 37.3 (948)

90 (2286) 54 (1373) 43.3 (1100)

➀ ➁ ➂ ➃➅

Floor Plan - 22" and 30" Wide Structures

IB01901001E


Figure 4-2 Indoor Equipment Location of Anchor Points and Conduit Location (continued)

Floor Plan - 44" Wide Structures

IB01901001E


Figure 4-3 Installation of Drip/Sprinkler Shields

IB01901001E


joint. Therefore, extreme care must be taken when makingor remaking bus joints in the field to assure their tightness.Bolts in bus connections should be tightened according toTable 4-2.

4.4.4 GROUND BUS

The joint in the ground bus is made by means of a singlesplice plate bolted directly to the inside of the rear steelframe (Figure 3-12). It is important that the ground bus beconnected first since it provides an integral ground for allthe equipment. It must be connected to the stationground before energizing equipment.

Terminals are provided on the ground bus for connectionto the station ground. This connection should be a directconnection and not run in metal conduit. The groundingconductor should be capable of carrying the maximumline-to-ground current for the duration of the fault.

4.4 BUS, CABLE AND CONTROL CONNECTIONS

4.4.1 BUS CONNECTIONS

All connections of the main and neutral buses, and theground bus at shipping breaks are made by means ofbolted splice plates. These are always plated, boltedjoints. Required hardware and splice plates are provided.Provision is made at the ends of the lineup, not adjacentto transformers, for future expansion by means of boltedbus joints.

See drawing 9253C18 for typical shipping split cross busand neutral installation instructions. This drawing isincluded in the information packet attached to the side ofthe switchgear assembly. Should additional copies of thisdrawing be needed, contact your nearest Cutler-Hammersales office.

4.4.2 BUS JOINT PREPARATION

The bolting areas of all bus materials are plated toprovide a reliable joint. In some atmospheres the platingwill become tarnished, but this does not reduce itseffectiveness. Dirt grease and other foreign material mustbe removed from the surfaces before they are joined. Fordirty surfaces use a lint-free, water-dampened cloth. Ifthis does not produce satisfactory results, use a lint-freecloth dampened with a mild solvent such as mineralspirits, Stoddard solvent or isopropyl alcohol. Again, wipeit dry after cleaning.

TORQUE FOR BOLTS IN BUS BAR JOINTS(USING GRADE 5 STEEL BOLTS)

BOLT SIZE TORQUE FT/LBS(NEWTON/METERS)

3/8 - 16 20 (27)

1/2 - 13 50 (65)

Table 4-2 Bolt Tightness For Bus Connections

CAUTION

THE MILD SOLVENTS DESCRIBED AREFLAMMABLE. PROVIDE ADEQUATE VENTILATIONAND KEEP AWAY FROM FLAMES AND OTHERIGNITION SOURCES. CONSULT YOUR SAFETYDEPARTMENT BEFORE USING. NO SOLVENT ISSAFE IN AN UNVENTILATED OR POORLYVENTILATED SPACE.

4.4.3 BOLT TIGHTNESS

All fasteners holding structural members, barriers andcovers are installed at the factory tight enough to assurerigidity of the assembly and to prevent vibration of thecovers after the equipment is energized. When covers orbarriers are removed during installation, care should betaken to solidly tighten all bolts after replacing.

Bolts installed in bus joints and connections are highstrength steel, SAE Grade 5. The reliability of currentconducting joints is dependent upon the tightness of the

DANGER

A PERMANENT, LOW-RESISTANCE GROUND ISESSENTIAL FOR ADEQUATE PROTECTION. A POORGROUND COULD BE WORSE THAN NONE, SINCE ITGIVES A FALSE FEELING OF SAFETY TO THOSEWORKING AROUND THE EQUIPMENT. IMPROPERLYGROUNDED EQUIPMENT COULD RESULT IN DEATH,BODILY INJURY OR PROPERTY DAMAGE.

4.4.5 POWER CABLE LASHING

Each switchgear assembly is provided with either crimp ormechanical lug landings arranged so that the lugs arepointed up or down at a 45 degree angle to reduce thecable bending required for installation. (Figure 4-4).

The lashing of cables are required for the following condi-tions:(1) All 800 ampere frame breakers

IB01901001E


(2) All breaker frames with short circuit ratings above 65kA.(3) When lugs described in 4.4.5 (A) or (B) are not used.

To assure the short circuit ratings of the switchgear, thefollowing cable lugs are to be used for power cables:

A) COMPRESSION CRIMP LUGS

1) Two mounting holes.2) Minimum of double crimp.3) Must be crimped with hydraulic crimper with minimum

of 12 tons (11 metric tons) compression.

B) MECHANICAL SCREW LUGS

1) Aluminum body lug with two mounting holes.2) One 1/2" hex cable holding screws torqued to 500 in.

lbs. (56.5 Newton/Meters).

If cable lashing is required, follow the methods given inFigure 4-5.

Figure 4-5 Cable Lashing Instructions

Figure 4-4 Lug Landings

2A97882

CABLE LASHING INSTALLATION INSTRUCTIONS

ROPE REQUIREMENTS3/8" DIAMETERNYLON, TWISTEDSIZE = #123 STRANDTENSILE STRENGTH = 3340 LBS. /1515 KGWORKING LOAD = 278 LBS. /126 KG

INSTRUCTIONS:

AFTER CABLE IS ROUTED AS CLOSE TOGETHER AS POSSIBLE, THE ROPE IS TO BE WRAPPED AROUND THECABLE 6" (15CM) FROM LUGS (SEE NOTE 1). THE SECOND WRAP IS TO BE APPLIED 6" (15CM) FROM THE FIRSTWRAP. AFTER THE SECOND WRAP, THE CABLES SHOULD BE WRAPPED AT 12" (30CM) INCREMENTS TO THEENTRY OR EXIT POINT OF THE SWITCHGEAR. EACH SET OF WRAPS CONTAINS 5 LOOPS.

NOTE 1: IF THE CABLE IS NOT COMPLETELY BUNDLED TOGETHER, THE ROPE BETWEEN CABLES SHOULD BE WRAPPED TO PROVIDE SUPPORT.

IB01901001E


Figure 4-6 Shipping Split Control Terminal Block Connection

4.4.5.1 LUG LANDING BOOTS

Boots for lug landings are provided for 800, 1600, 2000and 3200 ampere frames on an optional basis or whenservice entrance requirements mandate. These boots aremounted on the lug landings when shipped from thefactory. Prior to terminating cables, these boots must beremoved. Removal of these boots is completed by cuttingthe wire ties which hold the boot closed. After the wireties are removed, a flexible integral hinge permits easyremoval of the boot.

Provisions exist in the boot for bottom or top cable entry.In preparation for installation of the boot over the luglandings, the appropriate projections located on theseamed surface of the boot must be selected and the tipremoved (cut) to accommodate the cable diameter. Inaddition, for each projection utilized, a slit must beprovided by cutting from the cable opening to the seamof the boot. After the appropriate openings and slits areprovided, the boot can be installed over the lug landingby opening the boot around the landing and closing theboot. Care should be exercised in routing the slitsprovided in the boot around the cables. After boot instal-lation, fastening is completed by securing both halves ofthe boot together with wire ties in the holes providedaround the seam of the boot.

4.4.6 CONTROL CONNECTIONS

All control wiring that connects between two shippingsections must be reconnected to their correct points on theterminal blocks located on top of the vertical sections asshown in Figure 4-6. These connection points are locatedbeneath the top cover of the breaker compartment.

Male/female pull-a-part terminal blocks are utilized forshipping section control wiring connections (Figure 4-6).The connections are made by plugging the appropriatemale block into the corresponding female connector.Control wiring should be checked with the connectiondiagram to ensure that all connections have been madeproperly, all fuses installed, current transformer circuitscompleted, and connections tightened.

Before applying control power, check all control circuitsfor grounds, except current and voltage transformersecondaries. Integrally supplied AC control sources areprovided with a safety ground on the neutral side of 120V circuits. No grounds should be present on DC circuits.Make sure all circuits are clear and that any electricallyoperated circuit breakers are in the “remove” position.

If the control power source is other than a self-containedcontrol power transformer, the conductors from thesource to the assembly must be of adequate size toavoid excessive voltage drop during operation.

IB01901001E


4.5 TRAVELING CIRCUIT BREAKER LIFTER

The traveling overhead circuit breaker lifter is a standarddevice installed on outdoor assemblies. Check to becertain that the carriage assembly moves freely acrossthe entire length of the switchgear.

Indoor switchgear assemblies are supplied with overheadlifters as an optional item. When an optional lifter issupplied, it is shipped in a separate carton (Figure 2-1)with instructions for assembly.

In general, the installation of the lifter assembly is notdifficult. Certain steps should, however, be carefullyfollowed to ensure smooth operation.

For proper installation of the overhead breaker lifterfollow the instructions in Figures 4-7 and 4-8. Figure 4-9shows how to attach to the breaker for lifting.

DO NOT STAND UNDER THE CIRCUIT BREAKERDURING HOISTING OPERATIONS. THE CIRCUITBREAKER MIGHT SLIP AND CAUSE PERSONALINJURY. KEEP HANDS AND TOOLS AWAY FROMSPREADER BAR, LIFTING HOOKS AND BREAKER.SEVERE INJURY MAY RESULT. SUDDEN MOTIONSARE COMMON IN A CABLE UNDER TENSION AS ITWINDS AROUND A WINCH DRUM.

4.6 MOVING PARTS

There are few moving parts in the stationary structures ofswitchgear assemblies. It is recommended that all movingparts be carefully operated by hand. This will ensure thatno binding or damage has occurred during shipment orhandling. In some cases, accessories may be blocked orbraced for shipment. Thoroughly check apparatus, suchas meters and relays, for forms of blocking or bracingwhich must be removed.

DANGER

IB01901001E


Figure 4-7 Breaker Lifter Installation

2A97859

IB01901001E


Figure 4-8 Breaker Lifter Installation

2A97859

ALIGN HOLE IN WHEEL STOP WITH HOLEIN ROLLER BRACKET AND INSERTPIN

SEISMIC HOLD DOWN FOR BOOMFOR SEISMIC APPLICATIONS

THE BREAKER LIFTER SHOULDTO SECURED WHEN NOT IN USE

Figure 4-9 Hooking Arrangement for Lifting Breakers

2A97859

IB01901001E


5.3 CONNECTIONS

Wire connections, accessible bolted bus connections andbarriers should be examined to be sure that they have notbeen loosened or damaged during shipment or installa-tion.

The connections to equipment external from the switch-gear assembly such as remote control, interlock circuitsand auxiliary switches should be checked for continuity toensure that they are also correct. There must be definiteassurance that connections are correct before an attemptis made to operate the equipment.

Verify that all shipping split wiring has been correctlyconnected.

5.4 AUXILIARY EQUIPMENT

If space heaters are supplied, they should be energized toconfirm correct operation.

Relays included on the instrument panels are normally setfor production testing levels when shipped. The finalsettings of the relays should be coordinated with otherparts of the system in accordance with the purchaser’sstandards or operation practice. Any necessary modifica-tions to the relay settings should be carried out in accor-dance with the instruction leaflet for that particular relay.

All covers for meters, relays and other devices removedduring testing, should be carefully handled when re-moved. The covers should be put back in place promptlyto keep dust and dirt from collecting.

5.5 GROUND FAULT SYSTEMS (PER THENATIONAL ELECTRIC CODE)

Ground fault protection of service entrance equipmentshall be provided for solidly grounded wye electricalservices of more than 150 volts to ground, but not ex-ceeding 600 volts phase-to-phase, for each servicedisconnecting means rated 1000 amperes or more. Theground fault protection system shall be performancetested when first installed on site. The test shall beconducted in accordance with instructions outlined inSection 230-95 of the National Electrical Code.

Performance testing of ground fault protection systemsshould be undertaken only by qualified personnel. In thetests requiring the use of high current test equipment, it isusually necessary to obtain the services of a qualifiedtesting organization. See IB 32-693 for Magnum DSBreaker ground fault conformance testing.

5: INSPECTION AND TESTING PRIOR TO

DANGER

OPERATION



After the switchgear assembly and apparatus to becontrolled have been installed and all interconnectionsmade, the equipment should be given a final check andtested before being placed in service. This is necessaryto assure that the equipment has been correctly installedand that all connections are complete and have beenproperly made.

DANGER

TO AVOID POSSIBLE DEATH, BODILY INJURY ORELECTRICAL SHOCK, EXTREME CARE MUST BEEXERCISED TO PREVENT THE EQUIPMENT FROMBEING CONNECTED TO THE POWER SYSTEMWHILE THE PRELIMINARY TESTS ARE BEINGCONDUCTED. IF DISCONNECTING SWITCHES ARENOT AVAILABLE, LINE LEADS SHOULD BEDISCONNECTED TO ACCOMPLISH THISNECESSARY STEP.

Directions for testing relays, instruments, meters, circuitbreakers and other electronic devices, which may be apart of the assembly, are given in the instruction book foreach individual device. The proper settings for protectivedevices are normally determined from a coordinationstudy performed by the purchaser or consultant. Factorysettings were those used for production testing and donot reflect specific site requirements.

5.2 TEST EQUIPMENT

Test equipment will depend on the rating and type ofinstallation. Portable voltmeters of the multi-scale type willbe required. For larger installations, ammeters should beavailable in case unexpected circumstances arise. Anohmmeter and “megger” will prove invaluable in checkinginsulation and continuity of the circuits. A simple portabledevice for “ringing” or “lighting-out” circuits may be usedfor the continuity check.

IB01901001E


bus. Circuits Breakers must be in the withdrawn or re-moved position. Devices such as lightening arresters andcapacitors must also be disconnected.

5.9 FINAL STEPS

ENERGIZING THE SWITCHGEAR FOR THE FIRSTTIME IS POTENTIALLY DANGEROUS. THEREFORE,ONLY QUALIFIED PERSONNEL SHOULD BEPRESENT WHEN THE EQUIPMENT IS ENERGIZED. IFPROBLEMS CAUSED BY DAMAGE OR POORINSTALLATION PRACTICES HAVE NOT BEENDETECTED IN THE CHECKOUT PROCEDURE(PREVIOUSLY DESCRIBED), DEATH, PERSONALINJURY OR SERIOUS DAMAGE CAN RESULT WHENPOWER IS APPLIED.

Before energizing, another thorough check should bemade using the following checklist.

1. Have circuit breakers and other operation mechanismsbeen exercised?

2. Has electrical insulation resistance been testedphase-to-phase and phase-to-ground? Record thesereadings for future reference.

3. Have relay, meter and instrument connections beenchecked?

4. Have the electrically operated mechanisms of allcircuit breakers been checked?

5. Has the ground fault protection system been checkedin accordance with the National Electrical Code?

6. Are the adjustable trip units properly set?

7. Is all field wiring secured and not in contact with livebus?

8. Are all grounding connections properly made?

9. Has an inspection been performed to ensure that alldebris, dirt, tools, scrap wire, and any other foreignobjects were removed and that all vent openings arefree from obstructions?

10. Have all barriers and covers been replaced anddoors closed and latched?

11. Turn all circuit breakers to the OFF position beforeenergizing the bus.

12. Electrically-operated breakers:

Have all breakers in the disconnected position. Rackeach breaker in one at a time after the assembly isenergized. This way only one breaker will be electri-cally charged at a time. This is done so that controlcircuit fuses are not overloaded by all breakerscharging at the same time.

5.6 ELECTRIC AND ARC FLASH HAZARD

NEC Article 110.16 requires that low-voltage switchgearbe marked to indicate the potential for electric and arcflash hazard. Labels to this affect are to be applied at theinstallation site prior to energizing the equipment. Twolabels are supplied and are contained in the documentsleeve mounted on the side of the equipment. One label isto be applied on the front and the other on the rear of theequipment.

5.7 CIRCUIT BREAKERS AND TRIP UNITS

All circuit breakers should be checked to be sure that theyare in accordance with the requirements of the circuits.The circuit breakers and associated safety interlocksshould have been checked mechanically during theequipment installation phase. This was, however, onlypreliminary and a more detailed inspection and testingprocedure, both electrical and mechanical, must takeplace prior to putting the equipment into service. Forinformation on complete testing and maintenance of thecircuit breakers and trip units, refer to the separate circuitbreaker and trip unit instruction manuals.

5.8 BASELINE TEST DATA

Certain baseline tests should be preformed and recordedfor diagnostic maintenance purposes. Take “megger”readings again between the buses and ground andbetween phases. Keep a record of these readings forfuture reference in determining when trends occur thatwould indicate a decrease of resistance.

DANGER

A one-minute dielectric test was preformed on all bus atthe factory in accordance with ANSI C37.20.1. Repeatingthese tests is not required for field installation unless theequipment has been in extended or outdoor storage, ormajor bus modifications have been made. If required, 2200Vac should be applied between each phase, and eachphase-to-ground. All connections to the bus from controlpower or metering circuits must first be isolated from the

IB01901001E


SECTION 6: PERIODIC INSPECTION AND TESTING


6.2 ACCESS TO SWITCHGEAR ASSEMBLY PARTS

6.2.1 MAIN BUS AND CABLE COMPARTMENT

A Magnum DS Metal-Enclosed Low-Voltage SwitchgearAssembly is designed so that internal compartmentsprovide isolation between the Magnum DS circuit breakercompartment and the main bus compartment. Access tohigh current parts is provided by removable covers andbarriers.

DANGER


DANGER

WHEN INSPECTING, REPAIRING AND PREFORMINGMAINTENANCE ON A MAGNUM DS SWITCHGEARASSEMBLY, THE FACT THAT DANGEROUSVOLTAGES MAY EXIST MUST BE KEPT IN MIND.PRECAUTIONS MUST BE TAKEN TO ENSURE THATPERSONNEL DO NOT COME IN CONTACT WITHENERGIZED PARTS. FAILURE TO DO SO COULDRESULT IN DEATH, PERSONAL INJURY ORELECTRICAL SHOCK.

Some common general precautions for primary powercircuits are:

1. All connections should be considered energized untilthe crew expecting to work on them is assured thatthe circuits are de-energized, and all precautionshave been taken to ensure that there is no chance ofa circuit being energized after work is underway.

2. Breakers which have been opened to de-energize acircuit to permit work on the equipment should belocked open and a suitable visible warning deviceplaced on them.

3. Do not work on parts normally carrying high currentuntil they have been disconnected from the systemand connected to the ground bus. When performingmaintenance, provisions should be made for con-necting adequate flexible ground leads to every partof the switching equipment.

4. A good and reliable ground connection is necessaryfor every switchgear assembly installation. Thisground connection should be of sufficient capacity totake care of any abnormal condition that might occuron the system and should be independent of thegrounds used for any other apparatus.

DANGER

BARRIERS AND COVERS SHOULD NOT BEREMOVED UNLESS THE PARTS TO BE EXPOSEDARE DE-ENERGIZED. ADDITIONALLY, BE CERTAINTHAT ALL BARRIERS AND COVERS ARE PROPERLYREPLACED IMMEDIATELY UPON CONCLUSION OFMAINTENANCE OR INSPECTION PROCEDURES.FAILURE TO DO SO COULD CAUSE DEATH, BODILYINJURY OR PROPERTY DAMAGE.

6.2.2 DRAWOUT MAIN DISCONNECTINGCONTACTS AND CURRENT TRANSFORMERS

The primary stationary disconnecting contacts and ring-type current transformers are located on the breaker cellrear wall. These contacts and transformers are easilyexposed unless provided with an optional safety shuttersystem.

DANGER

BE EXTREMELY CAREFUL NOT TO TOUCH ANYCONTACTS OR TRANSFORMERS UNLESS ALLUPPER AND LOWER HIGH CURRENT PARTS AREDE-ENERGIZED. FAILURE TO DO SO COULD CAUSEDEATH, PERSONAL INJURY OR ELECTRICALSHOCK.

6.2.3 CONTROL EQUIPMENT

With the exception of apparatus such as current trans-formers and space heaters, control equipment is gener-ally accessible without exposing high voltage parts.

IB01901001E


6.3 INSPECTION AND MAINTENANCE SCHEDULE

To assure high quality service, a definite maintenanceschedule is essential. Plant operation and local condi-tions vary to such an extent that the schedule should betailored to the conditions. The following general require-ments should be helpful in establishing a program.

signs of overheating or weakened insulation. Remove asmuch dirt, dust and other foreign material as possiblefrom the insulation and conductors with minimum expo-sure to any solvents. The recommended cleaning proce-dure is to use an industrial quality vacuum cleaner and/ora lint-free cloth. In most cases, this will be sufficient. Foraccumulations which cannot be removed by the aboveprocedure, a lint-free cloth slightly dampened with watercan be used. Allow the switchgear apparatus to dry for atleast four hours at room temperature before energizing. Ifthis procedure does not produce satisfactory results, uselint-free cloth dampened with a mild solvent, such asmineral spirits, Stoddard solvent, or isopropyl alcohol.Dry the same as when using a water dampened cloth.

After buses and insulation have been dusted, wipedclean, and dried, take “megger” readings again betweenthe buses and ground and between phases. Keep arecord of these readings for future reference indetermining when trends occur that would indicate adecrease of resistance.

A one-minute dielectric test was preformed on all bus atthe factory in accordance with ANSI C37.20.1. Repeatingthese tests is not required for field installation unless theequipment has been in extended or outdoor storage, ormajor bus modifications have been made. If required,2200 Vac should be applied between each phase, andeach phase-to-ground. All connections to the bus fromcontrol power or metering circuits must first be isolatedfrom the bus. Circuits Breakers must be in the withdrawnor removed position. Devices such as lightening arrestersand capacitors must also be disconnected.

6.3.4 DRAWOUT, MAIN DISCONNECTINGCONTACTS AND SUPPORTS

Remove each breaker from its cell. Remember, allcircuits should be de-energized. Expose primary contactsand their supports. Inspect for abnormal wear or over-heating. Discoloration of the surface is not harmful unlesscorrosion due to atmospheric conditions is severe,leaving deposits on the surface. Follow the cleaninginstructions outlined in Section 6.3.3. Check eachbreaker while it is out of the housing for all items recom-mended in the instruction book applying to the breaker.

6.3.5 INSTRUMENTS, RELAYS AND OTHER PANELDEVICES

Individual devices should be maintained according to thespecific instructions supplied for each device. Removerelay covers and inspect interiors for dust or dirt. Alldevices should be checked for correct operation.

DANGER

WHEN ENERGIZED, A CIRCUIT BREAKER IS PARTOF A HIGH POWER SYSTEM. BEFORE ATTEMPTINGANY INSPECTION OR MAINTENANCE, BE SURETHAT ALL PRIMARY AND CONTROL CIRCUITS HAVEBEEN DE-ENERGIZED AND GROUNDED ASREQUIRED. ALSO MAKE CERTAIN THAT PROPERSTEPS HAVE BEEN TAKEN TO BE SURE THAT THEYWILL REMAIN DE-ENERGIZED UNTIL ALL WORK ISCOMPLETED. FAILURE TO DO SO COULD RESULTIN DEATH, BODILY INJURY OR ELECTRICAL SHOCK.

6.3.1 INDIVIDUAL DEVICES

The maintenance schedule for individual devices, suchas circuit breakers, relays and instruments, should bebased first on the recommendations contained in theirindividual instruction books. These operations should becoordinated with the overall program to result in the leastoperating inconvenience and circuit shutdown.

6.3.2 OVERALL ASSEMBLY MAINTENANCE

When operating and local conditions are normal, theswitchgear assembly should be given a thorough overallmaintenance check at least annually. Where abnormalconditions exist, more frequent inspection and mainte-nance is necessary.

6.3.3 BUSES AND CONNECTIONS

THE MILD SOLVENTS DESCRIBED AREFLAMMABLE. PROVIDE ADEQUATE VENTILATIONAND KEEP AWAY FROM FLAMES AND OTHERIGNITION SOURCES. CONSULT YOUR SAFETYDEPARTMENT BEFORE USING.

De-energize primary circuits and remove barriers fromprimary compartments. Before cleaning, record “megger”readings between phases and to ground. Inspect for

DANGER

IB01901001E


6.3.6 SECONDARY WIRING, BLOCKS ANDCONNECTIONS

Check all wiring connections for tightness, includingthose at the current and voltage transformers and at theterminal blocks where circuits leave the assembly. Makesure that all transformer secondary wiring connectionsare properly connected to the switchgear assemblyground bus where so indicated. Visually inspect controlcircuit secondary contact blocks, both fixed in the cell andmoveable on the breaker, for abnormal signs of wear,fatigue or overheating.

6.3.7 MECHANICAL PARTS

Visually check and manually operate mechanical movingparts, such as cell switches, position interlocks, cellprotective shutters (when provided), door latches/hinges,and drawout rails.

6.3.8 VENTILATION

Check all air passages and intakes for obstructions andaccumulations of dirt. When filters are used, replace orclean when dirty.

6.3.9 RECORDS

The condition of each vertical section at the time ofinspection should be listed in a permanent record tobecome a guide for anticipating the need for replace-ments or for special attention between regular mainte-nance periods.

6.3.10 ABNORMAL CONDITIONS

Type Magnum DS Switchgear Assemblies have beendesigned for “NORMAL” operating conditions as definedin ANSI C37.20.1. Local conditions such as high humid-ity, salt-laden atmosphere, corrosive gases, heavy dust,or severe circuit operating conditions are considered tobe abnormal. Any of these conditions will require morefrequent inspections.

It should be emphasized that a series of quarterly inspec-tions are advisable until the progressive facts of the localconditions can be analyzed to determine a schedulewhich will maintain equipment in satisfactory condition.

In some locations, conditions may be so bad that thefrequency of maintenance will interfere with operationand production schedules. In such cases, considerationshould be given to the possibility of enclosing the switch-gear assembly in a relatively air tight room. If this ap-proach is followed, a sufficient quantity of clean air must

be supplied to the room to ensure that a positive pres-sure is maintained in the room. Under such conditions, amore normal maintenance schedule can be established.Such an arrangement could also provide for cooling theair where the ambient temperature is relatively high,further improving operation conditions.

CAUTION

FAILURE TO INSPECT, CLEAN, LUBRICATE ANDMAINTAIN THE SWITCHGEAR ASSEMBLY ATRECOMMENDED FREQUENCIES COULD RESULT INFAILURE OF THE EQUIPMENT TO OPERATEPROPERLY UNDER FAULT CONDITIONS, WHICHCOULD CAUSE EQUIPMENT DAMAGE, DEATH AND/OR BODILY INJURY.

6.3.11 LUBRICATION

A metal-enclosed low-voltage switchgear assembly isdesigned so that lubrication is not required under normalconditions. Abnormal local conditions, such as highhumidity, salt-laden atmosphere, corrosive gases, orsevere circuit operating conditions, may demand the useof lubricants. In such cases, a dry or powder lubricantmay be used on moving or mating mechanical parts, anda thin film of “Vaseline” on disconnecting contacts. Theapplication of the lubricants should be held to minimumto reduce the accumulation of dust and dirt. Duringroutine maintenance old lubricants should be wiped offbefore fresh lubricants are applied.

6.3.12 RENEWAL PARTS

When ordering renewal or spare parts, include as muchinformation as possible. In many cases, the style numberof the new part can be obtained from identification on theold part. Always include a description of the old part.Specify the rating, vertical section and compartmentnumber. Always supply the general order number and/orthe shop order number of the assembly itself.

IB01901001E


NOTES

IB01901001E


GROUND FAULT TEST RECORDGround Fault Test Record should be retained by those in charge of the building’s electrical

installation in order to be available to the authority having jurisdiction.(See Article 5.5 in this Instruction)

Test Date Circuit Breaker No. Results Tested By

IB01901001E


FOR RENEWAL PARTS INFORMATION CALL YOUR LOCAL AUTHORIZED CUTLER-HAMMERDISTRIBUTOR. FOR THE NAME OF THE NEAREST CUTLER-HAMMER DISTRIBUTOR,PLEASE CALL:

1-800-525-2000

TO ASSURE SAFETY OF OPERATION AND CONTINUITY OF SERVICE, ALWAYS USE GENU-INE CUTLER-HAMMER AFTERMARKET PARTS AND PRODUCT UPGRADES.

SHOULD YOU NEED FACTORY ASSISTANCE ON THIS MAGNUM DS LOW-VOLTAGE ASSEM-BLY OR OPTIONS FOR UPGRADING YOUR OTHER LOW-VOLTAGE ASSEMBLIES PROD-UCTS, CALL:

1-800-BKR-FAST(1-800-257-3278)

IB01901001E


This instruction booklet is published solely for information purposes and should not be considered all inclusive. Iffurther information is required, you should consult Cutler-Hammer.

Sale of product shown in this literature is subject to terms and conditions outlined in appropriate Cutler-Hammerselling policies or other contractual agreement between the parties. This literature is not intended to and does notenlarge or add to any such contract. The sole source governing the rights and remedies of any purchaser of thisequipment is the contract between the purchaser and Cutler-Hammer.

NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULARPURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OFTRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CON-TAINED HEREIN. In no event will Cutler-Hammer be responsible to the purchaser or user in contract, in tort (includingnegligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatso-ever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss ofpower, additional expenses in the use of existing power facilities, or claims against the purchaser or user by itscustomers resulting from the use of the information, recommendations and descriptions contained herein.

Cutler-Hammer221 Heywood RoadArden, NC 28704

Effective January 2003Printed in U.S.A./CCI

instructions for magnum ds metal-enclosed low …

Documents