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DRAFT Powered by Safety ® 01.4IB.51000C PowlVac® Metal-Clad Switchgear 5kV & 15kV, 1200A, 2000A, 3000A, & 4000A Force Cooled Courtesy of NationalSwitchgear.com...
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PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV 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 Powered by Safety ® Courtesy of NationalSwitchgear.com...
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01.4IB.51000C Signal Words Qualified Person As stated in ANSI Z535.4-2007, the signal word is For the purposes of this manual, a qualified a word that calls attention to the safety sign and person, as stated in NFPA 70E®, is one who has designates a degree or level of hazard seriousness.
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PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV This page left blank intentionally. Powered by Safety ® Courtesy of NationalSwitchgear.com...
01.4IB.51000C Contents Ch 1 General Information ....................1 A. S ................................2 cope B. p ................................2 urpoSe c. I ....................2 nStructIon ulletInS vAIlABle lectronIcAlly D. A ............................3 SSocIAteD ulletInS Ch 2 Safety ........................4 A. S ............................4 onDItIon B. S ...............................4 Afety uIDelIneS c.
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PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV Contents Ch 4 Installation ......................17 A. G ................................. 17 enerAl B. r ................................ 17 eceIvInG c. h ............................... 17 AnDlInG D. S ................................. 18 torAGe e. p ........................19 repArAtIon of loor nchorInG f.
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01.4IB.51000C Contents f. e ............................44 lectrIcAl perAtIon G. S ................................ 44 hutterS h. r ) ..................... 45 emovABle lement oSItIon nterlock ptIonAl I. f ..............................45 loor J. t (toc) (o ) ....................46 ruck perAteD WItch ptIonAl k. m (moc) (o ) ..................
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PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV Figures Figure 1 Metal-Clad Switchgear Line-up ..............6 Figure 2 One High Basic Construction .................7 Figure 3 Two-High Basic Construction .................7 Figure 4 Interior Metal-Clad Switchgear (Lower Compartment) ......10 Figure 5 Front Cover of Circuit Breaker ..............10 Figure 6 Circuit Breaker Cover Removed ..............13 Figure 7...
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01.4IB.51000C Figures Figure 36 Lower Mechanism-Operated Cell Switch (MOC) and Operating Mechanism .................47 Figure 37 Upper Mechanism-Operated Cell Switch (MOC) and Operating Mechanism .................48 Figure 38 4000A Force Cooled Section Views ..............56 Tables Table A Standard Dimensions ...................8 Table B Ratings of Medium Voltage PowlVac® Metal-Clad Switchgear ......9 Table C Bolt Torque Values ....................25 Table D Bus Wrapping Components ................26 Table E Insulation of Bus Bar ...................27...
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PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV This page is intentionally left blank. Powered by Safety ® Courtesy of NationalSwitchgear.com...
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 hazard to be met in connection with installation, testing, operation, and maintenance of the equipment. For additional information and instructions for particular problems, which are not presented sufficiently for the user’s purposes, contact Powell at 1.800.480.7273.
This instruction bulletin provides: be implemented at any time and without notice. Go to powellind.com to ensure use 1. Safety guidelines of the current instruction bulletin for Powell equipment. 2. General descriptions of the operation and maintenance of the PowlVac metal-clad For more information visit powellind.com.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV Ch 2 Safety 6. Where the possibility of induced voltages or stored electrical energy exists, ground A. S the phase conductors or circuit parts onDItIon before touching them. Where it could be The information in Section A is quoted from reasonably anticipated that the conductors NFPA 70E 2012 - Article 120, 120.1 Establishing an or circuit parts being deenergized...
01.4IB.51000C c. G serviced only by skilled and knowledgeable enerAl personnel capable of releasing each spring 1. Only supervised and qualified personnel load in a controlled manner. Detailed trained in the usage, installation, operation, information regarding these mechanisms and maintenance of the switchgear shall is found in the circuit breaker instruction be allowed to work on this equipment.
Metal-Clad Switchgear Line-up A. G enerAl NOTICE Powell is committed to continuous product improvement. It is possible that improvements occurred between revisions to this document and therefore, may not be described in these instructions. If the equipment does not resemble the photographs and descriptions contained herein, do not attempt to perform the actions.
01.4IB.51000C B. D Note: Each construction includes primary ImenSIonS and secondary compartments, as The PowlVac® switchgear basic vertical sections shown in Figure 2 and 3. These are available in two configurations: instructions apply to both types of construction. Where significant 1) One-high Construction differences exist between the two construction types, each is explained...
01.4IB.51000C Table B Ratings of Medium Voltage PowlVac® Metal-Clad Switchgear Power Main Bus Symmetrical Short Time Momentary Obsolete Cell Width Maximum Nominal Frequency Continuous short-circuit Current withstand Crest inch/mm Voltage Voltage Withstand Current Rating 2 sec. Rating (kV) Rating (kV) (A rms) (kA rms) (kA)
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV Figure 4 Interior Metal-Clad Switchgear For a detailed description of the circuit breaker (Lower Compartment) and its operation refer to the appropriate instruction bulletin for PowlVac vacuum circuit breaker. Figure 5 Front Cover of Circuit Breaker a.
01.4IB.51000C h. c The shutters are open and the secondary IrcuIt reAker AckInG echAnISm circuits and control contacts are completed. NOTICE Interlocks deter the movement of a circuit breaker from one position to another unless When the circuit breaker main closing spring the circuit breaker is tripped open.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV I. S a “trip-free” condition while the circuit Afety nterlockS AnD rovISIonS breaker is being racked into or out of the NOTICE connected position. Safety shutters open and close over the Warning and Caution labels are located in stationary primary disconnect devices in various places.
01.4IB.51000C A rollout stop block is provided to deter k. A onDenSAtIon eAterS the removal of the circuit breaker from the Anti-condensation heaters are provided in compartment until the rollout latch on the all PowlVac switchgear in order to facilitate circuit breaker is depressed.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV l. v m. f oltAGe otentIAl rAnSformer ISconnectInG evIce ollout ArrIAGe ollout ArrIAGe Current limiting fuses with high interrupting The voltage transformers are mounted on a rating are sometimes used in metal-clad rollout carriage equipped with primary and switchgear to protect small transformers secondary disconnecting devices.
01.4IB.51000C When fuses are disconnected, they are at a WARNING safe striking distance from all live parts of the switchgear. In addition, a grounding device is Prior to adjustments, servicing, maintenance, provided which contacts the fuses after they or any act requiring the operator to make are disconnected, effectively removing any physical contact with the equipment, the static charge from the fuses.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV p. p rImAry ISconnect evIceS upportS The stationary primary disconnect devices have flat silver-plated copper contact bars located within the molded epoxy supports found at the rear of the circuit breaker compartment, behind the safety shutters. The rear of the contact is bolted to the main bus riser or to the line-side bus.
When the switchgear lineup reaches its destination, the purchaser should check the material actually received against the shipping Contact the Powell Service Division for installation, maintenance, and renewal parts assistance. list to be sure that all parts have been received.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV If bases are furnished, the switchgear may 1. Equipment designed for indoor installation be moved on an even surface by the use of must be stored indoors in a climate rollers or heavy-duty pipes placed under the controlled environment to prevent base.
01.4IB.51000C 3. The auxiliary control devices, ship loose The floor channels should have a minimum material and protective relays must also web dimension of 4 inches. The required be protected. This includes items such as quantity and location of the floor channels battery chargers, UPS systems, lighting, is shown on the drawings furnished with installation hardware and air conditioning.
Before any installation work is done, consult and study all drawings and the Bill NOTICE of Materials furnished by Powell for the particular order. The drawings include arrangement drawings and wiring and Applicable national or local codes or schematic diagrams.
01.4IB.51000C Additional shipping members may have G. D lIGnment been installed in the bus or primary area If for any reason it is necessary to realign the to ensure against shipping damage. All doors of the switchgear during installation shipping members must be removed from perform the following: the switchgear compartments.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV h. t Figure 14 Auxiliary Device with Shipping emovABle lement Bracket The removable element may be shipped loose in its own protective box or inserted in the switchgear when the equipment is installed in a PCR®. If the circuit breaker is in the switchgear, it will be locked in place by a special bracket designed to prevent motion during shipment.
01.4IB.51000C Removable elements located in the one-high A ground bus is furnished with lugs at each construction, or in the lower compartment of end for connection to the station grounding the two-high construction may be rolled into system. the vertical section of the switchgear from The ground is bolted to the rear of the vertical the floor.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV J. c Figure 15 Ground Bus Splice Plate Connection onnectIonS The main bus bars and other connection bars are copper. The connection surfaces are silver surfaced or equivalent. The silver plating used on bolted contact surfaces is approximately 0.0001”...
01.4IB.51000C 1) Main Bus Joint Insulation Table C Bolt Torque Values Bolt Torque Bolt Main bus joints are insulated with either a Dimensions Head Ft-Lbs Kg-M custom fitted boot or with hand applied (inches) insulating tape. Ch 4 Installation, k. m SSemBly AnD nSulAtIon 2) Wrapping of Joints will describe the...
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV Figure 17 Boot Installation a. Bus Bars 5kV & 15kV Apply appropriate number of layers of high voltage tape, mastic side down, at a medium tension to bus bars per Table D, Bus Wrapping Components. Note: All bus bars are to be round edge type.
01.4IB.51000C Figure 18 Insulation of Bus Bar Figure 19 Single Bus Bar Connection Joint .048 (1.2) Approximate Epoxy Insulation Dimension (Tape Tension) Thermoplastic Sleeving 1/2W or Tape Insulation “W” “B” - 1/2 LAP 1 - Layer, 1/2 LAP = 2 Thicknesses “A”...
01.4IB.51000C 3) Applying Bus Insulating Boots If wiping or vacuuming does not clean the bus adequately, only distilled water, a. Prepare all joints as outlined in denatured alcohol or isopropyl alcohol Ch 4 Installation, J. c should be used to remove any foreign onnectIonS b.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV m. I Figure 22 Cable Termination Joint nSulAtInG rImAry ABle ermInAtIonS All field assembled joints for primary cable Epoxy Insulation Thermoplastic Sleeving or Tape Insulation terminations should be prepared as outlined under Ch 4 Installation, J. c .
01.4IB.51000C Figure 23 Bar-Type Current Transformer Joint n. G rounD Ault urrent rAnSformerS Insulation InDoW Window-type current transformers are Pre-Insulation Epoxy insulation Thermoplastic Sleeving or furnished where specified for sensitive Tape Insulation protection against ground faults. These transformers are normally installed in a “A”...
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV o. c Where units have been split for shipment, any ontrol ABleS control or other secondary leads that must Space is provided for control cables to enter connect across the split will be arranged with the switchgear from either the top or the terminal blocks in a convenient location so that bottom of the units.
01.4IB.51000C When assembling the connection bar end Figure 24 Roof Bushing of the roof entrance bushings inside of the switchgear and other terminations where POTHEAD BUSHING TERMINATOR porcelain insulators are used, insulation should RB Putty * .75 (19.1) be applied as follows: “C”...
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV S. A To close the carriage, operate the secondary uxIlIAry evIce ollout ArrIAGe circuit breaker to the “off” position, lower Rollout carriages will be shipped in a slightly the interlock slider, and turn the “T” handle open position, which are held in place by two counterclockwise.
01.4IB.51000C Ch 5 Operation B. I nSertInG the emovABle lement nto the ompArtment WARNING CAUTION Compartment access shall be permitted ONLY Before inserting the circuit breaker into the to “Qualified Person”, as defined in NFPA 70E, compartment, be sure that the racking crank using “approved safe work practice”...
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV The standard lift truck is used when adequate 2) Inserting the Circuit Breaker Into the Upper aisle space (68” minimum) is available. Perform Compartment (Two-High Design) the following steps to insert a circuit breaker in NOTICE the upper compartment: 1) Inserting the Circuit Breaker Into the Lower...
01.4IB.51000C f. Roll the circuit breaker in the c. r AckInG echAnISm compartment until the racking crank The racking mechanism consists of two slotted arms make contact with the vertical cam plates mounted on each side of the slots in the compartment. The compartment (Figure 36, c) and the racking anti-rollout latch on the lower right side mechanism on the circuit breaker.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV Figure 26 Recommended Method for Lifting Circuit Breaker to Upper Cell a. Lift Truck Ready to receive the Circuit Breaker Lift Truck and Switchgear Position Circuit Breaker placed on the Lift Truck Circuit Breaker approaching hook c.
01.4IB.51000C Figure 27 Closed Door Racking CAUTION Use only the racking tools provided by Powell for inserting and removing the circuit breaker. The use of other tools such as electric drills, impact drills, etc., may damage the racking mechanism and render it inoperative.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV D. r Figure 28 Secondary Disconnecting Device AckInG roceDure AnuAl CAUTION Before inserting the circuit breaker into the compartment, be sure that the racking crank arms of the circuit breaker are in the fully withdrawn position, pointing towards the moveable primary disconnects.
01.4IB.51000C Figure 29 Standard Circuit Breaker in Test c. Turning the racking handle clockwise Position will begin to rack the circuit breaker into the compartment (Figure 31). When the circuit breaker is racked into the compartment, the force needed to rotate the racking handle will be low at the beginning of motion as the movement of the racking crank arms is only opening the shutters.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV d. Once the circuit breaker has reached 3) Removing the Circuit Breaker from the the connected position, remove the Connected Position racking handle, verify that the manual trip operator has returned to its normal CAUTION position, close the compartment door, and operate the circuit breaker as...
01.4IB.51000C d. Turn the racking handle c. Press the anti-rollout latch counterclockwise until the breaker (Figure 32, a) to release the circuit position indicator displays breaker and pull the circuit breaker out “BREAKER TEST/DISCONNECTED”. of the circuit breaker compartment e. Remove the racking handle and verify using the handles.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV f. e Figure 33 Shutters lectrIcAl perAtIon 1. A one-line, or three-line diagram, and a schematic diagram are prepared for each metal-clad switchgear line-up. All diagrams shall be thoroughly studied and completely understood by the user before the metal-clad switchgear is placed into service.
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01.4IB.51000C h. r The interlock is held by gravity in the open, or emovABle lement oSItIon nterlock ptIonAl non-interlock position. When the removable element is out of the compartment, rotating CAUTION the interlock 90° clockwise, and securing it will block the insertion of a removable Before racking a circuit breaker in or out element.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV J. t (toc) (o k. m (moc) ruck perAteD WItch ptIonAl echAnISm perAteD WItch ptIonAl The purpose of the truck-operated cell switch (TOC) (Figure 4, g) is to indicate whether or not The mechanism-operated cell switch (MOC) is the removable element is in the connected an auxiliary switch operated by linkages in the position.
01.4IB.51000C l. S Figure 36 Lower Mechanism-Operated Cell econDAry ISconnect evIce Switch (MOC) and Operating The switchgear has a secondary disconnect Mechanism device, which is a 16-point plug mounted at the lower end of an umbilical cord, which hangs at the right side of the compartment. The secondary disconnect plug (Figure 4, j) plugs into the secondary disconnect receptacle (Figure 5, m) on the lower right front of the...
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV Figure 37 Upper Mechanism-Operated WARNING Cell Switch (MOC) and Operating Mechanism Under no conditions may the dummy element be racked in or out when the circuit it is connected to is under load. This action could result in death or serious injury.
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The settings of the protective relays must supplemental documents. For assistance be coordinated with the other relays on the with testing and inspection, contact Powell on our website at powellind.com, or call system and, therefore, these relays must be set by the user. General instruction books are 1.800.480.6900.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV When transformers are furnished to supply The covers for meters, relays, and other devices the control power, the primary taps should be which have to be removed during the course selected so that the control voltage indicated of installation and test should be carefully on the wiring diagram is obtained on the handled when removed.
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A. G enerAl When performing maintenance the power source must be disconnected and the Contact Powell Service Division for assistance equipment grounded. Failure to do so may in performing maintenance or setting up a result in death or serious injury.
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PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV For all previous lubrication requirements CAUTION Powlube-104, A-grease replaces Anderol 757 and Rheolube 368A, B-grease replaces Use only the cleaners recommended in this Mobilgrease 28, and C-oil replaces Mobil 1 and document. Failure to do so could result in Anderol 456A.
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01.4IB.51000C 6) Control Contacts 10) Battery and Charging Equipment The contacts should be inspected and The control battery is such an important dressed or replaced when the surface accessary to the switchgear operation becomes seriously pitted. Unless repetitive that it must be given special periodic duty has been experienced, little attention attention if it is to have a long life of reliable should be required.
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PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV 13) Testing c. The resistance of bus connections may be checked by passing a measured The condition of each switchgear unit at DC current of 200A or more, through the time of inspection, should be listed in the joint and measuring the voltage a permanent record to become a guide for drop (in millivolts) across the joint.
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01.4IB.51000C 15) Interlocks c. A BnormAl onDItIonS a. Shutter position interlock front door Local conditions such as high ambient component - verify that the actuator temperature, high humidity, salt-laden on the opening side of the door slides atmosphere, corrosive gases, heavy dust, ash, freely and operates the shutter position severe circuit operating conditions, vermin, flag.
PowlVac® Metal-Clad Switchgear 01.4IB.51000C 5kV & 15kV Figure 38 4000A Force Cooled Section Views a. Force Cooled Ventilation Exit b. Fan Package c. Rear Cell Ventilation Duct d. Circuit Breaker Compartment Door e. Force Cooled Ventilation Entry Powered by Safety ®...
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A sufficient amount of stocked parts minimizes service 1. Order Renewal Parts from Powell at interruptions caused by breakdowns and saves powellind.com or call 1.800.480.7273. time and expense. When continuous operation is a primary consideration, a larger quantity of 2.
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