Instruction Book IB02707223E GE-VB1 PowerVac Ground …pub/@electrical/... · Test Device . This...

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Effective April 2011Instruction Book IB02707223E

GE-VB1 PowerVacGround and Test Device

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3SAFE PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . 5RECEIVING, HANDLING, AND STORAGE . . . . . . . 6INSTALLATION & INSPECTION . . . . . . . . . . . . . 10DESCRIPTION AND OPERATION . . . . . . . . . . . . 12INSPECTION AND MAINTENANCE . . . . . . . . . . 13REPLACEMENT OF COMPONENTS . . . . . . . . . . 14

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Instruction Book IB02707223EEffective April 2011


EATON CORPORATION www.eaton.com

WARNINGIMPROPERLY INSTALLING OR MAINTAINING THESE PRODUCTS CAN RESULT IN DEATH, SERIOUS PERSONAL INJURY OR PROPERTY DAMAGE.

READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING ANY UNPACKING, ASSEMBLY, OPERATION OR MAINTENANCE OF THESE GROUND AND TEST DEVICES.

INSTALLATION OR MAINTENANCE SHOULD BE ATTEMPTED ONLY BY QUALIFIED PERSONNEL. THIS INSTRUCTION BOOK SHOULD NOT BE CONSIDERED ALL INCLUSIVE REGARDING INSTALLATION OR MAINTENANCE PROCEDURES. IF FURTHER INFORMATION IS REQUIRED, YOU SHOULD CONSULT EATON’S ELECTRICAL SERVICES & SYSTEMS.

THE GROUND AND TEST DEVICES DESCRIBED IN THIS BOOK ARE DESIGNED AND TESTED TO OPERATE WITHIN THEIR NAMEPLATE RATINGS. OPERATION OUTSIDE OF THESE RATINGS MAY CAUSE THE EQUIPMENT TO FAIL, RESULTING IN DEATH, BODILY INJURY AND PROPERTY DAMAGE.

ALL SAFETY CODES, SAFETY STANDARDS AND/OR REGULATIONS AS THEY MAY BE APPLIED TO THIS TYPE OF EQUIPMENT MUST BE STRICTLY ADHERED TO.

THESE GROUND AND TEST DEVICES ARE DESIGNED TO BE INSTALLED PURSUANT TO THE AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI). SERIOUS INJURY, INCLUDING DEATH, CAN RESULT FROM FAILURE TO FOLLOW THE PROCEDURES OUTLINED IN THIS MANUAL.

This product was manufactured by Eaton Corporation at the Power Breaker Center: 310 Maxwell Avenue, Greenwood, SC 29646 .

All possible contingencies which may arise during installation, operation or maintenance, and all details and variations of this equipment do not purport to be covered by these instructions . If further information is desired by purchaser regarding his particular installation, operation or maintenance of particular equipment, contact Eaton Corporation .

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SECTION 1: INTRODUCTIONThe purpose of this book is to provide instructions for receiving and handling, storage, installation, operation and maintenance of the General Electric Type 5, 7 .5, and 15 VB1 PowerVac Ground and Test Device . This ground and test device is designed to be used in existing GE Type VB1 PowerVac metal-enclosed switchgear .

GE-VB1 manual ground and test devices are designed for insertion into the breaker compartment to gain access to the primary stationary contacts . It provides convenient means to:

1. Ground a circuit for maintenance work;

2. Apply potential for cable testing; and,

3. Access both bus and line circuits for “phasing out” tests.

CAUTIONBECAUSE OF THE UNIQUE APPLICATION AND VAST VARIETY OF SYSTEM / USER REQUIREMENTS, SPECIFIC SAFE OPERATING PROCEDURES FOR THE USE OF THIS DEVICE MUST BE DEVELOPED BY THE USER.

WARNINGSATISFACTORY PERFORMANCE OF THESE GROUND AND TEST DEVICES IS CONTINGENT UPON PROPER APPLICATION, CORRECT INSTALLATION AND ADEQUATE MAINTENANCE. THIS INSTRUCTION BOOK MUST BE CAREFULLY READ AND FOLLOWED IN ORDER TO OBTAIN OPTIMUM PERFORMANCE FOR LONG USEFUL LIFE OF THE GROUND AND TEST DEVICES.

THESE GROUND AND TEST DEVICES ARE PERSONNEL PROTECTIVE DEVICES, AS SUCH, THEY ARE MAXIMUM RATED DEVICES. THEREFORE, THEY SHOULD NOT UNDER ANY CIRCUMSTANCES BE APPLIED OUTSIDE THEIR NAMEPLATE RATINGS.

1.1 AVAILABLE GE-VB1 GROUND AND TEST DEVICES

Refer to Table 1 .1

Table 1. GE-VB1 Ground and Test Device Availability and Interchangeability

Nominal Voltage Class(kV)

Existing Breaker MVA Rating Existing Breaker Rated Continuous Current at 60 Hz (Amps)

Rated Short-Circuit Time Current

kA / RMS / Symmetrical

Rated Momentary Current

kA / Peak

BIL Capability(kV)

4.16 250 1200 / 2000 50 130 60

4.16 350 1200 / 2000 50 130 60

7.2 500 1200 / 2000 50 130 95

13.8 500 / 750 1200 / 2000 50 130 95

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Table 2. GE-VB1 Ground and Test Device Dimensional Data

GE-VB1-GT-1200/2000A

A 31.00

B 30.35

C 7.00

D 11.06

E 16.56

F 29.06

F

E

D

A

B

CC

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SECTION 2: SAFE PRACTICESGround and Test Devices are designed with several built-in interlocks and safety features to provide safe and proper operating sequences .

WARNINGTO PROTECT THE PERSONNEL ASSOCIATED WITH INSTALLATION, OPERATION, AND MAINTENANCE OF THE GROUND AND TEST DEVICES, THE FOLLOWING PRACTICES MUST BE FOLLOWED:

• Only qualified persons, as defined in the National Electrical Safety Code, who are familiar with the installation and main-tenance of medium voltage circuits and equipment, should be permitted to work on the ground and test device.

• Read these instructions carefully before attempting any installation, operation or maintenance of the ground and test device.

• Always remove the ground and test device from the enclo-sure before performing any maintenance. Failure to do so could result in electrical shock leading to death, severe per-sonnel injury or property damage.

• Do not leave the ground and test device in an intermediate position in the cell. Always have the ground and test device either in the DISCONNECT or CONNECTED position. Failure to do so could result in a flash over and possible death, per-sonnel injury or property damage.

• Keep all insulating surfaces, which include primary support insulation and insulation barriers, clean and dry.

• Check all primary circuit connections to make certain they are clean and tight.

• Take extreme care while using this device to avoid contact-ing “live” or “hot” (energized) terminals.

• These ground and test devices are equipped with safety interlocks. Do not defeat them. This may result in death, bodily injury or equipment damage.

• Correctly identify LINE and BUS terminals for the breaker compartment before using this device.

• Store the device in a clean, dry area free from dust, dirt, moisture, etc.

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SECTION 3: RECEIVING, HANDLING, AND STORAGEGround and test (G&T) devices are subjected to complete factory production tests and inspection before being packed . They are shipped in packages designed to provide maximum protection to the equipment during shipment and storage and at the same time to provide convenient handling . Accessories such as the grounding bus bars are shipped with the ground and test device .

3.1 RECEIVING

Until the ground and test device is ready to be delivered to the switchgear site for installation, DO NOT remove it from the shipping crate . If the ground and test device is to be placed in storage, maximum protection can be obtained by keeping it in its crate .

Upon receipt of the equipment, inspect the crates for any signs of damage or rough handling . Open the crates carefully to avoid any damage to the contents . Use a nail puller rather than a crow bar when required .

When opening the crates, be careful that any loose items or hardware are not discarded with the packing material . Check the contents of each package against the packing list . Examine the ground and test device for any signs of shipping damage such as broken, missing or loose hardware, damaged or deformed insulation and other components . File claims immediately with the carrier if damage or loss is detected and notify the nearest Eaton’s Electrical Services & System office .

Tools and Accessories

Racking Handle: The racking handle is used to drive the racking mechanism which moves the G&T device into and out of the cell . This racking handle is the same one provided with the original GE Vacuum Circuit Breaker and therefore is not provided as part of the G&T device . (Figure 3 .1)

Grounding Bus Bars: Three grounding bus bars are provided with each G&T device . These can be attached to either the top or bottom terminals . (Figure 3 .2)

Interlock Keys: The ground and test devices are interlocked for safety . They are designed using Kirk Key Interlocks to prevent exposing the top and bottom terminals simultaneously . Special coded keys are provided for use with each G&T device . If keys are lost or damaged, contact Eaton’s Electrical Services & Systems for replacement .

otee:N This feature is not applicable for single terminal ground and test .

3.2 HANDLING

WARNINGDO NOT USE ANY LIFTING DEVICE AS A PLATFORM FOR PERFORMING MAINTENANCE, REPAIR OR ADJUSTMENT. THE GROUND AND TEST DEVICE MAY SLIP OR FALL CAUSING SEVERE PERSONAL INJURY. ALWAYS PERFORM MAINTENANCE, REPAIR AND ADJUSTMENTS ON A WORKBENCH CAPABLE OF SUPPORTING THE GROUND AND TEST DEVICE TYPE.

GE-VB1 ground and test device shipping containers are designed to be handled by a forklift truck . If containers must be skidded for any distance, it is preferable to use roller conveyors or individual pipe rollers .

Once a G&T device has been inspected for shipping damage, it is best to return it to its original shipping crate until it is ready to be installed in the Metal-Clad Switchgear .

When a ground and test device is ready for installation, a lifting harness in conjunction with an overhead lift or portable floor lift can be used to move a G&T device . This could be preferable to rolling the G&T device on the floor using self-contained wheels . If the G&T device is to be lifted, position the lifting device (lifting straps should have at least a 1600 lb capacity) over the G&T . Stand a safe distance away from the device while lifting and moving .

Figure 3.1. Typical Racking Handle

Figure 3.2. Grounding Bus Bars

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3.3 STORAGE

If the ground and test device is to be placed in storage, maximum protection can be obtained by keeping it in the original shipping crate . Before placing it in storage, checks should be made to make sure that the G&T device is free from shipping damage and is in satisfactory operating condition .

Outdoor storage is NOT recommended . If unavoidable, the outdoor location must be well drained and a temporary shelter from sun, rain, snow, corrosive fumes, dust, dirt, falling objects, excessive moisture, etc . must be provided . Container should be arranged to permit free circulation of air on all sides and temporary heaters should be used to minimize condensation . Moisture can cause rusting of metal parts and deterioration of high voltage insulation . A heat level of approximately 400 watts for each 100 cubic feet of volume is recommended with the heaters distributed uniformly throughout the structure near the floor .

Indoor storage should be in a building with sufficient heat and circulations to prevent condensation . If the building is not heated, the same general rule for heat as for outdoor storage should be applied .

3.4 GE-VB1-GT APPROXIMATE WEIGHTS

Refer to Table 3 .

Table 3. Maximum Weight by Type

Type Amperes LBs

GE-VB1-GT (Double Terminal) 1200/2000 315

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Front External View (GE-VB1 G&T Shown)

1 Upper Door 4 Lower Door

2 Kirk Key Lock 5 Racking Engagement Lever

3 Padlock Provision 6 Ground Bus

Figure 3.3. Front External View of GE-VB1 G&T Device

5

2

6

2

4

3

1

5

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Rear External View (GE-VB1 G&T Shown)

1 Primary Disconnect 3 Code Plate

2 Ground Contact

Figure 3.4. Rear External View of GE-VB1 G&T Device

3

1

2

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SECTION 4: INSTALLATION & INSPECTION

WARNINGBEFORE PLACING THE GROUND AND TEST DEVICE IN SERVICE, CAREFULLY FOLLOW THE INSTALLATION PROCEDURE BELOW AND THE SAFE PRACTICES SET FORTH IN SECTION 2. NOT FOLLOWING THE PROCEDURE MAY RESULT IN INCORRECT G&T DEVICE OPERATION LEADING TO DEATH, BODILY INJURY, AND PROPERTY DAMAGE.

When the G&T device is first used and each time it is used in the future, it should be carefully examined and checked to make sure it is operating correctly .

4.1 EXAMINATION FOR DAMAGE

Examine the ground and test device for loose or obviously damaged parts . Never attempt to install nor operate a damaged ground and test device .

4.1.1 NAMEPLATE VERIFICATION

Verify the information on the new G&T device matches the information on the purchase order . If any discrepancies exist, notify Eaton’s Electrical Services & Systems for resolution prior to proceeding .

WARNINGVERIFY THAT THE CIRCUIT INTENDED FOR GROUNDING IS COMPLETELY DE-ENERGIZED BEFORE INSERTING ANY GROUND & TEST DEVICE WITH ITS TERMINALS GROUNDED.

FAILURE TO VERIFY LINE AND LOAD CONNECTIONS IN THE CIRCUIT BREAKER COMPARTMENT WILL CAUSE FLASH OVER RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY, AND POSSIBLE DEATH.

CAUTIONTHE MAIN SWITCHGEAR BUS IS CONNECTED TO THE LOWER STUDS WHEN THE DEVICE IS INSTALLED IN AN UPPER COMPARTMENT AND TO THE UPPER STUDS WHEN THE DEVICE IS INSTALLED IN A LOWER COMPARTMENT.

LOCATE THE EATON GROUND AND TEST BUS BARS AS REQUIRED NOTING THE LOCATION OF THE MAIN SWITCHGEAR BUS IN GENERAL ELECTRIC POWERVAC SWITCHGEAR.

4.2 INSTALLATION OF GROUNDING BUS BARS

otee:N Use hardware provided with the ground and test device installed as shown . (Figure 4 .1)

a . Determine the set of terminals to be grounded for test purposes . Ground and Test bus bars may be used on the upper or lower terminals of six terminal ground and test devices .

b . Using the key provided (Figure 3 .3) with each G&T device, unlock the appropriate door, exposing the terminals .

otee:N This feature is not applicable for single terminal ground and test devices .

c . Using the included 1 .5 inch long, ½-13 hex bolts with doubled flat washers, attach one end of each grounding bus bar (Figure 3 .2) to the internal terminal corresponding to each phase (Figure 4 .1) . Grounding bar can only be installed one way . Take care to align the mounting bolts with the integral nut block behind the copper terminal . Do not fully tighten the mounting hardware .

d . Attach the other end of the grounding bus bar to the horizontal ground bar (Figure 4 .1) with the included 1 .5 inch long, ½-13 bolt with double flat washers . Horizontal bus bar is between the upper

and lower terminal compartments . Weld nuts are located behind this bus bar . Do not fully tighten the mounting hardware .

e . Returning to the internal terminals, fully tighten this hardware . Torque to 50 ft lbs .

f . Finally tighten the hardware to secure grounding bus bar to horizontal ground bus . Torque to 50 ft lbs .

4.3 INSERTION PROCEDURES

NOTICETHIS IS NOT A BREAKER OR AN ELECTRICALLY OPERATED GROUND AND TEST DEVICE. THEREFORE THERE IS NO SECONDARY BLOCK. THIS MEANS THAT THERE IS NO TEST POSITION AND IT WILL NOT BE COVERED IN THIS INSTRUCTION MANUAL.

ENSURE THAT GROUNDING BUS BARS ARE INSTALLED PROPERLY BEFORE INSERTING GROUND AND TEST DEVICE INTO CELL.

WHILE RACKING THE GROUND AND TEST DEVICE, NOTE ANY SUDDEN RESISTANCE TO LEVERING OR SIGNS OF BINDING. DETERMINE THE CAUSE OF INTERFERENCE AND CORRECT, AS APPROPRIATE, BEFORE PROCEEDING.

WARNINGPRIOR TO INSERTION, FOLLOW LOCK OUT / TAG OUT PROCEDURES TO CONFIRM THAT ALL PRIMARY CIRCUITS OF THE SWITCHGEAR HAVE BEEN DE-ENERGIZED. FAILURE TO DO SO MAY CAUSE DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.

a . Move the ground and test device to the circuit breaker compartment in which it is to be inserted using the General Electric lifting device provided with the original switchgear .

otee:N The VB1 Ground and Test device has interference interlocking (code plates) that will only allow the correctly sized G&T to be inserted in the circuit breaker compartment . Example: A 1200 ampere G&T cannot be inserted into a 2000 ampere breaker compartment . Do not remove or alter the interference interlocking .

b . Confirm that the racking system of the circuit breaker compartment is in the disconnect position . The tape indicator should read “Disc/Test” and the drive nuts on the jack screws should be in the forward position against their respective stops .

c . Push the VB1 Ground and Test device into the metal-clad unit until the racking arms are engaged in the racking mechanism . A safety catch on the right hand metal-clad rail will prevent the G&T from rolling back out in case the racking arms are not engaged .

Figure 4.1. Attaching Grounding Bus Bars to Ground Bus

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d . As one of the front doors of the G&T will be open, and the primary circuits are de-energized, the G&T device may be racked into the circuit breaker compartment with the compartment front door open .

e . Attach the racking handle to the racking mechanism shaft on the left side of the circuit breaker enclosure and push it in fully .

f . Rack the VB1 G&T by rotating the handle clockwise (60 turns are required) until a positive stop is felt .

g . The G&T is now in the fully connected position as indicated by the tape indicator which should read ‘Conn’ . Do not exceed 60 ft . lbs . of force on the racking shaft .

4.4 REMOVAL PROCEDURE

a . After testing is complete, the Ground and Test device can be racked from the connected position .

b . Attach the racking handle to the racking mechanism shaft on the left side of the circuit breaker enclosure and push it in fully .

c . Rotate the racking handle counter-clockwise to move the G&T to the ‘Disc/Test’ position as indicated on the tape indicator .

d . It will be necessary to lift the safety catch on the right side of the breaker compartment to remove the G&T from the circuit breaker compartment .

Figure 4.2. Alignment of the G&T Device (Withdrawn Position)Figure 4.4. G&T Device in the Test Position

Figure 4.3. Racking In the VB1 G&T Device

Figure 4.5. G&T Device in the Connect Position

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SECTION 5: DESCRIPTION AND OPERATIONThe G&T is a draw out device that can be inserted into a circuit breaker cubicle in the same manner as the GE-VB1 Vacuum Circuit Breaker and Vacuum Replacement Circuit Breaker . It can be ordered as a single terminal device or a double terminal ground and test device . Each terminal is isolated from each other and the ground bus connections by insulating barriers . The upper and lower terminals are accessible upon opening the respective fronthinged door . The ground connection is located in the lower section of the device .

WARNINGIT IS MOST IMPORTANT THAT THE BUS OR LINE TERMINALS BE CORRECTLY IDENTIFIED FOR EACH COMPARTMENT BEFORE USING THIS DEVICE.

Type GE-VB1 manual Ground & Test devices are also available with either the upper or lower terminals only .

5.1 INSULATING BARRIERS

Insulating barriers are red pieces of GPO-3 glastic material used to isolate the primary terminals from each other and the ground connections . They are attached to the ground and test device frame using insulated hardware . Using other hardware than those provided will affect the insulating integrity of the ground and test device .

5.2 BUSHINGS AND DISCONNECTING CONTACT ASSEMBLIES

The upper and lower bushings, which are the primary circuit terminals of the ground and test device, consist of silver plated insulated conductors . Multiple finger type primary disconnecting contacts at the ends of the conductors provides means for connecting and disconnecting the G&T device to the bus terminals in the switchgear compartment . (Figure 3 .4)

5.3 INTERLOCKS

The only interlocks associated with these Ground and Test devices are the KIRK KEY interlocks located on the front of the device . (Figure 3 .4) This protects the user from having both top and bottom hinged doors open at the same time . While either the top or bottom door is unlocked, the key is unable to be removed from the lock . To remove the key, close the appropriate door and turn the key . This will lock the door and the key will now be able to be removed and inserted into the other lock . This feature is not applicable for single terminal ground and test .

NOTICEONLY ONE KEY WILL BE PROVIDED WITH EACH GROUND AND TEST DEVICE. THIS PREVENTS THE INTERLOCKING MECHANISM FROM BEING BYPASSED. IF A KEY IS LOST, CONTACT EATON FOR A REPLACEMENT. THIS FEATURE IS NOT APPLICABLE FOR SINGLE TERMINAL GROUND AND TEST.

WARNINGINTERLOCKS ARE PROTECTIVE DEVICES FOR PERSONNEL AND EQUIPMENT. DO NOT BYPASS, MODIFY, OR MAKE INOPERABLE ANY INTERLOCKS. DOING SO COULD CAUSE DEATH, SERIOUS PERSONNEL INJURY, AND / OR PROPERTY DAMAGE.

5.4 GROUNDING CONTACTS

The grounding contact (Figure 3 .4) is a solid bar that is received by an assembly of spring-loaded fingers contained within the cell . This grounds the device by engaging the switchgear cell grounding bus when the G&T device is levered into the “connect” position . The ground contact is located in the circuit breaker compartment .

5.5 CELL POSITION DESCRIPTION

Position A: (Withdrawn) When the device has passed the safety catch located on the right side of the cell it is in the withdrawn position .

Position B: (Test/Disconnect) The G&T device must be rolled into the test/disconnect position from the withdrawn position . Once the arching engagement levers are engaged the test/disconnect position is achieved .

Position C: (Connect) From the Test/Disconnect position, rack the G&T device approximately 10 inches into the cell to reach the connect position .

Figure 5.1. G&T Device in Connect Position

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SECTION 6: INSPECTION AND MAINTENANCE6.1 INTRODUCTION

WARNINGDO NOT WORK ON A GROUND AND TEST DEVICE IN THE “CONNECTED” POSITION.

DO NOT DEFEAT ANY SAFETY INTERLOCKS.

FAILURE TO FOLLOW ANY OF THESE INSTRUCTIONS MAY CAUSE DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. SEE SECTION 2 - SAFE PRACTICES FOR MORE INFORMATION.6.2 FREQUENCY OF INSPECTION

6.2 FREQUENCY OF INSPECTION

Inspect the ground and test device at least once a year or before each use, especially in a severe service condition .

6.3 INSPECTION AND MAINTENANCE PROCEDURES

Insulation

Visually inspect all insulating barriers . Ensure that there is not dirt visible on the surface of any of the barriers . If dirt is found, clean with a lint-free cloth . If a solvent is required to cut dirt, used Stoddard’s Solvent (Eaton part number 55812CA) or commercial equivalent .

Hardware

Visually inspect all hardware . Replace any damaged or missing hardware with parts equivalent to those provided with the ground and test device .

Power Frequency Withstand Test

Individually energize each terminal (without cables, but with insulating barriers) with the frame and device ground connection system and all other terminals grounded . See Section 6-4 for procedure .

6.4 INSULATION INTEGRITY CHECK

A sinusoidal AC voltage shall have a crest value of no less than 1 .414 times the rated power frequency withstand voltage value specified, and shall be applied to each terminal as specified in Section 6 .3 . The frequency shall be within +/- 20% of the rated power frequency . For 5kV, the test voltage shall be gradually increased from zero to 15 kV rms and held for 1 minute without flashover . For 7 .5kV and 15kV, the test voltage shall be gradually increased from zero to 27kV rms and held for 1 minute without flashover .

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SECTION 7: REPLACEMENT OF COMPONENTS7.1 GENERAL

In order to minimize production downtime, it is recommended that an adequate quantity of spare parts carried in stock . The quantity will vary from customer to customer, depending upon the service severity and continuity requirements . Each customer should develop his own level based on operating experience .

7.1.1 ORDERING INSTRUCTIONS

1. Always specify the ground and test device rating information and general order number, from the nameplate.

2. Describe the item, give the style number, and specify the quantity required.

3. Specify the method of shipping desired.

4. Send all orders or correspondence to the nearest Eaton’s Electrical Services & Systems sales office.

5. Include negotiation number with order when applicable.

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Eaton CorporationElectrical Sector1111 Superior Ave .Cleveland, OH 44114United States877-ETN-CARE (877-386-2273)Eaton .com

© 2011 Eaton CorporationAll Rights ReservedPrinted in USAPublication No . IB02707223EApril 2011

PowerChain Management is a registered trademark of Eaton Corporation .

All other trademarks are property of their respective owners .

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