50 / 75 / 150 DHP [Cable or Hard Bus Application] Ground and Test Device

Transcription

1 Instruction Book IB182217EN Supersedes May 2016 Effective October / 75 / 150 DHP [Cable or Hard Bus Application] 150 DHP (Cable Type Device) 150 DHP (Hard Bus Type Device)

2 DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY The information, recommendations, descriptions and safety notations in this document are based on Eaton s experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales office should be consulted. Sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser. THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or other-wise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and descriptions contained herein. The information contained in this manual is subject to change without notice. m WARNING IMPROPERLY 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. This product was manufactured by Eaton at the Power Breaker Center (PBC): 310 Maxwell Avenue, Greenwood, SC 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 an Eaton representative. 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. 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. ii Instruction Book IB182217EN October

3 Table of Contents SECTION 1: INTRODUCTION AVAILABLE 50/150 DHP GROUND AND TEST DEVICES 4 SECTION 2: SAFE PRACTICES 8 SECTION 3: RECEIVING, HANDLING, AND STORAGE RECEIVING HANDLING STORAGE DHP-GT APPROXIMATE WEIGHTS 10 SECTION 4: DESCRIPTION AND OPERATION INSULATING BARRIERS BUSHINGS AND DISCONNECTING CONTACT ASSEMBLIES INTERLOCKS GROUNDING CONTACTS BREAKER-CELL CODING PLATES CELL POSITION DESCRIPTION INSTALLATION OF GROUNDING BUS BARS DEVICE AMPERAGE CONVERSION PROCEDURE UNIVERSAL 1200A/2000A G&T CONFIGURATION (OPTIONAL) Changing 1200A Finger Clusters to 2000A Changing 2000A Finger Clusters to 1200A 20 SECTION 5: INSTALLATION & INSPECTION EXAMINATION FOR DAMAGE NAMEPLATE VERIFICATION INSTALLATION OF GROUNDING CABLES SNUBBER ADJUSTMENT INSERTION PROCEDURES REMOVAL PROCEDURE 23 SECTION 6: INSPECTION AND MAINTENANCE INTRODUCTION FREQUENCY OF INSPECTION INSPECTION AND MAINTENANCE PROCEDURES INSULATION INTEGRITY CHECK 24 SECTION 7: REPLACEMENT OF COMPONENTS GENERAL ORDERING INSTRUCTIONS 25 Instruction Book IB182217EN October iii

4 SECTION 1: INTRODUCTION This booklet provides instructions for both the cable-type and hard bus-type ground and test devices designed specifically for Westinghouse 50 and 150 DHP metalclad and metal enclosed switchgear. Instructions are provided for receiving and handling, storage, installation, operation and maintenance of the G&T. Various configurations of G&T devices are available: three terminals only on the upper (line) position, three terminals only on the lower (load) position, and six terminals in the upper and lower positions. This instruction booklet may be used for all types. The cable-type G&T devices are provided with sufficient cables per phase to perform the short time rating appearing on the device nameplate. The cable-type G&T cannot be converted to a hard busstyle G&T. Hard bus style G&T devices feature silver plated copper bus bars instead of cables. These bus bars decrease the possibly of G&T failure that can occur in cable designs. Their unique design does not allow cables to be installed. The hard bus shorting bars are configured so that, when installed, the G&T door for those terminals cannot be closed so that visual inspection can confirm that the shorting bars are in place. In this way, the hard bus type of G&T is similar in operation to the cable type as terminal doors cannot be closed when cables are installed. Type 50/150 DHP 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: m CAUTION BECAUSE 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. m WARNING SATISFACTORY 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 50/150 DHP GROUND AND TEST DEVICES Refer to Table 1 and Ground a circuit for maintenance work; 2. Apply potential for cable testing; and, 3. Access both bus and line circuits for phasing out tests. Table 1. 50/150DHP (Hard Bus Application) Availability and Interchangeability Maximum Voltage Class (kv) Existing MVA Rating Existing Rated Continuous Current at 60 Hz (Amps) Rated Short-Circuit Time Current ka / RMS / Symmetrical Rated Momentary Current ka / Peak / / 2000 / * / / 2000 / */ N Note: * Actual ground current (I 2 t) capability is limited to the cell ground bus. To achieve a full rating, ground connecting bus in cell must be replaced with Eaton part 94G7103H09 (one per circuit breaker compartment). BIL Capability (kv) Table 2. 50/150DHP (Cable Application) Availability and Interchangeability Maximum Voltage Class (kv) Existing MVA Rating Existing Rated Continuous Current at 60 Hz (Amps) Rated Short-Circuit Time Current ka / RMS / Symmetrical Rated Momentary Current ka / Peak / / 2000 / * / / * / N Note: * Actual ground current (I 2 t) capability is limited to the cell ground bus. To achieve a full rating, ground connecting bus in cell must be replaced with Eaton part 94G7103H09 (one per circuit breaker compartment). BIL Capability (kv) 4 Instruction Book IB182217EN October

5 A B B H C G D E F Table 3. DHP Dimensions (Cable Application Design) Breaker Type Existing Breaker Rated Continuous Current at 60 Hz (Amps) A B C D E F G H 50DHP 250 Dual 1200 / DHP 350 Dual a 1200 / DHP A Dual 1200 / / 150DHP 500 Dual 1200 / a - 50DHP 350 Dual features extended snubber design. Instruction Book IB182217EN October

6 B C C E A F H G D Table 4. DHP Dimensions (Hard Bus Application Design) Breaker Type Existing Breaker Rated Continuous Current at 60 Hz (Amps) A B C D E F G H 50DHP 250 Dual 1200 / Instruction Book IB182217EN October

7 A B B H C G D E F Table 5. DHP Dimensions (Hard Bus Application Design) Breaker Type Existing Breaker Rated Continuous Current at 60 Hz (Amps) A B C D E F G H 150DHP 500 Dual 1200 / Instruction Book IB182217EN October

8 SECTION 2: SAFE PRACTICES s are designed with several built-in interlocks and safety features to provide safe and proper operating sequences. m WARNING TO 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 maintenance 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 enclosure before performing any maintenance. Failure to do so could result in electrical shock leading to death, severe personnel 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, personnel 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 contacting 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. 8 Instruction Book IB182217EN October

9 SECTION 3: RECEIVING, HANDLING, AND STORAGE Ground 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 cables 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 office. Tools and Accessories Racking Handlee: A racking handle is not provided for all 50 and 150 DHP G&T types because it is identical in form, fit, and function to the racking handle provided with the original DHP air circuit breakers. Use the racking handle originally provided to engage the racking shaft of the G&T racking mechanism to move the device into and out of the circuit breaker compartment. Grounding Cablese: Grounding cables are provided only on the cable-type G&T devices. The appropriate size and number of cables are furnished to match the rated short time and momentary ratings. The terminated cables may be bolted to the appropriate terminals and to the ground connections provided on the G&T device. Grounding Shorting Barse: Three grounding shorting bars are furnished only on hard bus-type G&T devices. These bars may be positioned for grounding either the three upper or the three lower terminals of a six terminal device, as required. Bars are configured to prevent closing the terminal doors when they are installed (Figure 3.1.d). Bushing Wrenche: A special wrench is provided only on G&T devices that have interchangeable primary disconnects. These convertible devices are equipped with extra 1200, 2000, and/or 3000 ampere terminals. This bushing wrench is recommended for removal and installation of primary disconnects (knobs or finger cluster assemblies) to allow the G&T to be used in circuit breaker compartments that have the same short circuit currents available but differing continuous current ratings. Interlock Keyse: Key interlocked terminal access doors are provided to supplement site lock out, tag out strategies. Required by G&T standard C , these Kirk Key interlocks prevent simultaneous access to both the upper and lower terminals only on six terminal devices. Special coded keys are provided for use with each G&T device. If keys are lost or damaged, contact Eaton for replacement. Figure 3.1.a. RackingHandle Figure 3.1.b. Grounding Cable Figure 3.1.c. Bushing Wrench Figure 3.1.d. Grounding Copper Shorting Bars Instruction Book IB182217EN October

10 3.2 HANDLING m WARNING DO 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. DHP 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 3.2.a. Front External View of 50DHP G&T Device 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 air circulation to prevent condensation. If the building is not heated, the same general rule for heat as for outdoor storage should be applied. 3.4 DHP-GT APPROXIMATE WEIGHTS Refer to Table 6. Table 6. Maximum Weight by Type Type Amperes LBs 50DHP 250 / 350 Dual 1200 / DHP / 150DHP 500 Dual 1200 / 2000 / Figure 3.2.b. Front External View of 150DHP G&T Device 10 Instruction Book IB182217EN October

11 Figure 3.3.a. Front External View of DHP G&T Device Front External View (50DHP G&T Shown) 1 Kirk Key Interlocks 3 Ground Bus 5 Rail Latch 2 Door Latch 4 Levering Shaft Instruction Book IB182217EN October

12 Figure 3.3.b. Rear External View of DHP G&T Device Front External View (50DHP G&T Shown) 1 Primary Disconnects 3 Snubber Bolt 5 Code Plate 2 Shutter Roller 4 Racking Nut 6 Grounding Contact 12 Instruction Book IB182217EN October

13 Figure 3.3.c. Front External View of 50DHP 350 G&T 3000A Device Front External View (150DHP G&T Shown) 1 Lifting Points 3 Ground Bus 5 Rail Latch 2 Kirk Key Interlocks 4 Levering Shaft Instruction Book IB182217EN October

14 50 / 75 / 150 DHP [Cable or Hard Bus Application] Figure 3.3.d. Rear External View of 50DHP 350 G&T 3000A Device Back External View (150DHP G&T Shown) 1 Primary Disconnects 3 Snubber Bolt 2 Shutter Roller 4 Racking Nut 14 Instruction Book IB182217EN October Grounding Contact

15 Figure 3.3.e. Front External View of 150DHP-GT A/2000A Device Front External View 1 Padlock Provision 3 Lifting Points 5 Levering Shaft 2 G&T Storage Compartment* 4 Kirk Key Interlocks N Note: *Only offered for 150DHP-GT 1200A/2000A Convertible designs Instruction Book IB182217EN October

16 Figure 3.3.f. Rear External View of 150DHP-GT A/2000A Device Back External View 1 Primary Disconnect 3 Grounding Contact 5 Ground Bus 2 Snubber Bolt 4 Lifting Point 6 Code Plate 16 Instruction Book IB182217EN October

17 SECTION 4: DESCRIPTION AND OPERATION The G&T is a draw out device that can be inserted into a circuit breaker cubicle in the same manner as the 50/150DHP Air 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. m WARNING IT IS MOST IMPORTANT THAT THE BUS OR LINE TERMINALS BE CORRECTLY IDENTIFIED FOR EACH COMPARTMENT BEFORE USING THIS DEVICE. Type 50/150DHP manual Ground & Test devices are also available with either the upper or lower terminals only. 4.5 BREAKER-CELL CODING PLATES This is a combination of a notched plate in the cell and interference bars on the breaker, so that only appropriately rated breakers can be put into the cell (Figures 4.1 and 4.2). NNote: Code Plates provided on 1200A and 2000A devices only. m WARNING FOR 1200/2000A UNIVERSAL GROUND & TEST DEVICES A CODE PLATE HAS BEEN FACTORY INSTALLED TO MATCH THE RATING OF THE FACTORY- INSTALLED PRIMARY DISCONNECTS. ENSURE THAT THE CORRECT PRIMARY DISCONNECTS AND CODE PLATES HAVE BEEN INSTALLED FOR THE CORRECT APPLICATION. TO CHANGE THE CODE PLATE SIMPLY REMOVE AND TURN AROUND SO THAT THE BAR IS POSITIONED AT THE TOP. Figure 4.1. G&T Code Plates (1200A Shown) 4.1 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. 4.2 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 Set 3.3) 4.3 INTERLOCKS The only interlocks associated with these Ground and Test devices are the Kirk Key interlocks located on the front of the device. (Figure Set 3.3) 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. m NOTICE ONLY 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. 5kV 4.6 CELL POSITION DESCRIPTION Position A: This is the withdrawn position. In the withdrawn position, the ground and test device is out of the cell. The racking handle is not required for this position. Position B: As the G&T device is pushed into the cell, it will reach a mechanical stop. This is the disconnect / test position. Position C: Continue rotating the racking handle until the rotating handle turns freely, and the G&T device stops moving. The device will have reached the connect position. (Figure 4.2) Remove the racking handle. Figure 4.2. G&T Device In Connect Position - Position C 15kV m WARNING INTERLOCKS 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. 4.4 GROUNDING CONTACTS The grounding contact is an assembly of spring-loaded fingers, which ground 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 at the rear of the device, on the truck, and visible from the back of the device when out of the cell. (Figure Set 3.3) Instruction Book IB182217EN October

18 4.7 INSTALLATION OF GROUNDING BUS BARS NNote: Use hardware provided with the ground and test device installed as shown. (Figure 5.1) 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 Set 3.3) with each G&T device, unlock the appropriate door, exposing the terminals. 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 5.1). 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. Figure 4.3. Attaching Grounding Bus Bars to Ground Bus Figure 4.4. G&T Storage Compartment Figure 4.5. Primary Disconnect Amperage Conversion (2000A Adapter Bushing w/ 2000A Primary Disconnects Shown) d. Attach the other end of the grounding bus bar to the horizontal ground bar (Figure 5.1) 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. g. When properly installed, the hard bus grounding parts are configured to prevent closing the terminal access doors. Just as it is impossible to close terminal doors on cable-type G&T devices, the hard bus-style G&T device holds the access door open to provide a visible reminder that the hard bus shorting bars are installed. 4.8 DEVICE AMPERAGE CONVERSION PROCEDURE The primary circuit terminals of the ground and test device consists of cycloaliphatic bushings with silver plated copper conductor knobs. Primary disconnecting contacts are attached to the knobs; these primary disconnects are configured to engage the circuit breaker compartment primary disconnects. It is critical to confirm that 1200 ampere primary disconnects are installed prior to insertion in 1200 ampere circuit breaker compartments; likewise for tests in 2000 ampere circuit breaker compartments. THIS CONVERSION ALSO REQUIRES A CODE PLATE CHANGE PRIOR TO RACKING THE G&T INTO ITS CIRCUIT BREAKER COMPARTMENT. Follow the procedure below to convert from one primary current design to the other. a. With the ground and test device located in an appropriate work area, remove the existing primary disconnects installed on the G&T using only the wrench provided (Figure 4.4) at the location shown in Figure 4.5. Some wrenches can damage the primary disconnect knobs; they should be avoided. b. After removing the primary disconnect knobs, remove the primary disconnects to be installed from the G&T storage bin and thread them onto the bushings. The primary disconnects just removed should be promptly stored in the storage bin to avoid damage to them. c. Hand tighten the primary disconnects onto the primary bushings. Using the special wrench provided, complete tightening the primary disconnect knobs until they are snug tight. Overtightening these knobs is not necessary and may damage the knobs or make them very difficult to remove at a future time. d. THE GROUND AND TEST CODE PLATE MUST BE CHANGED AT THIS TIME. The ground and test device will be blocked from full insertion in the circuit breaker compartment until the code plate position is changed. The code plate is a mandatory safety feature that must not be removed and discarded. e. The code plate position is changed by removing the two nuts and bolts rotating the bracket 180 degrees and re-installing. Figure 4.1 shows the code plate positioned for insertion in 1200 ampere circuit breaker compartments. 18 Instruction Book IB182217EN October

19 4.9 UNIVERSAL 1200A/2000A G&T CONFIGURATION (OPTIONAL) A special design of the DHP (G&T) allows the separate grounding of both 1200A and 2000A circuit breaker cubicles. Since the device can be inserted into either cubicle design, the finger clusters and the G&T code plate must be matched to the ampere rating of the cell stabs. Figure A Universal G&T Finger Cluster m DANGER FAILURE TO CORRECTLY MATCH THE FINGER CLUSTER RATINGS AND G&T CODE PLATES TO THE CELL STAB AMPERE RATING CAN RESULT IN DEATH, SERIOUS PERSONNEL INJURY, AND / OR PROPERTY DAMAGE. Step 1 - Determine the ampere rating of the cell structure that is to be grounded or tested with the G&T device. Step 2 - Verify that the code plate is installed properly by referring to Section 4.5 in this instruction book based on the ampere rating. If the code plate is incorrectly mounted, remove it and remount to match the proper ampere rating. Step 3 - The correct finger cluster (1200A or 2000A) must match the cell stab ampere rating prior to inserting the G&T device. If the incorrect finger cluster is mounted on the G&T device, remove it and install the proper finger cluster. Figure 4.9. Waxing Primary Conductors Changing 1200A Finger Clusters to 2000A The 1200A DHP finger cluster is easily changed by removing the 5/16 hex head bolt, lock washer, and large retaining washer. (Figure 4.6 & 4.7) Retain the hex head bolt and lock washer for re-installation or for mounting a 2000A universal G&T finger cluster. Figure A Finger Cluster Removal Figure Waxing 2000A Universal G&T Finger Cluster Figure 4.7. Finger Cluster Hardware Pull the finger cluster assembly off the G&T primary conductor. Repeat the process for all finger clusters. Select a 2000A universal G&T finger cluster (Figure 4.8). Apply a thin film of wax (Johnson s Paste Wax-available from many retailers-used for furniture) to the outer surface of the primary conductors (Figure 4.9) and to the inside contact surfaces of the fingers (Figure 4.10). The finger cluster should be re-waxed each time a finger cluster is changed or approximately every 50 insertions and removals. The wax will not form a build-up and will not attract dirt and contaminants if properly applied. Instruction Book IB182217EN October

20 m DANGER DO NOT USE GREASE OF ANY KIND. GREASING OF THE FINGER CLUSTERS OR PRIMARY CONDUCTORS WILL VOID THE WARRANTY AND OVER TIME CAN CAUSE A BUILDUP OF CONTAMINANTS THAT CAUSE TRACKING OVER THE SURFACE OF THE INSULATION OR WITHIN THE CELL BOTTLES. FAILURE TO HEAD THIS WARNING CAN CAUSE DEATH, SERIOUS PERSONNEL INJURY, AND / OR PROPERTY DAMAGE. Figure Fitting 2000A Universal G&T Finger Cluster Orient the finger cluster with the smaller diameter of the fingers towards the primary conductor. Place the large retaining washer inside the finger cluster cavity. Insert the longer 5/16 hex bolt through the finger cluster and retaining washer. (Figure 4.11) Push the finger cluster against the primary conductor stem. (Figure 4.12) Figure Finger Cluster Hardware Changing 2000A Finger Clusters to 1200A The 2000A Universal G&T DHP finger cluster is easily changed by removing the 5/16 hex head bolt, lock washer, and large retaining washer. (Figure 4.7) Grasp the 2000A Universal G&T finger cluster firmly and pull to remove from the primary conductor. (Figure 4.14) Figure Finger Cluster Hardware Figure A Universal G&T Finger Cluster Removal Thread the hex bolt into the primary conductor stem and tighten to pull the finger cluster onto the primary stem. Once the finger cluster is drawn onto the primary conductor stem, but not fully seated, remove the long 5/16 hex bolt. Thread the shorter hex head bolt and lock washer into the primary conductor stem and tighten until the flat washer is collapsed. Do not over tighten. (Figure 4.13) Repeat the process until all finger clusters are changed to the proper rating. Remove the large retaining washer if the finger cluster is to be replaced or if mounting a 1200A DHP finger cluster. Repeat the process for all finger clusters. Select a 1200A DHP finger cluster. Apply a thin film of wax (Johnson s Paste Wax-available from many retailers-used for furniture) to the outer surface of the primary conductors (Figure 4.9) and to the inside contact surfaces of the fingers (Figure 4.15). The finger cluster should be re-waxed each time a finger cluster is changed or approximately every 50 insertions and removals. The wax will not form a build-up and will not attract dirt and contaminants if properly applied. 20 Instruction Book IB182217EN October

21 Figure Waxing 1200A DHP Finger Cluster m WARNING DO NOT USE GREASE OF ANY KIND. GREASING OF THE FINGER CLUSTERS OR PRIMARY CONDUCTORS WILL VOID THE WARRANTY AND OVER TIME CAN CAUSE A BUILDUP OF CONTAMINANTS THAT CAUSE TRACKING OVER THE SURFACE OF THE INSULATION OR WITHIN THE CELL BOTTLES. FAILURE TO HEAD THIS WARNING CAN CAUSE DEATH, SERIOUS PERSONNEL INJURY, AND / OR PROPERTY DAMAGE. Orient the finger cluster with the stainless steel retaining ring and spring marking as shown (Figure 4.7). Figure A DHP Finger Cluster Orientation Place the large retaining washer inside the finger cluster cavity. Push the 1200A finger cluster onto the primary conductor stem. Thread the shorter hex head bolt and lock washer into the primary conductor stem and tighten until the flat washer is collapsed. Do not over tighten. Repeat the process until all finger clusters are changed to the proper rating. Instruction Book IB182217EN October

22 SECTION 5: INSTALLATION & INSPECTION m WARNING BEFORE 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. Figure 5.2. Adjustments for Anti-Rotation Hold Downs (Shown Separate From Breaker For Clarity) 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. 5.1 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 NAMEPLATE VERIFICATION Verify the information on the new G&T device matches the information on the purchase order. If any discrepancies exist, notify Eaton for resolution prior to proceeding. Figure 5.1. Current Transformer Shelf 5.3 SNUBBER ADJUSTMENT m NOTICE FOR ALL TYPE DHP HOUSINGS, THE ADJUSTMENT STEPS OUTLINED IN THIS PARAGRAPH MUST BE PERFORMED BEFORE INSTALLING A DHP GROUND AND TEST DEVICE. FAILURE TO COMPLETE THESE STEPS COULD RESULT IN EQUIPMENT DAMAGE AND/OR IMPROPER OPERATION. Before levering a ground and test device into any and all housings, the snubber bolts must be adjusted as outlined in steps 1 and 2. Refer to Figures Set 3.3 and Figure 5.2 for reference purposes. If a ground and test device is moved from one housing to another, the procedure must be repeated for the new housing. Step 1: Measure the distance from the floor plate to the underside of the current transformer shelf on both sides of the housing in line with the location of the snubber bolts on each side of the ground and test device (Figure 5.1). 5.2 INSTALLATION OF GROUNDING CABLES NOTE: USE HARDWARE PROVIDED WITH THE GROUND & TEST DEVICE INSTALLED AS SHOWN. (Figure 5.3) a. Determine the set of terminals required for each occasion. b. Using the key provided (Figure 3-3) with each G&T device, unlock the appropriate door, exposing the terminals. This feature is not applicable for single terminal ground and test devices. c. Using 0.5-inch hardware provided, attach one end of each of the three grounding cables to a terminal corresponding to each phase. (Figure 4-3). Hardware should be torqued to 50 ft-lbs. d. Cables are bolted to the ground plate at the factory. If they have been unbolted, reattach the terminal of the grounding cables to the copper ground bar located at the front of the truck frame. Hardware should be torqued to 50 ft-lbs. Step 2: Adjust the height of the top of the snubber bolt to be between 0.0 and (0.0 and 1/32) inches below the measured height of the current transformer shelf and tighten the locking nut. 5.2 INSERTION PROCEDURES m NOTICE THIS 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 CABLES ARE INSTALLED PROPERLY BEFORE INSERTING GROUND AND TEST DEVICE INTO CELL. WHILE LEVERING 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. Press down on the rail latch on the front right side of the G&T device with your foot, and push the G&T device toward the rear of the cell 22 Instruction Book IB182217EN October

23 Figure 5.3. Terminal Cable Connection as far as it will go. (Figure 5.4) Be sure the G&T device is pushed in until it stops. This will bring the levering nut on the G&T device up to the screw in the cell. Engage the levering crank on the levering shaft, push moderately toward rear of the cell, and turn crank clockwise (Figure 5.5). The G&T device will move slowly toward the rear of the cell. After the G&T device starts to move, it is not necessary to push. Continue cranking until the crank turns freely, and the G&T device stops moving. The G&T device should now be in the OPERATING or ENGAGED position. 5.5 REMOVAL PROCEDURE To remove the G&T device from the operating position engage the levering crank on the levering device shaft. Turn the crank counterclockwise until the crank rotates freely. Pull the G&T device toward the front of the cell until the rail latch engages the slot in the rail. The G&T device is now secured in the TEST position. To remove the G&T device from the cell, press down on the rail latch to free the G&T device from the rail. Pull the G&T device out of the cell. Figure 5.4. Rail Latch Figure 5.3. Racking Instruction Book IB182217EN October

24 SECTION 6: INSPECTION AND MAINTENANCE 6.1 INTRODUCTION m WARNING DO 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 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. 24 Instruction Book IB182217EN October

25 SECTION 7: REPLACEMENT OF COMPONENTS 7.1 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 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 sales office. 5. Include negotiation number with order when applicable. Instruction Book IB182217EN October

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