GE CONSUMER & INDUSTRIAL

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1 GE CONSUMER & INDUSTRIAL GE POWER/VAC MANUAL GROUND AND TEST DEVICE Types PVV-1200/ PVV PVV PVV PVV-1200/ PVV PVV-1200/2000/ Instruction Number GEK-86125B

2 CONTENTS 1. Introduction Safety Precautions Receiving, Handling and Storage Receiving and Handling Storage Description Interlocks Current Rating Interlock Compartment Elevation Interlock Connection Bar Assembly Operating Procedures Grounding Testing Phasing Maintenance High-Potential Test FIGURES Fig. 1 Manual Ground and Test Device (Front View)... 5 Fig. 2 Manual Ground and Test Device (Side View)... 6 Fig. 3 Connection Bar Assembly 1200/2000A, 97kA peak/58ka rms total momentary... 8 Fig. 4 Connection Bar Assembly 1200A, 132kA peak/78ka rms total momentary... 9 Fig. 5 Connection Bar Assembly 2000A, 132kA peak/78ka rms total momentary... 9 Fig. 6 Connection Bar Assembly 1200/2000A, 132kA peak/78ka rms total momentary... 9 Fig. 7 Connection Bar Assembly 3000/3500/4000A, 132kA peak/78ka rms total momentary Fig. 8 Cable Termination

3 POWER/VAC* MANUAL GROUND AND TEST DEVICE TYPE PVV-1200/ , PVV FOR POWER/VAC* METAL-CLAD SWITCHGEAR TYPE 13.8 AND TYPES PVV , PVV , PVV-1200/ , PVV , PVV-1200/2000/ FOR POWER/VAC* METAL-CLAD SWITCHGEAR TYPES 4.16 and INTRODUCTION The Manual Ground and Test Device is an auxiliary removable device for use in POWER/VAC* Metal-Clad Switchgear Equipment during initial installation and at normal maintenance periods. The function of this device is to solidly ground the equipment manually as well as permit various types of tests. A convenient means of grounding a system is provided to safeguard personnel who may be working on the equipment. Exposed terminals can also be used for applying high-potential test, measuring insulation resistance to ground and phasing out cables. Two device types are available. The types differ in the method of attaching the ground cable. On the 10 units (PVV 1200/ and PVV ) the stud extensions and the ground attachment are designed to accept quick connecting ( hot stick type) clamps. On the 20 units (PVV , PVV ), PVV 1200/ , PVV and PVV 1200/2000/ ) holes are provided in the stud extensions and in the ground connection for attaching grounding cable lugs. The Manual Ground and Test Device may be of the type limited to a single compartment continuous current rating (1200A, 2000A, or 3000A) or it may be of the type configured for multiple compartment ratings (1200/2000A or 1200/2000/3000A). In applying a ground and test device to a metal-clad unit, only the current ratings need to be considered. Electrical insulation of the device has been designed to include ratings from 4.16kV to 13.8kV. Refer to the device nameplate to determine the current ratings of a particular device. CAUTION: This device does not have interrupters or a mechanism; therefore, it has no interrupting or closing capability. The Manual Ground and Test Device is designed and tested to meet applicable ANSI Standards. Proper installation and maintenance are necessary to insure continued satisfactory operation of the device. The following instructions will provide information for placing the device in service and for maintaining satisfactory operation. Since a clear conception of the function of all parts is helpful in understanding the operation during installation and maintenance periods, a brief description of the design and operating principles is also given. 2. SAFETY PRECAUTIONS The Manual Ground and Test Device and the metalclad compartment have interlocks to prevent unsafe operation. This device is often used during initial installation and for trouble shooting, when the possibility of making an error is greatest. Unfortunately, it is not possible to eliminate every hazard with interlocks; therefore, it will be the responsibility of the person using this device to recognize the potential hazards while working on this equipment and take adequate precautions. Refer to instruction manual GEK POWER/VAC* Metal- Clad Switchgear Types 4.16 and 13.8 before inserting the Manual Ground and Test Device. CAUTION: Interlocks are provided for safety of the operator and correct operation of the device. If an interlock does not function as described DO NOT MAKE ANY ADJUSTMENT OR FORCE THE DEVICE INTO POSITION. CONTACT THE NEAREST GENERAL ELECTRIC COMPANY INSTALLATION AND SERVICE OFFICE FOR ADDITIONAL INSTRUCTIONS. CAUTION: This device extends the primary terminals of the switchgear through the front cover to make them accessible for grounding and testing. Under certain conditions these terminals may be at high potential and could cause severe injury to the operator if they are contacted. *Registered Trademark of the General Electric Company 3

4 These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes, the matter should be referred to the General Electric Company. To the extent required the products described herein meet applicable ANSI, IEEE and NEMA standards; but no such assurance is given with respect to local codes and ordinances because they vary greatly Receiving and Handling Each Manual Ground and Test Device is carefully inspected and then packed by workmen experienced in proper handling of electrical equipment. Immediately upon receipt of a device, an examination should be made for any damage sustained during shipment. If injury or rough handling is evident, a damage claim should be filed at once with the transportation company, and the nearest General Electric Company sales office should be notified promptly. The device should be removed from the crating with sufficient care so that no damage will result from rough handling. Loose parts associated with the apparatus may be included in the crate. Care should be taken to make certain that these parts are not overlooked. 3. RECEIVING, HANDLING AND STORAGE 4. DESCRIPTION 3.2. Storage The Manual Ground and Test Device should be carefully protected against condensation. Store it in a warm, dry environment at moderate temperatures 40 F to 100 F since water absorption has an adverse effect on insulation components. The storage area should be clean, free from corrosive gases, fumes and dust-free. If the device is stored for any length of time, it should be inspected prior to use to verify that corrosion has not started and to insure proper working mechanical condition. Should the device be stored under unfavorable conditions, it should be cleaned and dried out before being placed in service. The Manual Ground and Test Device consists of a Power/Vac* circuit breaker mechanism frame (10) Fig. 2, on which three insulation supports (11) Fig. 2, are mounted to support the primary extension bars (5) Fig. 2, and connections bars (1 and 3) Fig. 2. A front cover (13) Fig. 2, supports the doors (21) Fig. 2, extension bar insulator (12) Fig. 2, and the label system, which indicates upper or lower compartment and bus or feeder terminals. A ground bar (5) Fig. 1, is provided at the lower right corner of the device. Six extension bars (1) Fig.1, for the bus and feeder terminals are brought forward towards the front cover. For grounding equipment, only the three upper studs or the three lower studs should be exposed at any one time. For phasing tests, both upper and lower extension bars need to be exposed, and six connection bar assemblies (1200A, 2000A, 1200/2000A or 3000/3500/4000A as required) installed. NOTE: Only three Connection Bar Assemblies are furnished with each device. The second set of Connection Bar Assemblies must be ordered if the device is to be used for phasing. Use of the dual rated 1200/2000A 132kA peak / 78kA rms total momentary Connection Bar Assemblies is not recommended for 2000A compartments due to elevated racking forces. The single rated 2000A Connection Bar Assembly is recommended. The Manual Ground and Test Device is equipped with a compartment elevation (upper and lower) selector lever (2) Fig.1, on the lower left hand corner of front cover. This lever serves to operate an interlock system coupled to sliding labels on the front cover, which shows whether the device is set up for the upper or lower compartment and identify the primary terminals. In Power/Vac* switchgear equipment, the upper compartment feeder studs are on top and the bus studs on the bottom. For the lower compartment, the opposite exists, namely the bus studs are on top and the line/load studs are on bottom. Thus, prior to inserting the device into an equipment compartment, the device compartment elevation label (upper and lower) must correspond to the equipment compartment elevation before the device can be inserted. If a mismatch exists, the interlock interference mechanism will prevent insertion of the device into the compartment. 4

5 1. Extension Bars Load/Line and Bus 2. Compartment Elevation Selector Lever 3. Compartment Elevation Interlock Mechanism 4. Compartment Elevation Indicator 5. Ground Bar Bracket (-10 only) 6. Ground Angle(-20 only) 7. Nameplate 8. Front Cover and Door Assembly 9. Padlock hasp 10. Bus/Feeder Label 11. Selection Lever Interlock Roller Fig. 1 MANUAL GROUND AND TEST DEVICE (FRONT VIEW) 5

6 1200/2000A 3000/3500/4000A Note: 1200A and 2000A Connection Bar Assemblies not shown TORQUE FT.LB. 6 REAR VIEW SINGLE CURRENT RATED DEVICE REAR VIEW MULTIPLE CURRENT RATED DEVICE -20 DEVICE -10 DEVICE 1. Connection Bar (1200/2000A) 2. Current setting (1200/2000A or 1200/2000/3000A) 3. Connection Bar (3000/3500/4000A) 4. Connection Bar Mounting Bolt 5. Primary Extension Bars 6. Grounding bar 7. Racking Engagement Lever 8. Compartment Elevation Selector Lever 9. Nameplate 10. Ground and Test Device Frame 11. Insulating Support 12. Extension Bar Insulating Tubes 13. Front Cover 14. Padlock hasp for doors 15. Current rating interlock interference plate (3000/3500/4000A) 16. Current rating interlock interference plate (1200/2000A) 17. Positioning Bolt 18. Lower door support 19. Ground bar 20. Optional second set of connection bars (1200, 2000, 1200/2000 or 3000A) 21. Doors 22. Ground Angle Fig. 2 MANUAL GROUND AND TEST DEVICE (SIDE VIEW)

7 5. INTERLOCKS 5.1. Current Rating Interlock Each Manual Ground and Test Device is equipped with a current rating interference plate (15 or 16) Fig. 2. The interference plate assures the current ratings of the device and metal-clad unit match. Refer to GEK Power/Vac* Metal-Clad Switchgear Types VM-4.16 and VM-13.8 for a more detailed description of the interference interlock in the metal-clad equipment. On the 1200/2000A and 1200/2000/3000A devices, a manual current setting is required to match the metalclad compartment. The continuous current rating interference plate has two positions for devices rated 1200/2000A, three positions for devices rated 1200A, 2000A and 3000/3500/4000A. The current setting is accomplished by loosening the Positioning Bolt (17) Fig. 2, on the plate and positioning the sliding plate (16) Fig. 2, to where the edge aligns with the current indication arrow (2) Fig. 2. Then bolt should then be tightened to 20~25 foot-pounds. On devices of a single current rating (1200, 2000 or 3000/3500/4000A), no such current setting is required. Due to interference plate interlocking schemes, devices with current ratings less than 50kA short time, 132kA peak / 78kA rms total momentary are interlocked for specific current ratings and are not interchangeable. Devices with current ratings of 50kA short time, 132kA peak / 78kA rms total momentary are interlocked to allow use in compartments of lower current ratings and are interchangeable. CAUTION: Make certain the setting of the sliding current rating interference plate of the Manual Ground and Test Device matches the continuous current rating of the metal-clad compartment being tested. If the continuous current ratings do not match and the Manual Ground and Test Device is forced into the compartment, serious injury could result to the operator and damage to the equipment. CAUTION: DO NOT attempt to rack a device into a compartment for which it is not intended. Refer to the device nameplate for current ratings. DO NOT force the Manual Ground and Test Device into the compartment or tamper with the interlock as this could result in serious injury to the operator and damage to the equipment. 5.2 Compartment Elevation Interlock A compartment elevation selection lever (2) Fig. 1, on the front of the Manual Ground and Test Device is used to select which compartment is to be tested. When the lever is Up the device can enter the upper compartment. When the lever is Down the device can enter the lower compartment. The selection lever distinguishes between the upper and lower compartment by operating an interlock mechanism (3) Fig.1, which contacts the interference plate in metal-clad unit. This is same plate as is used for current rating interlock. When the device is installed in a cubicle, the selector lever interlock roller (11) Fig. 1, prevents changing the compartment indicators. The elevation selector lever also operates the Compartment Indicator label (4) Fig. 1, and the Bus and Line/Load Indicator label (10) Fig. 1. This, after the compartment elevation position has been set, the upper and lower sets of extension bars are identified. CAUTION: These interlock are provided as a safeguard for the operator so that the terminals being tested are labeled. It is the responsibility of the operator to determine which terminals should be exposed for particular test. If these interlocks are forced, the terminals may be mislabeled so that serious injury could result to the operator and damage the equipment. 7

8 6. CONNECTION BAR ASSEMBLY Connection Bar Assemblies available for this device are dependant upon the device ratings and are as follows: Up to and including 97kA peak / 58kA rms total momentary /2000A Up to and including 132kA peak / 78kA rms total momentary A A /2000A* /3500/4000A *not recommended for 2000A compartment phase testing The 1200/2000A Connection Bar Assembly may be used for 1200A and 2000A metal-clad compartments. The 3000/3500/4000 Connection Bar Assembly may be used for 3000A, 3500A and 4000A metal-clad compartments. The 1200/2000A Connection Bar Assembly rated at 132kA peak / 78kA rms total momentary is not recommended for phase testing (installation of 6 assemblies) of compartments rated at 2000A due to high racking forces when engaging the Primary Disconnects. To minimize racking forces, the single rated 2000A Connection Bar Assemblies should be used. The rating of Connection Bar Assemblies may be identified by the size of the extension bar and the number of Primary Disconnect fingers or finger pairs on the bar. Figures 3 through 7 illustrate the assemblies available. CAUTION: Only use Connection Bar Assemblies that meet or exceed the momentary rating of the Ground and Test Device. Momentary current ratings of the device can be found on the device nameplate. Any attempt to install this device with Connection Bar Assemblies that have a lower momentary current rating than the metal-clad compartment could result in serious injury to the operators. Fig. 3 CONNECTION BAR ASSEMBLY (1200/2000A, 97kA peak / 58kA rms total Momentary) 8

9 Fig. 4 CONNECTION BAR ASSEMBLY (1200A, 132kA peak / 78kA rms total Momentary) Fig. 5 CONNECTION BAR ASSEMBLY (2000A, 132kA peak / 78kA rms total Momentary) Fig. 6 CONNECTION BAR ASSEMBLY (1200/2000A, 132kA peak / 78kA rms total Momentary) 9

10 Fig. 7 CONNECTION BAR ASSEMBLY (3000/3500/4000A, 132kA peak / 78kA rms total Momentary) 7. OPERATING PROCEDURES 7.1. Grounding 1. Identify the current rating of the Manual Ground and Test Device by reading the nameplate on the front or right side of the devices. On 1200/2000A and 1200/2000/3000A devices, position the current interference plate (16) Fig. 2, to the current setting of the metal-clad unit into which the device will be inserted (see section CURRENT RATING INTERLOCK). 2. Determine the compartment elevation (upper or lower) and set the selector switch on the front of the Manual Ground and Test Device Upper for upper compartment and Lower for lower compartment. 3. Attach the three Connection Bar Assemblies to the desired extension bars. Use the bolts (4) Fig. 2, provided and tighten to foot-pounds torque. 4. Close the door (21) Fig. 2, to cover the extension bars to which the Connection Bar Assemblies are not attached. 5. WITHOUT any cable connections to the Manual Ground and Test Device, rack the device into the metal-clad compartment using remote racking device (furnished separately). 6. Test the exposed studs to make certain that the circuit is dead. This should be done using established safety procedures. 7. Rack the Manual Ground and Test Device out to the test position. Attach cables for making the required connections between the ground bar bracket (-10) or ground angle (-20) and the load/line studs. Grounding cables, clamps and ferrules, or lugs and fasteners are to be as follows: Cable Specifications (-10) Maximum Fault Current - 23kA rms (2 sec) Cable 4/0, 2107 Strands, TC, (1 per terminal) UL Style 1284 Clamps Hubble Chance G36051 Hubble Chance C Ferrule plain shrouded Cable Specifications (-20) Maximum Fault Current - 50kA rms (2 sec) Cable 500MCM, 259 Strands,TC (2 per terminal) UL Style3591 Lugs Burndy YA36N ½ -13bolts, Washers, Lock Fasteners Washers and Nuts (Grade 5) 10

11 3. Attach three Connection Bar Assemblies to the desired extension bars.use the bolts provided (4) Fig. 2, and tighten to foot-pounds torque. 4. Position the door (21) Fig. 2, to cover the extension bars to which the Connection Bar Assemblies are not attached. Fig. 8 CABLE TERMINATION CAUTION: Use the Cable Specification to ensure satisfactorily withstand from the effect of a fault current. Failure to adhere to the Cable Specification may result in cables not capable of withstanding the forces or heat generated by fault currents and cause severe injury to nearby personnel. Maximum cable length should be no more than 4 feet for furthest terminal to ground connection. All cables should be sized to minimize length and bound together to minimize movement in case of a fault current. 8. Rack the Manual Ground and Test Device into metal-clad equipment using the remote racking device. Follow the Breaker Installation procedure contained in instruction book GEK Testing 1. Identify the current rating of the Manual Ground and Test Device by reading the nameplate on the front or right side of the device. On the multiple current rated devices, position the current interference plate (16) Fig. 2, to the current setting of the metal-clad unit into which the device will be inserted (see section CURRENT RATING INTERLOCK). 2. Determine the compartment elevation (upper or lower) and set the selector switch on the front of the Manual Ground and Test Device; Upper for upper compartment and Lower for lower compartment. 5. Rack the device into metal clad compartment. This should be accomplished by using the remote racking device (furnished separately). Follow the Breaker Installation procedure contained in instruction book GEK Phasing 1. Identify the current rating of the Manual Ground and Test Device by reading the nameplate on the front or right side of the device. On the multiple current rated devices, position the current interference plate (16) Fig. 2, to the current setting of the metal-clad unit into which the device will be inserted (see section CURRENT RATING INTERLOCK). 2. Determine the compartment elevation (upper or lower) and set the selector switch on the front of the Manual Ground and Test Device; Upper for upper compartment and Lower for lower compartment. 3. Attach the six Connection Bar Assemblies to the extension bars. Use the bolts provided (4) Fig. 2, and tighten to foot-pounds torque. 4. Rack the device into metal-clad compartment. This should be accomplished by using the remote racking device (furnished separately). Follow the Breaker Installation procedure contained in instruction book GEK Open both doors to gain access to the six extension bars for phasing. CAUTION: High voltage will be present on all six extension bars. 11

12 8. MAINTENANCE Proper maintenance of the Manual Ground and Test Device is necessary to insure satisfactory operation. The following items should be checked each time the device is used. 1. Make certain all primary and grounding connections are tightly connected. 2. Contact surfaces of primary disconnect fingers and ground shoe should be lightly coated with 0282A2048P009 grease. 3. The compartment elevation interlock assembly should operate freely when actuated by selector lever. Lubricate the rubbing surfaces with 0282A2048P009 grease. 4. Make certain insulation parts are free of dust and contaminants. 5. X retaining rings are used on retaining pins in the indicating linkage. These rings can be installed and removed with pair of pliers. When they are installed on a pin there should be a maximum gap of 1/16 inch between the ears. Reuse of X rings is not recommended. 9. HIGH POTENTIAL TEST If the Manual Ground and Test Device has been stored a long period of time or exposed to high humidity conditions, it is recommended that the insulation be checked before it is placed in service. A standard 60Hz high potential test at 27kV rms for 1 minute will normally indicate whether the device is satisfactory for service. Apply the voltage to each phase individually for one minute with two other phases and frame grounded. After the high potential test is made, inspect the primary stud support for leakage paths. Clean surfaces and retest if leakage paths are visible, or replace the support. 12

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16 These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes, the matter should be referred to the General Electric Company. GE Consumer & Industrial GEK-86125B GE Consumer and Industrial Switchgear Business Department 510 East Agency Road West Burlington, Iowa General Electric Company 16