ABB ENTELLIGUARD T User manual

1SDH00xxxxxxx ECN000xxxxx – Rev. A
PROCEDURE FOR QUALITY CHECKS
OF DR IEC
ENTELLIGUARD G , MPACT &ENTELLIGUARD L FAMILY

Introduction
The procedure described below must be used to assess the critical function quality checks and correct operation of
Moving portion in the cassette(Fixed Portion).
The kits described above can only operate correctly if the fixed part in which they are installed is in a good condition.
Strictly perform the following inspections in order to assess the condition of the fixed parts.
Rev. A PROCEDURE FOR QUALITY CHECKS OF
DR IEC ENTELLIGUARD G FAMILY
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DR KITS QUALITY CHECK PARAMETER
FIXED PORTION PARTS
ENTELLIGUARD T
ENTELLIGUARD G
MPACT/MPACT PLUS
ENTELLIGUARD L
ENTELLIGUARD T
ENTELLIGUARD G
MPACT/MPACT PLUS
ENTELLIGUARD L
ENTELLIGUARD T
ENTELLIGUARD G
MPACT/MPACT PLUS
ENTELLIGUARD L
ENTELLIGUARD T
ENTELLIGUARD G
MPACT/MPACT PLUS
ENTELLIGUARD L
RACKING TORQUE
TRIP FREE FUNCTION
CONTACT WELD
CLUSTER ENGAGEMENT
02/17

IMPORTANT WARNING
Before taking any action to service this equipment it is compulsory to:
- open the circuit breaker and make sure that the control springs are not loaded;
- in the event of a withdrawable circuit breaker, take action with the circuit breaker withdrawn from the fixed part;
- when taking action on circuit breakers with a fixed design, or on the fixed parts of a withdrawable breaker,
disconnect the supply to the power circuit and to the auxiliary circuits, and earth the terminals in a clearly
visible manner, both on the power side and on the load side;
- make the equipment safe in accordance with current laws and standards.
These servicing procedures shall be handled only by qualified personnel with a thorough understanding of the
equipment.
This procedure does not include instructions on safety or on maintenance and repair operations.
It is important to note that this procedure contains warnings and precautions against maintenance methods that
could cause injury to people, damage to devices or that could make them unsafe. These warnings do not cover all
the ways in which maintenance, even if not recommended by ABB, may be performed, or the possible dangerous
consequences that may arise from such actions.
Anyone who uses procedures and tools for maintenance, whether it is recommended by ABB or not prescribed,
must make sure that his/her own safety and that of the devices is not compromised by the method and by the
service tools used.
Should the need arise to obtain further information or should particular problems arise, and the information in this
procedure is not sufficiently clear, please contact the ABB Service representative.
When the switchgear is left unattended, even momentarily, the buyer, installer or end user is responsible for
ensuring that the hazard signs are positioned correctly, and that all access and control devices are locked securely.
All the information contained in this procedure is based on the latest version of the product documentation available
at the time of printing. We reserve the right to modify it at any time and without notice.
Rev. A PROCEDURE FOR QUALITY CHECKS OF
DR IEC ENTELLIGUARD G FAMILY
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RACKING TORQUE TABLE LIMITS
ENTELLIGUARD G _CASSETTE EMAX2_DR_MP RACKING TORQUE
ENTELLIGUARD T _3P EMAX2 1.2 3P <=20 N-M
ENTELLIGUARD T _4P EMAX2 1.2 4P <=20 N-M
ENTELLIGUARD G_FR1 _3P_1600A EMAX2 2.2 3P <=20 N-M
ENTELLIGUARD G _FR1 _4P_1600A EMAX2 2.2 4P <=20 N-M
ENTELLIGUARD G_FR1 _3P_2500A EMAX2 2.2 3P <=20 N-M
ENTELLIGUARD G _FR1 _4P_2500A EMAX2 2.2 4P <=20 N-M
ENTELLIGUARD G_FR2 _3P_3200A_4000A EMAX2 2.2 3P <=20 N-M
ENTELLIGUARD G _FR2 _4P_3200A_4000A EMAX2 2.2 4P <=25 N-M
MPACT_FR1 _3P_1600A EMAX2 2.2 3P <=20 N-M
MPACT_FR1 _4P_1600A EMAX2 2.2 4P <=20 N-M
MPACT_FR1 _3P_2500A EMAX2 2.2 3P <=20 N-M
MPACT_FR1 _4P_2500A EMAX2 2.2 4P <=20 N-M
MPACT_FR2 _3P_3200A_4000A EMAX2 2.2 3P <=20 N-M
MPACT_FR2 _4P_3200A_4000A EMAX2 2.2 4P <=25 N-M
ENTELLIGUARD L_FR1 _3P_1600A EMAX2 2.2 3P <=20 N-M
ENTELLIGUARD L _FR1 _4P_1600A EMAX2 2.2 4P <=20 N-M
ENTELLIGUARD L_FR1 _3P_2500A EMAX2 2.2 3P <=20 N-M
ENTELLIGUARD L _FR1 _4P_2500A EMAX2 2.2 4P <=20 N-M
ENTELLIGUARD L_FR2 _3P_3200A_4000A EMAX2 2.2 3P <=20 N-M
ENTELLIGUARD L _FR2 _4P_3200A_4000A EMAX2 2.2 4P <=25 N-M

Entelliguard T FIXED PART
NOTE
Rev. A PROCEDURE FOR QUALITY CHECKS OF
DR IEC ENTELLIGUARD G FAMILY
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Make sure that the previous class of protection remains unchanged. If not, it must be restored.
1..Visually check the rails are in proper condition and no part of it is damaged. Check if they move smoothly or not, apply
grease if necessary.
2. Make sure that there is no dust or carbon residue due to circuit breaker operations as they significantly reduce the
insulation clearance.
3. Check the protective coating of the materials are not damaged, e.g. paint coating on the plates and silver-plating
of conductive parts. Remove traces of oxidation with fine grain sand paper
4. Make sure that the screws on the fixed part are properly tightened, e.g, the screw that join the fixed part to the
switchboard, the ones that fasten the terminals of the fixed part to the switchboard bars and earthing plates.
5. Check the non metallic secondary disconnect part and Front panel are not damaged and no crack is there.
6. Make sure all the moving parts on the bottom of fixed part are properly moving and not getting stuck(Racking system,
CAMS, Front Panel shutter Screw. Apply grease if necessary.
7. Make sure that all indications are working correctly.
1
1
5
5
6
3
6
6
6
Need to perform the checks described below on Existing fixed part ,Before starting the ASM of Direct replacement cassette,
Please refer to the procedure to assemble all parts related to(1SDH002090A1001) and follow the instructions as per .
mentioned Instruction sheet document.
05/17

Entelliguard T FIXED PART
NOTE
Before continuing with the checks described below, please refer to the procedure to assemble all parts related to
Cradle – (1SDH002090A1001) and follow the instructions as per mentioned Instruction sheet document.
Rev. A PROCEDURE FOR QUALITY CHECKS OF
DR IEC ENTELLIGUARD G FAMILY
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Visual Check gas Deflectors components to be assembled as per DR kit instruction sheet
06/17

ENTELLIGAUARD G FIXED PART
Rev. A PROCEDURE FOR QUALITY CHECKS OF
DR IEC ENTELLIGUARD G FAMILY
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NOTE
Make sure that the previous class of protection remains unchanged. If not, it must be restored.
1..Visually check the rails are in proper condition and no part of it is damaged. Check if they move smoothly or not, apply
grease if necessary.
2. Make sure that there is no dust or carbon residue due to circuit breaker operations as they significantly reduce the
insulation clearance.
3. Check the protective coating of the materials are not damaged, e.g. paint coating on the plates and silver-plating
of conductive parts. Remove traces of oxidation with fine grain sand paper
4. Make sure that the screws on the fixed part are properly tightened, e.g, the screw that join the fixed part to the
switchboard, the ones that fasten the terminals of the fixed part to the switchboard bars and earthing plates.
5. Check the non metallic secondary disconnect part and Front panel are not damaged and no crack is there.
6. Make sure all the moving parts on the bottom of fixed part are properly moving and not getting stuck(Racking system,
CAMS, Front Panel shutter Screw.Apply grease if necessary.
7. Make sure that all indications are working correctly.
Need to perform the checks described below on Existing fixed part ,Before starting the ASM of Direct replacement cassette,
Please refer to the procedure to assemble all parts related to(1SDH002091A1001) and follow the instructions as per .
mentioned Instruction sheet document.
1
1
6
6
6
5
6
5
07/17

Rev. A PROCEDURE FOR QUALITY CHECKS OF
DR IEC ENTELLIGUARD G FAMILY
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ENTELLIGAUARD G FIXED PART FR1 AND FR2
Visual Check Trip Free Assembly, Contact Weld assembly, anti insertion plates and associated
components to be assembled as per DR kit drawing
Fr1 3P Fr1 4P
Visual Check Trip Free Assembly, Contact Weld assembly, anti insertion plates and associated
components to be assembled as per DR kit drawing
Fr2 3P Fr2 4P
08/17

MPACT/MPACT PLUS FIXED PART
Rev. A PROCEDURE FOR QUALITY CHECKS OF
DR IEC ENTELLIGUARD G FAMILY
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NOTE
Make sure that the previous class of protection remains unchanged. If not, it must be restored.
1..Visually check the rails are in proper condition and no part of it is damaged. Check if they move smoothly or not, apply
grease if necessary.
2. Make sure that there is no dust or carbon residue due to circuit breaker operations as they significantly reduce the
insulation clearance.
3. Check the protective coating of the materials are not damaged, e.g. paint coating on the plates and silver-plating
of conductive parts. Remove traces of oxidation with fine grain sand paper
4. Make sure that the screws on the fixed part are properly tightened, e.g, the screw that join the fixed part to the
switchboard, the ones that fasten the terminals of the fixed part to the switchboard bars and earthing plates.
5. Check the non metallic secondary disconnect part and Front panel are not damaged and no crack is there.
6. Make sure all the moving parts on the bottom of fixed part are properly moving and not getting stuck(Racking system,
CAMS, Front Panel shutter Screw. Apply grease if necessary.
7. Make sure that all indications are working correctly.
Need to perform the checks described below on Existing fixed part ,Before starting the ASM of Direct replacement cassette,
Please refer to the procedure to assemble all parts related to(1SDH002095A1001-MPACT/MPACT PLUS) .
and follow the instructions as per mentioned Instruction sheet document.
11
5
6
5
6
1
167
6
09/17

ENTELLIGAUARD L FIXED PART
Rev. A PROCEDURE FOR QUALITY CHECKS OF
DR IEC ENTELLIGUARD G FAMILY
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NOTE
Make sure that the previous class of protection remains unchanged. If not, it must be restored.
1..Visually check the rails are in proper condition and no part of it is damaged. Check if they move smoothly or not, apply
grease if necessary.
2. Make sure that there is no dust or carbon residue due to circuit breaker operations as they significantly reduce the
insulation clearance.
3. Check the protective coating of the materials are not damaged, e.g. paint coating on the plates and silver-plating
of conductive parts. Remove traces of oxidation with fine grain sand paper
4. Make sure that the screws on the fixed part are properly tightened, e.g, the screw that join the fixed part to the
switchboard, the ones that fasten the terminals of the fixed part to the switchboard bars and earthing plates.
5. Check the non metallic secondary disconnect part and Front panel are not damaged and no crack is there.
6. Make sure all the moving parts on the bottom of fixed part are properly moving and not getting stuck(Racking system,
CAMS, Front Panel shutter Screw.Apply grease if necessary.
7. Make sure that all indications are working correctly.
Need to perform the checks described below on Existing fixed part ,Before starting the ASM of Direct replacement cassette,
Please refer to the procedure to assemble all parts related to(1SDH002096A1001-ENTELLIGUARD L) .
and follow the instructions as per mentioned Instruction sheet document.
10/17
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ENTELLIGAUARD L FIXED PART FR1
Contact Weld Assembly
Secondary disconnect Assembly
Secondary disconnect Assembly
Fig.1
3pole
Fig.2
4pole
to be changed as per DR kit drawing
to be assembled as per DR kit drawing
to be changed as per DR kit
drawing
11/17

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ENTELLIGAUARD L & MPACT FIXED PART FR2
Trip Free Lever Aseembly
Outer and inner guide
has to assembled as depicted
in drawing / instruction sheet
on both side.
Trip Free Lever Aseembly
Outer and inner guide
has to assembled as depicted
in drawing / instruction sheet
on both side.
12/17

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MPACT FIXED PART FR1
Trip Free Lever Aseembly
Outer and inner guide
has to assembled as depicted
in drawing / instruction sheet
on both side.
Trip Free Lever Aseembly
Outer and inner guide
has to assembled as depicted
in drawing / instruction sheet
on both side.
13/17

CHECKS BEFORE LOADING THE BREAKER
Rev. A PROCEDURE FOR QUALITY CHECKS OF
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1.VISUAL CHECK ON FIXED PORTION BEFORE LOADING THE BREAKER
A. Ensure that the front display panel of the cassette shows disconnected position as shown below
2.Visually check presence and proper mounting of all the parts and assemblies in the fixed portion as per
instruction sheet.
DISCONNECT
14/17

CHECKS BEFORE LOADING THE BREAKER
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2. CHECK THE TERMINALS ALIGNMENT AS PER DRAWING / INSTRUCTION SHEET.
Before rack-in check whether all the terminals mounted on the breaker are aligned properly as instructed in the
Must ensure that the racking handle is not inserted before and during loading the breaker. Handle should only be .
3. RACK-IN HANDLE NOT INSERTED BEFORE AND DURING LOADING THE BREAKER.
inserted when the breaker is pushed inside the cassette to dead end condition. .
.
drawing or the instruction sheet..
4. GREASE APPLICATION.
Visual check of grease application on cluster fingers of moving portion. .
15/17

CHECKS DURING RACK-IN OF BREAKER
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DR IEC ENTELLIGUARD G FAMILY
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1. TRIP FREE WORKING (RACKING HANDLE INSERETED)
During rack-in and racking handle inside, charge the breaker and try to put breaker to ON condition. It should not
be possible to ON the breaker
2. TRIP FREE WORKING IN BETWEEN DISCONNECTED AND TEST (RACKING
In between disconnected and test condition, take the handle out and charge the breaker. Put breaker to ON
condition. Now try to put the handle inside.
HANDLE NOT INSERETED)
3. TRIP FREE WORKING IN BETWEEN TEST AND CONNECTED
In between disconnected and connected condition, charge the breaker. try to put breaker to ON condition,
It should not be possible to ON the breaker in any circumstances.
Entelligaurd G (all frames), Entelligaurd L (frame 1-3pole).
The breaker should trip before the racking handle is inserted in case of,
It should not be possible to insert the handle in case of Entelligaurd L (frame 1-4P, frame 2-3&4P)
It should not be possible to insert the handle in case of MPACT/MPACT PLUS
(frame 1-3&4P, frame 2-3&4P)
NOTE :
To check the functionality of trip free & Contact weld features
need to follow the corresponding DR instruction sheet & ASM VIDEOS
It should not be possible to insert the handle in case of Entelliguard T 3P & 4P
16/17

CHECKS AFTER RACK-IN OF BREAKER
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1. TRIP FREE WORKING (RACKING HANDLE INSERTED)
2. CONTACT WELD WORKING
Once the breaker is completely racked-in and the racking handle is inside, charge the breaker and
try to put the breaker to ON condition. It should not be possible to ON the breaker. Beaker will
only be put to ON condition when handle is taken out
Once the breaker is completely racked-in (connected position), take out the handle and charge the
breaker. Put the breaker to ON condition and try to insert the racking handle. It should not be
possible to insert the handle. Handle can only be inserted when breaker is in OFF condition.
CLUSTER ENGAGEMENT CHECK
ON-OFF operation must be taken.
2.Once the breaker is completely racked-in cluster engagement must be checked visually and three
1.Rack the breaker till it reaches to end of racking screw rotations.