ABB ReliaGear ND User manual

—
INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL
ReliaGear®ND
ANSI narrow design metal-clad switchgear

—
Table of contents
04 Important safety notes
and warnings
05 Introduction
06 Receiving, handling and storage
07 Site preparation
08–18 Indoor installation
19–20 Testing and final inspection
21 Placing switchgear into service —
safety precautions
22 Standard construction
23–27 Maintenance

4RELIAGEAR®ND ANSI NARROW DESIGN METAL-CLAD SWITCHGEAR
—
Important safety notes and warnings
Warnings
Equipment operation depends on proper
handling, installation and maintenance.
Neglecting fundamental requirements may lead
to injury of personnel, failure of the equipment
and property damage.
Safety as described in this instruction book
involves two conditions:
• Personal injury.
• Product or property damage.
Safety notations
Safety notations alert personnel to possible death,
injury or property damage situations. The safety
notations appear before the step in which the
condition applies.
Symbols
This is the safety alert symbol. It is used to alert
you to potential physical injury hazards. Obey all
safety messages that follow this symbol to avoid
possible injury or death.
Danger indicates a hazardous situation which, if
not avoided, will result in death or serious injury.
Warning indicates a hazardous situation which, if
not avoided, could result in death or serious injury.
Caution indicates a hazardous situation which, if
not avoided, could result in minor or moderate
injury.
Notice is used to address practices not related to
physical injury.
Although warning hazards are related to personal injury, it
is necessary to understand that under certain operational
conditions, operation of damaged equipment may result in
degraded process performance leading to personal injury
or death; therefore, comply fully with all danger, warning
and caution notices.
Personnel installing, operating or maintaining this
equipment must have thorough knowledge of all applicable
local, regional, industry, government and OSHA safety
procedures as well as commonly accepted safe working
practices. Personnel working in or around this equipment
must also exhibit common sense and good judgment
regarding the potential hazards for themselves and other
personnel in the area. These instructions are intended for
use by fully qualified personnel and are not a substitute for
adequate training, experience and supervision.
Should clarification or additional information be required,
refer the matter to your nearest ABB Sales office. When
communicating with ABB regarding the product covered
by this IOM manual, always reference the ABB assigned
order number.

5INTRODUCTION
—
Introduction
General instructions
Read these instructions carefully before
installation and use as a guide during installation
and initial operation.
File these instructions with other instruction
books, drawings and descriptive data of the
switchgear. Keep this book available for the
installation, operation and maintenance of this
equipment. Use of these instructions will facilitate
proper maintenance of the equipment and prolong
its useful life.
Scope of instructions
The instructions are general in nature. They cover
requirements for installation, setup, checkout and
maintenance as applied to ReliaGear® ND medium-
voltage, non-arc-resistant switchgear. These
instructions do not attempt to cover all variations
and combinations of equipment and installations.
Information on particular installations appears
in the following:
• Bills of materials that list electrical devices
and equipment.
• Single line drawings showing power connections.
• Floor plan, representing available space for power
and control conduits.
• Special construction details.
• Elementary and schematic diagrams.
• Connection diagrams

6RELIAGEAR®ND ANSI NARROW DESIGN METAL-CLAD SWITCHGEAR
—
Receiving, handling and storage
Receiving inspection
Before shipment, the equipment is inspected and
marked with its number and position. Switchgear
frames are factory-assembled and shipped with the
doors closed. The factory ships circuit breakers in
separate cartons, or as an option, inside the
switchgear frame with the breakers in disconnect
position.
Upon receipt of the equipment, examine the
shipment for damage or missing components.
Check the contents against the packing list before
discarding any packing material. Check the
consignment for completeness and lack of any
damage (e.g., moisture and its detrimental effects).
In case of doubt, the packing must be opened and
then properly resealed, putting in new drying agent
bags, when intermediate storage is necessary.
If any quantities are short, or defects or transport
damage are noted, these must be documented on
the respective shipping document. Notify ABB and
the carrier at once of any discrepancies. If there is
damage from improper handling, file a claim for
damages at once with the carrier and notify ABB.
Always photograph damage. Unless otherwise
noted in the project contract documents, ABB
standard shipments are “FOB Factory.” ABB is
not responsible for damage after delivery of
the equipment to the carrier.
3.2 Handling the equipment
Transport panels upright. Take the high center
of gravity into account. Carry out loading
operations only when it has been ensured that all
precautionary measures to protect personnel and
materials have been taken into consideration.
Notice: All doors and panels must be in place and
securely fastened before moving the equipment.
Storing the equipment
Leave the equipment on the shipping base. Store
all equipment indoors in a well-ventilated area.
The storage building should have a well-drained
paved floor. The temperature should be above 60 °F.
The air should be dry (60% maximum humidity).
The shipping sections are ship wrapped in plastic
for protection during shipment only. Remove the
plastic wrap after placing into storage. Cover with
heavy wrapping paper or other moisture barrier.
Use materials that will not trap moisture inside the
unit. Do not cover louvered openings.
For long-term storage, i.e., durations exceeding
two weeks, or in high-humidity areas, use heaters
to keep the interior dry. Bring power for the heaters
to the load terminals of the device that controls the
heater circuits (figure 1).
Notice: Remove all the packing
materials from the switchgear
before energizing the heaters.
Open the breaker or cutout device
that controls the heaters when using
a separate power source.
For circuit breakers shipped in crates, store circuit
breakers upright in their original shipping carton
oriented as indicated on the shipping crates. For
circuit breakers shipped in the switchgear, do not
remove for storage. See document 1VAL057601-MB
for details on breaker storage.
—
01 Heater load
terminals in low
voltage compartment
—
01

7SITE PREPARATION
—
Site preparation
General
Before installing, consult all drawings furnished
for the particular order. The drawings show top,
front and section views of the lineup, primary
and secondary connection diagrams and bills of
materials. Study these drawings and the following
recommendations before preparing the site plan
drawings. On commencement of installation on
site, the switchgear room must be completely
finished, provided with lighting and the electricity
supply, be lockable, dry and have facilities for
ventilation. All the necessary preparations, such
as wall openings, ducts, etc., for positioning the
power and control cables up to the switchgear
must already be complete.
The ceiling height must also be checked
considering the top-mounted ventilation.
Warning: Drilling or punching of holes in the
equipment in any way will affect the integrity
of the switchgear. Consult the factory engineer
before proceeding.
Location
Locate the lineup in accordance with local
regulations. Clearances at the front should allow
for installation and removal of the draw-out
equipment. A minimum of 7' 3" is recommended.
Provide rear access of 4' minimum for making
connections before start-up and for periodic
inspections and maintenance. Breaker doors
can swing 115with adjacent doors closed.
Foundation
The ABB factory supplies general arrangement and
floor plan drawings for each installation. Refer to
these drawings for floor leveling requirements. The
finished floor under and in front of the switchgear
lineup should be smooth, and must not extend
upwards above the switchgear floor line. Floor
leveling requirements are +0.0" to -0.25" over a
linear distance of 20'.
For installations with concrete floors, install all
power and secondary (control) conduits before
moving the units to the site. Available space for
the conduits appears on the floor plan drawings
supplied with the switchgear. Conduits should not
extend more than one inch above the station floor
level. Plug conduit openings before pouring
concrete.
For installations with steel floors, i.e.,
prefabricated metal buildings, cutouts for cable
entry should not extend outside the space provided
in the ReliaGear®ND frames as shown on the floor
plan drawings.

8RELIAGEAR®ND ANSI NARROW DESIGN METAL-CLAD SWITCHGEAR
—
Indoor installation
General
In order to obtain an optimum installation
sequence and ensure adherence to high quality
standards, site installation of the switchgear
should only be carried out by specially trained
and skilled personnel.
Metal-clad switchgear ships in sections. These
sections ship on disposable steel shipping bases.
Equipment is not to be permanently installed on
the shipping bases.
Unload the units as close to the installation site as
possible. Remove all drawout elements and secure all
doors and panels. To move the shipping sections to
their final position, one of four methods can be used.
Notice: Do not remove the shipping bases until
the units are set in place.
Moving the units without the shipping base will
cause irreparable damage and a hazardous
condition.
Forklift — Place forks through locations provided
in the shipping bases (figure 2, figure 3).
Make sure that forks have penetrated the entire
depth of the switchgear to engage all three
shipping channels: front, center and rear (figure 4).
Lift the switchgear frames slowly and tilt forks
slightly rearward to balance. Move carefully into
the final position, taking into account the center
of gravity (figure 5).
Towing — Use chains rated for safe handling of the
shipping splits. Consult the chain manufacturer or
local code requirements for proper safety factors.
Attach the chains to the holes at each end of the
shipping base. Secure chains to the towing
equipment. Make sure that the floor height is
consistent or provide heavy-duty steel sheets to
bridge any inconsistencies. Protect the lower edge
of the switchgear from damage by the chains.
—
02 Forklift provisions
in shipping channels
—
03 Forklift forks
penetrating shipping
channels
—
04 Complete fork
penetration of all three
shipping channels
—
05 Lifting of switchgear
frames with forklift
—
02
—
03
—
04
—
05

9INDOOR INSTALL ATION
Crane — Using a spreader bar and either chains
or slings connected to the shipping channel
extensions (provided upon request), lift carefully,
taking into account the center of gravity. Once
located, final positioning can be done with a
forklift. When using either chains or wire rope
slings, place a wooden 4" × 4" block between the
equipment and the sling to protect the equipment
from damage.
Jacks and Rollers — Raise the frames with jacks
located at the corners of the shipping bases and
move on steel pipe rollers with the shipping bases
attached.
Notice: Use of fork lift trucks for jacking or placing
the jacks other than as described may result in
stress distortions and irreparable damage to
the equipment.
Removal of the shipping base
Once the units are in their final place, the shipping
bases can be removed.
Open the equipment doors. Remove the bolts
holding each of the three shipping bases to the
equipment. If circuit breakers were installed for
shipment, the lower position breakers will need
to be removed prior to this step.
Close and secure all doors and panels. Raise the
units to a height that allows removal of the base.
Use four jacks located at each corner of the
shipping split, just inside of the shipping bases
for this operation. Keep the units uniformly level
to prevent distortion.
Select four pieces of wood thick enough to permit
removal of the jack after lowering. Place one under
each corner. Slowly lower one side until it rests on
the pieces of wood. Repeat this process on the
other side.
Use a pry-bar to lift each corner enough to remove
the four pieces of wood.
Attaching to the floor
Following the removal of the shipping bases, the
switchgear units should be secured to the floor
either by bolting per the guidelines outlined on the
ABB factory drawings or welding. Equipment
installed in seismic areas has special anchoring
requirements.
Connections
Danger: De-energize the primary
cables and properly ground the
equipment before making primary
source connections.
Bolt separate frames together. Reconnect the main
bus and control wiring at the shipping splits. Install
appropriate joint covers as required. Follow the
connection diagram when replacing secondary and
control wiring.
Bolted joints must be torqued per the values in
appendix A – target torque values.
Complete all internal connections. Make the
external connections to control power sources
and circuits, to secondary and potential circuits,
to feeders, power sources and to ground.
Temporary jumpers protect against voltages that
may occur if the current transformer primaries
carry currents while the secondary circuits are still
not complete. With the secondary circuits
connected, remove the jumpers (figure 6).
Warning: Ground bus connections
should not penetrate any part of
the switchgear not intended for
cable or bus entrance.

10 RELIAGEAR®ND ANSI NARROW DESIGN METAL-CLAD SWITCHGEAR
—
Indoor installation
Caution: After completing all
connections to secondary circuits,
follow these circuits and remove
temporary connections from current
transformer secondaries.
Failure to remove the jumpers will
interfere with meters, relays or other
devices in these circuits.
If shorting terminal blocks are used, review the
connection diagram that was shipped with the
unit for position of shorting screws. See step 11
of the control circuit checkout in section 6.2.
Connection to ground bus
The factory bolts the ground bus bars to each
frame. Connect the ground bus bars between
the shipping splits (figure 7) and to the station
ground with a cable or bus of equal or larger
gauge than the housing ground bus.
Do not run cable or bus in conduit. The cable or
bus should take the most direct path to ground.
Installation of bus bar connections between
shipping splits
The factory assembles the main bus bar in each
section. The splices at the shipping splits are
unbolted for shipment. Refer to the general
arrangement drawings.
The contact surfaces of the bus at bolted joints
are plated. Clean contact surfaces with a clean
cloth and an OSHA-approved solvent.
Caution: Do not use alcohol or freon.
Limit the use of solvents to removing
grease and contamination from
primary conductors, insulation and
unpainted metallic surfaces.
Use an OSHA-approved, non-
flammable solvent with a threshold
limit of 300 PPM or higher in
accordance with local regulations.
Use solvents in well-ventilated areas.
Take care not to remove or tarnish
plating.
Remove barriers to access the main bus
compartment. Bolt the main bus together using
supplied hardware. Conductivity of a bolted joint
depends on the pressure or torque applied. All
bolted joints must be torqued per the values in
appendix A — target torque values.
—
06 CT shorting blocks
—
07 Ground busbar
connections
—
06
—
07

11INDOOR INSTALL ATION
Secondary and control connections
The switchgear was wired in the factory in
accordance with the project-specific connection
diagrams. Refer to project-specific drawings for
locations of the incoming and outgoing wiring
terminal blocks.
Openings in the side of the switchgear in the
low voltage/instrument compartment area allow
control connections between sections. When
shipped in groups of several frames each, the
factory installs interconnection wiring between
shipping splits. The factory then disconnects and
tags one end of each of the connections, then pulls
the wire bundle back across the split within the
adjacent frame. Reconnect these interconnections
according to the project-specific connection
diagrams after the equipment shipping sections
are installed in place.
Primary cable connections
Area for connection of primary cables is provided
in the cable compartment either through the roof
or floor as indicated in the general arrangement

aluminum — these plates must be used in the final
assembly. Holes for entrance of power cables or
conduits must be cut in the gland plate(s) and a
sealing type bushing used. ABB recommends using
O-Z/Gedney sealing bushings for all installations.
Warning: Sealing bushings are
required for all power cable entries.
Connection to control source
The control source wiring should be properly sized
to support the requirements of the control circuit.
Connect the control source leads to the terminal
blocks as indicated on the project connection
diagrams.
Warning: Route secondary power
and control wiring through the
provided routes.
Use rubber grommets cut with
appropriate size center hole to
accommodate the wiring bundle.
Check electrical phasing before
connecting.
Circuit breaker: lockout, insertion and removal
Notice: Remove foreign objects,
tools, debris and obstructions from
inside the module before inserting
breaker.
Circuit breakers may ship separately. Remove
the plywood cover over the breaker that is securely
attached to the pallet (figure 8). Untighten both
clamp screws from the pallet (figure 9). Refer to
the breaker instruction manual for more details.
—
08 Breaker on pallet
—
09 Clamp screws
—
08 —
09

12 RELIAGEAR®ND ANSI NARROW DESIGN METAL-CLAD SWITCHGEAR
—
12
—
Indoor installation
All Vmax/A circuit breakers of the same rating
are interchangeable.
Circuit breakers have two positions in the housing
— TEST/DISCONNECTED and CONNECTED.
1. The DISCONNECT position disengages the main
disconnecting devices and the control contacts
on the breaker. The primary contacts are a safe
distance from the stationary contacts located
in the circuit breaker compartment.
2. The TEST position is available by connecting
the umbilical plug to its receptacle in the
switchgear. The TEST position disengages
the main disconnecting devices. This position
allows operation of the circuit breaker for
testing.
3. The CONNECTED position engages the main
and control disconnecting devices on the
breaker.
Mechanical interlocks prevent moving a circuit
breaker from one position to another unless the
circuit breaker is open. The interlocks also prevent
closing of the breaker between positions.
Locking out the circuit breaker
The circuit breaker may be locked out by padlocking
both the racking port and door handle. It is
recommended to use flat lockout hasps on both
provisions (figure 10).
Insertion
1. Open the breaker module door completely
(figure 11). Door stops, if available, can be
used to keep the door in position when
operating the equipment.
2. Use the lift truck for breakers to be installed
in the upper compartment, or non-roll on floor
equipped breakers in the lower compartment.
With the lift truck platform at ground level and
the foot brake engaged (figure 12), push the
interlock release handles on the breaker
inward and roll the breaker onto the lift truck.
Roll completely onto the platform until the
locking tabs engage the locking slot (figure 13,
figure 14).
3. Raise the lift truck platform slightly
(approximately 1") by cranking the winch or
stepping on the foot pedal (figure 15, figure 16).
Release the foot brake and push the lift truck
towards the breaker cubicle (figure 17).
—
10 Isometric view
of circuit breaker
door and available
lockout provisions
—
11 Breaker module
with open door
—
12 Lift truck foot
brake and release
—
11
—
10
Lockout provisions
Foot brake
release Foot brake

13INDOOR INSTALL ATION
—
13 Breaker locking
tab and interlock
release handle
—
14 Breaker lift truck
pan side view
—
15 Breaker lift
truck winch
—
16 Lift truck foot pedal
—
17 Lift truck
holding Vmax/A
—
15
—
13
—
16
Breaker
locking tab Interlocking release handle
—
14
Locking slots
—
17

14 RELIAGEAR®ND ANSI NARROW DESIGN METAL-CLAD SWITCHGEAR
—
Indoor installation
Warning: Engage breaker locking
tabs with locking slot BEFORE raising
the platform.
4. Align the lift truck with the front of the frame
and push the lift truck near the frame. Refer
to figure 18. Insert the platform hooks into
the bottom set of slots and use the outer slit
in the platform hooks for floor-rolling circuit
breakers. Insert the platform hooks into the top
set of slots and use the inner slit in the platform
hooks for non-floor rolling circuit breakers.
Make adjustments as needed by using the winch
or the lift truck lowering valve (figure 19). The
truck platform should be horizontal, secured
and aligned with the floor or rails in the module.
Set the foot brake.
5. Release the circuit breaker from the lift truck by
pulling both module interlock release handles
toward the center of the breaker simultaneously.
6. Push the circuit breaker straight into the
module. Keep the breaker as level as possible.
Do not raise or lift the circuit breaker.
7. Align the breaker locking tabs with the module
interlock slots (figure 20).
8. Engage the breaker locking tabs by returning
the handles to their outward position.
9. Verify that the handles are fully outward and the
breaker locking tabs have engaged fully into the
module interlock slots. The circuit breaker will
not rack into the CONNECT position if the
module interlock tabs are not properly engaged
with the frame.
10. Release the foot brake and move the lift truck
away from the frame. Lower the lift truck
platform immediately. The circuit breaker is now
in the DISCONNECTED position (figure 21).
—
18 Front view of circuit
breaker compartment
interface
—
19 Lift truck
lowering valve
—
20 Breaker module
with module interlock
slot shown
—
19
—
18
—
20
Module interlock slot

15INDOOR INSTALL ATION
—
21 Vmax/A in
disconnect position
—
22 Vmax/A in
test position
—
23 Racking tool inserted
into racking port
—
21
—
22
TEST position:
1. From the disconnect position, the circuit
breaker can be placed into the TEST position,
by inserting the umbilical cord plug into the
receptacle (figure 22).
To rack from the TEST position to the
CONNECTED position:
2. Close the circuit breaker door. If a door stop
was used, the door may be released by lifting
the bar — the hardware will then move along
the track.
3. Move the racking port padlock provision into
the open position.
4. Engage the racking screw with the racking
tool and rotate clockwise (CW) (figure 23).
5. Continue to rack the circuit breaker by
rotating the racking tool clockwise. A slight
increase in resistance indicates that the
circuit breaker is engaging the primary
contacts. When the racking screw stops, the
breaker is now in the CONNECTED position.
—
23

16 RELIAGEAR®ND ANSI NARROW DESIGN METAL-CLAD SWITCHGEAR
—
Indoor installation
Removal
To rack from the CONNECT position to the TEST
position:
Danger: DO NOT open the breaker compartment
door until the breaker is in test position.
The breaker MUST be open before starting the
removal operation.
1. Move the racking port blocking plate into the
open position.
2. Engage the racking screw with the racking tool
and rotate counterclockwise (CCW). Continue to
rotate counterclockwise from the CONNECTED
position into the TEST position.
Achieving DISCONNECTED position:
3. Open the circuit breaker door.
4. Remove the umbilical cord plug from the
receptacle to disconnect the device.
Removal from the DISCONNECTED position
with a lift truck:
1. Open the breaker compartment door.
2. Move to step 4 for floor-rolling breakers in the
bottom position.
3. Align the lift truck with the front of the frame
and push the lift truck near the frame. Insert the
platform hooks into the bottom set of slots and
use the outer slit in the platform hooks for floor-
rolling circuit breakers. Insert the platform hooks
into the top set of slots and use the inner slit in
the platform hooks for non-floor rolling circuit
breakers. The truck platform should be
horizontal, secured and aligned with the floor
or rails in the module. Set the foot brake.
4. Release the circuit breaker from the compartment
by pulling the interlock release handles toward
the center of the drawout element.
5. Pull the circuit breaker straight onto the lift
truck platform. Keep the drawout element level
as possible.
6. Align the breaker interlock tabs with the lift
truck slots. Engage the breaker interlock tabs by
returning the handles to their outward position.
7. Verify that the handles are fully outward and the
breaker interlock tabs are in the lift truck slots.
8. Raise the lift truck slightly to disengage the
platform hooks. Release the foot brake and pull
the lift truck away from the frame. Immediately
return the lift truck platform to ground level
before transport.
9. Close and latch the circuit breaker compartment
door.
Caution: Breaker interlock tabs must
engage slots in lift truck platform
before releasing foot brake and
moving lift truck.
Lower the lift truck platform before
transporting drawout modules from
upper positions.
5.11 Auxiliary modules
Drawout compartments are provided for potential
transformers (PT) and control power transformers
(CPT). Fuses can be replaced once the drawout
element is in the disconnected and withdrawn
position.
Notice: Remove foreign objects,
tools, debris and obstructions from
inside the module before inserting
breaker.
The procedure for insertion, withdrawing and
removal of auxiliary drawout elements is different
from the procedure for the circuit breaker. These
elements do not have a TEST position.
Insertion
To move the CPT or PT drawout element from the
DISCONNECTED to the CONNECTED position:
1. If provided, remove the padlock from the CPT
or PT module door and uncover the PT or CPT
module push/pull port.
2. If the PT or CPT element is withdrawn, use the
handles to push the PT or CPT element back into
the compartment to the disconnected position.

17INDOOR INSTALL ATION
—
24 Withdrawn
PT element
—
25 Front view of CPT
compartment with
secondary breaker
interlock shown
—
26 PT module door
closed and element in
disconnect position
—
27 PT push/pull tool
with extension
—
24
—
25
—
27
3. Open the CPT module door to verify the
secondary breaker, located on the CPT truck,
is in the “OFF” position. An interlock prevents
the CPT from being inserted unless the
secondary breaker is in the OFF position and
the slide moved towards the off position
(figure 25).
4. Close the CPT or PT module door (figure 26)
and insert the push/pull rod into the push/
pull port and turn the handle to release the
interlock lever. For PT or CPT elements in the
upper position, the push/pull extension may
be used to ease operation (figure 27). The
extension can be added by inserting the
extension into the push/pull tool and securing
it with a clevis pin. It can also be disassembled
for storage.
—
26
5. Push the rod into the compartment to insert the
CPT or PT element. The rod is held captive while
between disconnect and connect positions.
6. When fully inserted and connected, the rod can
be returned to its original insertion orientation
and removed from the push/pull port.
7. The secondary breaker can now be switched
to the “ON” position. To switch the secondary
breaker to the “ON” position, open the CPT
door and move the secondary breaker to the
on position. The slide will automatically move
towards the on position.

18 RELIAGEAR®ND ANSI NARROW DESIGN METAL-CLAD SWITCHGEAR
—
Indoor installation
Disconnection and withdrawal
To move the CPT or PT drawout element from the
CONNECTED to the DISCONNECTED position:
1. Remove the padlock, if provided, from the CPT
or PT module door and uncover the PT or CPT
module push/pull port.
2. Open the CPT module door and switch the
secondary breaker to the “OFF” position and
move the slide towards the off position.
3. Close the door and insert the push/pull rod into
the push/pull port. Turn the handle to release
the interlock lever.
4. Pull the rod to withdraw the CPT or PT element.
The rod is held captive while between
disconnect and connect positions.
5. When the device is fully disconnected, the
rod can be returned to its original insertion
orientation and removed from the push/
pull port.
To withdraw the CPT or PT drawout element:
6. Open the CPT or PT drawout element door.
7. The CPT or PT element can now be withdrawn
from the compartment by pulling on the
handles.
8. Fuses can be replaced in this position
(figure 28).
—
28 PT element
withdrawn with fuse
cover removed
—
28

19TESTING AND FINAL INSPECTION
—
Testing and final inspection
Testing
Danger: Disconnect the primary power source.
Do NOT exceed the listed voltages for the
voltage class of equipment under test.
Disconnect shunt connected coils such
as potential transformers.
Do NOT test sensors or relays with high voltage.
Disconnect all sensors and relays before
applying voltage.
With the system erected, assembled and
connected, perform the following 16-step process.
1. Remove all packing and shipping materials.
2. Make sure that all internal parts are clean
and dry. If moisture is present, blow dry
with warm air.
3. Remove any shipping blocks from relays.
4. Check for damaged insulation by applying
potential tests to the primary bus. Conduct
potential tests phase-to-phase and phase to
ground in accordance with “field test” values
as shown in table 1.
—
Table 1: 60 Hz, RMS, withstand voltages
(1 minute)
Rated
maximum
voltage (kV rms)
Factory test
(kV rms)
Field test
(kV rms)
DC field
test* (kV)
   none
   
* The column headed “DC field test” is a reference for those using
DC tests to verify the integrity of connected switchgear. It represents
values believed to be appropriate and approximately equivalent to
the corresponding power frequency withstand test values specified
for each voltage class of switchgear. The presence of this column in
no way implies any requirements for a DC withstand test on AC
equipment. Also, it does not imply that a DC withstand test is an

conformance tests. When making DC tests, raise the voltage to the

5. With the main circuit de-energized and
grounded, check the continuity of all circuits
after installing the circuit breakers. Energize
the control source and operate the equipment.
Indicating instruments verify the continuity
of current transformer circuits and energizing
of the main circuit.
Control circuit checkout
Danger: The breaker or cutout device
of the local control power circuit
must remain open when using a
separate control power source.
1. The preferred method to check the control
circuit is to furnish a separate temporary source
of control power of the required control voltage
rating. The temporary source must have a
properly coordinated backup protective device
in the circuit. Set the device to clear any faults
that might occur. Initially, all circuit breakers
should be in the DISCONNECT position and the
main circuit de-energized and grounded. When
AC control power is supplied from control power
transformers in the switchgear, remove all fuses
in the transformer circuits.
2. Rack and place all circuit breakers in the
DISCONNECT position.
3. Open all normal control power source
disconnects, if supplied.
4. Check each control switch or pushbutton.
Make sure that it is in the OPEN position.
5. Connect a temporary control power source to
the circuit load terminals in the switchgear.
Energize the control circuit from the temporary
control power source. Refer to the project-
specific electrical drawings for connections.
6. Place one circuit breaker into the TEST position.
When the on-off switch is in the ON position,
the charging of the closing springs of an
electrically operated circuit breaker indicates
connection to the control power.

20 RELIAGEAR®ND ANSI NARROW DESIGN METAL-CLAD SWITCHGEAR
—
Testing and final inspection
—
29 Shorting screw
locations
—
29
Final inspection
Danger: Turn off power ahead
of switchgear before performing
any inspection or maintenance
operations.
Check incoming line terminals
to verify that the equipment is
de-energized and grounded.
Check outgoing terminals to ensure
that no back-feed condition exists.
Once installed and all connections made, perform
a final check and test on the equipment and its
controls. Check for correct equipment installation
and that all connections are complete. Use extreme
care to prevent the controlled equipment from
being connected to the system while performing
preliminary tests.
7. Rack the remaining circuit breakers into the
TEST position, one at a time, and verify that
each is connected to control power.
8. Test all electrically and manually operated
breakers for closing and tripping, while they
are in the TEST position.
9. De-energize the control circuit. If AC control
power is from transformers in the switchgear,
remove the temporary separate source of
control power. Reinstall all fuses in the
transformer circuit.
10.Set all relays, regulators and other devices for
proper operation of loads. The factory does
not set the relays.
11. Remove shorting screws from the terminal
blocks in the current transformer circuits.
Store screws in the tapped holes in the corners
of the blocks.
Note: Verify the proper phasing of all main circuits
according to connection diagram.
To open the short circuiting device refer to figure
29 for shorting screw locations.
Single ratio — Refer to figure 29. Remove and store
the shorting screw (1).
Multi-ratio — Refer to figure 29. Remove the
shorting screw (1). Insert shorting screw according
to connection diagram. Do not remove the ground
screw (2).