ABB SmartRack MV User manual

— SmartRack™ MV Remote racking device
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INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL
SmartRack™ MV
Remote racking device

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Table of contents
04 Warranty and general information
05 Safety notices
06 Introduction
07 – 08 Receiving and storage
09 – 10 General description
11 Operation of device
16 Maintenance
17 Compatible devices
18 Specifications
19 – 20 Installation of SmartRack™ MV
adapter plate
21 PLC controller error codes
22 Renewal parts reference

4SMARTRACK™ MV REMOTE RACKING DEVICE
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Warranty and general
information
Read the following hazard classifications carefully,
and fully inspect the equipment for any identifiable
hazards prior to installation, operation,
or maintenance. The following classifications listed
below will appear throughout this document
or on labels located on the equipment. These are
standard symbols defined by ANSI Z535.4-2011
which were established for recognition of potential
hazards which pose risk to life and property.
The classification is based on the probability
and severity of injury if the hazard is not avoided.
Please follow instructions, warnings, labels,
and codes for proper installation, operation,
and maintenance of equipment and devices. Only
Qualified Persons, as defined by NFPA 70, should
provide installation, operation, and maintenance
on this equipment and devices.
This is 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
that, if not avoided, could result in death
or serious injury.
Caution: Indicates that if the hazard is not avoided
could result in minor or moderate injury.
Notice: Is used to notify of practices not related
to personal injury.
Trademarks
Emax 2®
Emax 2 Ekip®
ReliaGear® LV SG
All third-party trademarks are the property of their
respective owners.
Warranty
This document is based on information available
at the time of publication. While efforts have been
made to ensure accuracy, the information
contained herein does not cover all details
or variations in hardware and software, nor does
it provide for every possible contingency
in connection with installation, operation,
and maintenance. Features may be described
herein that are not present in all hardware and
software systems.
ABB assumes no obligation of notice to holders
of this document with respect to changes
subsequently made. ABB makes no representation
or warranty, expressed, implied, or statutory, with
respect to, and assumes no responsibility for the
accuracy, completeness, sufficiency, or usefulness
of the information contained herein.
No warrantees of merchantability or fitness for
purpose shall apply. Contact your local sales office
if further information is required concerning any
aspect of ReliaGear LV SG switchgear and Emax 2
breaker operation or maintenance.
DANGER
WARNING
CAUTION
NOTICE
DANGER
WARNING
CAUTION
NOTICE
DANGER
WARNING
CAUTION
NOTICE
DANGER
WARNING
CAUTION
NOTICE
DANGER
WARNING
CAUTION
NOTICE

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 5
Device specific
Warning: SmartRack™ MV remote
racking device incorporates
components, such as the DC power
supplies, which could contain stored
energy. Under no circumstances
should the protective covers on any
component of the device be removed.
Never tamper with, modify, or otherwise alter
the mechanical components, electronics, or control
software of the racking device. Failure to comply
could cause the device to fail resulting
in equipment damage or personal injury.
Never disconnect any of the cables from connected
components while the device is powered. Always
turn off the device and disconnect it from its power
source before attempting to unplug the data cables.
Do not open a cabinet door with SmartRack™ MV
attached. This could damage the racking device
coupling or circuit breaker truck. Always properly
remove the Motor Box using the rotary latch before
attempting to open the cabinet door.
SmartRack™ MV remote racking device is only
intended for use with switchgear breakers,
auxiliary devices such as PT or CPT drawout truck
and Model 2 MCC contactors listed in the
Compatible Devices section of this instruction
manual. ABB makes no claims to compatibility
regarding unlisted devices.
General
Always follow your company’s safety guidelines.
Wear appropriate Personal Protective
Equipment (PPE).
This product is intended to be operated and
maintained by qualified persons thoroughly trained
and knowledgeable of the hazards involved. This
publication is written only for such qualified
persons and is not intended to be a substitute for
adequate training and experience in the safety
procedures for this device.
Detailed descriptions of standard repair
procedures, safety principles, and service
operations are not fully elaborated in this
instruction book. It is important to note that this
document contains some warnings and cautions
against some specific service methods that could
cause personal injury to service personnel, or could
damage equipment or render it unsafe. These
warnings do not cover every conceivable method in
which service (whether or not recommended
by ABB) may be performed.
Secondly, ABB cannot predict or investigate all
potential hazards resulting from all conceivable
service methods. Anyone using service procedures
or tools, whether or not recommended by ABB, must
satisfy himself thoroughly that neither personal
safety nor equipment safety will be jeopardized by
the service method or tools selected.
All information contained in this manual is based
on the latest product information available at the
time of printing. ABB reserves the right to make
changes at any time without notice.
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Safety notices
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01
Personal Protective
Equipment
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01
DANGER
WARNING
CAUTION
NOTICE

6SMARTRACK™ MV REMOTE RACKING DEVICE
Additional product support
For additional product support and details not
covered in the content of this instruction manual,
please contact your local sales representative.
The SmartRack™ MV remote racking device is able
to perform this complex task through the use of a
programmable logic controller and servomotor.
Throughout operation, the controller and motor are
in constant communication allowing the device to
accurately position a circuit breaker or other device
in the switchgear cell. The racking device
incorporates an actuator to operate the interlock
lever which eliminates need for an additional unit to
perform this task or for additional manual
interaction.
Overview
SmartRack™ MV remote racking device is intended
to assist technicians with the process of racking
medium voltage circuit breakers and associated
equipment. The main function of the device is to
perform the racking operation with minimal manual
interaction. This allows the operator of the device
to maintain a significant distance between
themselves and the circuit breaker while racking
is performed as compared to the traditional hand-
crank method of racking.circuit breaker while
racking is performed as compared to the
traditional hand-crank method of racking.
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02
SmartRack™ MV
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02
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Introduction

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 7
Receiving inspection
Upon receiving SmartRack™ MV, carefully unpack
the device from its box and check for the following
components which are fully furnished in the
assembled unit:
Should any parts be missing, please contact your
ABB sales representative.
Next, plug the device into an appropriate source
of power. See the Electrical Specifications section
for power requirements. With the device plugged
in, locate the On/Off switch on the top of the cart
and turn it to the On position. Both the green
indicator lights should illuminate. The lights show
incoming power to the device and the status of the
main power supply.
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Receiving and storage
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Table 1: Receiving inspection
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03
On switch and
indicator lights
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04
Start-up screen
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03
Locate the Remote Control Box and make sure the
screen of the controller is properly displaying the
start-up screen as shown in Figure 5 below. If the
screen does not appear or does not look like Figure 5,
check all cable connections. If the start-up screen
does not appear after checking the connections,
do not use SmartRack™ MV and contact ABB
product support.
Handling the device
Plastic handles have been provided at multiple
places on the device to facilitate handling. These
should be used whenever possible to avoid
damage.
The cart includes a swinging push/pull bar with
plastic grip.
Component Quantity
Cart 1
Motor Box 1
Control Box 1
25 or 50ft. Connection Cable 2
Power Cable 1
Fuse 2
Socket Extension 1
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04
SmartRack MV

8SMARTRACK™ MV REMOTE RACKING DEVICE
The Control Box incorporates two plastic handles
for lifting and for use while operating the device.
The control housing should never be picked up or
held by the cord.
The Motor Box has three plastic handles that are
located on either side and one in the rear to assist
the operator in the installation and removal of the
motor box to the mounting adapter plate. The
Motor Box should never be lifted by the protruding
hex socket or by the cord.
Storing the device
SmartRack™ MV must be stored indoors in a cool,
dry, dust-free place away from sunlight. During
periods of non-use SmartRack™ MV should be
covered to protect from accumulation of dust and
keep sunlight off the controller screen. The device
should be stored in an environment that meets the
temperature and humidity specifications shown in
Section Environmental Specifications.
SmartRack™ MV cart is intended to store and
transport all the components of the device. It is
good practice to always return the power, control,
and motor cables to their respective sections of
the cart, replace the Control Box to its spot, and
latch the Motor Box to the provided bracket.
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05
Cart handle
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06
Control box handles
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07
Motor box handles
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08
Properly stored
SmartRack™ MV
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05
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07
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08
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06

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 9
Using the cart
Upon arrival, motor box, and control box will be
secured to the cart. All wiring and cables will be
inside of the cart.
The cart brakes need to be locked whenever the
cart is to be parked. Move the cart by disengaging
the brakes, lifting the handle, and pulling the cart.
Apply the brakes located behind the back wheels.
Connect the power cable, turn the power switch on,
and then follow the prompts on the control box.
After using the device, return the motor box and
control box to the original locations and replace the
cables to their original position within the cart.
Be sure to store the cart in a safe place and engage
the brakes when parking the cart.
Motor box
The motor box has a motor, gearhead, coupling,
and interlock actuator inside. The box is secured on
the door and cart using the rotary latches on the
sides of the motor box. There is one connector on
the back of the box, which is connected to the
actuator and the motor. There is also a three-color
indicator light on the back of the box, indicating an
idle state (green), the device in operation (yellow),
or an error (red).
The motor box has a socket protruding from the
motor, which connects to the end of the racking
screw. The socket can be removed and replaced
if required.
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General description
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09
Wheels and brake lever
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10
Indicator light
and connector
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09
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10

10 SMARTRACK™ MV REMOTE RACKING DEVICE
The motor box has three handles to lift and
position the box. The operator should not use any
other method to mount the motor operator on the
mounting plate.
Control box
The control box consists of aluminum housing with
two handles on the sides, one handle on the rear
and a connector on the back, enclosing a pre-
programmed PLC/HMI controller. The controller is
connected to the cart by a standard length 25 foot
cable, allowing the operator to move to a safe
distance before operating SmartRack™ MV.
The controller will give instructions and feedback
to the operator throughout the process.
Optional equipment
Cable extension
SmartRack™ MV can be equipped with a 25 foot
long optional extension cable (2RGA015184A0001)
connecting the standard controller cable to the
controller. This provides additional distance
between the operator and the racking operation as
well as providing an extra measure of safety.
63kA socket
If racking 63kA switchgear, or if a custom door has
been installed on the switchgear, the additional
socket provided can be pinned to the drive. Remove
the standard socket by removing the screw, replace
the standard socket with the socket extension, and
use the same screw to secure the longer socket in
the hole on the drive closest to the face of the
motor box. The 63kA socket is a 16mm with a 3/8
drive and is 2 ¼ inches long.
ReliaGear ND socket
If racking ReliaGear ND switchgear, or if a custom
door has been installed on the switchgear, the
additional socket adapter provided can be attached
to the drive. The ReliaGear ND adapter is
approximately 4 inches long with a hex head on one
side and a square drive on the other. To install, insert
the socket adapter into the racking tube of the
switchgear and align it with the racking screw of the
breaker. The adapter is properly engaged when you
can push the adapter and depress the racking
interlock on the breaker truck. The adapter should
return to its initial position when you remove
pressure. Proceed with the installation process of the
motor box in the Operation of device/Set-up section.
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11
Racking socket on
motor box
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12
Control box
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13a
Racking extended
socket for 63kA
13b
Extension socket
for ReliGear ND
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11
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12
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13a
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13b