Powell FlexGear Training manual

Instruction Bulletin - 01.4IB.26264A
FlexGear™ Low Voltage Arc Resistant
Switchgear
Equipped with GE EntelliGuard, Siemens WL, or Eaton Magnum DS
Circuit Breakers
Up to and including 635V
Powered by Safety®

Powered by Safety®
FlexGear™ Low Voltage Arc Resistant Switchgear 01.4IB.26264A
Contact Information
Powell Electrical Systems, Inc.
powellind.com
[e-mail]
Service Division
PO Box 12818
Houston, Texas 77217-2818
Tel: [phone]
Fax: [phone]

Powered by Safety®
01.4IB.26264A
Signal Words
As stated in ANSI Z535.4-2007, the signal word is
a word that calls attention to the safety sign and
designates a degree or level of hazard seriousness.
The signal words for product safety signs are
“Danger”, “Warning”, “Caution” and “Notice”.
These words are defined as:
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
!
DANGER
!
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
!
CAUTION
CAUTION, used with the safety alert symbol,
indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
CAUTION, used without the safety alert
symbol, is used to address practices not
related to personal injury.
CAUTION
NOTICE
NOTICE is used to address practices not related
to personal injury.
Qualified Person
For the purposes of this manual, a qualified
person, as stated in NFPA 70E®, is one who has
skills and knowledge related to the construction
and operation of the electrical equipment and
installations and has received safety training to
recognize and avoid the hazards involved. In
addition to the above qualifications, one must also
be:
1. trained and authorized to energize,
deenergize, clear, ground, and tag circuits
and equipment in accordance with
established safety practices.
2. trained in the proper care and use of
personal protective equipment (PPE)
such as rubber gloves, hard hat, safety
glasses or face shields, flash clothing, etc.,
in accordance with established safety
practices.
3. trained in rendering first aid if necessary.

Powered by Safety®
FlexGear™ Low Voltage Arc Resistant Switchgear 01.4IB.26264A
This page is intentionally left blank.

Powered by Safety®i
01.4IB.26264A
Contents
Ch 1 General Information ................................................................................................1
A. Scope ...............................................................................................................................................................2
B. purpoSe ............................................................................................................................................................2
c. InStructIon BulletInS AvAIlABle electronIcAlly ....................................................................................................2
Ch 2 Safety .......................................................................................................................3
A. SAfe Work condItIon .........................................................................................................................................3
B. SAfety GuIdelIneS ...............................................................................................................................................3
c. GenerAl ............................................................................................................................................................4
d. SpecIfIc .............................................................................................................................................................4
e. SAfety lABelS ....................................................................................................................................................5
Ch 3 Equipment Description ............................................................................................6
A. GenerAl ............................................................................................................................................................6
B. rAtInGS .............................................................................................................................................................7
Ch 4 Installation .............................................................................................................10
A. GenerAl ......................................................................................................................................................... 10
B. receIvInG ........................................................................................................................................................ 10
c. HAndlInG ....................................................................................................................................................... 10
1) Lifting the Switchgear ..........................................................................................................................................................11
d. StorAGe ......................................................................................................................................................... 13
e. poSItIonInG tHe flexGeAr™ .............................................................................................................................. 14
1) Drawings and Diagrams .....................................................................................................................................................14
f. prepArAtIon of floor AncHorInG for Indoor flexGeAr™ ................................................................................................14
G. GroundInG ..................................................................................................................................................... 18
H. connectIonS ................................................................................................................................................... 18
I. MAIn BuS ASSeMBly InSulAtIon ......................................................................................................................... 20
1) Applying PVC Boots ..............................................................................................................................................................20
2) Cleaning Bus Insulation .......................................................................................................................................................20
J. poWer cABleS ................................................................................................................................................. 21
k. control cABleS .............................................................................................................................................. 21
l. fIeld WIrInG precAutIonS for Arc reSIStAnt equIpMent ...................................................................................... 21
1) Adding Control Cable ...........................................................................................................................................................22
2) Removing Control Cable ......................................................................................................................................................22
M. InSertInG And reMovInG tHe cIrcuIt BreAker froM tHe cIrcuIt BreAker coMpArtMent ............................................. 23
n. InSpectIon And teStInG ..................................................................................................................................... 23
1) Inspection ................................................................................................................................................................................23
2) Testing ......................................................................................................................................................................................24

Powered by Safety®
ii
01.4IB.26264AFlexGear™ Low Voltage Arc Resistant Switchgear
Contents
Ch 5 Maintenance ..........................................................................................................25
A. GenerAl ......................................................................................................................................................... 25
B. overAll MAIntenAnce procedureS .................................................................................................................... 25
1) Equipment ...............................................................................................................................................................................26
2) Bus Insulation .........................................................................................................................................................................26
3) Mechanisms ............................................................................................................................................................................26
4) Primary Disconnect Device Contacts ...............................................................................................................................26
5) Control Contacts ....................................................................................................................................................................26
6) Secondary Wiring ..................................................................................................................................................................27
7) Mechanical Parts ...................................................................................................................................................................27
8) Ventilation ...............................................................................................................................................................................27
9) Battery and Charging Equipment .....................................................................................................................................27
10) Hardware .................................................................................................................................................................................27
11) Heaters .....................................................................................................................................................................................27
12) Records .....................................................................................................................................................................................28
c. ABnorMAl condItIonS ..................................................................................................................................... 28
Ch 6 Replacement Parts .................................................................................................29
A. orderInG InStructIonS ..................................................................................................................................... 29
B. recoMMended reneWAl pArtS .......................................................................................................................... 29

Powered by Safety®iii
01.4IB.26264A
Figures
Figure 1 Typical Powell FlexGear™ Low Voltage Arc Resistant
Switchgear Lineup ..........................................................................................8
Figure 2 Removing the Circuit Breaker from the Switchgear ......................................9
Figure 3 Switchgear on Lifting Crane ........................................................................11
Figure 4 Chain/Cable Sling Installation .....................................................................12
Figure 5 Base View .....................................................................................................15
Figure 6 Side View ......................................................................................................16
Figure 7 Ground Bus Splice Bolt Assembly ................................................................19
Figure 8 Typical Channel-Type Main Bus Splice Connection .....................................19
Figure 9 Plenum Vent .................................................................................................23
Figure 10 Arc Flash Preventers .....................................................................................24

Powered by Safety®
iv General Information
01.4IB.26264AFlexGear™ Low Voltage Arc Resistant Switchgear
Tables
Table A FlexGear™Ratings ................................................................................................7
Table B FlexGear™ Dimensions .......................................................................................16
Table C Bolt Torque Values for Powell FlexGear™ ..........................................................20
Table D Accessories .........................................................................................................30

Powered by Safety®1
General Information
01.4IB.26264A
Ch 1 General Information
!
WARNING
The equipment described in this document may contain high voltages and currents which can
cause death or serious injury.
The equipment is designed for use, installation, and maintenance by knowledgeable users of such
equipment having experience and training in the field of high voltage electricity. This document and all
other documentation shall be fully read, understood, and all warnings and cautions shall be abided by. If
there are any discrepancies or questions, the user shall contact Powell immediately at 1.800.480.7273.
!
WARNING
Prior to adjustments, servicing, maintenance, or any act requiring the operator to make physical
contact with the equipment, the power source must be disconnected and the equipment grounded.
Failure to do so may result in death or serious injury.
NOTICE
The information in this instruction bulletin is not intended to explain all details or variations of the
Powell equipment, nor to provide for every possible contingency or hazard to be met in connection
with installation, testing, operation, and maintenance of the equipment. For additional
information and instructions for particular problems, which are not presented sufficiently for the
user’s purposes, contact Powell at 1.800.480.7273.
Powell reserves the right to discontinue and to change specifications at any time without incurring
any obligation to incorporate new features in products previously sold.
NOTICE

Powered by Safety®
2General Information
01.4IB.26264AFlexGear™ Low Voltage Arc Resistant Switchgear
A. Scope
The information in this instruction bulletin
describes the Powell FlexGear™ low voltage arc
resistant metal-enclosed switchgear assemblies
equipped with any of the following:
• GE EntelliGuard - 800-5000A Continuous
Current rating
• Siemens WL - 800-5000A Continuous
Current rating
• Eaton Magnum DS - 800-4000A Continuous
Current rating
The equipment described is indoor type
switchgear for applications up to and including
635 Volts.
Standard construction details are provided in
the appropriate sections. The circuit breaker
operation and maintenance instructions can
be found in its instruction manual provided
with each circuit breaker. Any special
switchgear construction details are provided in
supplementary documentation.
B. purpoSe
The information in this instruction bulletin
is intended to provide details required to
properly operate and maintain the low voltage
arc resistant switchgear with either
GE EntelliGuard, Siemens WL, or Eaton
Magnum DS circuit breakers.
This instruction bulletin provides:
1. Safety guidelines
2. General descriptions of the operation
and maintenance of the low voltage arc
resistant switchgear
3. Instructions for installation of the
switchgear.
4. Information for ordering renewal parts
5. Illustrations, photographs, and description
of the switchgear. Refer to the instruction
manual provided with the circuit breaker
for details on the circuit breaker operation.
The illustrations contained in this document
may not represent the exact construction
details of each particular type of switchgear
section. The illustrations in this document
are provided as general information to aid in
showing component locations only.
All illustrations and photos are shown using
deenergized equipment.
Follow the appropriate safety precautions
while handling any of the equipment. Failure
to do so may result in death or serious injury.
!
WARNING
To the extent required, the products described
herein meet the applicable ANSI, IEEE, and
NEMA Standards; however, no such assurance
is given with respect to local codes and
ordinances which may vary greatly.
c. InStructIon BulletInS AvAIlABle electronIcAlly
Changes to the instruction bulletin may
be implemented at any time and without
notice. Go to powellind.com to ensure use of
the current instruction bulletin for Powell
equipment.
NOTICE
For more information visit powellind.com.
To contact the Powell Service Division call
1.800.480.7273 or 713.944.6900, or email
[email protected]om.
For specific questions or comments pertaining
to this instruction bulletin email
[e-mail] with the IB number
in the subject line.