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.

Powered by Safety®3
Safety
01.4IB.26264A
Ch 2 Safety
A. SAfe Work condItIon
The information in Section A is quoted from
NFPA 70E 2012 - Article 120, 120.1 Establishing an
Electrically Safe Work Condition.
120.1 Process of Achieving an Electrically Safe
Work Condition
1. Determine all possible sources of electrical
supply to the specific equipment. Check
applicable up-to-date drawings, diagrams,
and identification tags.
2. After properly interrupting the load current,
OPEN the disconnecting device(s) for each
source.
3. Wherever possible, visually verify that all
blades of the disconnecting devices are
fully OPEN or that drawout type circuit
breakers are withdrawn to the fully
disconnected position.
4. Apply lockout/tagout devices in accordance
with a documented and established policy.
5. Use an adequately rated voltage detector
to test each phase conductor or circuit part
to verify they are deenergized. Test each
phase conductor or circuit part both
phase-to-phase, and phase-to-ground.
Before and after each test, determine
that the voltage detector is operating
satisfactorily.
Informational Note: See ANSI/ISA-61010-1
(82.02.01)/UL 61010-1, Safety Requirements
for Electrical Equipment for Measurement,
Control, and Laboratory Use - Part 1: General
Requirements, for rating and design
requirements for voltage measurement
and test instruments intended for use on
electrical systems 1000 V and below.
6. Where the possibility of induced voltages
or stored electrical energy exists, ground
the phase conductors or circuit parts
before touching them. Where it could be
reasonably anticipated that the conductors
or circuit parts being deenergized
could contact other exposed energized
conductors or circuit parts, apply ground
connecting devices rated for the available
fault duty.
B. SAfety GuIdelIneS
Study this instruction bulletin and all other
associated documentation before installing the
switchgear.
Each user has the responsibility to instruct
and supervise all personnel associated with
usage, installation, operation, and maintenance
of this equipment on all safety procedures.
Furthermore, each user has the responsibility of
establishing a safety program for each type of
equipment encountered.
The low voltage circuit breakers used in the
metal-enclosed switchgear described in this
instruction bulletin are operated by a
high-energy, high-speed mechanism that
is interlocked to provide specific operating
sequences. It is mandatory that the following
rules be observed to ensure the safety of
personnel associated with usage, installation,
operation, and maintenance of these circuit
breakers.
The safety rules in this instruction bulletin are
not intended to be a complete safety program.
The rules are intended to cover only some of the
important aspects of personnel safety related
to Powell FlexGear™ low voltage arc resistant
switchgear.

Powered by Safety®
4Safety
01.4IB.26264AFlexGear™ Low Voltage Arc Resistant Switchgear
c. GenerAl
1. Only qualified personnel trained in
the usage, installation, operation, and
maintenance of the circuit breaker shall
be allowed to work on this equipment. It
is mandatory that this instruction bulletin,
the applicable circuit breaker manual, any
supplements, and service advisories be
studied, understood, and followed.
2. Maintenance programs must be consistent
with both customer experience and
manufacturer’s recommendations,
including service advisories and instruction
bulletin(s). A well planned and executed
routine maintenance program is essential
for the equipment’s reliability and safety.
3. Service conditions and circuit breaker
applications shall also be considered in the
development of safety programs. Variables
include ambient temperature; humidity;
actual continuous current; thermal cycling;
number of operations; interrupting duty;
and any adverse local conditions including
excessive dust, ash, corrosive atmosphere,
vermin and insect infestations.
d. SpecIfIc
1. DO NOT WORK ON ENERGIZED
SWITCHGEAR. If work must be performed
on the switchgear, remove it from service
and place it in an electrically safe condition.
2. DO NOT WORK ON THE SWITCHGEAR
WITH THE CONTROL CIRCUIT ENERGIZED.
3. EXTREME CARE MUST BE EXERCISED
TO KEEP ALL PERSONNEL, TOOLS, AND
OTHER OBJECTS CLEAR OF MECHANISMS
WHICH ARE TO BE OPERATED,
DISCHARGED, OR RELEASED. These
circuit breakers utilize stored energy
mechanisms. These mechanisms must be
serviced only by skilled and knowledgeable
personnel capable of releasing each spring
load in a controlled manner. Detailed
information regarding these mechanisms
is found in the appropriate circuit breaker
instruction bulletin.
4. DO NOT ATTEMPT TO CLOSE THE CIRCUIT
BREAKER MANUALLY ON AN ENERGIZED
CIRCUIT.
5. DO NOT USE AN OPEN CIRCUIT BREAKER
AS THE SOLE MEANS OF ISOLATING A
HIGH VOLTAGE CIRCUIT. For complete
isolation, the circuit breaker shall be in
the disconnected position or shall be
withdrawn completely.
6. ALL COMPONENTS SHALL BE
DISCONNECTED BY MEANS OF A VISIBLE
BREAK AND SECURELY GROUNDED FOR
SAFETY OF PERSONNEL PERFORMING
MAINTENANCE OPERATIONS ON THE
SWITCHGEAR.

Powered by Safety®5
Safety
01.4IB.26264A
e. SAfety lABelS
The equipment described in this document
has DANGER, WARNING, CAUTION, and
instruction labels attached to various locations.
All equipment DANGER, WARNING, CAUTION,
and instruction labels shall be observed when
the circuit breaker is handled, operated, or
maintained.
Warning and Caution labels are located in
various places. Do NOT remove or deface any
of these warning/caution labels.
NOTICE

Powered by Safety®
6Equipment Description
01.4IB.26264AFlexGear™ Low Voltage Arc Resistant Switchgear
Ch 3 Equipment Description
A. GenerAl
Powell is committed to continuous product
improvement. It is possible that improvements
occurred between revisions to this document
and therefore, may not be described in these
instructions. If the equipment does not
resemble the photographs and descriptions
contained herein, do not attempt to perform
the actions. Contact the Powell Service
Division.
NOTICE
Powell FlexGear™ Low Voltage Arc Resistant
Metal-Enclosed Switchgear described in
this bulletin is designed to comply with IEEE
Standard C37.20.1 (Standard for
Metal-Enclosed Low Voltage Power Circuit
Breaker Switchgear) and IEEE C37.20.7 (Guide
for Testing Metal-Enclosed Switchgear for
Internal Arcing Faults). The metal-enclosed
switchgear is a lineup of one or more
switchgear vertical sections, which are
enclosed on all sides, top, and bottom except
for the ventilation openings, lower unit
cable penetrations, and view windows. The
switchgear sections consist of full depth
structural frames and components providing
separate compartments for circuit breakers,
buses, cable and auxiliary components.
Powell FlexGear consists of multiple sections,
fastened together as a single group (Figure 1).
It is completely operational when installed and
connected directly to the customers’ power
supply. Circuit breaker compartments
(Figure 2, g) are provided with lift-off hinged
access doors for installing or removing the
circuit breakers. Auxiliary compartments
(Figure 2, d) are provided with lift-off hinged
access doors for mounting and maintenance
of instruments, relays, and wiring. An overhead
breaker lifting device (Figure 2, a) is provided as
an option.
Powell Flexgear low voltage arc resistant
switchgear is complex, high-current electrical
equipment designed to operate within the
voltage and current limitations shown on
the equipment nameplate. Do not apply this
equipment to systems with voltages and/or
currents in excess of these limits.
The equipment has been designed to operate
within the customers’ specifications with
regard to circuit capacity.

Powered by Safety®7
Equipment Description
01.4IB.26264A
B. rAtInGS
Table A FlexGear™Ratings
Maximum
Voltage
(Volts)
Continuous
Current Rating
(Amperes)
Arc Fault
Current
(kA)
Short Time Current Short Circuit Current
Main Bus
(kA)
Riser Bus
(kA)
Main Bus
(kA)
Riser Bus
(kA)
635 800-5000 85(.5s) 85 85 100 85
Notes: 1. For specific circuit breaker ratings refer to the appropriate manufacturer’s application guide.
2. Eaton Magnum DS up to 4000A Continuous Current Rating.

Powered by Safety®
8Equipment Description
01.4IB.26264AFlexGear™ Low Voltage Arc Resistant Switchgear
Figure 1 Typical Powell FlexGear™ Low Voltage Arc Resistant Switchgear Lineup

Powered by Safety®9
Equipment Description
01.4IB.26264A
Figure 2 Removing the Circuit Breaker from
the Switchgear
a. Powell Overhead Lifting Device
b. Overhead Lifting Device Handle
c. Overhead Lifting Device Cable
d. Instrument Compartment
e. Lifting Device Yoke
f. Circuit Breaker
g. Circuit Breaker Compartment
a
d
f
b
c
e
g
The arc resistant rating is only valid when
all doors are closed and properly latched or
bolted, and components are installed and
working properly. In addition, removal of
any breaker from its compartment without
reinstalling a circuit breaker maintenance
cover will void the arc resistant rating.
!
DANGER
Note: Circuit breaker maintenance covers for
compartments not equipped with circuit
breakers are not shown for illustrative
purposes only.

Powered by Safety®
10 Installation
01.4IB.26264AFlexGear™ Low Voltage Arc Resistant Switchgear
Ch 4 Installation
Contact the Powell Service Division for installation,
maintenance, and renewal parts assistance. To
contact the Powell Service Division call
1.800.480.7273 or 713.944.6900,
or email [email protected]om.
It is the responsibility of the purchaser to set
or program components such as protective
relays, meters, timers, etc., in accordance with
the requirements of the particular installation,
before placing the switchgear with vacuum circuit
breakers into service. Programmable devices may
be shipped with temporary programming, used to
test the switchgear. Electromechanical relays may
be shipped in a blocked position to avoid damage
during shipment. Refer to separate instructions for
these components for information on setting or
programming.
A. GenerAl
This section contains information on receiving,
handling, positioning, power cable termination,
grounding, and checks to make the equipment
ready for operation.
Once the assembly of the metal-enclosed
switchgear is completed on site, all joints and
hardware, including bus connections, structural
assemblies, and control connections, should
be checked for tightness and proper torque
values. See Table C, Bolt Torque Values for Powell
FlexGear™.
B. receIvInG
Powell FlexGear™ is fabricated in rigid,
floor-mounted, self-supporting steel vertical
sections. The switchgear vertical sections
are shipped in an upright position and when
received should be kept upright.
When the switchgear is received, check for
signs of damage. If damage is found or
suspected, file claims as soon as possible with
the transportation company and notify the
nearest Powell representative.
Refer to the instruction bulletin furnished with
the circuit breaker for receiving, handling, and
storage instructions on the circuit breaker.
Some components such as top-mounted
resistors or potential transformers, may be
shipped separately. These components are
identified by a number coinciding with that of
the switchgear vertical section on which they
are to be mounted.
c. HAndlInG
Powell recommends the switchgear be
handled or moved by means of an overhead
crane. If an overhead crane is not available the
switchgear may be moved on an even surface
by the use of rollers or heavy duty pipes placed
under the switchgear. The use of a forklift
is not recommended, since the forks may
damage the compartments or interior parts
of the switchgear vertical sections. If no other
method of handling is available, the forks must
go completely under the switchgear base to
avoid damage to the switchgear.
The switchgear is shipped with the circuit
breakers installed unless other instructions
are given. If the circuit breakers are shipped
installed, they are done so in the open and fully
connected position. Refer to the appropriate
publication shipped with the device for
removal instructions of the circuit breakers.

Powered by Safety®11
Installation
01.4IB.26264A
1) Lifting the Switchgear
The maximum shipping section width is
102 inches. The equipment should be lifted
using an appropriately rated overhead
crane. The equipment should be lifted one
shipping section at a time or a maximum
total weight of 10,000 lbs. Lifting rings are
permanently attached at the front and rear
corners of the center compartment of each
section. Four lift points shall always be
used when lifting the switchgear
(Figure 3). If lifting a single section, then
three lift points are available. It is important
to note that when a spreader bar is not
being used that each lift chain/cable when
loaded maintain at least a 45°angle from
the horizontal plane (Figure 4).
Note: At 45° the force on each lifting
chain/cable is equal to the total load
divided by four divided by 0.707
making each less efficient. Angles less
than 45°can damage the switchgear.
Note: The customer is responsible for
providing the spreader bar.
Figure 3 Switchgear on Lifting Crane

Powered by Safety®
12 Installation
01.4IB.26264AFlexGear™ Low Voltage Arc Resistant Switchgear
Figure 4 Chain/Cable Sling Installation
45˚ 45˚
1
45˚ 45˚
12
45˚ 45˚
123
Minimum
Minimum
Minimum