Powell PV 38 IB-51807 User manual

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IB-51807
PV System 38® Remote Racking Device
Mechanical Connection

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IB-51807
PV System 38® Remote Racking Device
Mechanical Connection
Contact Information
Powell Electrical Systems, Inc.
www.powellind.com
[e-mail]
Service Division
PO Box 12818
Houston, Texas 77217-2818
Tel: [phone]
Fax: [phone]

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IB-51807
Signal Words
As stated in ANSI Z535.4-2002, § 4.13-4.13.3 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”, and
“Caution”. These words are defined as:
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
DANGERDANGER
!
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
WARNINGWARNING
!
CAUTIONCAUTION
!
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
Not stated in ANSI Z535.4-2002, § 4.13-4.13.3
as a signal word but used in this manual is
“IMPORTANT”. This is defined as:
IMPORTANT indicates a section of the manual
covering a non hazardous situation, but
one where Powell feels proper attention is
warranted.
IMPORTANTIMPORTANT
!
Qualified Person
For the purposes of this manual, a qualified person,
as stated in NFPA 70®, is one familiar with the
construction and operation of the equipment and
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.

Ch 1 General Information ................................................................................................1
A. Sc o p e ...............................................................................................................................................................2
B. pu r p o S e ............................................................................................................................................................2
c. In S t r u c t I o n Bu l l e t I n S Av A I l A B l e el e c t r o n I c A l l y ....................................................................................................2
Ch 2 Safety .......................................................................................................................3
A. SA f e Wo r k co n d I t I o n .........................................................................................................................................3
B. SA f e t y Gu I d e l I n e S ...............................................................................................................................................3
c. Ge n e r A l ............................................................................................................................................................3
d. SA f e t y lA B e l S ....................................................................................................................................................4
Ch 3 Equipment Description ............................................................................................5
A. Ge n e r A l ............................................................................................................................................................5
B. Mo t o r co n t r o l Bo x ..........................................................................................................................................5
c. el e c t r I c rA c k I n G de v I c e ......................................................................................................................................5
Ch 4 Installation & Operation ..........................................................................................8
A. re c e I v I n G ...........................................................................................................................................................8
B. HA n d l I n G ..........................................................................................................................................................8
c. op e r A t I o n .........................................................................................................................................................8
d. In S e r t I n G t H e cI r c u I t Br e A k e r I n t o SW I t c H G e A r co M p A r t M e n t ............................................................................... 12
1) Racking Mechanism .............................................................................................................................................................12
2) Inserting the Circuit Breaker Into the Compartment ....................................................................................................12
e. re M o v I n G t H e cI r c u I t Br e A k e r f r o M t H e SW I t c H G e A r co M p A r t M e n t ....................................................................... 14
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IB-51807
Contents

Figure 1 PV System 38®Remote Racking Device .........................................................6
Figure 2 Close-up of Control Box .................................................................................7
Figure 3 Opening Racking Access Window ..................................................................9
Figure 4 Installing Remote Racking Device ...............................................................10
Figure 5 Remote Racking Device Installed ................................................................10
Figure 6 Connecting the Motor to the Control Box ...................................................11
Figure 7 Activate Remote Racking Device .................................................................11
Figure 8 Circuit Breaker in Test/Disconnect Position ................................................11
Figure 9 Circuit Breaker in Connected Position .........................................................11
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IB-51807
PV System 38® Remote Racking Device
Mechanical Connection
Figures

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General Information
WARNINGWARNING
!
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.
WARNINGWARNING
!
Before any adjustment, servicing, part replacement, or any other act is performed requiring
physical contact with the electrical working components or wiring of this equipment, the power
supply must be disconnected. Failure to follow this warning may result in injury or death.
IMPORTANTIMPORTANT
!
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.
IMPORTANTIMPORTANT
!
IB-51807
Ch 1 General Information

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2General Information
A. Sc o p e
The information in this instruction bulletin
describes the following Remote Racking
Devices for PV System 38® vacuum circuit
breakers:
• 51897G09-38kV,1200&2000
B. pu r p o S e
The information in this instruction bulletin is
intended to provide information required to
properly operate and maintain the
PV System 38 Remote Racking Devices
described in Ch 1 General Information,
A. Sc o p e .
This instruction bulletin provides:
1. Safety guidelines
2. Generaldescriptionsontheoperationof
the PV System 38 Remote Racking Device
3. Instructions for installation
4. Illustrations, photographs, and description
of the equipment described in
Ch 1 General Information, A. Sc o p e .
The illustrations in this document are provided
as general information to aid in showing
component locations only.
All illustrations are shown using deenergized
equipment.
Be sure to follow the appropriate safety
precaution while handling any of the
equipment. Failure to do so may result in
serious injury or death.
WARNINGWARNING
!
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. In S t r u c t I o n Bu l l e t I n S Av A I l A B l e el e c t r o n I c A l l y
For more information visit www. powellind .com.
To contact the Powell Service Division call
1.800.480.7273 or 713.944.6900, or email
[e-mail].
IB-51807
PV System 38® Remote Racking Device
Mechanical Connection

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Safety
Ch 2 Safety
A. SA f e Wo r k co n d I t I o n
The information in Section A is quoted from
NFPA 70E 2004 - 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.
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. SA f e t y Gu I d e l I n e S
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 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
PV System 38® Remote Racking Device.
c. Ge n e r A l
1. Only supervised and qualified personnel
trained in the usage, installation, operation,
and maintenance of the metal-clad
switchgear shall be allowed to work on
this equipment. It is mandatory that this
instruction bulletin, 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 reliability and safety.
3. Service conditions and applications shall
also be considered in the development
of safety programs. Variables include
ambient temperature; humidity; actual
continuous current; thermal cycling;
number of operations; and any adverse
local conditions including excessive dust,
ash, corrosive atmosphere, vermin and
insect infestations.
IB-51807

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4Safety
d. SA f e t y lA B e l S
Warning and Caution labels are located in
various places in and on the switchgear and
on the circuit breaker. Always observe these
warnings and caution labels. Do NOT remove
or deface any of these warning/caution labels.
IMPORTANTIMPORTANT
!
IB-51807
PV System 38® Remote Racking Device
Mechanical Connection

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Equipment Description
Ch 3 Equipment Description
A. Ge n e r A l
The PV System 38® Remote Racking Device is
an accessory which enables circuit breakers
to be racked into and out of switchgear from
a distance. The accessory consists of a motor
control box (Figure 1, h) and electric racking
deviceassembly(Figure1,a,b,c,d,&e).
B. Mo t o r co n t r o l Bo x
The motor control box (Figure 1, h) supplies
power and enables the selection of operating
modes for the electric racking device. The
motor control box has a 50 foot cord
(Figure 1, g) with a plug that is inserted into the
electric racking device twist lock power cord
receptacle (Figure 1, e). The length of the cord
enables the user to move to a remote location
from the circuit breaker during the racking in
or racking out procedures. The motor control
box power supply cord (Figure 1, f) plugs into a
110VAC outlet.
c. el e c t r I c rA c k I n G de v I c e
The electric racking device uses a hanger
bracket (Figure 1, b) to connect to the bottom
flange of the upper compartment. The drive
socket (Figure 1, c) engages the racking shaft
through the racking shaft access window
located on the switchgear between the upper
and lower doors (Figure 3). After the racking
device is installed, the motor adjustment knob
(Figure 1, d) can be turned to engage the drive
socket with the circuit breaker racking shaft.
When the racking device is connected to the
motor control box and energized, the drive
socket operates the circuit breaker racking
mechanism during the racking in or racking
out procedures.
IB-51807

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6Equipment Description
IB-51807
PV System 38® Remote Racking Device
Mechanical Connection
Figure 1 PV System 38®Remote Racking Device
b
c
d
e
g
f
h
a
a. Adjusting Screws
b. Hanger Bracket
c. Drive Socket
d. Motor Adjustment Knob
e. Power Cord Receptacle
f. Power Cord
g. Control Box Cord
h. Control Box

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Equipment Description
IB-51807
Figure 2 Close-up of Control Box
a
bc
e
f
d
a. Electrical Cord
b. In Indicator Light
c. Out Indicator Light
d. Power Switch
e. In/Out Selector Switch
f. Push Button
g. Handle
g

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8Installation & Operation
Ch 4 Installation & Operation
A. re c e I v I n G
Upon receipt, remove any shipping material
and inspect the electric racking device for
damage that may have occurred during
shipment. Check the equipment received
against the shipping documents to ensure
receipt of the complete shipment.
B. HA n d l I n G
The electric racking device weighs 20 lbs.
and the motor control box assembly weighs
5 lbs.. The preferred method for moving the
electric racking device and motor control box
is to place them securely on a hand operated
shop cart. When handling the electric racking
device, personnel should securely grasp the
device by its handle during movement and
installation to avoid possible personal injury or
damage to the electric racking device. Avoid
dropping or hitting the electric racking device
with hard objects.
Protect the motor control box and the racking
device from moisture. Failure to do so may
cause damage to the equipment.
CAUTIONCAUTION
!
Do NOT handle or carry the racking device
by the power cords. Damage to the power
connections may cause an electrical short.
The power cords should be inspected for any
signs of damage before each use.
CAUTIONCAUTION
!
c. op e r A t I o n
Do NOT work on an energized circuit breaker.
Follow circuit breaker safety guidelines and
operating instruction provided in the specific
circuit breaker instruction bulletin.
WARNINGWARNING
!
Attaching and operating the electric racking
device can be accomplished by one person.
When circuit breaker racking is required, the
electric racking device engages the racking
shaft through the access window on the
front of the switchgear. The racking device is
operated by the motor control box.
When racking in a circuit breaker, move the
circuit breaker to the required switchgear
location. Push the circuit breaker in to the
switchgear compartment until the anti-rollout
latch engages the switchgear rollout stop
block.
For more information on the circuit breaker
handling, see the instruction bulletin for the
circuit breaker in use.
IB-51807
PV System 38® Remote Racking Device
Mechanical Connection

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Installation & Operation
Figure 3 Opening Racking Access Window
IB-51807

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10 Installation & Operation
Figure 4 Installing Remote Racking Device Figure 5 Remote Racking Device Installed
IB-51807
PV System 38® Remote Racking Device
Mechanical Connection

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Installation & Operation
Figure 6 Connecting the Motor to the
Control Box
Figure 7 Activate Remote Racking Device
Figure 8 Circuit Breaker in Test/Disconnect
Position
Figure 9 Circuit Breaker in Connected Position
IB-51807

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12 Installation & Operation
d. In S e r t I n G t H e cI r c u I t Br e A k e r I n t o SW I t c H G e A r
co M p A r t M e n t
Before installing any circuit breaker into a
compartment, the user MUST verify that the
circuit breaker rating meets or exceeds the
metal-clad switchgear rating.
CAUTIONCAUTION
!
Follow the steps below to insert the circuit
breaker into the switchgear compartment:
Prior to inserting the circuit breaker into the
circuit breaker compartment, make sure that
the control circuits are deenergized.
CAUTIONCAUTION
!
Prior to inserting the circuit breaker into the
circuit breaker compartment, ensure that the
circuit breaker is OPEN and the mechanism is
discharged.
CAUTIONCAUTION
!
Before using the electric racking device verify
compliance with IB-65010A and IB-65000.
Prior to inserting a circuit breaker into the
compartment, the levering-in mechanism
must be in the “TEST/DISCONNECT” position
or damage may occur to the circuit breaker or
the switchgear.
CAUTIONCAUTION
!
1) Racking Mechanism
The racking mechanism is an integral
part of the switchgear for PV System 38®
equipment. The racking device provides a
means of moving the circuit breaker from
the “TEST” to “CONNECT” position, a means
of mechanically tripping the breaker with
the door closed, and the required safety
interlocks. The mechanism is located
directly above the circuit breaker, engaging
the circuit breaker in the center and moving
it between the “TEST” and “CONNECT”
positions smoothly. A visual indication of
the circuit breaker position is given on the
front of the racking mechanism.
2) Inserting the Circuit Breaker Into the
Compartment
To insert the circuit breaker into the
compartment:
a. Align the breaker wheels with the
enclosure floor pan channels.
b. Roll the breaker part way into the
enclosure. It will be stopped by an
interlock rod on the top left side of
the circuit breaker once it reaches the
“DISCONNECT” position.
c. Insert the secondary disconnect plug
into the socket on the circuit breaker.
The interlock rod will drop and the
secondary disconnect plug will be held
captive in the circuit breaker.
d. Roll the breaker forward to the “TEST”
position. The breaker will be stopped
by the roller on the end of the racking
shaft, which will enter the L-shaped slot
on the top of the circuit breaker.
e. The outer door of the compartment
may be closed over the circuit breaker
at this point.
IB-51807
PV System 38® Remote Racking Device
Mechanical Connection

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Installation & Operation
f. Depress the push-to-trip button and
slide the racking shaft shutter covering
the racking shaft to the left (Figure 3).
This trips the circuit breaker if it is closed
and holds it open during the racking
process.
g. Open the upper door on the cubicle.
The electric racking device is designed
to hang from the bottom flange of the
upper compartment (Figure 4). Note
the hanger is equipment with slotted
holes for adjustment (Figure 1, a) in
order to fit on standard and arc resistant
equipment. The device might need
adjustment to achieve alignment.
Lower the device over the flange and
position the drive socket on the electric
racking device over the levering-in shaft
(Figure 4). Turn the red knob on the
back of the electric racking device until
the socket engages the racking shaft.
Close and latch the upper compartment
door and latch it to capture the hanger
bracket.
h. Insert the cylindrical plug into the
remote racking device outlet (Figure 6).
Lock the plug by turning it clockwise.
i. Ensure the control box power switch is
in the “OFF” position.
j. Connect the device to a 120VAC power
source.
k. Move the power switch to the “ON”
position.
l. Move the selector switch on the push
button to the“IN” position.
Note: The housing on the push button is a
switch, and can be rotated to either
the “IN” or “OUT” positions.
m. Physically move the motor control
box to a remote area and operate the
electric racking device.
n. To begin racking the circuit breaker into
the compartment, depress the push
button on the control box (Figure 7).
Note: If the push button is released during
operation the motor will stop.
o. When the push button is depressed, the
“IN” indicating light (Figure 2, b) will be
energized and illuminated.
p. When the circuit breaker is fully racked
IN, the remote racking device torque
limiter will begin to slip and there will
be a clear clicking sound along with a
vibration of the racking device. At this
point, release the push button. The
breaker position indicator will read
“Connect” (Figure 9).
q. Disconnect the 120VAC source and
remove the remote racking device.
r. Slide the racking shaft shutter to the
right.
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14 Installation & Operation
©2006PowellIndustries,Inc.•Allrightsreserved.
e. re M o v I n G t H e cI r c u I t Br e A k e r f r o M t H e SW I t c H G e A r
co M p A r t M e n t
Prior to removing the remote racking motor
from the circuit breaker compartment, make
sure that the control circuits are deenergized.
CAUTIONCAUTION
!
Prior to removing the circuit breaker from the
circuit breaker compartment, ensure that the
circuit breaker is OPEN.
CAUTIONCAUTION
!
Follow the steps below to remove the circuit
breaker from the compartment:
1. Open the upper compartment door.
Depress the push-to-trip button and slide
the racking shaft shutter covering the
racking shaft to the left (Figure 3). This trips
the circuit breaker if it is closed and holds it
open during the racking-out process.
2. Open the upper door on the cubicle.
The electric racking device is designed
to hang from the bottom flange of the
upper compartment (Figure 4). Note the
hanger is equipment with slotted holes for
adjustment (Figure 1, a) in order to fit on
standard and arc resistant equipment. The
device might need adjustment to achieve
alignment. Lower the device over the
flange and position the drive socket on the
electric racking device over the levering-in
shaft (Figure 4). Turn the red knob on the
back of the electric racking device until the
socket engages the racking shaft. Close
and latch the upper compartment door and
latch it to capture the hanger bracket.
3. Insert the cylindrical plug into the remote
racking device outlet (Figure 6). Lock the
plug by turning it clockwise.
4. Ensure the control box power switch is in
the “OFF” position.
5. Connect the device to a 120VAC power
source.
6. Move the power switch to the “ON”
position.
7. Move the selector switch on the push
button to the“OUT” position.
Note: The housing on the push button is a
switch, and can be rotated to either
the “IN” or “OUT” positions.
8. To begin racking the circuit breaker out of
the compartment, depress the push button.
Note: If the push button is released during
operation the motor will stop.
9. When the push button is depressed, the
“OUT” indicating light (Figure 2, c) will be
energized and illuminated.
10. When the circuit breaker is fully racked OUT,
the remote racking device torque limiter
will begin to slip and there will be a clear
clicking sound along with a vibration of the
racking device. At this point, release the
push button. The breaker position indicator
will read “Test/Disconnect” (Figure 8).
11. Disconnect the 120VAC source and
remove the remote racking device.
12. Slide the racking shaft shutter to the right.
IB-51807
PV System 38® Remote Racking Device
Mechanical Connection

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Powell Electrical Systems, Inc.
Service Division - Houston
POBox12818•Houston,TX•77217
Tel:713.944.6900•Fax:713.948.4569
www.powellind.com
[e-mail]
©2006PowellIndustries,Inc.•Allrightsreserved.
Mechanical Connection
IB-51807
PV System 38® Remote Racking Device
April 2010