Powell SM-1100 User manual

SM-1100 Auxiliary Switch Assembly
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Auxiliary Switch Assembly SM-1100
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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SM-1100
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.

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SM-1100
Contents
Figures
Figure 1 Auxiliary Switch Assembly .............................................................................6
Figure 2 Auxiliary Switch Assembly Installed ..............................................................7
Figure 3 “E” Ring Removal ...........................................................................................7
Figure 4 Removing Auxiliary Switch ............................................................................7
Figure 5 Reconnecting Operating Arm to Operations Counter Linkage ....................8
Ch 1 General Information ................................................................................................1
A. Sc o p e ...............................................................................................................................................................2
B. pu r p o S e ............................................................................................................................................................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 ............................................................................................................................................................4
d. Sp e c i f i c .............................................................................................................................................................4
e. X-rA y S .............................................................................................................................................................5
f. SA f e t y lA B e l S ....................................................................................................................................................5
Ch 3 Equipment Description ............................................................................................6
A. Ge n e r A l ............................................................................................................................................................6
Ch 4 Installation .................................................................................................................7
A. re m o v i n G t h e ol d Au X i l i A r y SW i t c h AS S e m B l y A n d in S t A l l i n G t h e re p l A c e m e n t Au X i l i A r y SW i t c h AS S e m B l y .................7
1) Removing the Old Auxiliary Switch Assembly .................................................................................................................. 7
2) Installing the Replacement Auxiliary Switch Assembly ................................................................................................. 8

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Auxiliary Switch Assembly SM-1100
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Ch 1 General Information
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
!
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General Information
SM-1100
WARNINGWARNING
!
The equipment described in this document may contain high voltages and currents which can
cause serious injury or death.
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.

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2General Information
Auxiliary Switch Assembly SM-1100
A. Sc o p e
The information in this maintenance procedure
describes the following Auxiliary Switch
Assembly:
• 102108LN (SliponLugs)
• 102108LP (RingLugs)
This device can be used in the following circuit
breakers:
• PowlVac®STD
• PowlVac®CDR
• PowlVac®ASD
• PowlVac®38kVCDR
B. pu r p o S e
The information in this maintenance procedure
is intended to provide information required to
properly install the auxiliary switch assembly
described in Ch 1 General Information,
A. Sc o p e .
This instruction bulletin provides:
1. Safety guidelines
2. Instructions for installation and placing the
auxiliary switch into service
3. Illustrations, photographs, and description
of the auxiliary switch assembly
The illustrations contained in this document
may not represent the exact construction
details of each particular type of auxiliary
switch assembly. The illustrations in this
document are provided as general information
to aid in showing component locations only.
All photos and 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.

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Safety
SM-1100
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
Study this maintenance procedure and all other
associated documentation before installing the
undervoltage device.
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.
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
the auxiliary switch.

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4Safety
Auxiliary Switch Assembly SM-1100
c. Ge n e r A l
1. Only supervised and 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,
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 circuit breaker’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. Sp e c i f i c
1. DO NOT WORK ON AN ENERGIZED
CIRCUIT BREAKER. If work must be
performed on a circuit breaker, remove it
from service and remove it from the
metal-clad switchgear.
2. DO NOT WORK ON A CIRCUIT BREAKER
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 this 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
CIRCUIT BREAKERS.
7. Interlocks are provided to ensure the
proper operating sequences of the circuit
breakers and for the safety of the user. If for
any reason an interlock does not function
as described, do not make any adjustments,
modification, or deform the parts. DO
NOT FORCE THE PARTS INTO POSITION.
CONTACT POWELL FOR INSTRUCTIONS.

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Safety
SM-1100
e. X-rA y S
When high voltage is applied across the
contacts of a vacuum interrupter, there is the
possibility of generation of X-rays. The intensity
of the X-radiation is dependent on the peak
voltage and the contact gap. At the normal
operating voltage for this type of equipment,
the radiation levels are negligible. At the
voltages specified for testing, test personnel
shall be in front of the circuit breaker such that
the two layers of steel used in the frame and
front cover construction are between the test
personnel and the vacuum interrupters, and
that the test personnel be no closer than one
meter (3’) from the front of the circuit breaker.
THE CIRCUIT BREAKER SHALL BE EITHER
FULLY OPEN, OR FULLY CLOSED WHEN
MAKING HIGH POTENTIAL TESTS. DO NOT
TEST WITH CONTACTS PARTIALLY OPEN.
f. SA f e t y lA B e l S
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 in and on the switchgear and
on the circuit breaker removable element.
Always observe these warnings and caution
labels. Do NOT remove or deface any of these
warning/caution labels.
IMPORTANTIMPORTANT
!

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6Equipment Description
Auxiliary Switch Assembly SM-1100
Ch 3 Equipment Description
A. Ge n e r A l
The auxiliary switch (Figure 1) is located on the
lower left front of the mechanism area
(Figure 2, b).
CAUTIONCAUTION
!
Ensure that the control circuits are
deenergized and the circuit breaker is
deenergized, disconnected by means of a
visible break, and securely grounded. Do NOT
start to work on a closed circuit breaker or a
circuit breaker with the main closing spring
charged.
You should have the following when receiving
the auxiliary switch assembly:
• AuxiliarySwitchAssembly
Use existing hardware when replacing Auxiliary
Switch Assembly:
• 10-32x⁄”RoundHeadMachineScrew(2)
• 10-32StarNut(2)
• “E”Ring
Tools required:
• Flatheadscrewdriver
• ⁄ Open End Wrench
• Pliers
Figure 1 Auxiliary Switch Assembly

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Installation
SM-1100
Ch 4 Installation
A. re m o v i n G t h e ol d Au X i l i A r y SW i t c h AS S e m B l y
A n d in S t A l l i n G t h e re p l A c e m e n t Au X i l i A r y SW i t c h
AS S e m B l y
1) Removing the Old Auxiliary Switch Assembly
Perform the following steps to replace the
auxiliary switch assembly:
CAUTIONCAUTION
!
Ensure that the control circuits are
deenergized and the circuit breaker is
deenergized, disconnected by means of a
visible break, and securely grounded. Do NOT
start to work on a closed circuit breaker or a
circuit breaker with the main closing spring
charged.
a. Removethefrontcoverofthecircuit
breaker.
Figure 2 Auxiliary Switch Assembly Installed
a. Operations Counter
b. Auxiliary Switch
c. Mounting Bracket
a
b
c
b. Removethe“E”ring(Figure3,b)
securing the switch operating arm to
the operations counter linkage.
Figure 3 “E” Ring Removal
a. Odd numbered terminals
b. “E” Ring
a
b
c. Removethetwo10-32x ⁄”R.H.
Machine Screws holding the auxiliary
switch to its mounting bracket and
remove the switch (Figure 4).
Figure 4 Removing Auxiliary Switch
ab
a. 10 -32 Star Nut
b 10 -32 x ⁄” R.H. Machine Screw
d. Disconnectthewiresfromtheauxiliary
switch (Figure 5), being careful to note
which wires go to which terminal.
Note: It is important to note that when
removing and replacing the auxiliary
switch that the position of the switch
will always be with the odd numbered
terminals facing up as shown in
Figure 3.

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8Installation
Auxiliary Switch Assembly SM-1100
Figure 5 Disconnecting Wires from Auxiliary
Switch
ab
a. Auxiliary Switch
b. Auxiliary Switch Wires
2) Installing the Replacement Auxiliary Switch
Assembly
CAUTIONCAUTION
!
Ensure that the control circuits are
deenergized and the circuit breaker is
deenergized, disconnected by means of a
visible break, and securely grounded. Do NOT
start to work on a closed circuit breaker or a
circuit breaker with the main closing spring
charged.
Perform the following steps to install
replacement auxiliary switch assembly:
a. Insert the new switch and reconnect the
wiring (Figure 8). Make sure the wires
are connected to the same terminals
from which they were removed.
Note: It is important to note that when
removing and replacing the auxiliary
switch that the position of the switch
will always be with the odd numbered
terminals facing up as shown in
Figure 3.
Figure 6 Installing Auxiliary Switch
a
b
a. 10 - 32 x ⁄” R.H. Machine Screw
b. 10 - 32 Star Nut
b. Insert the operating arm (Figure 7, a)
of the switch into the hole at the end
of the operations counter linkage and
attach it to the mounting bracket with
the two 10 - 32 x ⁄”R.H.MachineScrews
removed in section Ch 4 Installation,
A. re m o v i n G t h e ol d Au X i l i A r y SW i t c h
AS S e m B l y A n d in S t A l l i n G t h e re p l A c e m e n t
Au X i l i A r y SW i t c h AS S e m B l y , 1) Removing
the Old Auxiliary Switch Assembly, Step c.
Figure 7 Reconnecting Operating Arm to
Operations Counter Linkage
a
a. Auxiliary Switch Operating Arm

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SM-1100
c. Secure the operating arm to the
operations counter linkage with
the “E”ring removed in section
Ch 4 Installation, A. re m o v i n G t h e ol d
Au X i l i A r y SW i t c h AS S e m B l y A n d in S t A l l i n G
t h e re p l A c e m e n t Au X i l i A r y SW i t c h AS S e m B l y ,
1) Removing the Old Auxiliary Switch
Assembly, Step b.
Figure 8 Reconnecting Wires to Auxiliary
Switch
d. Verifytheauxiliarysparecontactsare
wired in accordance with the original
circuit breaker diagram.
e. Operate the circuit breaker electrically
several times to ensure the switch
functions properly.
f. Replacethefrontcover.

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10
Auxiliary Switch Assembly SM-1100
©2006PowellIndustries,Inc.•Allrightsreserved.
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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.
SM-1100
Auxiliary Switch Assembly
January 2009