Powell PowlVac PV38 User manual

POWELL
INDUSTRIES, INC.
IB-65060
INSTRUCTIONS
POWELL ELECTRICAL MANUFACTURING COMPANY
8550 MOSLEY DRIVE • HOUSTON, TEXAS 77075 • USA
PHONE [phone] • FAX [phone]
©2001 POWELL ELECTRICAL MANUFACTURING COMPANY ALL RIGHTS RESERVED 01/2004
http://www.powellelectric.com
http://www.powellservice.com
Installation Maintenance Renewal Parts
PowlVac®PV38 Electrically Operated
Ground and Test (G&T) Device
Instructions for the Consolidated Edison
Electrically-Operated Ground and Test Device
Per Con Edison Specification EO-2022

PowlVac®Electrically-Operated Ground and Test Device IB-65060
2
THIS SPACE IS INTENTIONALLY BLANK.

3
PowlVac®Electrically-Operated Ground and Test Device IB-65060
Contents
I. INTRODUCTION............................................................................................................. 5
A. SCOPE ................................................................................................................................................ 5
B. PURPOSE ........................................................................................................................................... 5
C. INSTRUCTION BULLETINS AVAILABLE ELECTRONICALLY........................................................... 5
II. SAFETY .......................................................................................................................... 5
A. GENERAL............................................................................................................................................ 5
B. SPECIFIC ............................................................................................................................................ 6
C. X-RAYS ................................................................................................................................................ 7
III. EQUIPMENT DESCRIPTION.......................................................................................... 7
A. GENERAL DESCRIPTION .................................................................................................................. 7
B. POWER GROUNDING SWITCH OPERATION .................................................................................. 7
1) Closing ........................................................................................................................................... 7
2) Opening ......................................................................................................................................... 7
C. KEY LOCKS......................................................................................................................................... 7
1) Key Lock K1 (Keys KU and KB) .................................................................................................... 7
2) Key Lock K2 (Keys KB and KC) .................................................................................................... 7
3) Key Lock K3 (Key KC) ................................................................................................................... 8
4) Key Lock K4 (Keys KB and KD) .................................................................................................... 8
5) Key Lock K5 (Key KD) ................................................................................................................... 8
D. CONTROL SELECTOR SWITCH .......................................................................................................8
E. INTERCHANGEABILITY ..................................................................................................................... 8
IV. INSTALLATION ............................................................................................................ 12
A. RECEIVING ....................................................................................................................................... 12
B. HANDLING ........................................................................................................................................ 12
C. STORAGE ......................................................................................................................................... 12
D. PREPARING THE ELECTRICAL GROUND AND TEST DEVICE FOR USE ................................... 13
1) High Voltage Insulation Integrity.................................................................................................. 13
2) Vacuum Integrity .......................................................................................................................... 13
3) Control Voltage Insulation Integrity.............................................................................................. 14
4) Electrical Operation Check .......................................................................................................... 14
E. INSERTING THE ELECTRICAL GROUND AND TEST DEVICE INTO THE METAL-CLAD
SWITCHGEAR .................................................................................................................................. 14
1) Electrical Ground and Test Device Inspection............................................................................. 14
V. OPERATING PROCEDURES ....................................................................................... 15
A. PROCEDURE FOR APPLYING GROUNDS ..................................................................................... 15
B. PROCEDURE FOR TESTING FEEDER ........................................................................................... 20
C. PROCEDURE FOR REMOVING TEST PROBES ............................................................................ 27
D. PROCEDURE FOR REMOVING GROUNDS ................................................................................... 33
VI. MAINTENANCE ............................................................................................................ 37
A. GENERAL.......................................................................................................................................... 37
B. INSPECTION AND CLEANING ......................................................................................................... 37
C. LUBRICATION ................................................................................................................................... 37
VII. RENEWAL PARTS ........................................................................................................ 37
A. ORDERING........................................................................................................................................ 37
Figure Page

PowlVac®Electrically-Operated Ground and Test Device IB-65060
4
WARNING
THIS EQUIPMENT MAY CONTAIN HIGH VOLTAGES AND CURRENTS WHICH CAN CAUSE
SERIOUS INJURY OR DEATH.
THE EQUIPMENT IS DESIGNED FOR USE, INSTALLATION, AND MAINTENANCE BY KNOWL-
EDGEABLE USERS OF SUCH EQUIPMENT HAVING EXPERIENCE AND TRAINING IN THE
FIELD OF HIGH VOLTAGE ELECTRICITY. THIS DOCUMENT, AND ALL OTHER DOCUMEN-
TATION 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 ELECTRICAL MANUFACTURING COMPANY IMMEDIATELY
AT 1-800-480-7273.
CAUTION
BEFORE ANY ADJUSTMENT, SERVICING, PARTS REPLACEMENT, OR ANY OTHER ACT IS
PERFORMED REQUIRING PHYSICAL CONTACT WITH THE ELECTRICAL WORKING COMPO-
NENTS OR WIRING OF THIS EQUIPMENT, THE POWER SUPPLY MUST BE DISCONNECTED.
FAILURE TO FOLLOW THIS CAUTION MAY RESULT IN INJURY OR DEATH.

5
PowlVac®Electrically-Operated Ground and Test Device IB-65060
IMPORTANT
THESE INSTRUCTIONS ARE NOT INTENDED TO EXPLAIN ALL DETAILS OR VARIATIONS OF
THE ELECTRICAL GROUND AND TEST DEVICES, NOR TO PROVIDE FOR EVERY POSSIBLE
CONTINGENCY OR HAZARD TO BE MET IN CONNECTION WITH USAGE, INSTALLATION, TEST-
ING, OPERATION, AND MAINTENANCE OF THE EQUIPMENT. SHOULD FURTHER INFORMA-
TION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED
SUFFICIENTLY FOR THE USER’S PURPOSES, THE MATTER SHOULD BE REFERRED TO
POWELL ELECTRICAL MANUFACTURING COMPANY, 1-800-480-7273.
I. INTRODUCTION
A. SCOPE
This instruction bulletin describes the following:
Electrically Operated Ground and Test Device (G&T)
(CON EDISON and CUSTOMER interlocked versions)
B. PURPOSE
The information in this document is intended to
provide instructions for users to properly operate and
maintain the electrically operated ground and test
device described in Section A. Scope.
The instruction bulletin contains details of the follow-
ing topics:
1. Safety
2. Equipment Description
3. Installation
4. Operation of the Ground and Test device
• Procedure for Applying Grounds -
Con Edison Feeder
• Procedure for Testing Feeder
• Procedure for Removing Test Probes
• Procedure for Removing Grounds
5. Maintenance
6. Recommended Renewal Parts
To the extent required, the products described herein
meets applicable ANSI, IEEE, and NEMA Standards.
No assurance for compliance is given for local codes
and ordinances which vary greatly.
C. INSTRUCTION BULLETINS AVAILABLE
ELECTRONICALLY
Many Powell Electrical Manufacturing Company
Instruction Bulletins are posted on the company Web
site at www.powellservice.com. For more informa-
tion, contact Powell Apparatus Service Division
(PASD) at 1-800-480-7273.
II. SAFETY
The user should study this instruction bulletin and all
other associated documentation before uncrating the
ground and test device.
Each user has the responsibility to instruct and
implement thorough maintenance and safety proce-
dures for each type of equipment used. The user
shall train all personnel, who are associated with the
equipment, on usage, installation, operation mainte-
nance and safety procedures. All safety procedures
must be observed.
A. GENERAL
1. The PowlVac®PV 38 Electrically Operated
Ground and Test Device includes high-energy,
fast-acting closing and tripping mechanisms. It is
designed to allow access, under carefully con-
trolled conditions, to energized high-voltage
electrical circuits. Improper operation or servic-
ing techniques can be dangerous to the operator.
These devices should be operated and/or ser-
viced only by persons who are skilled in operation
and/or service of high-voltage electrical appara-
tus and who are thoroughly familiar with these
instructions and any supplementary information
contained in drawings furnished with the ground
and test device and/or switchgear in which it is
used.

PowlVac®Electrically-Operated Ground and Test Device IB-65060
6
2. The PowlVac®PV 38 Electrically Operated
Ground and Test Device is designed for use in
P-65000 PowlVac®Metal-Clad Switchgear
manufactured by Powell Electrical Manufacturing
Company. Do not attempt to use this device in
any other class of electrical equipment manufac-
tured by Powell or any other manufacturer. This
device is designed to be inserted in a metal-clad
switchgear unit in place of a vacuum circuit
breaker for grounding and testing purposes.
3. Only supervised and qualified personnel who are
trained in the usage, installation, operation, and
maintenance of electrical ground and test device
shall be allowed to work on this equipment. It is
mandatory that this instruction bulletin, any
supplements, and service advisories are studied,
understood, and followed.
4. Maintenance programs must be consistent with
the customer experience and the manufacturer’s
recommendations, including information avail-
able in service advisories and the instruction
bulletin(s). A well-planned and executed routine
maintenance program is essential for the electri-
cal ground and test device reliability and safety.
5. Service conditions and electrical ground and test
device applications shall be considered in the
development of maintenance programs. Service
conditions include variables such as ambient
temperature, humidity, number of operations, and
any adverse local conditions such as excessive
dust, ash, corrosive atmosphere, vermin, and
insect problems.
B. SPECIFIC
When operating the ground and test device safety
precautions must be observed. IMPROPER USE
CAN RESULT IN DEATH, SERIOUS PERSONAL
INJURY, OR DAMAGE TO PROPERTY. It is
important for the user to develop specific and safe
operating procedures to be observed when using the
ground and test device.
The following specific safety precautions MUST be
observed:
1. Do not close the grounding switch on an ener-
gized circuit. The circuit to be grounded should
always be treated as energized until proven
otherwise.
2. Use great care when opening the test port
shutters to gain access to the test receptacles.
The test receptacles should always be treated as
energized circuits until proven otherwise.
3. Any test device plugged into the test receptacles
must be properly rated for the circuit voltage
being tested, and all connections must be prop-
erly insulated.
4. Use only the test probes furnished with the
device to plug anything into the test receptacles.
Use of other plugs may damage the test recep-
tacle or may result in a poor connection which
could be dangerous to the operator and/or
damaging to the equipment.
5. Even through insulated, the test probes must not
be inserted or extracted from energized test
jacks. The test probe insulation is only one part
of a complete line-to-ground insulation system,
and the surface of the test probe may be ener-
gized at a voltage above ground potential when
connected to an energized test jack.
6. Do not attempt to force or bypass any interlocks.
The interlocks are furnished for the safety of the
operator and the protection of the equipment
being tested and the test device. Forcing or
bypassing the interlocks can result in a condition
dangerous to the operator and/or damaging to the
equipment.
7. Do not attempt to service the device while it is
installed in a switchgear cell or on a lift truck. For
service, the device must be located either on the
floor or on a sturdy, level work bench, and
blocked from rolling.
8. For service, the device must be in the OPEN
position and all operating springs must be dis-
charged. These conditions should be verified
before removing any covers or attempting any
service.
9. Store the ground and test device in a clean, dry
area free from dust, dirt, moisture, caustic
atmosphere, and vermin.
10. Keep all insulating surfaces, which include
primary support insulation and insulation barriers,
clean and dry.
11. Check all primary circuit connections to make
certain that they are clean and tight.
12. Take extreme care while using this device to
avoid contacting “live” or “hot” (energized)
terminals.
13. Always OPERATE the grounding switch electri-
cally from the farthest distance with the remote
operating station control switch.

7
PowlVac®Electrically-Operated Ground and Test Device IB-65060
III. EQUIPMENT DESCRIPTION
A. GENERAL DESCRIPTION
The PowlVac® Electrically Operated Ground and Test
Device (see Figures 1 and 2) is a drawout element
that can be inserted into the circuit breaker compart-
ment in the same manner as a Powl-Vac®circuit
breaker.
The PowlVac® PV 38 Electrically Operated Ground
and Test Device provides a means for obtaining
access to the primary disconnect devices of the
switchgear cell for purposes of grounding the primary
circuits or conducting certain high voltage test
procedures such as conducting high voltage with-
stand (hipot) tests.
The grounding switch is operated by a stored energy
mechanism. It is capable of applying the ground
against a LIVE circuit if operational errors have not
cleared the circuit. However, in such a case, the
relaying at the source of power is expected to cause
the source interrupter to clear the circuit.
B. POWER GROUNDING SWITCH OPERATION
1) Closing
The power grounding switch is closed by the remote
operating station at the end of a 50 ft. long cable that
is supplied with the device (Figure 9). Upon depress-
ing the CLOSE push-button (note that the push-
button does not have to be held depressed):
1. The closing springs start to charge.
2. After the springs are fully charged, the springs
automatically discharge to close the switch
contacts.
Once the ground switch is closed, it can be locked
into the CLOSED position by removing the cable
from the receptacle on the device.
2) Opening
The grounding switch can be opened electrically
using the remote operating station. The OPEN push-
button must be depressed. For safety reasons, the
switch is prevented from opening in less that 20
seconds after closing.
C. KEY LOCKS
1) Key Lock K1 (Keys KU and KB)
The key lock K1 interlock is a two cylinder lock used
to electrically enable or disable the ground and test
device.
Key lock K1 interlock is a two cylinder transfer lock
equipped with an electrical switch element. The
switch is closed when key KB is retained. When the
switch is open, the ground and test device is electri-
cally disabled and key KU is retained (see Figure 1, u
and Figure 3).
NOTE: When multiple electrical ground and test
devices are supplied for an installation, the customer
feeder ground and test devices are normally supplied
with similar interlock functions as that of the Con
Edison specification. In these cases, key KU is not
present, but is instead supplied with a key KCF (Key,
Customer Feeder) for Con Edison customer use.
Key KU and key KCF are non-interchangeable.
2) Key Lock K2 (Keys KB and KC)
Key lock K2 interlock is a two cylinder lock used to
mechanically lock the ground and test device in the
OPEN position (see Figure 1, k and Figure 4).
14. Check for dielectric integrity at 60kVAC across
the terminals to ground with the grounding switch
OPEN.
C. X-RAYS
When high voltage is applied across the contacts of a
vacuum interrupter, there is the possibility of the
generation of X-rays. The intensity of this radiation is
dependent on the amount of the peak voltage and the
distance of the contact gap. Radiation levels are
negligible at the normal operating voltage for this
type of equipment. At the voltages specified for
testing, personnel must be located in front of the
electrical ground and test device such that the two
layers of steel used in the frame and front cover
construction are between personnel and the vacuum
interrupters. Personnel must be located no less than
one meter from the front of the electrical ground and
test device. THE ELECTRICAL GROUND AND
TEST DEVICE SHALL BE EITHER FULLY OPEN
OR FULLY CLOSED DURING HIGH POTENTIAL
TESTING. TEST SHALL NOT BE CONDUCTED
WITH THE CONTACTS PARTIALLY OPEN.

PowlVac®Electrically-Operated Ground and Test Device IB-65060
8
The key lock K2 interlock is equipped with an electri-
cal switch element that electrically blocks a closing
command. The key lock K2 switch is in series with
the key lock K1 switch. Although the switch is not
required for operational sequencing logic, it is applied
for operational sequence protection redundancy.
The key lock K2 interlock is operable when key KB is
inserted. When the key lock K2 interlock is operated
with the locking bolt extended (by rotating key KC),
the ground and test device is electrically locked open,
key KB is retained, and key KC is released.
3) Key Lock K3 (Key KC)
The key lock K3 interlock is a single cylinder lock
(see Figures 1, d and Figure 5). When key lock K3
interlock is locked, the ground and test device is
prevented from being inserted into or removed from
the connected position of the circuit breaker compart-
ment.
When the ground and test device is in the discon-
nected position, the key lock K3 interlock prevents
the compartment-mounted racking device drive roller
from entering the corresponding racking slot on the
ground and test device, thereby preventing the
insertion of the ground and test device into the
connected position in the circuit breaker compart-
ment.
When the ground and test device is in the connected
position, the key lock K3 interlock captures the
compartment-mounted racking device drive roller in
the ground and test device racking slot, thus prevent-
ing the roller from further movement. This action
prevents the removal of the ground and test device
form the connected position.
With key KC inserted and the locking bolt retracted to
enable racking of the ground and test device into or
out of the connected position, key KC is retained.
4) Key Lock K4 (Keys KB and KD)
The key lock K4 interlock is a two cylinder lock used
to mechanically lock the ground and test device in
the CLOSED position (see Figure 1, v and Figure 6).
In the PowlVac®ground and test device design, the
locking bolt of the key lock K4 interlock cannot be
extended unless the ground and test device is in the
CLOSED position. The key lock K4 interlock is
equipped with an electrical switch element that
electrically blocks an opening command. The key
lock K4 switch is in series with the key lock K1
switch. Although the switch is not required for
operational sequencing logic, it is applied for opera-
tional sequence protection redundancy.
The key lock K4 interlock is operable only when key
KB is inserted and the ground and test device is
CLOSED. When the key lock K4 interlock is oper-
ated with the locking bolt extended, the tripping
function is electrically disabled, key KB is retained
and key KD is released.
5) Key Lock K5 (Key KD)
The key lock K5 interlock is a single cylinder lock.
The key lock K5 interlock is used to open and lock
the test port shutters (see Figure 1, f and Figure 7).
Key KD, which normally resides in the key lock K4
interlock, is available only when the ground and test
device is in the CLOSED and locked position. Key
KD is then inserted into key lock K5. With the
locking bolt retracted and the test port shutters
unlocked, key KD is retained. Key KD is removable
only when the locking bolt is extended in either of two
positions. One position is with the test port shutters
closed, and the other position is with the test probes
installed in the test ports and the shutter moved to
the test probe locking position.
D. CONTROL SELECTOR SWITCH
A control selector switch is mounted on the front of
the ground and test device. This selector switch
enables and disables the closing function and the
opening function (see Figure 1, i and Figure 8) of the
ground and test device.
The selector switch is a three position rotary switch
that operates in association with the remote OPEN/
CLOSE push-button control station. The snap-action
detented positions are OPEN, OFF, and CLOSE.
The selector switch is pad-lockable in the OFF
position.
E. INTERCHANGEABILITY
The PowlVac®ground and test devices are non-
interchangeable between the Con Edison and Cus-
tomer compartments. The coding plates will allow a
ground and test device labeled “Con Edison” into only
Con Edison incoming feeder compartments. Like-
wise, a ground and test device labeled “Customer”
can be inserted into only customer feeder compart-
ments.

9
PowlVac®Electrically-Operated Ground and Test Device IB-65060
a
b
a. Instruction Book
b. Wheel
c. Racking Access Handle
d. Lock K3
e. Key KC
f. Lock K5
g. Key KD
h. Test Port Shutter Operator
i. Control Selection Switch
j. Front Handle
k. Lock K2
l. Key KB, Lock K2
m. Key KC
n. Ground Connection
o. Remote Operating Station Plug
Receptacle
p. Position Indicator
q. Key KD
r. Key KB, Lock K4
s. Key KB, Lock K1
t. Key KU, Lock K1
u. Lock K1
v. Lock K4
w Secondary Disconnect
Figure 1. Electrical Ground and
Test Device Front
c
d
e
Key Lock K3 Detail
fgjih
rq knlmop
u
v
w
Front Panel Detail
st

PowlVac®Electrically-Operated Ground and Test Device IB-65060
10
ab
e
c
d
Figure 2. Electrical Ground
and Test Device (Rear View)
a. View Port Windows
b. Racking Roller Plate
c. Shutter Operator
d. Primary Disconnect
e. Interference Plate

11
PowlVac®Electrically-Operated Ground and Test Device IB-65060
Figure 8. Control Selector Switch
Figure 4. Key Lock K2 Interlock
Figure 7. Key Lock K5 Interlock
Figure 5. Key Lock K3 Interlock Figure 6. Key Lock K4 Interlock
Figure 3. Key Lock K1 Interlock
Figure 10. Test Probe Accessory
Figure 9. Remote Operating Station

PowlVac®Electrically-Operated Ground and Test Device IB-65060
12
IV. INSTALLATION
A. RECEIVING
Inspect the electrically-operated ground and test
device for any signs of damage when it is received.
If damage is found or suspected, immediately file
applicable claims with the transportation company
and notify the nearest representative of Powell
Electrical Manufacturing Company.
The estimated size and weight of the electrical
ground and test device, when it is crated and placed
on a pallet is:
Size: 42" width x 42" depth x 47" height
Weight: 750 lbs
The ground and test device is shipped enclosed in a
carton and strapped to a shipping pallet. The carton,
which contains the ground and test device, is at-
tached to the pallet by two metal bands. Remove the
metal bands and lift the carton to remove it from the
ground and test device. With the carton removed,
there are two more metal bands that attach the
ground and test device to the pallet. Remove the two
metal bands from the ground and test device and the
pallet, and remove the ground and test device from
the shipping pallet.
B. HANDLING
To avoid personal injury while handling the ground
and test device, personnel should not stand under the
raised ground and test device nor place hands or feet
under the ground and test device frame as it is being
lowered.
After the ground and test device has been removed
from its shipping pallet, the preferred method for
moving and handling a ground and test device is to
roll it on its own wheels on a level surface. When
rolling the ground and test device, it should be
pushed and steered by the device frame or by the
handles on the front cover. DO NOT HANDLE OR
MOVE THE DEVICE BY THE PRIMARY DISCON-
NECTING STABS, AS DAMAGE TO THE
GROUND AND TEST DEVICE MAY OCCUR.
An overhead crane (Figure 11) can be used to move
the ground and test device. When using an overhead
crane to move the ground and test device use a
lifting harness and a single crane hook. Place the
ground and test device securely on the harness as
shown in Figure 11. Place the crane hook in the
harness lifting link on the top of the harness. Lift the
ground and test device and move it to the required
location.
C. STORAGE
Since the ground and test device is an accessory
device not normally in continuous service, it is very
important that it be stored carefully so that it will be
available when needed. The following precautions
must be taken to assure proper storage of the ground
and test device.
1. THE GROUND AND TEST DEVICE MUST
NOT BE STORED IN A CIRCUIT BREAKER
COMPARTMENT. IT CAN ONLY BE STORED
IN A STORAGE COMPARTMENT.
2. The ground and test device should be carefully
protected against condensation, preferably by
storing it in a warm, dry room of moderate
temperature, such as 40°-100°F, since dampness
has an adverse effect on the insulating parts.
3. The ground and test device should be stored in a
clean location, free from corrosive gasses or
fumes. Particular care should be taken to protect
the device from moisture and cement dust, as
this combination has a very corrosive effect on
many parts.
4. Unplated surfaces, such as, rollers, latches, etc.,
should be coated with grease or oil to prevent
rusting.
Figure 11. Crane with Electrical ground and test
Device in Harness

13
PowlVac®Electrically-Operated Ground and Test Device IB-65060
The tests described in this section are the only tests
required to determine the insulation integrity. Be-
cause of the design of the PowlVac®insulation
system, no valid data can be obtained using other
types of high-voltage insulation tests.
2) Vacuum Integrity
Powell recommends AC testing and reliable verifica-
tion of vacuum integrity. PowlVac®38kV ground and
test devices shall be tested with a minimum of
60kVAC applied across fully open contacts for 10
seconds. No dielectric breakdown during the test
period constitutes a successful test.
NOTE: This test does not replace the AC high
potential testing (HIPOT) used to determine “High
Voltage Insulation Integrity.”
Powell offers a compact and lightweight PowlVac®
Vacuum Integrity Tester designed specifically for
PowlVac® circuit breakers. If the test device is used,
refer to the instruction bulletin provided with the
vacuum integrity tester.
Powell recognizes the widespread use of DC hipot
equipment to verify vacuum integrity. However, the
capacitive component of the vacuum interrupter
during DC testing may yield false negative test
results, which are often misinterpreted as vacuum
interrupter failure. When DC testing is performed, a
test set providing a full wave rectified 60kVDC hipot
voltage can be applied for 5 seconds as a “go – no
go” test.
It is not necessary to record the leakage readings
because a dielectric breakdown will trip all portable
DC hipot test sets. If a DC test breakdown occurs, the
test must be repeated after reversing the DC high
voltage test supply connection across the vacuum
interrupter. Only when the vacuum interrupter has
failed both tests should the operation condition be
questioned.
No attempt should be made to try to compare the
condition of one vacuum interrupter with another, nor
to correlate the condition of any vacuum interrupter
with low values to DC leakage current. There is no
significant correlation.
5. If the ground and test device is stored for any
length of time, it should be inspected periodically
for rust and to ensure it is in good mechanical
condition. Should the ground and test device be
stored under adverse conditions, it should be
cleaned and dried before performing the commis-
sioning tests and before placing the ground and
test device into an energized circuit breaker
compartment.
D. PREPARING THE ELECTRICAL GROUND AND
TEST DEVICE FOR USE
Before shipment from the factory, all functions of the
ground and test device are thoroughly checked.
Powell Electrical Manufacturing Company recom-
mends that prior to each use, the ground and test
device should be thoroughly checked and the follow-
ing tests be performed in the sequence listed below:
1. High Voltage Insulation Integrity
2. Vacuum Integrity
3. Control Voltage Insulation Integrity
4. Electrical Operation Check
1) High Voltage Insulation Integrity
The primary circuit insulation on the ground and test
device may be checked phase-to-phase and phase-
to-ground using a 2500V insulation resistance tester.
Since definite limits cannot be given for satisfactory
insulation values when testing with an insulation
resistance tester, a record should be kept of the
insulation resistance tester readings, as well as the
temperature and humidity readings. The records
should be used to detect any weakening of the
insulation system from one check period to the next.
To check insulation integrity, the AC high potential
test described below is strongly recommended.
The ground and test device insulation should be
tested with the ground and test device vacuum
interrupter contacts in the closed position. Test each
pole of the ground and test device separately, with
the other 2 poles and the frame grounded. Perform
the field dielectric test described in ANSI Standard
C37.20.2, at the voltage level appropriate for the
equipment. This test should check all primary phase-
to-ground and phase-to-phase insulation.

PowlVac®Electrically-Operated Ground and Test Device IB-65060
14
3) Control Voltage Insulation Integrity
If the user wants to check the insulation integrity of
the control circuit, it may be done with a 500-volt or
1000-volt insulation resistance tester or with an AC
high potential tester. The AC high potential test
should be made at 1125 volts, 50 to 60 Hz for one
minute. The charging motor must be disconnected
prior to testing the control circuit. The charging
motor itself may be similarly tested at a voltage not
to exceed 675 volts, 50 to 60 Hz. Be sure to remove
any test jumpers and reconnect the charging motor
when the tests are complete.
4) Electrical Operation Check
To check the basic electrical operation of the ground
and test device, it must be placed near a circuit
breaker test cabinet. To close the device, connect
the secondary disconnect from the test cabinet to the
ground and test device to be tested. The test cabinet
provides control voltage via a secondary disconnect
plug to the ground and test device and the appropri-
ate control switches to verify the CLOSE and OPEN
functions of the ground and test device. With the
Secondary Disconnect plug installed in the ground
and test device being tested, and with key KB cap-
tive, perform the following steps.
To CLOSE the Device
1. Connect the Remote Operating Station to the
ground and test device and rotate the plug
clockwise to lock (Figure 23).
2. Turn the Test Cabinet power ON. Verify that the
Control Selector Switch is in the OFF position
(Figure 22).
4. Move the Control Selector Switch to the CLOSE
position (Figure 25).
5. Turn the Remote Operating Station to the ON
position and depress the CLOSE push button
(Figure 26).
6. Move the Control Selector Switch to the OFF
position (Figure 27).
To OPEN the Device
7. Move the Control Selector Switch to the OPEN
position (Figure 56).
8. Turn the Remote Operating Station to the ON
position and depress the OPEN push button on
the Remote Operating Station to open the ground
and test device (Figure 57).
9. Move the Control Selector Switch to the OFF
position (Figure 58) and turn the Test Cabinet
powerOFF.
10. Disconnect the Remote Operating Station umbili-
cal cord from the ground and test device (Figure
59).
When the electrical check is completed, disconnect
the Secondary Disconnect of the test cabinet from
the ground and test device.
E. INSERTING THE ELECTRICAL GROUND AND
TEST DEVICE INTO THE METAL-CLAD
SWITCHGEAR
Inserting the ground and test device into the metal-
clad switchgear is similar to inserting a circuit breaker
into the switchgear. Refer to instruction book,
IB-65000, for general information about inserting
circuit breakers into metal-clad switchgear. Study
instructions and cautions before attempting to insert a
ground and test device into the switchgear equip-
ment.
NOTE: Access information bulletins on line at the
Powell Industries Web site: [email protected].
To order instruction bulletins by telephone, call Powell
Electrical Manufacturing Company: 1-800-480-7273.
Each ground and test device and metal-clad
switchgear cell are provided with interference plates
(see Figure 2, e). The interference plates are de-
signed to ensure that the ground and test device is
not placed in an incorrect circuit breaker compart-
ment. If an attempt is made to insert an improper
ground and test device into a cell, the coding plates
will interfere with each other and deter the insertion.
The interference occurs before the device reaches
the DISCONNECT position. DO NOT attempt to
force the device past the coded interference plate nor
remove the plate from either the cell or the device.
Remove the incorrect device and insert the proper
one.
For normal insertion of the ground and test device
into the switchgear, the maximum force required on
the levering-in crank will not exceed 35 foot-pounds.
Excessive force may damage the device or the
switchgear equipment.
1) Electrical Ground and Test Device Inspection
1. Inspect the primary disconnecting devices for
proper lubrication, damage, debris, and dirt.
Ensure that disconnecting devices are in align-
ment and are not bent. If damage or dirt are

15
PowlVac®Electrically-Operated Ground and Test Device IB-65060
V. OPERATING PROCEDURES
A. PROCEDURE FOR APPLYING GROUNDS
The CON EDISON and CUSTOMER ground and
test devices are supplied with similar interlock
functions. However, the CON EDISON device
uses key KU for key lock K1, and the CUSTOMER
device uses key KCF for key lock K1. Key KU and
Key KCF are NOT INTERCHANGEABLE.
Althoughthese operatingprocedures containillustra-
tions of the CON EDISON device, these procedures
also apply to the CUSTOMER device. For proce-
dures that refer to key KU for the CON EDISON
device, the same procedures apply to key KCF for
the CUSTOMER device.
1. Verify the correct ground and test device is being
inserted in the compartment of the feeder to be
grounded.
•The ground and test devices are prominently
marked CON EDISON or CUSTOMER.
•Interference plates (Figure 2, e) prevent either
of the ground and test devices from being
inserted into an unauthorized compartment.
2. Obtain key KU from the Con Edison lock box.
3. Insert key KU into key lock K1 and rotate key KB.
Key KU is captive and has electrically locked the
ground and test device in the OPEN position
(Figure 12). Key KB is available (Figure 13).
4. Insert key KB into key lock K2 and rotate key KC
(Figure 14). The ground and test device is now
mechanically locked OPEN. Key KB is captive
and key KC is available (Figure 15).
5. Insert key KC into key lock K3 and rotate. Key
KC key is now captive. Pull the racking access
interlock handle out fully (Figure 16).
6. Insert the ground and test device into the com-
partment until a “stop” is encountered (no figure
provided).
7. Depress the manual trip operator on the
switchgear compartment front panel and open the
racking access shutter (Figure 17).
8. Rack the ground and test device into the CON-
NECT position using the supplied torque limiting
racking handle. A mechanical position indicator
indicates the CONNECT position (no figure
provided).
9. Push the Racking Access Interlock handle in fully
and rotate key KC to lock the ground and test
device in the CONNECT position. Key KC is
available (Figure 18).
10. Transfer key KC to key lock K2 and rotate. Key
KC is captive and key KB is available. The
ground and test is now mechanically unlocked
(Figure 19).
11. Transfer key KB to key lock K1 and rotate (Figure
20). The ground and test device control circuit is
now enabled. Key KB is captive and key KU is
available (Figure 21).
12. Verify that the Control Selector Switch is in the
OFF position (Figure 22).
13. Connect the Remote Operating Station to the
ground and test device and rotate the plug
clockwise to lock (Figure 23).
14. Connect the compartment secondary disconnect
to the receptacle on the ground and test device
(Figure 24).
15. Move the Control Selector Switch to the CLOSE
position (Figure 25).
16. Turn the Remote Operating Station ON and
depress the CLOSE push button (Figure 26).
17. Move the Control Selector Switch to the OFF
position (Figure 27).
18. Turn the Remote Operating Station OFF and
disconnect the Remote Operating Station umbili-
cal cord from the ground and test device (Figure
28).
19. Rotate key KU in key lock K1 electrically dis-
abling the ground and test device (Figure 29).
Remove key KB from key lock K1 (Figure 30).
20. Secure key KB in the Con Edison lock box.
present, see Section V. MAINTENANCE, A.
INSPECTION AND CLEANING.
IMPORTANT: If the primary disconnecting
devices are damaged, make no attempt to repair
them. Contact Powell Electrical Manufacturing
Company for further information.
2. Inspect the switchgear compartment to ensure
that it is clean and clear of debris that might
interfere with ground and test device travel.

PowlVac®Electrically-Operated Ground and Test Device IB-65060
16
Figure 13. Key KB is Available
Figure 16. Insert Key KC in
Key Lock K3 and Rotate
Figure 14. Insert Key KB in Key Lock K2
and rotate Key KC Figure 15. Rotate Key KC
Figure 17. Depress the Manual Trip Operator
on the Switchgear Compartment Front Panel
a. Manual Trip Operator (Does not trip the ground
and test Device)
b. Racking Access Shutter
c. Position Indicator
abc
Figure 12. Insert Key KU into
Key Lock K1 and Rotate Key KB

17
PowlVac®Electrically-Operated Ground and Test Device IB-65060
Figure 20. Transfer Key KB to
Key Lock K1 and Rotate
Figure 21. Key KB is Captive
and Key KU is available
Figure 19. Transfer Key KC to
Key Lock K2 and Rotate
Figure 22. Verify the Control Selector
Switch is in the OFF Position Figure 23. Connect the Remote Operating Station Cord to the Ground and Test Device
and Rotate to Lock
Figure 18. Rotate Key KC to Lock the Ground
and Test device in the CONNECT position

PowlVac®Electrically-Operated Ground and Test Device IB-65060
18
Figure 24. Connect the Compartment
Secondary Disconnect
Figure 27. Move the Control Selector
Switch to the OFF Position
Figure 25. Move the Control Selector
Switch to the CLOSE Position
Figure 28. Disconnect the Remote Operating
Station Umbilical Cord
Figure 26. Depress the CLOSE Push Button
on the Remote Operating Station

19
PowlVac®Electrically-Operated Ground and Test Device IB-65060
Figure 29. Rotate Key KU in Key Lock K1 Figure 30. Remove Key KB from Key Lock K1
THIS SPACE IS INTENTIONALLY BLANK.

PowlVac®Electrically-Operated Ground and Test Device IB-65060
20
B. PROCEDURE FOR TESTING FEEDER
The CON EDISON and CUSTOMER ground and test
devices are supplied with similar interlock functions.
However, the CON EDISON device uses key KU for
key lock K1, and the CUSTOMER device uses key
KCF for key lock K1. Key KU and Key KCF are NOT
INTERCHANGEABLE.
Although these operating procedures contain illustra-
tions of the CON EDISON device, these procedures
also apply to the CUSTOMER device. For proce-
dures that refer to key KU for the CON EDISON
device, the same procedures apply to key KCF for
the CUSTOMER device.
Perform the following steps:
1. Verify the Con Edison ground and test device is
being inserted in the compartment of the feeder
to be grounded.
•The ground and test devices are prominently
marked “Con Edison” or “Customer.”
•Interference plants (Figure 2, e) prevent either
of the ground and test devices from being
inserted into an unauthorized compartment.
2. Obtain key KU from the Con Edison lock box.
3. Insert key KU into key lock K1 and rotate key KB.
(Figure 31). Key KU is captive and has electri-
cally disabled the ground and test device while in
the OPEN position. Key KB is now available
(Figure 32).
4. Insert key KB into key lock K2 and rotate key KC
(Figure 33). The ground and test device is now
mechanically locked OPEN. Key KB is now
captive and key KC is available.
5. Insert key KC into key lock K3 and rotate. Key
KC key is now captive (Figure 34). Pull the
racking access interlock handle out fully.
6. Insert the ground and test device into the com-
partment until a “stop” is encountered (no figure
provided).
7. Depress the manual trip operator on the
switchgear compartment front panel and open the
racking access shutter (Figure 35).
8. Rack the ground and test device into the CON-
NECTED position using the supplied torque
limiting racking handle. A mechanical position
indicator indicates the CONNECTED position (no
figure provided).
9. Push the Racking Access Interlock handle in fully
and rotate key KC to lock the ground and test
device in the CONNECTED position. Key KC is
now available (Figure 36).
10. Transfer key KC to key lock K2 and rotate (see
Figure 37). The key KC is now captive and key
KB is available. The ground and test is now
mechanically unlocked.
11. Transfer key KB to key lock K1 and rotate (Figure
38). The ground and test device control circuit is
now enabled. Key KB is captive and key KU is
available.
12. Verify that the Control Selector Switch is in the
OFF position (Figure 39).
13. Connect the Remote Operating Station to the
ground and test device and rotate the plug
clockwise to lock (Figure 40).
14. Connect the compartment secondary disconnect
to the receptacle on the ground and test device
(Figure 41).
15. Move the Control Selector Switch to the CLOSE
position (Figure 42).
16. Turn the Remote Operating Station ON and
depress the CLOSE push button switch on the
Remote Operating Station to close the ground
and test device (Figure 43).
17. Move the Control Selector Switch to the OFF
position (Figure 44).
18. Turn the Remote Operating Station OFF and
disconnect the Remote Operating Station umbili-
cal cord from the ground and test device (Figure
45).
19. Rotate key KB in key lock K1 electrically dis-
abling the ground and test device. Remove key
KB from key lock K1 (Figure 46).
20. Transfer key KB to key lock K4 and rotate key KD
(Figure 47). The ground and test device is now
electrically and mechanically locked in the
CLOSED position. Key KB is captive and key
KD is available.
21. Transfer key KD to key lock K5 and rotate (Figure
48). Key KD unlocks the test port shutters.
22. Open the test port shutters using the slide handle
(Figure 49). With the test ports, 2/3 open, key
KD remains captive.
23. Install the test probes into the test ports (Figure
50). Move the test port shutter to the left to
capture the test probes in the test probe shutter.