Southern States ES-1 Service manual

Type ES-1 2 & 3 Way
Aluminum Side Break
Phase-Over-Phase
Disconnect Switch
For All Ratings
INSTRUCTION
INSTALLATION &
MANUAL

ATTENTION:
Southern States will begin supplying a portion of new operating mechanism designs with
Rapid-Set clevises for orders designed after 9/1/23. If your Operating Mechanism print calls
for Rapid-Set clevises (see image below for an example), please utilize the instructions
on the following pages for all linkage adjustments. If not, please adhere to the standard
instructions provided.

Please scan or use the link below for video instructions of Rapid-Set.
Southern States Rapid Set Instructions
STEP 1:
Install the auxiliary arm by aligning the straight edge of the arm with the center of the vertical pipe and
bolting it into place using two of the provided mounting holes. Do this with the switch phase set to the
full closed position as shown below.

STEP 2:
Install the adjustable arm with the radius “R” set to the recommended length provided in the operating
mechanism drawings.
STEP 3:
Install the auxiliary arm Rapid-Set clevis and drive pipe. Ensure that roughly 12” of pipe extends beyond
the adjustable arm clevis connection so that the pipe makes contact with the adjustable arm in the
position shown. This may be the open or closed position depending on the job specific drawings. The
pipe should contact the adjustable arm in this position.

STEP 4:
With the auxiliary arm properly aligned with the vertical pipe and the switch phase in the full closed
position, pierce the pipe at both ends. NOTE: U-bolt style clevises require pre-drilling on all pipes thicker
than SCH40. Drill guides are provided on the operating mechanism BOM when required. Pierce the
adjustable arm clevis by hand tightening until it penetrates the pipe and continue until snug (note
piercing screw may still have threads showing). Do not remove plastic caps from the Rapid-Set clevis
at this time. To pierce the Rapid-Set clevis, tighten each piercing screw until the head contacts the
aluminum extrusion. Do not over tighten.
STEP 5:
Begin to manually open the phase using the operator. Observe the phase closed and open stops during
operation and modify the length of the adjustable arm as needed to provide the proper amount of travel.
Lengthen the arm to add travel and shorten the arm to decrease travel. The mechanism should have
sufficient toggle (spring load) during closed and open position. To balance the force at closed and open
positions, adjust the length “L” of the Rapid-Set clevis by adjusting the four nuts shown below. Ensure
that both the top and bottom sets are adjusted in equal increments.

STEP 6:
After the drive phase is adjusted to operate correctly, set all phases to full closed, and install the
interphase pipe following the procedure below.
For switches driven by the center phase:
a. With the interphase pipe centered and all clevises in place, pierce the interphase pipe at the
locations shown. Do not remove plastic caps at this time.
b. Adjust the timing of the two driven phases by adjusting the length “L” of each Rapid-Set clevis.

For switches driven by one of the end phases:
a. With the interphase pipe centered and all clevises in place, pierce the interphase pipe with at the
locations shown. Do not remove plastic caps at this time.
b. Adjust the timing of the center phase by adjusting the length “L” of the Rapid-Set clevis attached
to the drive phase.

c. Set the timing of the last phase by adjusting the length “L” of the Rapid-Set clevis attached to the
last phase.
STEP 7:
With all the phases adjusted, open and close the three phase assembly and inspect for proper operation.
Once adjustments are finalized, pierce all remaining connections (switch operator, adjustable arm, etc).
STEP 8:
Each Rapid-Set clevis is provided with 2 extra piercing screws. These are for optional use. To install
these, remove the plastic cover caps and install them as shown below. Note, adding these will restrict
any additional adjustment. Remove them before making any adjustments and then reinstall them on
the bottom side of the clevis.
Optional piercing screws

Safety Information
DANGER
THE EQUIPMENT COVERED IN THIS MANUAL SHOULD BE HANDLED, INSTALLED, AND
MAINTAINED BY TRAINED PERSONNEL ONLY. IMPROPER HANDLING, INSTALLATION,
OPERATION OR MAINTENANCE OF THIS EQUIPMENT MAY CAUSE IMMEDIATE HAZARDS WHICH
WILL LIKELY RESULT IN SERIOUS PERSONNEL INJURY OR DEATH.
WARNING
The equipment covered by this publication must be handled, installed, operated and maintained by
qualified persons who understand any hazards involved and are thoroughly trained in the handling,
installation, operation and maintenance of high voltage transmission and distribution equipment. These
instructions are meant for only such qualified persons. They are not intended to be a substitute for
adequate training and experience in safety procedures for this type of equipment.
A qualified person is one who is trained in and has skills necessary:
to distinguish between energized and non energized parts
to determine proper approach distances to energized parts
to determine proper approach to energized or de-energized equipment that may be pressurized
with gas
proper use of personal protective equipment, insulating and shielding materials, insulated tools
for working near energized and /or pressurized electrical equipment
Knowledge of special purpose equipment that may be unbalanced, pressurized or may have
other special attributes that require precautions in handling, installation, operation and
maintenance
The instructions in this manual are general guidelines for this type of equipment and not specific to the
equipment supplied. Portions of it may not be applicable or may not have complete instructions for your
specific equipment. If you do not understand any part of these instructions or need assistance, contact
Southern States Service Division at 770-946-4562.

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The Quality Name in High Voltage Switching
Preliminary Release 11/11/2011
Type ES-1 2 Way

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The Quality Name in High Voltage Switching
Preliminary Release 11/11/2011
Type ES-1 3 Way

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The Quality Name in High Voltage Switching
Preliminary Release 11/11/2011
Table of Contents
Introduction...............................................................................................................................6
Receiving ...............................................................................................................................6
Storage...................................................................................................................................6
General Information .............................................................................................................6
Principles of Operation .........................................................................................................7
Installation and Adjustment Procedures.................................................................................9
Typical Disconnect Switch....................................................................................................9
Preferred Switch Assembly Method...................................................................................10
Unfold Switch ...................................................................................................................10
Mount Cross Braces to Switch Base ...............................................................................14
Check Contact Adjustment ...........................................................................................15
Check Blade Stop Adjustment .......................................................................................17
Mount Switch Base to Structure......................................................................................21
Mount Frame to Structure ...............................................................................................22
Install Operating Mechanism Components ..................................................................23
Adjust Switch and Operating Mechanism ....................................................................26
Optional Attachments ...........................................................................................................30
Interrupters...........................................................................................................................30
Whips ....................................................................................................................................30
Arcing Horns ........................................................................................................................30
Recommended Inspection and Maintenance ...................................................................31
Patrolling Inspection (6 Months).........................................................................................31
Routine Inspection and Maintenance (5 year) ................................................................32
Periodic Inspection and Maintenance (10 year) .............................................................32
Table 1: Recommended Tools and Torque Values ...............................................................6
Table 2: Recommended Inspection and Maintenance Schedule ....................................31

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The Quality Name in High Voltage Switching
Preliminary Release 11/11/2011
Figure 1: Typical Pole Mounted Switch with Operating Mechanism....................................8
Figure 2: Common ES-1 2 & 3 Way Terminology.....................................................................9
Figure 3: Folded Switch ..........................................................................................................10
Figure 4: Unfolding First Base Member ..................................................................................11
Figure 5: Both Base Members Unfolded................................................................................11
Figure 6: Base Member Hardware.........................................................................................12
Figure 7: Closed Switch ..........................................................................................................12
Figure 8: Bearing Stop Bolt Height .........................................................................................13
Figure 9: Base Frame Components Attached......................................................................14
Figure 10: Blade Alignment ....................................................................................................15
Figure 11: Male Blade Tip Depth............................................................................................15
Figure 12: Blade Open Gap...................................................................................................16
Figure 13: Left-handed Switch Blade Over Toggle ..............................................................17
Figure 14: Left-Handed Live Parts Closed Position Stop.......................................................17
Figure 15: Closed Position Bearing Stop................................................................................18
Figure 16: Left-Handed Blade Catch Position ......................................................................19
Figure 17: Left-Handed Open Position Live Parts Stop.........................................................19
Figure 18: Left-Handed Minimum Open Angle ....................................................................20
Figure 19: Lifting Strap Locations ...........................................................................................21
Figure 20: Typical Frame Design ............................................................................................22
Figure 21: Typical 2 Way ES-1 Operation Mechanism..........................................................23
Figure 22: Top Phase Operation Mechanism .......................................................................24
Figure 23: Vertical Bearing Support .......................................................................................24
Figure 24: Typical Vertical Bearing Support Locations.........................................................25
Figure 25: Typical Swing Handle ............................................................................................26
Figure 26: Typical Initial Setting. .............................................................................................27
Figure 27: Adjusting the Adjustable Arm ...............................................................................28
Figure 28: Bearing Opened Position Stop .............................................................................29
Figure 29: Quick Break Style Whip .........................................................................................30

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The Quality Name in High Voltage Switching
Preliminary Release 11/11/2011
Summary
These instructions do not purport to cover all details or variations in equipment, or
provide for every possible contingency to be met in connection with installation,
operation or maintenance. Should information be desired or should particular
problems arises which are not covered sufficiently for the purchaser’s purposes, the
matter should be referred to the local Southern States Representative. The contents
of this instruction manual should not become part of or modify any prior or existing
agreement, commitment or relationship. The sales contract contains the entire
obligation of Southern States. The warranty contained in the contract between the
parties is the sole warranty of Southern States. Any statements contained herein do
not create new warranties or modify the existing warranty.
Important
The information contained herein is general in nature and not intended for specific
application purposes. It does not relieve the user of responsibility to use sound
practices in application, installation, operation, and maintenance of the equipment
purchased. Southern States reserves the right to make changes in the specifications
shown herein or to make improvements at any time without notice or obligations.
Should a conflict arise between the general information contained in this publication
and the contents of drawings or supplementary material, or both, the latter shall take
precedence.

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The Quality Name in High Voltage Switching
Preliminary Release 11/11/2011
Introduction
The Southern States Type ES-1 2 & 3 Way switches are three phase, group operated,
side break air disconnect switches. The switches may be operated using a manual
operator or an electric motor operator. The installation procedure for all mounting
positions and operating schemes is similar and explained herein. A system of pipes,
bearings, and adjustable length arms is utilized to open and close the switch from a
ground level operator.
Receiving
Unpack the equipment and check for damages or shortages immediately. The bill of
material from the Unit Assembly (switch) and Operating Mechanism drawings should be
used for this purpose. If damage or a shortage is noted, file a claim immediately with
the carrier and contact the factory.
Storage
All components of the ES-1 disconnect switch are suitable for outdoor use and do not
have any special storage requirements. If a motor operator is furnished be sure to
connect the heater circuit, using the provided external wiring, while the unit is in
storage. Discard the wiring upon installation. Typical crating is intended for storage less
than 1 year. If long term storage is required please notify factory at time of order
placement so that special crating can be furnished.
General Information
All photographs and sketches in this manual are for illustration purposes only and may
not be to scale. Refer to the Unit Assembly drawing or the Operating Mechanism
drawing provided with each disconnect switch for specific details. During installation, it
may be necessary to make adjustments other than those described in this manual.
Contact your local representative or the factory if questions should arise. Southern
States After Sales and Service Department is available for field installation assistance
along with providing parts support for all Southern States products. Contact After Sales
and Service at 770-946-4562.
Table 1: Recommended Tools and Torque Values
Tools
Torque Values
Type
Sizes
Bolt Size
Torque (Ft-lb)
Hand Wrenches
1 1/8”, 15/16”, 3/4", 9/16”, 7/16”
1/4”
8
Sockets
1 1/8”, 15/16”, 3/4", 9/16”, 7/16”
3/8”
16
Screw Drivers
Flat Head
1/2"
40
Pliers
Needle Nose
5/8”
92
3/4”
127

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The Quality Name in High Voltage Switching
Preliminary Release 11/11/2011
Principles of Operation
These switches are designed to be opened and closed as a three-phase unit by a
system of pipes that translates the rotational movement of an operator on the ground
(whether manual or electrical) to simultaneous rotation of the end insulator of each
switch pole. Figure 1 shows a typical operating mechanism for a 2 Way ES-1 switch. In
all cases the operating principle remains the same and the methods of installation and
adjustment are virtually identical.
The operating mechanisms are intended to fully open and fully close the disconnect
switch by rotating the vertical operating pipe 180ousing an operator (manual or
electrical). Each switch blade is operated by a separate operating mechanism. A 2
Way has two operating mechanism and a 3 Way has three mechanisms. The reach rod
translates the motion of the vertical operating pipe to the rotating insulator. The
adjustable arm controls the total amount of switch operation available.
The 2 & 3 Way ES-1 Switches have both right-hand (clockwise rotating) and left-hand
(counterclockwise rotating) switch blades and operating mechanisms. This is necessary
so that both switch blades closest to the pole open away from the pole, thereby
preserving line to ground clearance on a smaller frame.

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The Quality Name in High Voltage Switching
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Figure 1: Typical Pole Mounted Switch with Operating Mechanism
Left-handed switch blade
Right-handed switch blade
Clockwise
Operating
Mechanism
Counterclockwise
operating mechanism
Structure

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The Quality Name in High Voltage Switching
Preliminary Release 11/11/2011
Installation and Adjustment Procedures
Typical Disconnect Switch
In general, installing a Southern States Type ES-1 2 or 3 Way Disconnect Switch consists
of the following:
Unfolding the switch.
Mounting the cross braces to the switch base.
Mounting the switch base to the structure.
Mounting the remaining frame components to the structure.
Installing operating mechanism components.
Final adjustment of the switch and operating mechanism.
Figure 2: Common ES-1 2 & 3 Way Terminology
Operating Arm
Terminal Pad
Male Blade Assembly
Contacts
Female Blade Assembly
Insulator
Insulator Adapter
Switch Base
Insulator Bearing

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The Quality Name in High Voltage Switching
Preliminary Release 11/11/2011
Preferred Switch Assembly Method
Unfold Switch
1) Remove any shipping braces or straps from the switch. Leave the shipping stands
attached to the switch base to facilitate assembly. See Figure 3.
Figure 3: Folded Switch
Important
Safety precautions must be taken and safety guidelines carefully followed.
Follow all NESC, OSHA, user, manufacturer, and local safety requirements.
Steps shown apply equally to both 2 and 3 Way ES-1 switches.
Shipping Stand
Shipping Stand
Shipping Stand

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The Quality Name in High Voltage Switching
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2) Rotate switch base member 90°. See Figure 4.
Figure 4: Unfolding First Base Member
3) Repeat with the other switch base member. See Figure 5.
Figure 5: Both Base Members Unfolded