Document Revision 2516 C-2 March 12, 2008 Instruction Manual Switchgear System Series 82XSYS Cooper Industries Crouse-Hinds Division Crouse-Hinds Airport Lighting 1200 Kennedy Road Windsor, CT 06095 For Parts or Technical Service Call (860) 683-4300 Copyright © 2008 Cooper Technologies Company Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Revisions Revision Number A B Issue/Reissue Letter Number A205-190 A205-285 Description Released to production, no changes 1.2.1 & 1.2.3.1, Dead-Front Switchboard was Dead-Front Switchgear; 1.2.3.3, CCR cabinet wt. was 700 lbs & added info in regards to “K” option; 1.3 & 2.1.1, added max pad ht.; 2.1.4, left side rear was left side & 2 Bussman FNQ-R4/10 Fuses was 3; 2.1.5, added info on magnetic trip adjustment; 2.1.8, added info on levelers and wheels & max pad ht.; 2.1.9, added info to complete load wiring & installation of CCR power modules from hinge side; 2.1.11.2, added wire lengths & info to mark with colored tape and use control wire troughs; Addendum, added S-1 Cutout 30771 & related data, Kirk Key Type D, Lock-Out Bracket KLB-001 & revised Kirk Key Type F & deleting Superior Interlock; revised Figure 18 side view; added photos 6, 7 & 8; dwg 34123 revised to rev B & dwgs 34126 revised to rev D & 34127 revised to rev C; Figure 15, 27.5 was 26.5, 43.75 was 42.0, 53.5 was 52.6 and added 10" dim note about tangs; added lift, track extensions and concrete pad to Figure 13 ii Checked 05/19/05 08/18/05 Approved PG PG Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS C A206-107B C-2 A208-028 Revised drawings 34122-34125;added figure 14A; Fig 18, added trough dims; Fig 14, ¼” bolt torque was 7ft-lbs; Fig 12, added note to use only 4 corner holes for seismic bolting; Fig 11, added holes at 9.0 dim; 1.1.1, 2506 was 2512; 2.1.2 added “refer to figure 14A…hardware”; 2.1.4, added factory settings for thermostat; 2.1.8 added additional instructions for track extensions; 2.1.9 added 2605 and that door includes main circuit cards, Addendum parts, added Microswitch P/N 2DM409 & deleted CH S-1 cutout 30771, Square D indicator KM38LR & added C-H Kirk key lock out brkt P/N 34176; added copyright to cover page 1.2.1 & 1.2.3.2, bus stabs were rated 400A; 2.1.6, added note to torque stn stl hardware; Addendum, Bus Stabs, E10742 was E1016-1621S & E1074-4 was E1016-1635S & Cooper Interconnect was Crouse-Hinds Molded Products; pg 53, 34123 revision was F ii-1 PG 3/12/2008 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Limited Product Warranty The following warranty is exclusive and in lieu of all other warranties, whether express, implied or statutory, including, but not by way of limitation, any warranty of merchantability or fitness for any particular purpose. Crouse-Hinds Airport Lighting Products (the “Company”) warrants each original Buyer of Products Manufactured by the Company that such Products are, at the time of deliver to the Buyer free of material and workmanship defects, provided that no warranty is made with respect to: (a) any product which has been repaired or altered in such a way, in Company’s judgement as to affect the Product Adversely; (b) any Product which has in Company’s judgement, been subject to negligence, accident or improper storage; (c) any Product which has not been operated and maintained in accordance with normal practice an in conformity with recommendations and published specifications of company; and, (d) Any Products, components parts or accessories manufactured by others but supplied by Company (any claims should be submitted directly to the manufacturer thereof). Crouse-Hinds Airport Lighting Products’ obligation under this warranty is limited to use reasonable efforts to repair or, at is option, replace, during normal business hours at any authorized service facility of Company, any Products which in its judgement proved not to be as warranted within the applicable warranty period. All cost of transportation of Products claimed not to be as warranted and of repaired or replacement Products to or from such service facility shall be borne by Purchaser. Company may require the return of any Product claimed not to be warranted to one of its facilities as designed by Company, transportation prepaid by Purchaser, to establish a claim under this warranty. The cost of labor for installing a repaired or replacement product shall be borne by the Purchaser. Replacement parts provided warranty period of the Products upon which they are installed to the same extent of such parts were original components thereof. Warranty services provided under the Agreement not assure uninterrupted operations of Products; Company does not assume any liability for damages caused by any delays involving warranty service. The warranty period for the Products is 24 months from date of shipment or 12 months from date of first uses whichever occurs first. iii Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Safety Notices This equipment is normally used or connected to circuits that may employ voltages which are dangerous and may be fatal if accidentally contacted by operating or maintenance personnel. Extreme caution should be exercised when working with this equipment. While practical safety precautions have been incorporated in this equipment, the following rules must be strictly observed: KEEP AWAY FROM LIVE CIRCUITS Operating and maintenance personnel must at all times observe all safety regulations. DO NOT PERFORM MAINTENANCE ON INTERNAL COMPONENTS FOR RELAMP WITH POWER ON. STORED ENERGY Ensure Capacitors are discharged before working on equipment. RESUSCITATION Maintenance personnel should familiarize themselves with the technique for resuscitation found in widely published manuals of first aid instruction. See FAA Advisory Circular AC 150/5340-26 for additional information. iv Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Safety Symbols DANGER: DANGER The hazard or unsafe practice will result in severe injury or death. WARNING: WARNING The hazard or unsafe practice could result in severe injury or death. CAUTION: CAUTION The hazard or unsafe practice could result in severe injury or death. NOTICE: NOTICE Possibly dangerous situation, goods might be damaged. IMPORTANT: IMPORTANT Helpful information. v Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Table of Contents Title Page ......................................................................................................................................... i Revisions......................................................................................................................................... ii Limited Product Warranty ............................................................................................................. iii Safety Notices ................................................................................................................................ iv Safety Symbols ................................................................................................................................v Table of Contents........................................................................................................................... vi Figures....................................................................................................................................... ix Photos..........................................................................................................................................x Drawings .....................................................................................................................................x Section 1. General Information........................................................................................................1 1.1 Introduction............................................................................................................................1 1.1.1 Purpose...........................................................................................................................1 1.1.2 Applicability ..................................................................................................................1 1.2 Equipment Description ..........................................................................................................2 1.2.1 Features ..........................................................................................................................2 1.2.2 Options...........................................................................................................................2 1.2.3 Specifications.................................................................................................................2 1.2.3.1 Compliance ............................................................................................................2 1.2.3.2 Electrical Characteristics .......................................................................................3 1.2.3.3 Physical Characteristics .........................................................................................3 1.3 Installation Requirements ......................................................................................................4 Section 2. Installation.......................................................................................................................5 2.1 Installation..............................................................................................................................5 2.1.1 Location .........................................................................................................................5 2.1.2 Cabinet Installation ........................................................................................................6 2.1.3 Field Load Wiring..........................................................................................................7 vi Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 2.1.4 Fan Operating Control Setting .......................................................................................8 2.1.5 Main Input Power Connections .....................................................................................8 2.1.6 Load Balancing ..............................................................................................................9 2.1.7 Counterbalanced Lift Operation ....................................................................................9 2.1.8 Track Extension Use ....................................................................................................10 2.1.9 CCR Power Module Installation..................................................................................11 2.1.10 Digitrac and Megatrac Option Installation ................................................................13 2.1.10.1 Digitrac Option Installation ...............................................................................13 2.1.10.2 Megatrac Option Installation .............................................................................13 2.1.11 Control Wiring ...........................................................................................................13 2.1.11.1 Standard CCR Control Wiring ..........................................................................13 2.1.11.2 Digitrac Option Control Wiring Connections....................................................14 2.1.11.3 Auxiliary Cabinet Option Control Wiring Connections ....................................14 Section 3. Operation.......................................................................................................................15 3.1 Initial System Power-Up......................................................................................................15 3.1.1 Bus Power Engaged Indicator Light ............................................................................15 3.1.2 CCR Power Module Power-Up ...................................................................................16 3.1.3 Remote Control Wiring Check ....................................................................................16 3.1.3.1 Standard Remote Control Wiring ........................................................................16 3.1.3.2 Digitrac Option Network Wiring .........................................................................17 3.2 Optional Features Operation ................................................................................................17 3.2.1 Megatrac Option Test ..................................................................................................17 3.2.2 S-1 Cutout Auxiliary Cabinet Option ..........................................................................17 3.2.3 L-847 Auxiliary Cabinet Option..................................................................................17 vii Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Section 4. Periodic Maintenance, Switchgear System...................................................................18 4.1 Scope of Maintenance..........................................................................................................18 4.1.1 Cabinet Maintenance ...................................................................................................18 4.1.2 Cabinet Bus and Wiring Connection Maintenance......................................................18 Section 5. Switchgear Cabinet Addition to System .......................................................................19 5.1 Adding Cabinets...................................................................................................................19 5.1.1 Adding CCR Switchgear Cabinets...............................................................................19 5.1.2 Adding Switchgear System Auxiliary Cabinets ..........................................................19 Section 6. Hot Swapping CCR Power Modules ............................................................................19 6.1 Hot Swapping Procedure .....................................................................................................19 Addendum......................................................................................................................................21 viii Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Figures Figure 1 – Cabinet Installation.......................................................................................................23 Figure 2 – Cabinet Installation.......................................................................................................24 Figure 3 – Cabinet Installation.......................................................................................................25 Figure 4 – Cabinet Installation.......................................................................................................26 Figure 5 – Cabinet Installation.......................................................................................................27 Figure 6 – Cabinet Installation.......................................................................................................28 Figure 7 – Cabinet Installation.......................................................................................................29 Figure 8 – Cabinet Installation.......................................................................................................30 Figure 9 – Cabinet Installation.......................................................................................................31 Figure 10 – Cabinet Installation.....................................................................................................32 Figure 11 – Bottom View, Cabinet Wiring Entrances...................................................................33 Figure 12 – Seismic Bolting ..........................................................................................................34 Figure 13 – Cabinet Wall Clearances ............................................................................................35 Figure 14 – Bus Splice Installation................................................................................................36 Figure 14A – Bus Splice Connection Hardware Details ...............................................................37 Figure 15 – Typical CCR Power Modules Installation/Removal – Forklift..................................38 Figure 16 – Typical CCR Power Module Installation/Removal – Track Extension .....................39 Figure 17 – Recommended Building Ceiling Height ....................................................................40 Figure 18 – Typical Cable Wiring .................................................................................................41 Figure 19 – Optional L-847 Control Wiring Connected to Digitrac .............................................42 Figure 20 – Opt. S-1 Aux. Cab. Intentional Grounded S-1 Cutout Wiring Scheme……………..43 ix Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Photos Photo 1 – Lower Track Extension with CCR Power Module........................................................44 Photo 2 – Lower CCR Power Module Installed in Cabinet...........................................................45 Photo 3 – Upper Track Extension with CCR Power Module & Counterbalanced Lift.................46 Photo 4 – Upper Track Extension and CCR Power Module .........................................................47 Photo 5 – Upper Track Extension with Upper CCR Power Module Installed ..............................48 Photo 6 – Switchgear Installation on an Elevated Pad ..................................................................49 Photo 7 – Switchgear Cabinet with Fan Option and Doors Opened..............................................50 Photo 8 – Switchgear Cabinet Door with Digitrac and Megatrac Options Installed .....................51 Drawings Drawing 34122 – Switchgear System Main Input Cabinet ...........................................................52 Drawing 34123 – Switchgear Cabinet – CCR for 2 Power Modules ............................................53 Drawing 34124 – Switchgear System S-1 Cutout Cabinet (Optional) ..........................................54 Drawing 34125 – Switchgear System Auxiliary Cabinet (Optional) ............................................55 Drawing 34126 – Switchgear System (Upper Track Extension)...................................................56 Drawing 34127 – Switchgear System (Lower Track Extension) ..................................................57 x Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 1 General Information 1.1 Introduction Equipment described in this manual is produced for Crouse-Hinds Airport Lighting by EasterOwens Electric to be compliant to UL 891, standard for deadfront Switchgear. 1.1.1 Purpose This instruction manual provides information for installing and maintaining Switchgear Cabinets for use with FAA Type L-828 Constant Current Power Modules manufactured by Crouse-Hinds Airport Lighting Products, Windsor, Connecticut 06095, USA. See manual 2447 and Instruction Sheet 2605 (Door Installation) for information in regards to the Constant Current Regulator operation and maintenance requirements. See Manual 10056-1002 for optional Megatrac® operation and maintenance requirements. See manual VDIV-0001-0-00 for optional Digitrac® operation and maintenance requirements. See manual 9313 for FAA L-847 Circuit Selector Switch operation and maintenance requirements if the system was ordered with this optional auxiliary cabinet feature. See manual 10056-2005 for Logitrac adapter operation and maintenance requirements if the system was ordered with this optional auxiliary cabinet feature. 1.1.2 Applicability Only Switchgear Cabinets shown on drawings 34122, 34123, 34124, 34125, 34126, and 34127 are covered by this manual. Drawing 34089 shows the counter balanced lift supplied with the system for installing the CCR (Constant Current Regulator) power modules. Operation instructions for the counterbalanced lift are not discussed in this manual, but the use of it is. 1 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 1.2 Equipment Description 1.2.1 Features The Switchgear cabinets are designed to provide input power and control and load wiring cable ways for Crouse-Hinds Airport Lighting CCR power modules. The main input circuit breaker cabinet is supplied with a circuit breaker rated for 65KAIC. The power bus bars mounted in the cabinets are rated for 800A, 65KAIC. The ground bus bar is rated for 300A. the bus stabs are rated for 175A. All line side wiring to the bus stabs are braced for 65 KAIC and rated for 125A. The CCR power modules when installed in the cabinets are “hot swappable” when its associated field load has been disconnected and the integral circuit breaker for the CCR power module is in the off position. The Switchgear cabinets and CCR power modules are seismic rated to 200% NFPA 500 RRS (Required Response Spectra) and 200% IBC RRS for electrical equipment. The Switchgear cabinets meet the requirements of NEMA 1. The Switchgear cabinets are compliant to UL 891, standard for Dead-Front Switchboard. All hinged Switchgear cabinet doors are supplied standard with a 3 point lockable door handle. The main input circuit breaker is supplied standard with a lockout device. All Switchgear cabinets are steel painted with a powder coat gray color. All Switchgear cabinets are supplied with 4 lifting eyebolts. Switchgear CCR power modules cabinets allow two Crouse-Hinds CCR power modules up to 30kW each (max 20kW each, 50Hz) to be vertically contained and operated in a single cabinet without the use of cabinet exhaust fans. 1.2.2 Options The Switchgear cabinets can be supplied with a number of options. Refer to drawing 34122, 34123, 34124, 34125, 34126 and 34127. Switchgear cabinets are custom order and most of the options listed are factory installed/fabricated only. 1.2.3 Specification 1.2.3.1 Compliance Switchgear cabinets are compliant with the following specifications: • UL 891, Standard for Dead-Front Switchboard • NEMA Type 1, Indoor Enclosures • Seismic Rated to 200% NFPA 500 RRS (Required Response Spectra) and 200% IBC RRS for electrical Equipment 2 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 1.2.3.2 Electrical Characteristics Primary Power: 480 V, 60Hz, 3 Phase 3 Wire, 800A or 380V, 50 Hz 3 Phase 3 Wire, 800A when main input circuit breaker cabinet is ordered with maximum circuit breaker size 8. Refer to drawing 34122 for other available main circuit breaker sizes. Note: CCR Power Modules must be ordered to match frequency of input power. Maximum bus bar system capacities are 280 kW for 480V input and 220 kW for 380 V input to accommodate a safety margin of 125% of the rated current for an 800A bus bar system. The horizontal bus bar is rated for 800A maximum. The ground bus is rated for 300A maximum. The vertical drops to the bus stabs are rated 125A maximum. The bus stabs are rated 175A maximum. The bracing rating for the entire Switchgear system is 65KAIC. All power bus bars, ground bus, bus stabs and conductor leads are copper. CCR Power Module Integral Circuit Breaker Sizes. Circuit breakers provided with the power modules are rated for 65KAIC, 480V, 60Hz 380V, 50HZ kW Size CCR Pwr Module CCR Pwr Module 4 15A 20A 7.5 25A 30A 10 30A 40A 15 45A 60A 20 60A 80A 30 90A Not available 1.2.3.3 Physical Characteristics Dimensions: Refer to drawing 34122, 34123. 34124, and 34125. See figure 11 for additional dimensional information. Shipping Weights: Main Input circuit breaker Cabinet CCR Cabinet (Does not includes power module weights, CCR power modules shipped separately) Auxiliary Cabinets, Standard S-1 (Cutouts installed) Auxiliary Cabinet, L-847 (3 Selector Switches Installed) Upper and Lower Track Extensions (combined weight as shipped) Counterbalanced lift 3 700 lbs. 1200 lbs. 700 lbs. 700 lbs. 700lbs 5,550 lbs. Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Mechanical: Switchgear cabinets are intended for indoor use only and should be stored in a dry indoor location if being staged for installation. Cabinets are rated NEMA 1. Cabinets are steel and painted a powder coat gray color. Standard CCR cabinet tops, bottom section rear and both front door sections are louvered. All Switchgear cabinet hinged doors are supplied with a 3 point lockable door handle. Lockout devices on all circuit breakers (main system input and CCR power modules) are standard (padlocks not supplied). Note, option “K”, Kirk Key Interlock for power module cabinet door and its circuit breaker is key locked, not padlocked. Side panels are removable and the rear panels are welded on all Switchgear cabinets. All hinged doors can be removed from cabinets. Four lifting eyebolts are supplied with each Switchgear cabinet. Environmental: Temperature: -40º C to +55º C -40º F to +131º F * 0º C to +55º C * 32º F to +131º F * Operating Limits for FAA L-829 Constant Current Regulator * Operating Limits for LCD Display used with CCR power module equipped with optional Digitrac or optional Megatrac Relative Humidity: 10 percent to 95 percent Altitude: Zero to 6,600 Feet (2000 M) 1.3 Installation Requirements The Switchgear Cabinets are shipped from the manufacturer complete (shipped as separate cabinets, not as a fully assembled system) and ready to install. The agency responsible for installation must supply all necessary connectors, wire and conduit. Additionally, this same agency is responsible for off-loading the Switchgear cabinets, CCR power modules and counterbalanced lift on arrival at the installation or shipping address site. Consult your local Yellow Pages for riggers in your area. The Switchgear cabinets are intended for indoor installation only in an area that should be well ventilated or has air conditioning. The floor the Switchgear cabinets mount on must be level. If mounting to an elevated pad, cabinet fronts can be no more than 3 inches maximum back from the front face of the elevated pad. Pad height is limited to 6 inches maximum. This is to accommodate the use of the track extensions for installing the CCR power modules and height limitations on the counterbalanced lift. Be sure to order the track extension with the elevated concrete pad dimensional correction. Switchgear cabinets should be bolted to the floor (this is mandatory to meet seismic rating). Installation of main input power wires to the main input circuit breaker should be done only by a qualified electrician. The installation site must have adequate space to maneuver the counterbalanced lift. 4 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 2 Installation WARNING: WARNING Installation, Maintenance and Operation should only be performed by qualified personal 2.1 Installation Prior to Installation, check all equipment for shipping damage. NOTICE: NOTICE Read all instructions entirely through before proceeding with installation following the order written when installing. 2.1.1 Location The Switchgear Cabinets are designed for indoor installation in an environment as specified in 1.2.3.3 having adequate ventilation. Location should also have a minimum ceiling height as shown in Figure 17. Cabinet rears and side should be at least one foot minimum away from walls as shown in Figure 13. If Cabinets are to be moved into a structure laying on their sides, see Figure 8 for height dimension to raise back to vertical. Adequate space should be available to maneuver the counterbalanced lift to install the CCR power modules once the Switchgear Cabinets are mounted in place. Refer to Figure 15. Refer to Figure 11 for cabinet wiring entrances. The slotted hole located at the rear of the cabinet is the best entrance to bring field load wiring into individual CCR cabinets. If all field load wiring is being brought into an auxiliary Switchgear cabinet first before being routed to appropriate CCR cabinet CCR Power Module utilizing the load cable way, use the large “cutout” in the base of the auxiliary cabinet. The four .625 diameter holes in the corners of each Switchgear cabinet are for bolting the cabinets to the floor. If mounting to an elevated concrete pad, cabinet front must be flush to 3 inches back maximum from the front face of the elevated concrete pad. Concrete pad can be no more than 6 inches high maximum. 5 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 2.1.2 Cabinet Installation Check your drawings for cabinet numbering and match with the appropriate Switchgear Cabinet to install in the correct sequence. All Switchgear Cabinets should be left bolted to shipping skids as long as possible to avoid damage when moving. Move cabinet onto its final installation location and with shipping skid removed set into place. See Figures 1-7 and 9 for moving suggestions. When moving with a nylon strap, be sure to pad contact points with cabinet to avoid damaging cabinet. If bolting cabinet to floor, attach hardware but do not tighten. IMPORTANT: IMPORTANT If Switchgear System was specified to be seismic rated, all Switchgear Cabinets must be bolted to the floor as shown in Figure 12 as a minimum recommendation. Level the cabinet. Install the next adjacent cabinet in sequence. If bolting to the floor, attach hardware but do not tighten. Level the cabinet. Repeat this process until all cabinets are in place. Once all cabinets are in place, bolt cabinets together with hardware supplied. 8 bolts connect the cabinets together, 4 in the front vertical side channel and 4 in the rear vertical side channel. Re-check levelness, see Figure 10. Tighten all floor mounting hardware. Re-check levelness. Remove the three metal covers in the rear of the CCR cabinets upper section which cover the bare copper input power Phase A, B, and C horizontal bus bars. Attach the input power bus bar splices using the hardware provided. Refer to Figure 14A for proper hardware sequence. Be sure connection areas are free of grease, oils, and burrs. Be sure that the busses being connected are flat and parallel before torque is applied to hardware. Attach the ground bus bar splices to the ground bus in the rear bottom section of each Switchgear Cabinet using the hardware provided. Torque the appropriate size bus hardware on the splices per the table shown in Figure 14. Re-attach the metal covers previously removed that were covering the horizontal bus bars. 6 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 2.1.3 Field Load Wiring If routing from an Auxiliary Cabinet, use field load wiring cable trough to go between cabinets, see Figure 18. If wiring from floor up to individual CCR Cabinets, use the right side rear slotted hole in the CCR Cabinet to bring cable into CCR Cabinet. Field load cable ends should be marked. CCR Power Module field load connections are supplied with a female and male L-823 primary connector on their connection ends. An L-823 primary connector kit (male and female; not supplied) should be attached to the field load wire ends to connect to CCR Power Module L-823 primary connectors. Cables should be routed from the CCR Cabinet field load-wiring trough right side as follows: Bottom CCR Cabinet Bay: Up 22 inches, then forward to cabinet door 30 inches and then add an extra 48 inches. All cabling (22 & 30 inches) should be ty-rapped to cabinet interior (use care not to interfere with door interlock or cabinet latch pin location). The extra 48 inches should be ty-rapped to itself and L-823 primary connector kits applied to lead ends. Upper CCR Cabinet Bay: Up 22 inches, then through the slotted access hole between the upper and lower CCR Cabinet bays, the up 48 inches to top of upper cabinet bay, then forward 30 inches to cabinet door. Then add an extra 48 inches. All cabling inside cabinet (22, 48, and 30 inches) should be ty-rapped to cabinet interior (use care not to interfere with door interlock or cabinet latch pin location). The extra 48 inches should be ty-rapped to itself and L-823 primary connector kits applied to lead ends. If installing field load wiring through the bottom of individual CCR cabinets, add 25 inches to go through the right side rear bottom slot up to the right side trough slot. If installing through the large “cutout”, add an extra 10 inches to the 25-inch dimension to reach cabling trough. This will allow the cable to be routed up from the bottom “cutout” behind the bottom bus stab support and then over to the cabinet right side. Field load cables to be routed behind bus stab support must not have L-823 primary connector kits attached at this time. See Figure 11. All load wiring inside the optional S-1 Cutout auxiliary cabinets and the optional L-847 circuit selector switch auxiliary cabinets should be done at this time. 7 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 2.1.4 Fan Operating Control Setting If the CCR Cabinets are installed with the fan option, do the following: 1. Turn the fused disconnect switch to the ON position. 2. Adjust the temperature setting on the fan thermostat. The thermostat can be set between 30 and 140 degrees F. The thermostat is factory set at 100 degrees F. Controls for the fan option are location in the upper right side rear of the CCR Bay of each Switchgear Cabinet equipped with this option. Four fans are connected in the top of each CCR cabinet Bay to the thermostat. The thermostat is connected to a 480/120V step down transformer. DANGER: DANGER When power is present on transformer, line side of the transformer has exposed 480V terminals and the load side has exposed 120V terminals. The step down transformer is connected to a fused disconnect switch which contains 2 Bussman FNQ-R-4/10 Fuses. The line side of the disconnect switch is connected to the horizontal input power bus. 2.1.5 Main Input Power Connections WARNING: WARNING Connections to the main input circuit breaker should be done by a qualified electrician only. Connect earth ground to the Switchgear system bus ground. The ground conductor should be copper, 4/0 minimum. CAUTION: CAUTION Do not connect counter poise system to the Switchgear system ground. 8 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Install input power wires to the line side of the Switchgear main input cabinet circuit breaker. Be sure the correct input voltage is being applied to the Switchgear System. Wiring is 3 phase, 3 wire. Connection leads should be sized for the full current rating of the main Switchgear input circuit breaker. Apply input power to the main breaker and switch main circuit breaker on. The circuit breaker has a yellow push-to-trip button on its front face. Turn breaker OFF. Lockout breaker in the OFF position. Note, do not move the magnetic trip adjustment. It should be left at the factory setting which is at the minimal position, unless issues arise once the complete system is up and running. The adjustment is only to be used to compensate for large, turn on inrush currents. Basically, this adjustment increases the magnetic trip element by a factor of 5 to 10%, which in turn increases the breaker’s trip point. 2.1.6 Load Balancing The stabs in the Switchgear CCR Cabinets are wired for 3 phase (black color stabs) from the main horizontal bus bars and ground (green color stab) connected to the system ground bus bar. All CCR Power Modules are single phase only and are factory wired single phase. The CCR Power Modules have matting stab connectors on the rear of the trolley, which match its corresponding stab in the Switchgear CCR Cabinet. All CCR Power Modules have a ground connected to the green colored stab. CCR Power Module power connections to the black color trolley stabs are wired with one of the following single-phase connection combinations: Phase A and B, Phase A and C, or Phase B and C. The factory phase wiring combination was predetermined by selecting the best possible combinations for the CCR Power Modules to have the load as evenly (or as close as possible) distributed on the three phases based on the Switchgear system ordered. If you want to change the phasing connections, do so on the CCR Power Modules prior to installation of the Modules. Note: if factory connections are broken on CCR Power Module stab connectors, the ½ inch stainless steel hardware must be torqued to 35 foot-pounds maximum after re-connecting. 2.1.7 Counterbalanced Lift Operation Familiarize yourself with the operation of the counterbalanced lift prior to use in installing the CCR Power Modules. IMPORTANT: IMPORTANT Contact your local lift truck distributor for narrow aisle counterbalanced lift training. It may be necessary to remove counterbalanced lift “backrest” when installing the upper CCR power module into the Switchgear CCR cabinet if your location has a low ceiling height. 9 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 2.1.8 Track Extension Use The Switchgear System is provided with an upper and lower track extension for use in installing or removing CCR Power Modules. IMPORTANT: IMPORTANT Standard track extensions provided with the system do not take into account if Switchgear System cabinets are mounted on an elevated pad. Track extensions for use with systems installed on elevated mounting pads must be ordered prior to manufacture with a dimensional adjustment for pad height. Pad height maximum is 6 inches. Lower Track Extension Use: Open the lower CCR cabinet bay door. Remove the 2 sets of ½ inch hardware (requires a ¾” socket or wrench) located in the front of the cabinet on the base channel. At initial installation, test safety hooks in cabinet are in proper working order by pushing down and then releasing. Spring attached to hook should allow it to return to it’s normal upright position. If this does not occur, it may be necessary to loosen hardware retaining the hook to the cabinet. Insert the track extension into the cabinet, aligning the extension track with cabinet track. The front forks on the track extension engage the safety hooks and push them in a down position. Install the removed ½ hardware back into the cabinet front base channel through the slotted holes in the track extension. Adjust track extension levelers (requires a 15/16” socket or wrench). If equipped, and then screw the larger wing nuts on the levelers down to tighten. See Figure 16. After use, remove the ½ inch hardware and track extension. Re-install the ½ inch hardware in the cabinet from channel. NOTE: Lower track extension wheels are for moving the structure similar to a wheel barrow. 10 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Upper Track Extension Use: Follow the Lower Track Extension procedure except open the door on the upper CCR cabinet bay. Use the ½ inch hardware located in the upper bay front channel. When installing upper track extension, adjust levelers on base of upper track assembly. It may be easier to adjust the front levelers (nearest cabinet) and then push extensions structure into cabinet to engage safety hooks. Install the ½ inch hardware and then adjust the rear levelers. This method may allow the use of the rear casters to help move the structure during the safety hook engagement process. Be sure to tighten the wing nuts. Track extension must rest on levelers only before placing the trolley/CCR power module on it. Track extension wheels will not support the weight of the trolley/CCR power module. Casters are mounted to plates attached to the extension structure with wing nuts. The only time these casters plates need to be removed if you need to adjust the track extension below its designed height (pad height). This feature will allow some additional negative (downward) adjustment. WARNING: WARNING 2.1.9 Upper track extensions equipped with wheels are intended to only be used for installing and removing CCR Power Modules when secured to the cabinet and resting on extension levelers. Use of the upper or lower track extension as a cart is not intended and will cause CCR Power Module to roll off and cause damage, serious injury, or death. Use the counter balanced lift to remove or install power modules on the track extensions. CCR Power Module Installation WARNING: WARNING Be sure Switchgear System main circuit breaker is in the off position and locked-out during the initial Switchgear System installation. 11 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS When installing CCR Power Modules, always install the lower CCR cabinet bay power module first before installing the upper CCR cabinet bay power module. Installation of load wiring into cabinets should be complete prior to installation of CCR power modules. Inspect the power module prior to installation and check for shipping damage. The door, which includes the main circuit card should be mounted after the CCR power module is installed in the cabinet. Be sure to mount the door shipped with a particular CCR power modules as settings on the board have been configured and tested with that particular power module. See instruction sheet 2605 supplied with power module. Located near the CCR power module handle on the base of the trolley is a location number which should match a location number located above the red display window on the face of each CCR cabinet door. Be sure to install the CCR power module in the matching CCR cabinet bay. Open the CCR cabinet bay door in which the CCR power module is to be installed. Remove the 2 pins attached with lanyards and their hairpin cotters. See Figures 15 and 16, Photos 1 – 5. Install the track extension. Lift the CCR power module up utilizing the fork lift slots in the sides of the trolley base using the counterbalanced lift. The forks should extend through the trolley be about 2 inches. If installing CCR power modules from the hinge side of cabinet, it will be necessary to remove the door from the cabinet. Door is held to cabinet by 3 pins and 3 retaining rings (Rotor Clip part number SE-21 ST ZD). See figure 15. NOTICE: NOTICE There is a metal plate on the trolley interior which the lift fork must clear. This plate is to prevent the fork from coming into contact with the track extension rails preventing removal of the lift fork or disturbance of the trolley during the fork lift removal. Place the trolley on top of track extensions aligning the trolley wheel grooves with the track extension rail grooves. Lower the trolley onto the track extension. Be sure wheels are in the track extension grooves. Back lift truck out of trolley forklift slots. Attach the field load leads for the associated CCR power modules to the mating primary connectors on the power module. Apply a layer of electrical tape around the connection. Push the CCR power module trolley all the way into the Switchgear CCR cabinet hold the two black handles located at the trolley front down. Be sure not to pinch field load leads between CCR power module trolley and cabinet wall. Engage the black handle bosses into their mating bosses located on the CCR cabinet front rail. Push the black handles up to engage. Re-install the pins and hairpin cotters into the cabinet through their matching slotted hole in the trolley base. Remove the track extension. Install the card and door harness onto the cabinet door following the instructions 12 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS provided with it. Close the cabinet door. Adjust cabinet door circuit breaker plate if required. Adjust CCR module circuit breaker position so actuator handle and lockout brackets protrude through the door. See CCR Power Module Manual for adjustment screw locations. Be sure CCR power module circuit breaker and the rotary step selector switch on the door is in the OFF position. Repeat installation procedure for all CCR power modules until they are all installed. NOTICE: NOTICE If a CCR Cabinet section has no CCR installed, it will not be equipped with a trolley. Additionally, the door will have P/N 34189-U( upper door) or 34189-L (lower door) is installed in place of the standard door configuration (does not include a main circuit card with it’s protective plate). 2.1.10 Digitrac and Megatrac Option Installation 2.1.10.1 Digitrac Option Installation If the Digitrac option circuit cards did not come pre-installed from factory, mount on the CCR cabinet door interior per instructions provided with the CCR power module manual under drawing 828SYS-D. Wire the Digitrac option to the CCR power module main circuit card on the door per the Digitrac option drawing. 2.1.10.2 Megatrac Option Installation The Megatrac option high voltage module and current sensing module come pre-installed on the CCR power module from the factory. If the Megatrac option circuit cards did not come pre-installed on the CCR cabinet door from the factory, mount on the door interior per instructions provided with the CCR power module manual under drawing 828SYS-M. 2.1.11 Control Wiring Control wiring to the CCR power modules should be done by utilizing the control wiring cables troughs provided in the cabinets. See Figure 18. A conduit entrance will need to be cut into the top of one of the cabinets (first CCR cabinet in line-up is recommended) to allow control wiring entrance/exit from Switchgear System to a control panel or computer. 2.1.11.1 Standard CCR Control Wiring Refer to the CCR Power Module manual remote control wiring section for standard Connections. 13 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 2.1.11.2 Digitrac Option Control Wiring Connections If CCR’s are to be controlled by means of an optional Digitrac, do not make “standard” remote control wiring connections as outlined in the CCR Power Module manual. Two #24 AWG shielded minimum twisted pairs are daisy chained between CCR Power Module Digitrac control boards. Starting at the first top bay CCR cabinet Digitrac control board, connect one 88 inch long twisted pair to terminals 39 & 40 and the other 88 inch long twisted pair to terminals 41 & 42 noting the red or black color connection point on each pair. Mark both ends on twisted pair outer jacket with a colored tape to keep the two sets of twisted pair wires from being confused. From this top CCR bay Digitrac, connect to the bottom CCR bay Digitrac control board in the same cabinet. Connect one twisted from the top bay Digitrac board to the same points (noting color of wires) on the bottom Digitrac board. Repeat this process for the other twisted pair wires from the top bay Digitrac board to the bottom bay Digitrac board. From the bottom bay Digitrac board, connect the two twisted pairs – 123 inches long (noting color and connection points) to the top bay Digitrac board in the next adjacent cabinet. Mark both ends on twisted pair outer jacket with a colored tape to keep the two sets of twisted pair wires from being confused. From this top Digitrac board, go to the bottom bay Digitrac board in its cabinet making the twisted pair wiring connections. Utilize the control wiring troughs to run all twisted pairs between top and bottom cabinets and to adjacent cabinets. Ty-rap twisted pairs as necessary to existing cables in cabinet. Repeat this process until all CCR module Digitrac boards have the twisted pair control wiring installed. 2.1.11.3 L-847 Auxiliary Cabinet Option Control Wiring Connections Connect control wiring to the L-847 units per its instruction manual. If the L-847 remote control is to be used with a CCR power module with an optional Digitrac control, do not make standard remote control wiring connections per the L-847 manual. Instead, refer to Figure 19 for L-847 to CCR power module Digitrac control wiring. 14 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 3 Operation CAUTION: CAUTION Do not megger test the series lighting load while it is connected to the regulator. 3.1 Initial System Power-Up All cabinet doors must be closed. Turn the main Switchgear System circuit breaker ON. All CCR cabinet bays which have an installed CCR power module will now have the red “Bus Power Engaged” indicator light on the front door illuminated. 3.1.1 Bus Power Engaged Indicator Light The Red indicator “Bus Power Engaged” light on the front doors of CCR cabinets indicates a CCR power module stabs have mated with its cabinet bus stabs and input voltage is now available at the CCR power module circuit breaker. The main Switchgear circuit breaker must also be in the on position with power present at its input terminals. If the indicator does not illuminate, open cabinet door and check for the following: WARNING: WARNING Power is present at the CCR power module circuit breaker line side terminals even when the breaker is in the OFF position. Check that the harness connections have been made to the indicator light terminals. Check if 120V is present on the indicator light harness wires, if present the indicator light LED is defective. IF 120V is not present, attach the track extension and roll CCR power module out of the cabinet. WARNING: WARNING The cabinet bus stabs have power present in their sockets when the main Switchgear System circuit breaker is in the on position. 15 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Check the wiring for any damage or loose connections and also check T8 transformer on the CCR power module for damage. Refer to CCR Power Module Manual for indicator light wiring connections. 3.1.2 CCR Power Module Power-Up Be sure cabinet door is closed. Be sure the rotary selector switch on the CCR bay cabinet door is in the OFF position. Turn CCR power module circuit breaker on. The red button on the face of the CCR power module circuit breaker is a push-to-trip button. Observe that thee red display above the door rotary switch illuminates. Display will briefly show software version and then change to show output current, which should read 0.00 at this time. If display does not illuminate, open the cabinet door. WARNING: WARNING Voltage above 1000 volts are present when regulators are operating. Pull the actuator on the door interlock switch out (door interlock located in each CCR bay upper right side front corner). If display does not illuminate, go to the troubleshooting section in the CCR power module manual. If display does illuminate, then interlock switch actuator is not making contact with door. Shut CCR power module circuit breaker off. Using a pair of pliers, bend the interlock switch bracket forward. Close door and re-apply power to the CCR power module circuit breaker. Once display illuminates, push on door to make sure if the door moves slightly in/out in the closed position there will be no nuisance trips with the door interlock switch. Turn the rotary switch to the lowest step and observe current reading changes on the display. Do this for all steps. If regulator (CCR power Module) does not function correctly, go to the trouble shooting section in the CCR Power Module manual. Repeat the CCR Power Module power-up process for each power Module in the Switchgear System. 3.1.3 Remote Control Wiring Check After the initial CCR Module power-up has been preformed, check the remote control circuit wiring if installed. 3.1.3.1 Standard Remote Control Wiring With the CCR Module circuit Breaker on, turn the rotary selector switch on the CCR cabinet bay from the OFF position to the remote position. Verify remote control works in all steps and OFF via 2-way communication. 16 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 3.1.3.2 Digitrac Option Network Wiring The Digitrac option network wiring requires that the wiring be hooked-up to a controlling computer system with the computer system software programmed for particular Switchgear System location installation. Be sure to have made prior arrangements with Crouse-Hinds Airport Solutions Computer Group for the task and final connection/operation scheduling. 3.2 Optional Features Operation 3.2.1 Megatrac Option Test If the CCR Power Module is installed with an optional Megatrac earth leakage detector, refer to Megatrac manual for operation. 3.2.2 S-1 Cutout Auxiliary Cabinet Option To isolate a regulator output from its field load, pull the handle out to is associated S-1 Cutout. DANGER: DANGER Do not pull out or insert S-1 Cutout handle when regulator is in the ON position. Turn power off at associated regulator (CCR Power Module) and lock-out breaker. On optional S-1 Cutout assembly cabinets which utilize an intentional grounding scheme, be sure to familiarize yourself with its intended function. See Figure 20. 3.2.3 L-847 Auxiliary Cabinet Option If you have this option installed, refer to the L-847 Instruction Manual for operation. All L847 circuit selector switches obtain their control power from the Switchgear System horizontal bus bars. A fused disconnect switch containing three Bussman FNQ-R-3/4 fuses is wired to the L-847’s 480/120V step-down transformer. The fused disconnect switch must be in the ON position for the L-847 unit to function. The CCR module connected to the particular L-847 unit should have its circuit breaker in the off position to avoid accidental turn-on of the L-847 high voltage switches when the L-847 disconnect switch is turned on. DANGER: DANGER When power is present o the L-847 unit step-down transformer, the line side of the transformer has exposed 480V terminals and the load side has exposed 120V terminals. 17 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS NOTICE: NOTICE 4 Each L-847 unit panel (gold color) ground lug must have #8 AWG (minimum) ground lead connected to the Switchgear System ground bus. Periodic Maintenance, Switchgear System 4.1 Scope of Maintenance Only maintenance to the Switchgear System Cabinets and bus bars will be discussed. For maintenance and troubleshooting of the CCR Power Modules, optional Digitrac, optional Megatrac, and optional L-847 Circuit Selector Switches, refer to their individual manuals. 4.1.1 Cabinet Maintenance Every 6 months inspect cabinets for rusting metal panels and interior dust build-up. Remove rust from panels and apply touch-up paint. Turn power off at the main Switchgear System circuit breaker and lockout. CAUTION: CAUTION Power is present to the line side of the Switchgear System main input circuit breaker even in the OFF position. Open the CCR cabinet bay doors and vacuum out any interior dust build-up, in particular around vent opening and fans if installed. 4.1.2 Cabinet Bus and Wiring Connection Maintenance Every 2 years, re-torque all bus bar connections and check ALL wiring connections to all connection points. This maintenance task will require the input power prior to the Switchgear System main input circuit breaker to be turned off and locked-out. It will also require the removal of the CCR Power Modules from the CCR Switchgear Cabinets to access the bus bars. 18 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS 5 Switchgear Cabinet Additions to System 5.1 Adding Cabinets 5.1.1 Adding CCR Switchgear Cabinets Switchgear CCR Cabinets for adding additional power modules to the Switchgear system can be added after initial installation by following the same steps used for installing the initial system. The Switchgear System main input circuit breaker must be off and locked-out when adding cabinets. The only limitations are the capacity of the bus bar and/or the current rating of the Switchgear System main input circuit breaker. An added Switchgear CCR Cabinet may only be added to an adjacent first or last CCR Switchgear cabinet in the existing system because of the required horizontal bus connections. 5.1.2 Adding Switchgear System Auxiliary Cabinets Switchgear Auxiliary Cabinets can be added to any existing Switchgear System already installed. Follow the same steps for installing the initial Switchgear cabinets. The Switchgear System main input circuit breaker must be off and locked-out when adding cabinets. 6 Hot Swapping CCR Power Modules 6.1 Hot Swapping Procedure Turn CCR Power Module door rotary switch to OFF position on all units to be moved. Turn the CCR Power Module circuit breaker OFF on all units to be moved. Install the track extension. Disconnect field load cables from CCR Power Module. Disconnect the door harness mating plugs. Remove pin on lanyards and hairpin cotter. Roll the CCR Power Module out of CCR Cabinet onto the track extension. Lift the CCR Power Module off the track extension. Move the track extension to CCR cabinet bay in which moved unit will be installed. This bay should be empty or already had the CCR Power Module from its bay moved out of the cabinet. Place moved CCR Power Module onto track extension. See manual section s 2.1.6, 2.17, 2.18, and 2.19. Note: it is recommended that the main control board be moved with its corresponding CCR Power Module that it was tested with. Check to see if DIP Switch setting for steps and option on the main control board are correct for the new installed location. 19 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS DANGER: DANGER Power is present on the line side of the CCR Power Module even when its circuit breaker is in the OFF position. Never disconnect the field load from the regulator when the power is in the ON position. The stabs in the rear of the CCR Cabinet have live voltage present when the Switchgear System main input circuit breaker is on. Connect the field load leads to the CCR Power Module. Roll the CCR Power Module into the cabinet. Re-install all pins and hairpin cotters in cabinet. Remove the track extension. Reconnect the door harness. Close the cabinet door. Turn CCR Power Module circuit breaker on. Verify local and remote control rotary switch settings function. See manual sections 3.1, 3.1.2, and 3.1.3. 20 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Addendum The following is a list of manufacturer’s part number and tools used in the Switchgear System. Pages following are actual manufacturer’s catalog or data sheets. Copies of these catalog and data sheets are only included with hard copies at the end of this manual and not with electronic copies. Switchgear System Main Input Circuit Breaker – Square D part number MHL36300, MHL 36400, MHL 36600, and MHL 36800. Switchgear System Transient Voltage Surge Suppressor (TVSS), optional – Square D part number TVS4EBA24A Switchgear CCR Cabinet Door Interlock Switch – Microswitch Part number 2DM409 Switchgear Disconnect Switch, used with fan option and L-847 Auxiliary Cabinet Option – Bussman part number OPM-1038RSWC Switchgear Disconnect fuses used with Bussman disconnect switch – Bussman part number FQN-R-4/10 (used with fans) or Bussman part number FNQ-R-3/4 (used with L-847) Switchgear CCR Cabinet fan option stepdown transformer – Acme Electric Corporation part number TA-2-81213. Switchgear CCR Cabinet optional fan – EBM-PAPST Inc. part number W2E143-AA15-01 Switchgear CCR Cabinet Fan option thermostat – Hoffman Enclosures Inc., part number ATEMNO Switchgear CCR Cabinet Bus Stabs – cooper Interconnect part number E1074-2 (power) and Cooper Interconnect part number E1074-4 (Ground) Switchgear S-1 Cutout auxiliary cabinet S-1 Cutout, optional - Crouse-Hinds Airport Lighting part number 30775. L-823 Primary Connector Kits for FAA L-824 Cable - Crouse-Hinds Airport Lighting data sheet CKP (provided for information only). 21 Document 2516 Rev. C-2 Instruction Manual Switchgear System Series 82XSYS Crimping Tools for Crouse-Hinds Connector Kits - Crouse-Hinds Airport Lighting data sheet TEK-Tool (provided for information only) Cable Penciller for preparing ends of L-824 cable for Connector Kits - Crouse-Hinds Airport Lighting part number 10036-36 (provided for information only). Counterbalanced Lift for installation of Switchgear CCR Power Modules – Blue Giant Equipment Corp. part number BGL-22 with optional 36 inch long forged forks. Key Mechanical Interlock option for Switchgear CCR Cabinet door – Kirk Key Interlock Co., part number Type F, 3 inch locking bolt length. Power Module Circuit Breaker Lock-Out Bracket for use with Kirk Key Type F Interlock – Crouse-Hinds 34176 (this bracket replaces the normal circuit breaker lock-out brackets supplied with the power module). Data/catalog sheet not supplied. Key Mechanical Interlock Option for Switchgear Auxiliary Cabinet hinged box around S-1 Cutout – Kirk Key Interlock Co., part number Type D. 22 Document 2516 Rev. C-2 Power trac TM DEVICE FUNCTION ENTER SETUP CON TRAST REMOTE OFF 1 2 LOCAL CONTROL SWITCH 3 5 4 Power trac TM DEVICE FUNCTION ENTER SETUP CON TRAST REMOTE OFF 1 2 LOCAL CONTROL SWITCH 3 5 4 CABINET INSTALLATION 23 Document 2516 Rev. C-2 TM DEVICE FUNCTION ENTER SETUP C ONTRAST REMOTE OFF 1 2 LOCAL CONTROL SWITCH 3 5 4 Power trac DEVICE FUNCTION ENTER SETUP C ONTRAST REMOTE OFF 1 2 LOCAL CONTROL SWITCH 3 5 4 CABINET INSTALLATION 24 TM Document 2516 Rev. C-2 Power trac TM DEVICE FUNCTION ENTER SETUP CONTR AST REMOTE OFF 1 2 LOCAL CONTROL SWITCH 3 5 4 Power trac TM DEVICE FUNCTION ENTER SETUP CONTR AST REMOTE OFF 1 2 LOCAL CONTROL SWITCH 3 5 4 CABINET INSTALLATION 25 Document 2516 Rev. C-2 Power trac D EVICE F UNCTION ENTER S ET UP REMOTE OFF CON TRAST 1 2 LOCAL CONTROL SWITCH 3 5 4 Power trac D EVICE FUNC TION ENTER S ETUP REMOTE OFF CO NT RAST 1 2 LOCAL CON TR OL SWITCH 3 5 4 CABINET INSTALLATION 26 Document 2516 Rev. C-2 Power trac DEVICE F UNCTION ENTER REMOTE SET UP OFF CO NT RAST 1 2 LOC AL CON TR OL SWITCH 3 5 4 Power trac DEVICE F UNCTION ENTER R EMOTE SETUP OFF 1 2 LOCAL CON TROL SWITCH 3 5 CABINET INSTALLATION 27 4 C ONT RAST Document 2516 Rev. C-2 Power trac TM DEVICE FUNCTIO N ENTER SETUP CO NTRAST REMOTE OFF 1 2 LOCAL CONTROL SWITCH 3 5 4 Power trac DEVICE FUNCTIO N ENTER SETUP CO NTRAST REMOTE OFF 1 2 LOCAL CONTROL SWITCH 3 5 4 CABINET INSTALLATION 28 TM Document 2516 Rev. C-2 Power trac TM DEVICE FUNCTION ENTER SETUP C ONTRAST R EMOTE OFF 1 2 LOCAL CONTROL SWITCH 3 5 4 Power trac DEVICE FUNCTION ENTER SETUP C ONTRAST R EMOTE OFF 1 2 LOCAL CONTROL SWITCH 3 5 4 CABINET INSTALLATION 29 TM Document 2516 Rev. C-2 DEVIC REMOT E E Powe rtrac 1 DEVICE REMO TE TM OFF LOCA CONT L SWITCROL H FUNCT 5 4 SETUP ENTER D EVICE REMOT E Powe rtrac DEVICE REMOT E FUNCT LOCA CONT L SWITC ROL H ION 5 SETUP Powe rtrac OFF TM 1 2 3 4 1 TM FUNC TION 2 3 4 SETUP ENTER ENTER C ONTRAST CONTRAST CABINET INSTALLATION 30 ac TM FUNC TION ENTER CONTRAST OFF 5 1 2 3 4 SETUP CONTRAST LOCA CONT L SWITC ROL H Powe rtr OFF LOCA CONT L SWITC ROL H ION 2 3 5 Document 2516 Rev. C-2 CABINET INSTALLATION 31 Document 2516 Rev. C-2 Power trac Power trac DE VICE 4 Power trac 4 4 E NT ER OFF 1 2 L OC AL CONT ROL SWITCH 3 5 4 CABINET INSTALLATION 32 Power trac R EM OTE O FF 1 2 3 5 F UNCT I ON E NT ER R EM OTE O FF 1 L OC AL CONT ROL SWITCH DE VICE DE VICE F UNCT I ON E NT ER R EM OTE 2 4 Power trac DE VICE F UNCT ION E NT ER 1 3 4 3 5 Power trac DE VICE O FF 5 2 L OC AL CONTROL SWITCH 3 5 F UNCT ION RE MOTE LOCAL CONTROL SWITCH E NT ER OFF 1 2 L OC AL CONT ROL SWITCH 3 5 R EM OTE O FF 1 2 L OC AL CONT ROL SWITCH F UNCT I ON E NT ER R EM OTE O FF 1 2 DE VICE F UNCT I ON E NT ER R EM OTE 1 3 4 Power trac DE VICE F UNCT ION E NT ER O FF 5 Power trac DE VICE F UNCT ION RE MOTE LOCAL CONTROL SWITCH 2 L OC AL CONTROL SWITCH 3 5 4 Document 2516 Rev. C-2 3.00" LONG x 1 1/2" WIDE SLOT TYP (REF) 20.0 10.0 5.0 27.0 Power trac Power trac Power trac 4 Power trac FU NCT ION E NTER E NTER S ET UP CO N TRAST SETUP C O NT RAST CO N TRAST REMOTE OFF REMOTE OFF OFF 1 1 1 2 2 2 LOC AL CONTROL SWITCH 3 5 Power trac D EVICE D EV ICE FUN CT ION ENTER SETU P REMOTE L OCAL C ONTROL SWITCH 4 Power trac DEV ICE CO N TRAST 3 5 FUN CTI ON ENTER 2 2 LOC AL CONTROL SWITCH 3 5 SETUP 1 4 OFF 1 2 LOC AL CONTROL SWITCH 4 DEVICE OFF 3 4 LOC AL CONTROL SWITCH 3 5 4 3 5 4 36.0 TYP 10.0 10.0 TYP CUTOUT CUTOUT CUTOUT CUTOUT 5.0 15.0 Ø.625 TYP.(6) PER SECTION 20.0 CABINET WIRING ENTRANCES 33 3.00" LONG x 1 1/2" WIDE SLOT TYP 16.0 TYP 9.00 12.00 CUTOUT 5 C O NT RAST REMOTE OFF 1 2 3 5 E NTER SETUP CO N TRAST REMOTE OFF 1 L OCAL C ONTROL SWITCH FUNC TION REMOTE FU NCT ION E NTER S ET UP CO N TRAST REMOTE 2 LOC AL C ONTROL SWITCH D EVICE FUN CT ION ENTER SETU P CO N TRAST 1 4 Power trac D EV ICE FUN CTI ON ENTER SETUP OFF 3 5 Power trac DEV ICE DEVICE FUNC TION REMOTE LOC AL C ONTROL SWITCH 38.0 30.0 TYP 42.0 TYP TYP 12.00 31.0 TYP 1.9 TYP 2.5 TYP 6.0 TYP Document 2516 Rev. C-2 SWITCHGEAR CABINET 2 1/8" MIN EMBEDMENT EPOXY RESIN SEISMIC BOLTING 34 Document 2516 Rev. C-2 MAIN INPUT CABINET CCR CABINET FOR 2 POWER MODULES BLUE GIANT LIFT TOP VIEW TRACK EXTENSION CABINET WALL CLEARANCES 35 BLUE GIANT LIFT Document 2516 Rev. C-2 BUS HARDW ARE T O R Q U E S P E C IF IC A T IO N S B U S S P L IC E IN S T A L L A T IO N (D O O R S A N D P A N E L S R E M O V E D F O R C L A R IT Y ) 36 Document 2516 Rev. C-2 BUS SPLICE CONNECTION HARDWARE DETAILS 37 Document 2516 Rev. C-2 MAIN INPUT CCR CABINET FOR 2 POWER MODULES CCR CABINET FOR 2 POWER MODULES CCR CABINET FOR 2 POWER MODULES CCR CABINET FOR 2 POWER MODULES NOTICE Powertrac Power trac DEVICE DEVICE F UN CTION F UNC TION ENTER ENTER SET UP SET UP CO N TRAST REMOTE 4 Powertrac Power trac F UNC TION SET UP CO N TRAST REMOTE CO NTRAST RE MOTE OFF OFF 1 1 2 3 4 ENTER ENTER S ETU P C ON TRAST OFF Powertrac DEVICE F UN CTION ENTER SET UP CO N TRAST 4 D EV ICE F UNCT ION ENTER SETUP 3 5 DEVICE D EV ICE 2 L OCAL C ONTROL S WITCH 3 5 Power trac 1 2 L OC AL C ON TROL S WITCH 4 F UNC TION 5 OFF 1 2 RE MOTE CO NTRAST RE MOTE OFF 1 L OCAL C ONTROL S WITCH ENTER S ETU P C ON TRAST OFF 3 5 Powertrac D EV ICE F UNCT ION RE MOTE L OCAL C ONTROL S WITCH 1 2 L OC AL C ON TROL S WITCH 3 5 4 2 L OCAL C ONTROL S WITCH 3 5 4 TYPICAL CCR POWER MODULE INSTALLATION/REMOVAL - FORKLIFT 38 Document 2516 Rev. C-2 NOTICE IMPORTANT IMPORTANT TYPICAL CCR POWER MODULE INSTALLATION/REMOVAL - TRACK EXTENSIONS 39 Document 2516 Rev. C-2 Power trac D EVI CE DEVI CE FUNC TI ON DEVI CE FU NCTIO N EN TER FUNC TI ON EN TER SETUP C ONTRAST EN TER SETUP CONTRAST SETUP CONTRAST OFF O FF 1 CONTRAST R EMOTE OFF 1 2 4 OFF 4 2 LOCAL CON TROL SWITCH 3 5 R EMOTE 1 2 LOCAL CON TROL SWITCH 3 4 R EMOTE 1 2 3 5 D EVICE FUNC TI ON EN TER SETUP R EMOTE LOCAL CONTROL SWITCH LOCAL C ONTROL SWITCH 3 4 5 5 Power trac D EVI CE DEVI CE FUNC TI ON EN TER EN TER SETUP CONTRAST SETUP CONTRAST O FF CONTRAST R EMOTE OFF 1 1 2 4 FUNC TI ON FUNC TI ON EN TER SETUP C ONTRAST OFF 3 5 D EVICE DEVI CE FU NCTIO N EN TER SETUP R EMOTE LOCAL CONTROL SWITCH R EMOTE OFF 1 2 LOCAL CON TROL SWITCH 3 4 5 LOCAL CON TROL SWITCH 3 4 5 RECOMMENDED BUILDING CEILING HEIGHT 40 R EMOTE 1 2 2 LOCAL C ONTROL SWITCH 3 4 5 Document 2516 Rev. C-2 DEVICE DEVI CE FUNCTION FUNCTION ENTER ENTER S ETUP S ETUP C ONT RAST REMOTE C ONT RAST REMOTE OFF OFF 1 1 2 LOCAL CONTROL SWITCH 2 LOCAL CONTROL SWITCH 3 5 4 3 5 4 DEVICE DEVI CE FUNCTION FUNCTION ENTER ENTER S ETUP S ETUP C ONT RAST REMOTE C ONT RAST REMOTE OFF OFF 1 1 2 LOCAL CONTROL SWITCH 3 5 4 2 LOCAL CONTROL SWITCH 3 5 4 SIDE VIEW TYPICAL CABLE WIRING 41 Document 2516 Rev. C-2 OPTIONAL L-847 CONTROL WIRING CONNECTED TO DIGITRAC 42 Document 2516 Rev. C-2 1A GND 1A OPTIONAL S-1 CUTOUT AUXILIARY CABINET INTENTIONAL GROUNDED S-1 CUTOUT WIRING SCHEME 43 Document 2516 Rev. C-2 Lower Track Extension with CCR Power Module Photo 1 44 Document 2516 Rev. C-2 Lower CCR Power Module Installed in Cabinet Photo 2 45 Document 2516 Rev. C-2 Upper Track Extension with CCR Power Module and Counterbalanced Lift Photo 3 46 Document 2516 Rev. C-2 Upper Track Extension and CCR Power Module Photo 4 47 Document 2516 Rev. C-2 Upper Track Extension with Upper CCR Power Module Installation Photo 5 48 Document 2516 Rev. C-2 Switchgear Installation on an Elevated Pad with Auxiliary Cabinets, Main Input Cabinet and CCR Cabinets with Fan Option Pagoda Top Photo 6 49 Document 2516 Rev. C-2 Switchgear CCR Cabinet with Fan Option with Doors Opened and CCR Power Modules Installed with Digitrac and Megatrac Option Photo 7 50 Document 2516 Rev. C-2 Switchgear CCR Cabinet Door with Digitrac and Megatrac Option Installed Photo 8 51 Document 2516 Rev. C-2 EYEBOLTS 98.0 5.0 5.0 10.0 10.0 9.0 TYP 38.0 TYP 30.0 TYP 27.0 42.0 TYP .63 DIA (6) PLC'S 2.5 TYP 1.9 TYP 15.0 20.0 6.0 TYP 52 Document 2516 Rev. C-2 OPTION "F CONFIGURATION SHOWN WITH POGODA TOP REMOVED. NOTE; THERMOSTAT, TRANSFORMER AND FUSED DISCONNECT MOUNTED ON A PLATE ATTACHED NEAR REAR UPPER RIGHT SIDE OF CABINET INTERIOR. THE ITEMS MOUNTED ON THIS PLATE SHOULD ALLOW ACCESS TO THE BUS FOR INSTALLATION AND MAINTENENCE. THERMOSTAT TO BE SET AT 100° F. LOUVERED TOP STANDARD ON INTERIOR NEAR INTERLOCK SWITCH, ADD LABEL WITH BLACK LETTERS ON SMUDGE AND MOISTURE RESISTANT MATERIAL WITH THE FOLLOWING TEXT: LIMIT SWITCH ON THIS DOOR DISCONNECTS POWER TO THE LOAD WHEN THE DOOR IS OPENED. PAGODA TOP 6.0 EYEBOLTS FANS ON INTERIOR 98.0 ON CABINET INTERIOR IN MIDDLE OF POWER STABS, APPLY LABEL "DANGER HIGH VOLTAGE" EMED CO. P/N SQS30 IN CENTER. STABS TO BE LABEL LEFT TO RIGHT "PHASE A", "PHASE B" AND "PHASE C" DEPENDENT ON BUS LEG. GREEN STAB TO BE LABELED "GND". 10.0 TYP .63 DIA (6) PLC'S 16.0 TYP 9.00 9.0 TYP 2.5 TYP 38.0 TYP 12.00 CUTOUT OPTION "H" CONFIGURATION, HASP & STAPLE. PADLOCK NOT SUPPLIED 30.0 TYP 42.0 TYP 12.00 31.0 TYP 1.9 TYP 36.0 TYP 6.0 TYP 3.00 LONG x 1.50 WIDE SLOT 53 Document 2516 Rev. C-2 54 Document 2516 Rev. C-2 55 Document 2516 Rev. C-2 CCR CABINET FOR 2 POWER MODULES TOP VIEW TYPICAL UPPER CCR POWER MODULE INSTALLATION/REMOVAL D E V IC E FU NC TION E NT E R S ETU P C O N T RAS T FRONT VIEW 56 Document 2516 Rev. C-2 CCR CABINET FOR 2 POWER MODULES TOP VIEW TYPICAL CCR LOWER POWER MODULE INSTALLATION/REMOVAL DE VICE FUN CTIO N ENTER FRONT VIEW DETAIL B 57