Instruction Manual - Cooper · PDF fileInstruction Manual Switchgear System Series 82XSYS ii...

Document 2516

Revision

G

September 10, 2012

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 © 2012 Cooper Technologies Company

Document 2516

Rev. G Instruction Manual

Switchgear System

Series 82XSYS

ii

Revisions

Revision

Number

Issue/Reissue

Letter Number Description Checked Approved

A A205-190 Released to production, no changes 05/19/05 PG

B A205-285 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-R-

4/10 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

08/18/05 PG

Document 2516


Switchgear System

Series 82XSYS

ii.1

C A206-107B 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 C-

H S-1 cutout 30771, Square D indicator

KM38LR & added C-H Kirk key lock

out brkt P/N 34176; added copyright to

cover page

4/12/06 PG

D A206-035 Fig 14A, bolt length was 1-1/4 & added

Belleville washers & deleted 3/8-16 split

lock washer; Fig 13, 50.0 was 44.0 &

60.0 was 54.0; revised 34122, 34126 &

34127; replaced 34123 with 34192;

revised Fig 1-11 & 15-18 pictorials to

agree with 34192; 1.1.1, 2642 was 2605;

1.1, Switchboard was Switchgear; 1.1.2

& 1.2.2, 34192 was 34123; 1.2.3.2,

added “& splice plates are silver plated

copper”; 2.1.9, door panel was door, all

locations & 2642 was 2605 & deleted

“Located near the CCR pwr module

handle on the base of the tolley is a

location # which should match a location

# located above the red display window

on the face of each CCR cabinet door.”;

2.1.10.1 & 2.1.10.2, added “panel”;

3.1.1, added “panels”; 2.1.9, blank door

panel, P/N 34186 was P/N 34189-U

(upper door) or 34189-L (lower door) &

also added does not include “display….

panel cover)” ; 2.1.9, added note to

install panel cover & to flip circuit

breaker plate if req’d

10/13/06 PG

Document 2516


Switchgear System

Series 82XSYS

ii.2

E A208-028 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, E1074-

2 was E1016-1621S & E1074-4 was

E1016-1635S & Cooper Interconnect

was Crouse-Hinds Molded products; pg

53, 34192 revision was A

3/12/2008 PG

F A210-201 Title page, Copyright 2010 was 2008;

page 22, added optional System Power

Meter info; page 52, revised 34122 to

Rev H; page 55, revised 34125 to Rev G

10/25/2010 PG

G A212-316 Title page, Copyright 2012 was 2010;

1.2.3.3 Mechanical, added CCR pagoda

top std and adds 3.0 inches; page 53,

revised 34192 to rev D

9/10/2012 PG

Document 2516


Switchgear System

Series 82XSYS

iii

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.

Document 2516


Switchgear System

Series 82XSYS

i iv

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 RE-

LAMP 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.

Document 2516


Switchgear System

Series 82XSYS

v

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.

Document 2516


Switchgear System

Series 82XSYS

vi

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

Document 2516


Switchgear System

Series 82XSYS

vii

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

Document 2516


Switchgear System

Series 82XSYS

viii

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

Document 2516


Switchgear System

Series 82XSYS

ix

Figures

Figure 1 – Cabinet Installation .......................................................................................................23









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

Document 2516


Switchgear System

Series 82XSYS

x

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 34192 – 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

Document 2516


Switchgear System

Series 82XSYS

1

1 General Information

1.1 Introduction Equipment described in this manual is produced for Crouse-Hinds Airport Lighting by Easter-

Owens Electric to be compliant to UL 891, standard for Dead-Front Switchboard.

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 2642 (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, 34192, 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.

Document 2516


Switchgear System

Series 82XSYS

2

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,

34192, 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

Document 2516


Switchgear System

Series 82XSYS

3

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 and splice plates are

silver plated copper. 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,

kW Size

480V, 60Hz

CCR Pwr Module

380V, 50HZ

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 700 lbs.

CCR Cabinet (Does not includes power module

weights, CCR power modules shipped separately)

1200 lbs.

Auxiliary Cabinets, Standard S-1 (Cutouts installed) 700 lbs.

Auxiliary Cabinet, L-847 (3 Selector Switches

Installed)

700 lbs.

Upper and Lower Track Extensions (combined weight

as shipped)

700lbs

Counterbalanced lift 5,550 lbs.

Document 2516


Switchgear System

Series 82XSYS

4

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 CCR cabinets are supplied with a pagoda top

that adds 3.0 inches to the cabinet overall height. 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.

Document 2516


Switchgear System

Series 82XSYS

5

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.

Document 2516


Switchgear System

Series 82XSYS

6

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.

Document 2516


Switchgear System

Series 82XSYS

7

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.

Document 2516


Switchgear System

Series 82XSYS

8

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.

Document 2516


Switchgear System

Series 82XSYS

9

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 pre-

determined 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.

Document 2516


Switchgear System

Series 82XSYS

10

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.

Document 2516


Switchgear System

Series 82XSYS

11

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

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.

2.1.9 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.

Document 2516


Switchgear System

Series 82XSYS

12

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 panel,

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 panel 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 2642 supplied with power module.

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 door panel and panel cover onto the cabinet door following the

instructions

Document 2516


Switchgear System

Series 82XSYS

13

provided with it. Close the cabinet door. Adjust cabinet door panel circuit breaker plate if

required. The panel circuit breaker plate can be flipped 180 degrees to accommodate

installation in either the upper or lower CCR cabinet position. 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 blank panel, P/N 34186

installed in place of the standard door panel configuration (does not

include a main circuit card, display circuit card, touch pad, rotary

switch and door panel cover).

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 panel 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 panel 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.

Document 2516


Switchgear System

Series 82XSYS

14

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.

Document 2516


Switchgear System

Series 82XSYS

15

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 door panels 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.

Document 2516


Switchgear System

Series 82XSYS

16

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.

Document 2516


Switchgear System

Series 82XSYS

17

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 L-

847 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.

Document 2516


Switchgear System

Series 82XSYS

18

NOTICE:

NOTICE

Each L-847 unit panel (gold color) ground lug must have #8 AWG

(minimum) ground lead connected to the Switchgear System ground

bus.

4 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.

Document 2516


Switchgear System

Series 82XSYS

19

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.

Document 2516


Switchgear System

Series 82XSYS

20

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. Re-

connect 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.

Document 2516


Switchgear System

Series 82XSYS

21

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 A-

TEMNO

Switchgear CCR Cabinet Bus Stabs – Cooper Interconnect part number E1074-2 (power) and

Cooper interconnect part number E1074-4 (Ground) (no catalog page available).

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).

Document 2516


Switchgear System

Series 82XSYS

22

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.

Switchgear System Power Meter, optional – Tyco Electronics Crompton Instruments Integra

Ci3 Digital Metering System.

Document 2516

Rev. F

23

CABINET INSTALLATION

Document 2516

Rev. F

24


Document 2516

Rev. F

25


Document 2516

Rev. F

26


Document 2516

Rev. F

27


Document 2516

Rev. F

28


Document 2516

Rev. F

29


Document 2516

Rev. F

30


Document 2516

Rev. F

31


Document 2516

Rev. F

32


Document 2516

Rev. F

33

12.00

CU

TO

UT

CU

TO

UT

CU

TO

UT

CU

TO

UT

CU

TO

UT

15.0

20.0

CABINET WIRING ENTRANCES

TYP

31.0

TYP

PER SECTION

Ø.625 TYP.(6)

2.5

TYP6.0

TYP

1.9

5.0

10.0

9.00

12.00

30.0

TYP

38.0

TYP 42.0

TYP

10.0

TYP

3.00" LONG x 1 1/2" WIDE SLOT

36.0

TYP

TYP16.0

TYP

20.0

27.0

5.0

10.0

TYP (REF)

3.00" LONG x 1 1/2" WIDE SLOT

Document 2516

Rev. F

34

EPOXY RESIN

SWITCHGEAR CABINET

2 1/8" MIN

EMBEDMENT

SEISMIC BOLTING

Document 2516

Rev. F

35

CABINET WALL CLEARANCES

INPUT

CABINET

CCR CABINET

FOR 2 POWER

MODULES

BLUE GIANT LIFT

TRACK EXTENSION

TOP VIEW

BLUE GIANT LIFT

Document 2516

Rev. F

36

BUS SPLICE INSTALLATION (DOORS AND PANELS REMOVED FOR CLARITY)

TORQUE SPECIFICATIONS

BUS HARDWARE

Document 2516

Rev. F

37

BUS SPLICE CONNECTION HARDWARE DETAILS

Document 2516

Rev. F

38

MODULES

FOR 2 POWER

CCR CABINET

MODULES

FOR 2 POWER

CCR CABINET

FOR 2 POWER

CCR CABINET

MODULES

FOR 2 POWER

MODULES

CCR CABINET

TYPICAL CCR POWER MODULE INSTALLATION/REMOVAL - FORKLIFT

MAIN

INPUT

NOTICE

Document 2516

Rev. F

39

TYPICAL CCR POWER MODULE INSTALLATION/REMOVAL - TRACK EXTENSIONS

IMPORTANT

IMPORTANT

NOTICE

Document 2516

Rev. F

40

RECOMMENDED BUILDING CEILING HEIGHT

Document 2516

Rev. F

41

SIDE VIEW

TYPICAL CABLE WIRING

Document 2516

Rev. F

42

OPTIONAL L-847 CONTROL WIRING CONNECTED TO DIGITRAC

Document 2516

Rev. F

43

1A1A

GND

OPTIONAL S-1 CUTOUT AUXILIARY CABINET

INTENTIONAL GROUNDED S-1 CUTOUT WIRING SCHEME

Document 2516

Rev. F

44

Lower Track Extension with CCR Power Module

Photo 1

Document 2516

Rev. F

45

Lower CCR Power Module Installed in Cabinet

Photo 2

Document 2516

Rev. F

46

Upper Track Extension with CCR Power Module and Counterbalanced Lift

Photo 3

Document 2516

Rev. F

47

Upper Track Extension and CCR Power Module

Photo 4

Document 2516

Rev. F

48

Upper Track Extension with Upper CCR Power Module Installation

Photo 5

Document 2516

Rev. F

49

Switchgear Installation on an Elevated Pad with Auxiliary Cabinets, Main Input Cabinet

and CCR Cabinets with Fan Option Pagoda Top

Photo 6

Document 2516

Rev. F

50

Switchgear CCR Cabinet with Fan Option with Doors Opened and

CCR Power Modules Installed with Digitrac and Megatrac Option

Photo 7

Document 2516

Rev. F

51

Switchgear CCR Cabinet Door with Digitrac and Megatrac Option Installed

Photo 8

Document 2516

Rev. F

52

98.0

42.0

TYP

38.0

TYP

30.0

TYP

20.0

15.0

5.0 10.0

EYEBOLTS

1.9

TYP

6.0

TYP

2.5 TYP

.63 DIA

(6) PLC'S

5.0 10.0

27.0

9.0 TYP

Document 2516

Rev. F

53

30.0

TYP

38.0

TYP

42.0

TYP

CU

TO

UT

31.0

TYP

36.0

TYP

2.5

TYP

6.0

TYP

TYP

1.9

16.0

TYP

10.0

TYP

.63 DIA

98.0

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.

PAGODA TOP

FANS ON

INTERIOR

OPTION "H"

CONFIGURATION,

HASP & STAPLE.

PADLOCK

NOT SUPPLIED

EXPANDED METAL TOP STANDARD

EYEBOLTS

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".

(6) PLC'S

12.00

12.00

9.00

3.00 LONG x 1.50 WIDE SLOT

9.0 TYP

ON INTERIOR NEAR INTERLOCK SWITCH,

ADD LABEL WITH BLACK LETTERS ONSMUDGE AND MOISTURE RESISTANTMATERIAL WITH THE FOLLOWING TEXT:LIMIT SWITCH ON THIS DOOR DISCONNECTSPOWER TO THE LOAD WHEN THE DOORIS OPENED.

DANGER

INSIDE

HIGH VOLTAGE

DANGER

INSIDEHIGH VOLTAGE

CONT ROL DOOR

OPE N BREAKER

BEFORE OP ENING

CONST RUCT ED IN

ACCORDANCE TO THE

UL891 S T ANDARD FOR

DEADFRONT S WITCHGEAR

IN E FFE CT AT THE

T IME ON CONSTRUCTION

MONTH & YEAR

T HIS SE CT ION OF

S WITCHGEAR IS

CONST RUCT ED IN

ACCORDANCE TO THE

UL891 S T ANDARD FOR

DEADFRONT S WITCHGEAR

IN E FFE CT AT THE

T IME ON CONSTRUCTION

MONTH & YEAR

T HIS SE CT ION OF

S WITCHGEAR IS

LABEL ON DOOR INTERIOR.MAKE LABEL AS SHOWN.BLACK LETTERS ON SMUDGEAND MOISTURE RESISTANTWHITE MATERIAL.

"DANGER HIGH VOLTAGE INSIDE"LABEL, EMED CO. QS423

OPTION "K".

MOUNTING HOLES TOHAVE PLUGS WHENOPTION "K" IS NOTORDERED.

MAKE LABEL AS SHOWN.

BLACK LETTERS ON SMUDGEAND MOISTURE RESISTANTWHITE MATERIAL.

CONT ROL DOOR

OPE N BREAKER

BEFORE OP ENING

DANGERHIGH VOLTAGE

INSIDE

BEFORE OP ENING

OPE N BREAKER

CONT ROL DOOR

CONT ROL DOOR

OPE N BREAKER

BEFORE OP ENING

HIGH VOLTAGEINSIDE

DANGER

"COOPER CROUSE-HINDS" NAME PLATE

PER DRAWING 34129, UPPER DOORSONLY.

3.0STANDARD,INSTALLED BYCUSTOMER

Document 2516

Rev. F

54

Document 2516

Rev. F

55

Document 2516

Rev. F

56

FRONT VIEW

FUNCTION

SETUP

DEVICE

ENTER

CONTRAST

CCR CABINET

FOR 2 POWER

MODULES

TOP VIEW

TYPICAL UPPER CCR POWER MODULE INSTALLATION/REMOVAL

Document 2516

Rev. F

57

FOR 2 POWER

CCR CABINET

TOP VIEW

FRONT VIEW

FUNCTION

CONTRAST

ENTER

SETUP

DEVICE

MODULES

TYPICAL CCR LOWER POWER MODULE INSTALLATION/REMOVAL

DETAIL B

Instruction Manual - Cooper · PDF fileInstruction Manual Switchgear System Series 82XSYS ii...

Documents

Transcript of Instruction Manual - Cooper · PDF fileInstruction Manual Switchgear System Series 82XSYS ii...