01.4SM.1200 Charging Motor Assembly
Contents
1. PA POWELL SM 1200 Powered by Safety Charging Motor Assembly PA POWELL Charging Motor SM 1200 Contact Information Powell Electrical Systems Inc www powellind com info powellind com Service Division PO Box 12818 Houston Texas 77217 2818 Tel 713 944 6900 Fax 713 948 4569 Powered by Safety SM 1200 W POWELL Signal Words Qualified Person As stated in ANSI Z535 4 2002 4 13 4 13 3 the signal word is a word that calls attention to the safety sign and designates a degree or level of hazard seriousness The signal words for product Safety signs are Danger Warning and Caution These words are defined as For the purposes of this manual a qualified person as stated in NFPA 70 is one familiar with the construction and operation of the equipment and the hazards involved In addition to the above qualifications one must also be VAN DANGER 1 DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury trained and authorized to energize deenergize clear ground and tag circuits and equipment in accordance with established safety practices 2 trained in the proper care and use of personal protective equipment PPE such as rubber gloves hard hat safety glasses or face shields flash clothing etc VAN WARNING WARNING indicates a potentially hazardous situation which if not avoided c2. Safety Powered by Safety 5 PA POWELL Charging Motor SM 1200 Ch3 Equipment Description A GENERAL The charging motor is normally located in the lower right hand corner of the circuit breaker Ensure that the control circuits are deenergized and the circuit breaker is deenergized disconnected by means of a visible break and securely grounded Do NOT start to work on a closed circuit breaker or a circuit breaker with the main closing spring charged The charging motor assembly consists of the following e Charging Motor e Motor Coupler Y 20 x 1 4 Hex Head Socket Screw V4 x 1 14 Spiral Pin e 8 32 x 3 s Socket Head Cap Screw e Motor Mounting Bracket e Wire Connections Faston Tools required for installation Socket Wrench 7 16 Socket e Wire Cutters 6 Power ed by Sa fety Equipment Description W POWELL SM 1200 Figure 1 Charging Motor Assembly Equipment Description an Sa TO AD Motor Mounting Bracket Charging Motor Spiral Pin 8 32 Socket Head Cap Screw showing location only Motor Coupler 14 20 x 14 Hex Head Socket Screw Acrylic Sleeving Wire Connections Fastons Powered by Safety W POWELL Charging Motor SM 1200 Ch 4 Installation Note The instructions in Ch 4 Installation A REMOVING THE OLD CHARGING MOTOR ASSEMBLY FROM THE Circuit BREAKER B Installing the New Charging Motor Assembly into the Ci
3. 12 Note If wire tags aren t visible contact Powell Service Division before proceeding to the next step Insert the motor coupler end of the charging motor assembly into the motor shaft slot Figure 6 Secure the charging motor to the circuit breaker by tightening the four 4 20 x 34 Hex Head Bolts to the charging motor assembly bracket Figure 10 Note Use Loctite 242 or equivalent on the four 4 20 x 34 Hex Head Bolts before installing Reinstall the front cover of the circuit breaker F TESTING THE CHARGING Motor USING A PowLVac ND Test CABINET 1 Roll the circuit breaker to the test cabinet area Ensure that the Test Cabinet Power Switch is in the OFF position 2 Connect the test cabinet umbilical cord 3 Figure 13 d into the circuit breaker secondary disconnect receptacle Turn the test cabinet power switch Figure 13 c to the ON position This will charge the circuit breaker If the circuit breaker charges fully then the motor is installed correctly If the motor does not charge the main spring double check that the wire connections are correct If problems persist contact Powell Service Division at 1 800 480 7273 Note The motor should charge in less than 10 seconds at nominal control voltage A IMPORTANT If a knocking noise is observed during charging refer to the Ratchet Wheel Holding Pawl Adjustment section of the appropriate circuit breaker instruction bull
4. Cord Test Cabinet Umbilical Plug vana 12 Powered by Safety Installation PA POWELL SM 1200 w D REMOVING THE OLD CHARGING MOTOR FROM THE Figure11 Removing the Charging Motor from PowLVac ND Circuit BREAKER the Pow lVac ND Circuit Breaker Perform the following steps to remove the old charging motor assembly from the circuit breaker A N CAUTION Ensure that the control circuits are deenergized and the circuit breaker is deenergized disconnected by means of a visible break and securely grounded Do NOT start to work on a closed circuit breaker or a circuit breaker with the main closing spring charged 4 Disconnect the black and white wires from 1 Remove the front cover of the circuit the wiring harness Figure 12 breaker 2 Remove the four 1 4 20 x 3 4 Hex Head Bolts Figure12 Disconnecting Connecting Wires from the charging motor assembly bracket located at bottom right side of the circuit breaker Figure 10 Figure 10 Charging Motor Assembly Bracket 3 Pull the charging motor out of the circuit breaker frame Figure 11 Installation Powered by Safety 13 W POWELL Charging Motor SM 1200 E INSTALLING THE New CHARGING Motor ASSEMBLY INTO THE PowL_Vac ND Circuit BREAKER 1 Connect the black wire from the charging motor to wire M1 from the wiring harness to and connect the white wire from the charging motor to wire M2 from the wiring harness to Figure
5. Installation W POWELL sm 1200 gt E 3 Disconnect the white and black wires from Figure4 Removing Hex Head Bolts the wiring harness Figure 3 Figure3 Disconnecting Charging Motor Wires a ae _ eo form the Wiring Harness E i A mir We 6 Remove the charging motor from the circuit breaker by pulling to the right and tilting towards the front of the circuit breaker Figure 5 4 Elevate and secure the circuit breaker so there is at least 6 inches of clear space Figure5 Removing the Charging Motor under the circuit breaker base pan A N CAUTION Ensure that the circuit breaker is stable and secure before performing Step 5 Failure to do so may result in personal injury 5 Once the circuit breaker is stable and secure remove the two 1 4 20 x 34 Hex Head Bolts from the circuit breaker Figure 4 Retain the bolts for reassembly Installation Powered by Saf ety 9 W POWELL Charging Motor SM 1200 INSTALLING THE New CHARGING Motor ASSEMBLY INTO THE CIRCUIT BREAKER Ensure that the control circuits are deenergized and the circuit breaker is deenergized disconnected by means of a visible break and securely grounded Do NOT start to work on a closed circuit breaker ora circuit breaker with the main closing spring charged Perform the following steps to install the new charging motor assembly into the circuit breaker 1 Remove the front cov
6. POSITION CONTACT POWELL FOR INSTRUCTIONS Powered by Safety Safety SM 1200 W POWELL E X Rays F SAFETY LABELS When high voltage is applied across the contacts of a vacuum interrupter there is the possibility of generation of X rays The intensity of the X radiation is dependent on the peak The equipment described in this document has DANGER WARNING CAUTION and instruction labels attached to various locations All equipment DANGER WARNING CAUTION voltage and the contact gap At the normal operating voltage for this type of equipment the radiation levels are negligible At the and instruction labels shall be observed when the circuit breaker is handled operated or maintained voltages specified for testing test personnel shall be in front of the circuit breaker such that the two layers of steel used in the frame and front cover construction are between the test personnel and the vacuum interrupters and that the test personnel be no closer than one meter 3 from the front of the circuit breaker THE CIRCUIT BREAKER SHALL BE EITHER FULLY OPEN OR FULLY CLOSED WHEN MAKING HIGH POTENTIAL TESTS DO NOT TEST WITH CONTACTS PARTIALLY OPEN man IMPORTANT Warning and Caution labels are located in various places in and on the switchgear and on the circuit breaker removable element Always observe these warnings and caution labels Do NOT remove or deface any of these warning caution labels
7. aseevesssveiancevsnusdsdeonseestesses sonadesseasstussasexsuonaneeasscosissssvaonssessnnsevesceseuoounsseagnasestsecersouaduennnssessvestssubacreuaiscostes 6 CHEE TISTGIIGUON casncan ccasivacisaventvacencssvcecicesacicesecsesouscsesecesuesssanvedussoucasucenssesesivesesiseseacvevesssans 8 A REMOVING THE OLD CHARGING MOTOR ASSEMBLY FROM THE CIRCUIT BREAKER sccsscsssssccesssscccsssscccsssscccssscsccssssscsssssseseees 8 B INSTALLING THE NEw CHARGING MOTOR ASSEMBLY INTO THE CIRCUIT BREAKER sscccccccssescssssscccsccccccesescsscsccccccccsccssesesseees 10 C TESTING THE CHARGING MOTOR USING A TEST CABINET ssssscccccsssssssccccccssssssccecscssssscccecesessssscccccsessssscccececesssassesssesses 11 D REMOVING THE OLD CHARGING MOTOR FROM THE POWLVAC ND CIRCUIT BREAKER eccssssscssccccccccsssessssscccccccccssecesseees 13 E INSTALLING THE New CHARGING Motor ASSEMBLY INTO THE POWLVAC ND CIRCUIT BREAKER cccccccesessssscccscccccessecesseees 14 F TESTING THE CHARGING MOTOR USING A POWLVAC ND TEST CABINET ccccccessssscssssssscsscscscsscsssssscssccccccccccescscssceeees 14 Figures Figure 1 Charging Motor Assembly sccccoccsssccccccssscccccccsscsccccccscscccccsccscccsssscsccsssees 7 Fig ure2 CUTTING TAS Tie Wrap seseveseiscaesessensexcuvedcecvessdsncsieassevenecodvavesussesddessevecsessseesusesss 8 Figure3 _Disconnecting Charging Motor Wires form the Wiring Harness 00000 9 Figure 4 Removing Hex Head Bolts ccccccsss
8. being deenergized Electrically Safe Work Condition could contact other exposed energized conductors or circuit parts apply ground 120 1 Process of Achieving an Electrically Safe connecting devices rated for the available Work Condition fault duty 1 Determine all possible sources of electrical B Sarety GUIDELINES supply to the specific equipment Check applicable up to date drawings diagrams Study this maintenance procedure and all other and identification tags associated documentation before installing the undervoltage device 2 After properly interrupting the load current OPEN the disconnecting device s for each Each user has the responsibility to instruct source and supervise all personnel associated with usage installation operation and maintenance 3 Wherever possible visually verify that all of this equipment on all safety procedures blades of the disconnecting devices are Furthermore each user has the responsibility of fully OPEN or that drawout type circuit establishing a safety program for each type of breakers are withdrawn to the fully equipment encountered disconnected position It is mandatory that the following rules be 4 Apply lockout tagout devices in accordance observed to ensure the safety of personnel with a documented and established policy associated with usage installation operation and maintenance of these circuit breakers 5 Use an adequately rated voltage detector to test each phase conductor o
9. csccssscccssssccccsscscccssscccccsssccccssscccssssccooees 9 Figure 5 Removing the Charging Motor ccccccssccccsssccccsssscccssscccccsssccccsssccccsssscosees 9 FIGUIEG Motor Shalt Slot sissctvccscensahecsvaccascesess tivewcsunens reen er EEN EEE EESE EEEE 10 Figure7 Securing the Charging Motor to the Circuit Breaker 0scccccsssccccssssceee 10 Figure8 Connecting the Charging Motor Wires to the Wiring Harness 00ss000 11 Figure9 Typical Test Cabinet with Umbilical Cord ccccccccsssscccccccccscscccccscccccceces 12 Figure 10 Charging Motor Assembly Bracket ccccccccccsssscccccssccccccccsccccccccccccosscees 13 Figure 11 Removing the Charging Motor from the PowlVac ND Circuit Breaker 13 Figure 12 Disconnecting Connecting Wires cccccccccsssccsssccsssccssscccsscccsscocsscccesscosees 13 Figure 13 Typical PowlVac ND Test Cabinet with Umbilical cccccccssscccccccceeccccees 15 Powered by Safety PA POWELL Charging Motor SM 1200 This page is intentionally left blank i Powered by Safety W POWELL sm 1200 Ch1 General Information VAN WARNING The equipment described in this document may contain high voltages and currents which can cause serious injury or death The equipment is designed for use installation and maintenance by knowledgeable users of such equipment having experience and training in the field of high voltage electricity T
10. equired to properly install the charging motor described in Ch 1 General Information A Score This instruction bulletin provides 1 Safety guidelines 2 Instructions for installation and placing the charging motor into service 3 Illustrations photographs and description of the charging motor The illustrations contained in this document may not represent the exact construction details of each particular type of charging motor The illustrations in this document Charging Motor SM 1200 are provided as general information to aid in showing component locations only All illustrations are shown using deenergized equipment VAN WARNING Be sure to follow the appropriate safety precaution while handling any of the equipment Failure to do so may result in serious injury or death To the extent required the products described herein meet the applicable ANSI IEEE and NEMA Standards however no such assurance is given with respect to local codes and ordinances which may vary greatly Power ed by S a fety General Information PA POWELL SM 1200 w Ch2 Safety 6 Where the possibility of induced voltages or stored electrical energy exists ground A Sare Work ConDITION the phase conductors or circuit parts before touching them Where it could be The information in Section A is quoted from reasonably anticipated that the conductors NFPA 70E 2004 Article 120 120 1 Establishing an or circuit parts
11. er of the circuit breaker 2 Elevate and secure the circuit breaker so there is at least 6 inches of clear space under the circuit breaker base pan 3 Using Rheolube 368A Grease lubricate the end of the motor coupler Ensure that the circuit breaker is stable and secure before performing Step 4 Failure to do so may result in personal injury 4 Insert the motor coupler end of the charging motor assembly into the motor shaft slot Figure 6 Figure6 Motor Shaft Slot F f f yaaaaa ahah PP PHI ppnepenppeyyrtt WP TTL ttt i f ya y 5 Secure the charging motor to the circuit breaker by tightening the two 4 20 x 34 Hex Head Bolts to the charging motor mounting bracket 5 7 ft lbs Figure 7 Note Use Loctite 242 or equivalent on the two 4 20 x 34 Hex Head Bolts before installing Securing the Charging Motor to the Circuit Breaker Figure 7 _ Bay w L Py i 3 m an a E itil 7 i i J 5 i Se F 2 O e e Powered by Safety Installation PA POWELL SM 1200 w 6 Connect wire M1 from the wiring harness to C TESTING THE CHARGING Motor Us inG a Test CABINET the black wire from the charging motor and connect wire M2 from the wiring harness 1 Roll the circuit breaker to the test cabinet to the white wire from the charging motor area Figure 8 Note I f wire tags aren t visible contact A CAUTION Powell Service Division before proceeding t
12. etin Powered by Safety Installation N POWELL sM 1200 Figure 13 Typical PowlVac ND Test Cabinet with Umbilical Close Push Button Trip Push Button Test Cabinet Power Switch Test Cabinet Umbilical Cord Test Cabinet Umbilical Plug PANEG Installation Powered by Safety 15 PA POWELL Charging Motor SM 1200 This page is intentionally left blank Powered by Safety W POWELL SM 1200 Charging Motor Assembly June 2008 Powell Electrical Systems Inc Powered by S afety Tel 713 944 6900 Fax 713 948 4569 Service Division Houston www powellind com PO Box 12818 Houston TX 77217 2006 Powell Industries Inc All rights reserved info powellind com
13. his document and all other documentation shall be fully read understood and all warnings and cautions shall be abided by If there are any discrepancies or questions the user shall contact Powell immediately at 1 800 480 7273 VAN WARNING Before any adjustment servicing part replacement or any other act is performed requiring physical contact with the electrical working components or wiring of this equipment the power supply must be disconnected Failure to follow this warning may result in injury or death VAN IMPORTANT Powell reserves the right to discontinue and to change specifications at any time without incurring any obligation to incorporate new features in products previously sold General Information Power ed by S a fety 1 W POWELL A Scope The information in this service manual describes the following Charging Motor e 50960G04P 120VAC 125VDC e 50960G05P 240VAC 250VDC e 50960G06P 48VDC e 77318G02P 120VAC 125VDC PowlVac ND e 77318G03P 240VAC 250VDC PowlVac ND e 77318G01P 48VDC PowlVac ND This device can be used in the following circuit breakers e PowlVac STD e PowlVac CDR e PowlVac ASD e PowlVac 38kV CDR e PowlVac ND Note This charging motor can also be used in certain PowlVac replacement circuit breakers however the placement and procedures may vary for installation PURPOSE The information in this maintenance procedure is intended to provide information r
14. o the next step Ensure that the Test Cabinet Power Switch is in the OFF position Figure8 Connecting the Charging Motor Wires to the Wiring Harness 2 Connect the test cabinet umbilical cord Figure 8 d into the circuit breaker secondary disconnect receptacle Note If there is an Undervoltage Device in the circuit breaker refer to SM 1800 Undervoltage Assembly Service Manual 3 Turn the test cabinet power switch Figure 8 c to the ON position This will charge the circuit breaker If the circuit breaker charges fully then the motor is installed correctly If the motor does not charge the main spring double check that the wire connections are correct If 7 Secure the wires to the wiring harness problems persist contact Powell Service located in front of the two point terminal Division at 1 800 480 7273 block using a tie wrap 8 Lower the circuit breaker from its elevated Note The motor should charge in less position than 10 seconds at nominal control 9 Reinstall the front cover of the circuit voltage breaker VAN IMPORTANT If a knocking noise is observed during charging refer to the Ratchet Wheel Holding Pawl Adjustment section of the appropriate circuit breaker instruction bulletin Installation Powered by Safety 11 VW POWELL Charging Motor SM 1200 Figure9 Typical Test Cabinet with Umbilical Cord Close Push Button Trip Push Button Test Cabinet Power Switch Test Cabinet Umbilical
15. ould result in in accordance with established safety practices trained in rendering first aid if necessary death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Not stated in ANSI Z535 4 2002 4 13 4 13 3 as a signal word but used in this manual is IMPORTANT This is defined as A IMPORTANT IMPORTANT indicates a section of the manual covering anon hazardous situation but one where Powell feels proper attention is warranted Powered by Safety PA POWELL Charging Motor SM 1200 This page is intentionally left blank Powered by Safety W POWELL sM 1200 Contents CHT General information oscccsstesesisiccsesiencecsacsnsecasccsvdtietscduissecdsavetcessaecsuaassusea cusses qaavacsiseies 1 E E o OEI O OE NAE OOII IA A IOA O AONTA A E E A AT 2 B PORPOSE oriin oni ri EEIE A IEEE O EEEE E E EEEE EE A 2 IZ SO r E E E EE TEE EEEE E E 3 Ais SN EWORK C ONDMON secesii enera ore EE A E S E A EE 3 Be SAFEN GODINE E rriei neer ENSE SEE EEEE EEEE EAEAN EESE EENEN O EEEIEE OESE LETE ENS 3 C COEN RAE SEES E E AEE EE E EEEE A EEA E A 4 O PEOC aarre EENE EEE EEA NEEE OEA EEOAE ENE 4 E ARONS aa A A O E AE E A E E E 5 E ana E E E E EO A OA A A ES O E AEN OA A ETIA EEA EER ANEN E ET 5 CHS Equipment Description seescceccccccecccccccccccecccecccccccecccecccoccecccecccccccecccecccecccecseecceecceeo 6 As GENERAL se
16. r circuit part The safety rules in this instruction bulletin are to verify they are deenergized Test each not intended to be a complete safety program phase conductor or circuit part both The rules are intended to cover only some of the phase to phase and phase to ground important aspects of personnel safety related to Before and after each test determine charging motor that the voltage detector is operating satisfactorily Safety Powered by Safety 3 W POWELL Charging Motor SM 1200 C GENERAL i Only supervised and qualified personnel trained in the usage installation operation and maintenance of the circuit breaker shall be allowed to work on this equipment It is mandatory that this instruction bulletin any supplements and service advisories be studied understood and followed Maintenance programs must be consistent with both customer experience and manufacturer s recommendations including service advisories and instruction bulletin s A well planned and executed routine maintenance program is essential for circuit breaker s reliability and safety Service conditions and circuit breaker applications shall also be considered in the development of safety programs Variables include ambient temperature humidity actual continuous current thermal cycling number of operations interrupting duty and any adverse local conditions including excessive dust ash corrosive atmosphere vermin and insec
17. rcuit Breaker and C TESTING THE CHARGING Motor USING A Test Casinet cover the following circuit breakers only e PowlVac STD e PowlVac CDR e PowlVac ASD e PowlVac 38kV CDR A REMOVING THE OLD CHARGING Motor ASSEMBLY FROM THE CIRCUIT BREAKER Perform the following steps to remove the old charging motor assembly from the circuit breaker Ensure that the control circuits are deenergized and the circuit breaker is deenergized disconnected by means of a visible break and securely grounded Do NOT start to work on a closed circuit breaker ora circuit breaker with the main closing spring charged 1 Remove the front cover of the circuit breaker 2 Cut the tie wrap holding the two wires from the charging motor to the wiring harness if present Figure 2 Figure 2 VAN IMPORTANT Locate the Wiring Diagram section on the circuit breaker nameplate If the wiring diagram number begins with 507 replace Step 3 with Steps 2a 2b and 2c If the wiring diagram number begins with 504 go directly to Step 3 2a Remove the existing motor plug by cutting the wires on the harness side of the motor plug assembly Note If wire tags aren t visible contact Powell Service Division before proceeding to the next step 2b Strip the wires appropriately to allow for crimping 2c Crimp the Faston connector to the wiring harness and proceed to Step 4 Cutting the Tie Wrap 8 Powered by Safety
18. t infestations D SPECIFIC P DO NOT WORK ON AN ENERGIZED CIRCUIT BREAKER If work must be performed on a circuit breaker remove it from service and remove it from the metal clad switchgear DO NOT WORK ON A CIRCUIT BREAKER WITH THE CONTROL CIRCUIT ENERGIZED EXTREME CARE MUST BE EXERCISED TO KEEP ALL PERSONNEL TOOLS AND OTHER OBJECTS CLEAR OF MECHANISMS WHICH ARE TO BE OPERATED DISCHARGED OR RELEASED These circuit breakers utilize stored energy mechanisms These mechanisms must be serviced only by skilled and knowledgeable personnel capable of releasing each spring load in a controlled manner Detailed information regarding these mechanisms is found in this instruction bulletin DO NOT ATTEMPT TO CLOSE THE CIRCUIT BREAKER MANUALLY ON AN ENERGIZED CIRCUIT DO NOT USE AN OPEN CIRCUIT BREAKER AS THE SOLE MEANS OF ISOLATING A HIGH VOLTAGE CIRCUIT For complete isolation the circuit breaker shall be in the disconnected position or shall be withdrawn completely ALL COMPONENTS SHALL BE DISCONNECTED BY MEANS OF A VISIBLE BREAK AND SECURELY GROUNDED FOR SAFETY OF PERSONNEL PERFORMING MAINTENANCE OPERATIONS ON THE CIRCUIT BREAKERS Interlocks are provided to ensure the proper operating sequences of the circuit breakers and for the safety of the user If for any reason an interlock does not function as described do not make any adjustments modification or deform the parts DO NOT FORCE THE PARTS INTO
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