S&C Scada-Mate Switching Systems Outdoor Distribution Interrupter Replacement 14.4 kv through 34.5 kv

S&C Scada-Mate Switching Systems Outdoor Distribution Interrupter Replacement 14.4 kv through 34.5 kv Instructions for Field Replacement TABLE OF CONTENTS Section Page Section Page INTRODUCTION Qualified Persons.............................. 2 Read this Instruction Sheet...................... 2 Retain this Instruction Sheet..................... 2 Proper Application............................. 2 Warranty...................................... 2 SAFETY INFORMATION Understanding Safety-Alert Messages............. 3 Following Safety Instructions.................... 3 Replacement Instructions and Labels............. 3 Location of Safety Labels and Tags for Scada-Mate Switches Shipped Before May 2000............... 4 Location of Safety Labels and Tags for Scada-Mate Switches Shipped After May 2000................ 5 SAFETY PRECAUTIONS............................ 6 PACKING AND INSPECTION........................ 7 REPLACING THE INTERRUPTERS Preparing the Switch............................ 8 Removing the Interrupter....................... 11 Installing the Interrupter........................ 13 S&C ELECTRIC COMPANY Specialists in High-Voltage Switching and Protection Instruction Sheet 768-520 April 17, 2000 2000 Supersedes Instruction Sheet 768-520 dated 6-6-94

INTRODUCTION Qualified Persons Ç WARNING The equipment and components covered by this publication must be installed, operated, and maintained by qualified persons who are knowledgeable in the installation, operation, and maintenance of underground electric power distribution equipment along with the associated hazards. A qualified person is one who is trained and competent in: The skills and techniques necessary to distinguish exposed live parts from non-live parts of electrical equipment. The skills and techniques necessary to determine the proper approach distances corresponding to the voltages to which the qualified person will be exposed. The proper use of the special precautionary techniques, personal protective equipment, insulating and shielding materials, and insulated tools for working on or near exposed energized parts of electrical equipment. These instructions are intended only for such qualified persons. They are not intended to be a substitute for adequate training and experience in safety procedures for this type of equipment. Read this Instruction Sheet Retain this Instruction Sheet Proper Application Read this instruction sheet thoroughly and carefully before replacing the interrupters on your Scada-Mate Switch. Familiarize yourself with SAFETY INFORMATION on pages 3 through 5. This instruction sheet is a permanent part of your S&C Scada-Mate Switch. Designate a location where you can easily retrieve and refer to this publication. Ç CAUTION The equipment in this publication must be selected for a specific application. The application must be within the ratings furnished for the equipment. Warranty The standard warranty contained in S&C s standard conditions of sale, as set forth in Price Sheet 150, is applicable to the S&C Scada- Mate Switch covered in this instruction sheet. 768-520 2

SAFETY INFORMATION Understanding Safety-Alert Messages There are several types of safety-alert messages which may appear throughout this instruction sheet as well as on labels and tags attached to the Scada-Mate Switch. Familiarize yourself with these types of messages and the importance of the various signal words, as explained below. Ç DANGER DANGER identifies the most serious and immediate hazards which will likely result in serious personal injury or death if instructions, including recommended precautions, are not followed. Ç WARNING WARNING identifies hazards or unsafe practices which can result in serious personal injury or death if instructions, including recommended precautions, are not followed. Ç CAUTION CAUTION identifies hazards or unsafe practices which can result in minor personal injury or product or property damage if instructions, including recommended precautions, are not followed. NOTICE NOTICE identifies important procedures or requirements that, if not followed, can result in product or property damage if instructions are not followed. Following Safety Instructions If you do not understand any portion of this instruction sheet and need assistance, contact your nearest S&C Sales Office or S&C Authorized Distributor, or call S&C Headquarters at (773) 338-1000, Monday through Friday between 8:30 AM and 5:00 PM Central Standard Time. (In Canada, call S&C Electric Canada Ltd. at (416) 249-9171, Monday through Friday between 8:00 AM and 5:00 PM Eastern Standard Time.) NOTICE Read this instruction sheet thoroughly and carefully before replacing the interrupters on your S&C Scada-Mate Switch. Replacement Instructions and Labels If you need additional copies of this instruction sheet, contact your nearest S&C Sales Office, S&C Authorized Distributor, S&C Headquarters, or S&C Electric Canada Ltd. It is important that any missing, damaged, or faded labels on the equipment be replaced immediately. Replacement labels are available by contacting your nearest S&C Sales Office, S&C Authorized Distributor, S&C Headquarters, or S&C Electric Canada Ltd. 3 768-520

SAFETY INFORMATION Location of Safety Labels and Tags for Scada-Mate Switches Shipped Before May 2000 A C E B D Reorder Information for Safety Labels Location Safety-Alert Message Description Part Number A None Lifting Instructions G-6252R1 B Ç WARNING Electrical Shock Before energization and at all times when energized... G-6289R3 C Ç CAUTION Stored-energy operating mechanism and switch base contain high-speed moving parts... G-6308R1 D Ç WARNING Electrical Shock Before energization and at all times when energized... G-6350R1 E Ç IMPORTANT Shorting blocks for sensor secondaries are shipped installed in switch connector... G-6351 This part is a tag which is to be removed and discarded after the switch is installed and adjusted. 768-520 4

SAFETY INFORMATION Location of Safety Labels and Tags for Scada-Mate Switches Shipped After May 2000 A E D Upright (other configurations are similar) B F C Tiered-Outboard Reorder Information for Safety Labels Location Safety-Alert Message Description Part Number A Ç WARNING Stored-energy operating mechanism and switch base contain fast-moving parts... G-6810 B NOTICE To manually operate interrupters, pull ring using a hookstick. G-6811 C Ç DANGER Electrocution Hazard Always consider parts live... G-6812 D Ç DANGER Electrocution Hazard (for tiered-outboard) Always consider parts live... G-6813 E Ç WARNING Electrocution Hazard Switch and control unit enclosure must be installed and grounded ONLY by qualified personnel... G-6815 F Ç WARNING Lifting Instructions G-6816 G Ç IMPORTANT G-6351 Shorting blocks for sensor secondaries are shipped installed in switch connector... Available only on switches bearing catalog number supplement R2, except for vertical mounting configuration. This label is placed on both sides of switch base on opposite ends. This part is a tag which is to be removed and discarded after the switch is installed and adjusted. G 5 768-520

SAFETY PRECAUTIONS Ç DANGER Scada-Mate Switches contain high voltage. Failure to observe the precautions below will result in serious personal injury or death. Some of these precautions may differ from company operating procedures and rules. Where a discrepancy exists, users should follow their company s operating procedures and rules. 1. QUALIFIED PERSONS. Access to switches and controls must be restricted only to qualified persons. See Qualified Persons on page 2. 2. SAFETY PROCEDURES. Always follow safe operating procedures and rules. 3. PERSONAL PROTECTIVE EQUIPMENT. Always use suitable protective equipment such as rubber gloves, rubber mats, hard hats, safety glasses, and flash clothing in accordance with safe operating procedures and rules. 4. SAFETY LABELS. Do not remove or obscure any of the DANGER, WARNING, CAUTION, or NOTICE labels. 5. OPERATING MECHANISM AND BASE. Storedenergy operating mechanism and switch base contain fast-moving parts that can severely injure fingers. Do not remove or disassemble operating mechanism, or remove access panel on switch base unless directed by S&C Electric Company. 6. ENERGIZED COMPONENTS. Always consider all parts live until de-energized, tested, and grounded. 7. GROUNDING. v Before energization and at all times when energized, the switch base and control unit enclosure must be connected to suitable earth ground at the base of pole in accordance with the S&C instruction sheet furnished with this device. v The switch base ground must also be connected to the system neutral. If the system neutral is not present, proper precautions must be taken to ensure that the local earth ground cannot be severed or removed. 8. LOAD-INTERRUPTER SWITCH POSITION. v Always confirm the open/close position of loadinterrupter switches by visually observing the indicator. v Interrupters and terminal pads may be energized from either terminal. v Interrupters and terminal pads may be energized with the interrupters in any position. 9. MAINTAINING PROPER CLEARANCE. Always maintain proper clearance from energized components. 768-520 6

PACKING AND INSPECTION Packing Inspection The replacement kit will be packaged and crated appropriately to avoid damage during shipment. It will include one replacement interrupter and the associated hardware. The replacement hardware used in the installation of the interrupters will vary with the different Scada-Mate Switch ratings. Examine the shipment for external evidence of damage as soon after receipt as possible, preferably before removal from the carrier s conveyance. Check the bill of lading to make sure that all shipping skids, crates, and containers listed thereon are present. If there is visible loss and/or damage: 1. Notify the delivering carrier immediately. 2. Ask for a carrier inspection. 3. Note condition of shipment on all copies of the delivery receipt. 4. File a claim with the carrier. If concealed damaged is discovered: 1. Notify the delivering carrier within 15 days of receipt of shipment. 2. Ask for a carrier inspection. 3. File a claim with the carrier. Also notify S&C Electric Company in all instances of loss and/or damage. 7 768-520

Preparing the Switch Step 1 Place the local/remote switch on the switch control in the control unit in the LOCAL position. After following the user s standard procedures for clearing and tagging equipment on which work is to be performed, open the Scada-Mate Switch interrupter contacts by pressing the OPEN push button in the control unit. Also place the power switch on the battery charger in the control unit in the OFF position. Mechanical block-bolt hole insert ³ ₈ 16 2 ¹ ₂ hex-head stainless-steel cap screw High-speed operating mechanism Figure 1. Installing the mechanism blocking bolt (for switches with the high-speed operating mechanism or -H suffix). Step 2 For switches with the high-speed operating mechanism or -H suffix, remove the short bolt from the blocking-bolt hole on the bottom of the operating mechanism and replace with a ³ ₈ 16 2¹ ₂ hex-head stainless-steel cap screw (provided with the replacement kit). Tighten the screw until a resistance is felt but do not firmly tighten with a wrench. This will prevent inadvertent tripping of the high-speed mechanism while the switch is being serviced. See Figure 1. Because the R2 operating mechanism does not have the block-bolt hole, there will be no short bolt to remove or replace. See Figure 2. R2 operating mechanism Figure 2. Scada-Mate Switch with R2 operating mechanism. 768-520 8

Ç CAUTION To prevent serious injury to hands, resulting from inadvertent tripping of the mechanism, do not remove the operating or access panels from the switch unless the blocking bolt is installed on the mechanism (applicable only on switches with high-speed operating mechanism or -H suffix). Wildlife protection covers Two ⁵ ₁₆ 16 ³ ₄ Delrin shoulder bolt Step 3 Remove the high-voltage conductor from the interrupter-end terminal pad. If the switch includes optional wildlife protection (Switch Catalog Number Suffix -A1 ), the wildlife protection cover must first be removed by removing the ⁵ ₁₆ 16 ³ ₄ Delrin shoulder bolt attaching the protection cover to the hinge pivot. Discard the shoulder bolt but save the wildlife protection cover for reuse. See Figure 3. Figure 3. Removing Delrin shoulder bolt. 9 768-520

Step 4 To access the linkages inside the switch base, the indicator, end cover, or access panel nearest the interrupter that is being replaced must be removed. To remove the indicator or end cover: Remove the four #10 32 ¹ ₂ stainless-steel fillister-head machine screws which are used to attach the indicator (or end cover) to the base. Save the indicator (or end cover) and hardware for reuse. See Figure 4. Indicator (or end cover) Four #10 32 ¹ ₂ fillister-head stainless-steel machine screws Figure 4. Removing indicator (or end cover). To remove an access panel: Remove the ¹ ₄ 20 1 hex-head stainless-steel cap screws and flat washers which are used to attach the access panel to the base. Save the access panel and hardware for reuse. See Figure 5. Access panel (typical) with ¹ ₄ 20 1 hex-head stainlesssteel cap screws and flat washers Figure 5. Removing access panel(s). 768-520 10

Step 5 Loosen the ¹ ₄ 20 1 socket-head stainlesssteel cap screw used to clamp the interrupter drive lever to the interrupter drive shaft. Next, remove and discard the ¹ ₄ 20 ¹ ₄ sockethead nylon-tip set screw from the knurled collar. (To access the set screw, it may be necessary to rotate the three-phase disconnect by moving the disconnect operating lever.) Then turn the knurled collar counterclockwise and completely unthread it from the interrupter. See Figure 6. Knurled collar ¹ ₄ 20 ¹ ₄ socket-head nylon-tip cap screw ¹ ₄ 20 1 sockethead stainless-steel cap screw Figure 6. Loosening the knurled collar. Interrupter drive lever Interrupter drive shaft Removing the Interrupter Step 6 Remove and discard the 1-inch stainless-steel pin and X washer used to connect the disconnect drive lever to the disconnect interphase linkage. Then carefully lift the interrupter from the support casting, take care to save the thrust washer for reuse. Discard the knurled collar. See Figure 7. 1 stainless-steel pin and X washer Disconnect interphase linkage Knurled collar Disconnect drive lever Figure 7. Removing the interrupter. 11 768-520

Step 7 Remove and discard the two ⁵ ₁₆ 16 ³ ₄ Delrin shoulder bolts used to attach the contact guard to the end of the existing interrupter. Also, discard the contact guard. See Figure 8. Two ⁵ ₁₆ 16 ³ ₄ Delrin shoulder bolts Contact guard Figure 8. Removing Delrin shoulder bolts. Step 8 Remove the two ³ ₈ 16 ³ ₄ hex-head stainless-steel cap screws and Belleville washers used to attach the contact assembly to the end of the interrupter. Save the contact assembly and associated hardware for reuse on the new interrupter. See Figure 9. Contact assembly Two ³ ₈ 16 ³ ₄ hex-head stainless-steel cap screws and Belleville washers Figure 9. Attaching the contact assembly to the replacement interrupter. 768-520 12

Installing the Interrupter Step 9 Carefully position the new interrupter into the support casting making sure that the thrust washer (saved in Step 6) is between the support casting and the interrupter. Position the knurled retainer (included with the replacement kit) inside the switch base such that the interrupter drive shaft passes through the knurled retainer, and that the interrupter drive shaft engages the interrupter drive lever. See Figure 10. Tighten the knurled retainer onto the threads of the interrupter securely by hand. Then back off the knurled collar slightly (approximately ¹ ₂ turn) to allow the interrupter to move freely. Coat the threads of the ¹ ₄ 20 ¹ ₄ hex-head nylon-tip set screw with Loctite Blue (both included in the replacement kit) and tighten the set screw into the hole in the knurled collar. Position the interrupter drive lever approximately 2 inches from the bottom of the base and tighten the ¹ ₄ 20 1 socket-head stainless-steel cap screw which secures the interrupter drive lever to the interrupter drive shaft. See Figure 10. Support casting Knurled collar ¹ ₄ 20 1 sockethead stainless-steel cap screw Thrust washer ¹ ₄ 20 ¹ ₄ socket-head nylon-tip cap screw Interrupter drive lever Interrupter drive shaft Figure 10. Installing the interrupter. 13 768-520

Step 10 Apply a coating of Penetrox A (provided with the replacement kit) to the mounting surface of the contact assembly saved in Step 8. Scrub this surface with an abrasive pad (provided with the replacement kit). Then apply another coating of Penetrox A and attach the contact assembly to the end of the interrupter using the two ³ ₈ 16 ³ ₄ hex-head stainlesssteel cap screws and Belleville washers saved in Step 8. Do not securely tighten the hardware yet. See Figure 11. Slowly close the three-phase disconnect to verify that the interrupter contact squarely meets the sensor contact. Allow the contact to align itself, then securely tighten the hardware. Contact assembly Two ³ ₈ 16 ³ ₄ hex-head stainless-steel cap screws and Belleville washers Figure 11. Preparing mounting surface of contact assembly. Step 11 Coat the threads of two ¹ ₄ 20 1 sockethead stainless-steel cap screws with Loctite Blue and use the cap screws along with two spacers and washers to attach the new disconnect drive lever to the interrupter. Attach the disconnect drive lever to the disconnect interphase linkage using a 1-inch stainless-steel pin and X washer. (All of these components are included in the replacement kit.) See Figure 12. 1 stainless-steel pin and X washer Disconnect interphase linkage Disconnect drive lever Two ¹ ₄ 20 1 socket-head stainless-steel cap screw Figure 12. Attaching disconnect drive lever to interphase linkage. Penetrox is a registered trademark of Burndy Corporation. 768-520 14

Step 12 With the three-phase disconnect in the fully closed and latched position (handle in closed toggle), alternately tighten and loosen the disconnect drive lever cap screws to obtain the proper force to hold the interrupter closed. Apply approximately 30 pounds of force against the interrupter as shown in Figure 13. The end of the interrupter must not move more than ¹ ₁₆ inch. If it moves more than ¹ ₁₆ inch, alternately tighten and loosen the two cap screws on the disconnect drive lever ¹ ₂ turn until proper adjustment is achieved. Step 13 Open and close the three-phase disconnect several times. Verify that the interrupters are properly adjusted by pushing against each interrupter with approximately 30 pounds of force as shown in Figure 13. The end of the interrupter must not move more than ¹ ₁₆ inch. If it moves more than ¹ ₁₆ inch, alternately loosen and tighten the two cap screws on the disconnect drive lever ¹ ₂ turn until proper adjustment is achieved. If any of the interrupters are out of adjustment, loosen the cap screws on the new interrupter and repeat this step. Do not loosen the disconnect drive lever cap screws on interrupters that were not replaced. After all three interrupters are properly adjusted, operate the three-phase disconnect several times and reconfirm proper adjustment. Then attach a replacement contact guard to the end of the interrupter using two ⁵ ₁₆ 16 ³ ₄ Delrin shoulder bolts (provided with the replacement kit). See Figure 13. Two ⁵ ₁₆ 16 ³ ₄ Delrin shoulder bolts Contact guard Figure 13. Checking adjustment of the replacement interrupter. 15 768-520

Step 14 Reattach the end cover, indicator, or access panels that were removed in Step 4. For switches with the high-speed operating mechanism or -H suffix, remove the blocking bolt from the mechanism and replace it with the short bolt that was removed in Step 2. See Figure 14. Ç CAUTION To avoid serious personal injury, do not electrically operate the switch unless the access panels, end cover, and indicator have been reinstalled. Mechanical block-bolt hole insert ³ ₈ 16 2¹ ₂ hex-head stainlesssteel cap screw High-speed operating mechanism Ç CAUTION Do not electrically operate the switch with the mechanism blocking bolt installed (applicable only on switches with the highspeed operating mechanism or -H suffix). Damage to the operating mechanism could result. Access panel (typical) with ¹ ₄ 20 1 hex-head stainlesssteel cap screws and flat washers Figure 14. Removing the blocking bolt (for switches with the highspeed operating mechanism or -H suffix). Step 15 Reconnect the high-voltage conductor to the interrupter-end terminal pad. If the switch includes optional wildlife protection (Switch Catalog Number Suffix -A1 ), reinstall the wildlife protection cover that was removed in Step 3 using a ⁵ ₁₆ 16 ³ ₄ Delrin shoulder bolt (included in the replacement kit). See Figure 15. Step 16 Place the power switch on the battery charger in the control unit in the ON position. Make sure that the local/remote switch on the switch control is in the LOCAL position. Close the interrupter contacts by pressing the CLOSE push button in the control unit to verify proper operation. Wildlife protection covers Two ⁵ ₁₆ 16 ³ ₄ Delrin shoulder bolt Figure 15. Installing the optional wildlife protection components. Step 17 Set the replaced interrupter into the replacement interrupter shipping crate. Secure the interrupter and close the lid. Ship the replaced interrupter, transportation charges prepaid, to S&C Electric Company, Repair Center, 1800 Devon Avenue, Chicago, Illinois 60660-1010. To ensure proper handling, purchasers are asked to obtain from the nearest S&C Sales Office a special serially numbered label to place on the shipping crate. Please enclose a packing slip showing purchase order or requisition number covering the exchange. 768-520 16