ABB SafeGear - User Manual

The document describes the SafeGear® Motor Control Center Controller, a protective device designed for medium voltage (2.4 kV to 6.9 kV) applications. It comes in both drawout (removable) and fixed-mount versions, conforming to international standards such as UL 347 and ICS3 part 2, with NEMA Class E2 ratings.

Function Description:

The SafeGear® Controller is a magnetically actuated and latched controller, capable of a high number of operations due to its robust design. It functions as a protective device within a Motor Control Center (MCC) and is designed to operate within its nameplate ratings. The controller's primary function is to provide switching and protection for motor circuits. The drawout version offers two physical ANSI operating positions within the cell: "Connected" and "Test/Disconnected." In the connected position, both primary and secondary contacts are engaged, allowing the controller to operate. In the test/disconnected position, primary contacts are separated from the bus contacts, while secondary contacts remain engaged, enabling testing of the controller without energizing the primary circuit. The fixed-mount version is a stationary device with hard-bussed primary connections and secondary wiring terminated to plugs or direct connections.

A key safety feature is the blown fuse mechanism, which ensures that if one or two fuses blow in a three-phase system, all three phases are disconnected to prevent single-phasing, which can cause motor burnout. The controller also incorporates a shutter's charger mechanism that covers primary contacts when the controller is removed, providing energy to open the shutter for connection when inserted.

Important Technical Specifications:

Voltage Ratings: 2.4 kV to 6.9 kV (Medium Voltage).
Current Ratings: 400 A and 720 A.
Standards Compliance: UL 347, ICS3 part 2, NEMA Class E2.
Weight (Approximate):
- 400 A Controller: 375 lbs (170 kg)
- 720 A Controller: 750 lbs (240 kg)
- (Values are approximated with 500VA CPT)
Normal Operation Conditions:
- Minimum ambient temperature: -5°C
- Maximum ambient temperature: 40°C
- Maximum 24 hours ambient relative humidity: 85% Non-condensing
- Normal operational altitude above sea level: 1000m
- Normal non-corrosive and non-contaminated atmosphere.
Opening Time (HCV-5HA No Latch):
- With terminals 3 & 4 jumpered, and switching power on and off to terminals 1 & 2: 280-320 ms.
- With terminals 1 & 2 continuously powered, and switching (opening) contacts connected to terminals 3 & 4: 20-30 ms.
Ride-Through Capability: The contactor coil can store energy to maintain contact closure during voltage sags or complete voltage dropouts.

Usage Features:

Drawout (Removable) Design: Allows for safe removal from a cell without unbolting connections, utilizing specific interlock devices for personnel safety.
Fixed-Mount Design: Stationary device with hard-bussed primary connections, suitable for permanent installations.
Controller Features (Front Panel):
- Fuse status indicator
- Position indicator
- Operation counter
- Controller status
- Local trip on the front side
- Blown Fuse Mechanism
- Extraction truck (integral to the controller for drawout versions)
Racking System: Integral to the controller, allowing racking only with the door closed. It has "Connected" and "Test/Disconnected" positions.
Interlocks: Three mechanical interlocks ensure safe operation:
1. Prevents racking in with the door open.
2. Prevents opening the door with the controller in the connected position.
3. A padlock mechanism on the principal screw (worm gear) prevents racking when the controller is in connected or disconnected positions.
Control Circuit Checkout: Instructions are provided for checking the control circuit using a temporary control power source, ensuring proper operation before energizing the main circuit.
Local Trip (Optional): A button on the front of the controller for manual tripping when de-energized, available for latched controllers.

Maintenance Features:

Extraction Truck Assembly: Requires visual inspection of hardware, lubrication, and operations during routine maintenance. Wheels should rotate freely, and all visible hardware tightness should be verified.
Racking Screw Lubrication: Apply grease "Moykote 33" to the entire racking screw, pin, and bushing surfaces when the controller is outside the cell.
Inspection of Components: Inspect the position Release Shaft, cell locking tabs, and secondary Locking Tab for damage.
Fuse Replacement: Detailed instructions are provided for replacing fuses, emphasizing safety procedures, including electrical disconnection, grounding, lockout, and tagout. This involves removing the dead front, verifying the blown fuse mechanism's pin position, removing plastic bolts and the blown fuse switch, extracting the insulation barrier, replacing the fuse, tightening bolts to 13 lb-ft, and reinserting components.
Vacuum Interrupter Maintenance:
- Check upper and lower flanges and interrupter shaft for contamination or corrosion; clean with rubbing alcohol or replace if corroded. Avoid touching ceramic surfaces.
- Check main contact wear using a wear gauge; replace the interrupter if the gauge cannot be inserted.
- Check vacuum by applying 10kVAC between upper and lower terminals for one minute; replace if voltage breakdown occurs or if the interrupter shaft can be easily moved (indicating vacuum loss).

Accessories:

Lift Truck: Required for all primary devices, docks with the MCC to raise/lower devices for insertion/removal. Available with wheels for maneuvering and an optional motor lift.
Racking Handle: Used to adjust the device into and out of the MCC compartment and change its position between Disconnect and Connect.
Test Jumper: An extension cord for connecting secondary contacts of a vacuum controller to the MCC while outside the compartment, enabling electrical operation and charging.
Test Cabinet: A wall-mounted control cabinet with a separate power source and switches to open/close a controller, used for inspection and maintenance in MCC aisles.

Safety Practices:

The manual emphasizes strict adherence to ANSI and NEC safety codes, standards, and regulations. Only qualified personnel familiar with medium voltage circuits should work on these controllers. Critical safety warnings include:

DO NOT work on an energized controller.
DO NOT work on a controller unless all components are disconnected, visibly broken, securely grounded, locked out, and tagged.
DO NOT work on a controller with power supplied to the secondary control circuit.
DO NOT defeat safety interlocks.
DO NOT work on a closed controller or a controller with charged energy.
DO NOT use a controller as the sole means of isolating a medium or high voltage circuit.
Always place the controller in the Disconnect/Test or Connect position without hesitation.
Avoid wearing polyester, acetate, nylon, or rayon clothing when exposed to electric arcs or flames, as per U.S. OSHA Standard 1910.269.
DO NOT stack controllers or shipping boxes.
Use only ABB-approved racking devices; unauthorized devices void the warranty.
Always compare controller and MCC nameplate ratings for agreement.
Ensure the controller and compartment are free of obstructions before insertion.
DO NOT force a controller into or out of the cell.

End of Life and Disposal:

ABB products comply with ISO 9001 and ISO 14001 standards. The company is committed to facilitating recycling and proper disposal at the end of the product's life, in accordance with local and national legal requirements. Recommended disposal methods are provided for various raw materials, including separation and recycling for metal materials, recycling or disposal for thermoplastics, separation of metal and disposal of remains for epoxy resin, disposal for rubber, draining and recycling or proper disposal for transformer oil, discharging from equipment for SF6 gas, and recycling or disposal for packing material.