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ABB SafeGear User Manual

ABB SafeGear
28 pages
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SafeGear
®
Motor Control Center
Controller
Installation, Operation and Maintenance Manual
2017

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ABB SafeGear Specifications

General IconGeneral
BrandABB
ModelSafeGear
CategoryControl Unit
LanguageEnglish

Summary

1. Foreword

2. Introduction and Safe Practices

Manual Introduction

Provides instructions for unpacking, storage, installation, operation, and maintenance.

Critical Safety Warnings

Equipment operation outside rated limits can cause failure, damage, injury, or death. Adhere to safety codes.

Safe Operating Practices

Recommendations for safe installation, operation, removal, and maintenance by qualified persons.

3. Receiving, Handling, and Storage

Receiving and Handling Procedures

Inspect for damage, handle safely, and avoid component damage.

Storage Environment Guidelines

Store in a well-ventilated, dry, dust-free, non-corrosive environment.

Storage Safety Precautions

Do not stack controllers; shipping boxes can collapse causing damage.

4. General Overview

Controller Features

Lists key features like fuse status indicator, position indicator, etc.

5. Normal Service Conditions

Operating Conditions and Storage Requirements

Specifies ambient conditions, humidity, altitude for operation and storage.

6. Construction

Key Controller Components

Identifies parts like Fuse Box, Contact Fingers, Vacuum bottles, CPT.

7. Extraction Truck Assembly

MCC Extraction Truck Design

Describes the integral truck assembly for MCCs, allowing removal for maintenance.

8. Racking System and Disconnect

Mechanical Interlock System

Details three mechanical interlocks ensuring safe racking and door operation.

9. Shutter's Charger Mechanism

Manual Spring Charging Procedure

Step-by-step guide for manually charging the springs of the shutter mechanism.

10. Insertion and Removal

Insertion Safety and Warnings

Do not remove without lift truck; charge springs before insertion; use approved devices.

Controller Insertion Process

Step-by-step guide for inserting the controller into the MCC compartment.

General Safety and Removal Process

Follow safety procedures; guide for safely removing the controller from the MCC compartment.

Racking System and Control Circuit Checkout

Describes racking positions and procedure for testing the control circuit.

11. Compartment Detail

Basic Cell Component Identification

Labeled diagram identifying components like Ground Bus, Secondary Disconnects, Shutter.

12. Maintenance

Extraction Truck Assembly Maintenance

Maintenance requirements for the extraction truck assembly, including inspection and lubrication.

13. Accessories

Lift Truck and Racking Handle

Information on lift truck use, safety, and racking handle operation.

Test Jumper and Test Cabinet

Description of tools for controller testing and maintenance.

14. Appendix A: Basic Controller Layout

Appendix B: Basic Controller Dimensions

Appendix C: Antisingle Phasing

Phase Loss and Fuse Mechanism

Explanation of phase loss, its causes, and the blown fuse mechanism.

Appendix D: Fuse Replacement Instructions

Removing Fuse Cover and Verifying Mechanism

Remove cover bolts, verify fuse mechanism pin position.

Fuse Mechanism and Fuse Extraction

Remove cover bolts, extract blown fuse mechanism and failed fuse.

Fuse Extraction and Barrier Removal

Remove fuse fixing bolts, extract insulation barrier, remove failed fuse.

Fuse Replacement and Reassembly Steps

Replace with new fuse, torque bolts, reinsert insulation barrier.

Final Fuse Replacement Procedures

Reinsert blown fuse mechanism, tighten cover bolts, complete replacement.

Appendix E: Opening Time and Ride Through

Contactor Opening Times and Ride Through

Details standard opening time and specific times for HCV-5HA contactors.

Appendix F: Local Trip Functionality

Appendix G: Vacuum Interrupter Maintenance

Vacuum Interrupter Checks and Testing

Procedures for checking flanges, shaft, contact wear, and vacuum integrity.

15. End of Life of Product

16. Methods of Disposal

Recommended Disposal Methods

Lists recommended disposal methods for various raw materials used in the product.

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