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ABB Power T&D Company Inc.
North America Distribution Systems Group
Installation and Maintenance Instructions
K-Line Plus
™
Low Voltage Switchgear
IB3.1.4.7B
07-31-98
INSTRUCTIONAL BOOKLET
K-Line Plus
™
Low Voltage Switchgear
ABB Power T&D Company Inc.
201 Hickman Drive
Sanford, Florida 32771-8201
Phone 407/323-8220 • Fax 407/322-8934
Table of Contents
INTRODUCTION TO K-LINE PLUS
™
LOW
VOLTAGE SWITCHGEAR................................1
GENERAL INSTRUCTIONS.......................................1
SCOPE OF INSTRUCTIONS.......................................1
IMPORTANT SAFETY NOTES AND
WARNINGS..........................................................3
SAFETY NOTATIONS..............................................3
RECEIVING AND HANDLING..........................6
RECEIVING ...........................................................6
HANDLING............................................................6
STORAGE..............................................................7
SITE PREPARATION..........................................9
GENERAL..............................................................9
LOCATION ............................................................9
FOUNDATION......................................................10
INDOOR/ OUTDOOR INSTALLATION .........11
GENERAL............................................................11
MOVING BY JACKS AND ROLLERS ........................11
RAISING BY SLINGS.............................................15
REMOVAL OF SHIPPING BASE...............................16
CIRCUIT BREAKER OVERHEAD LIFTING DEVICE....17
OPERATION OF THE CIRCUIT BREAKER OVERHEAD
LIFTING DEVICE..................................................20
UNIT SUBSTATIONS.............................................21
CONNECTIONS ....................................................22
CONNECTION TO GROUND BUS............................23
CONNECTION TO CONTROL SOURCE.....................24
SECONDARY AND CONTROL CONNECTIONS..........24
INSTALLATION OF BUS BAR CONNECTIONS
BETWEEN GROUPS ..............................................24
OUTDOOR INSTALLATION...........................26
GENERAL............................................................26
BUS DUCT FLANGE .............................................26
JOINING THE SHIPPING SPLITS...............................28
TRANSFORMER TRANSITION UNIT........................33
TESTING AND FINAL INSPECTION..............35
TESTING.............................................................35
CONTROL CIRCUIT CHECKOUT ............................37
FINAL INSPECTION ..............................................40
PLACING SWITCHGEAR INTO SERVICE....45
SAFETY PRECAUTIONS.........................................45
ENERGIZING THE MAIN BUS.................................46
STANDARD CONSTRUCTION.........................47
STANDARD COLOR ..............................................47
GALVALUME .......................................................47
BUS SUPPORT INSULATION...................................47
PRIMARY DISCONNECT DEVICE............................48
SECONDARY DISCONNECTING DEVICES ................48
GROUND BUS AND CONTACTS..............................48
CONTROL WIRES.................................................49
CIRCUIT BREAKERS .............................................49
MAINTENANCE ................................................51
GENERAL............................................................51
SEMI-ANNUAL INSPECTION..................................52
ANNUAL INSPECTION...........................................53
18 TO 36 MONTH INSPECTION..............................54
10 YEAR MAXIMUM INSPECTION..........................54
SUSPECT JOINT MAINTENANCE.............................55
CARE OF FINISH...................................................55
RENEWAL PARTS.................................................56
DISCLAIMER OF WARRANTIES AND
LIMITATION OF LIABILITY..........................57
K-Line Plus
1
Introduction to K-Line Plus
™
Low Voltage Switchgear
GENERAL INSTRUCTIONS
Read these instructions carefully before installation and use as a
guide during installation and initial operation.
File these instructions with other instruction books, drawings and
descriptive data of the switchgear. Keep this book available for the
installation, operation, and maintenance of this equipment. Use of
the instructions will facilitate proper maintenance of the equipment,
and prolong its useful life.
SCOPE OF INSTRUCTIONS
The instructions are general in nature. They cover requirements for
installation, setup, checkout and maintenance as applied to ABB K-
Line Plus Metal Enclosed Low Voltage Power Circuit Breaker
Switchgear. These instructions do not attempt to cover all variations
and combinations of equipment and installations.
Information on particular installations appears in the following:
• Bills of Materials that list electrical devices and equipment
• Front view showing layout of relays, instruments and circuit
breakers
• Single line drawings showing power connections
• Floor plan showing available space for power and control
conduits
• Special construction details
• Elementary and schematic diagrams
• Connection diagrams
Chapter
1
1
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2
K-Line Plus
3
Important safety notes and warnings
Switchgear operation depends on proper handling, installation, and
maintenance. Neglecting fundamental requirements may lead to
personal injury, failure of the switchgear, and property damage.
Safety as described in this instruction book involves two conditions:
• Personal injury
• Product or property damage
See important “Disclaimer of warranties and limitation of liability” on page 58.
SAFETY NOTATIONS
Safety notations alert personnel to possible death, injury, or property
damage situations. The safety notations appear before the step in
which the condition applies. The four hazard levels are:
DANGER
"Danger" indicates a hazardous situation that has a high probability of
death or severe injury and substantial property damage.
WARNING
"WARNING" indicates a hazardous situation that has some probability of
death or severe injury and substantial property damage.
CAUTION
"CAUTION" indicates a hazardous situation that may result in minor or
moderate injury and/or property damage.
"NOTICE" indicates a statement of company policy as it relates
directly to the safety of personnel or protection of property.
Chapter
2
ü
K-Line Plus
4
Personnel installing, operating, or maintaining this equipment must
have thorough knowledge of all applicable local, regional, industry,
governmental, and OSHA safety procedures as well as commonly
accepted safe working practices. Personnel working in, on or around
this equipment must also exhibit common sense and good judgment
regarding the potential hazards for themselves and other personnel in
the area. These instructions are intended for use by fully qualified
personnel and are not a substitute for adequate training, experience,
and supervision.
Should clarification or additional information be required, refer the
matter to your ABB Power T&D Company sales office. When
communicating with ABB regarding the product covered by this
Instruction Book, always reference the ABB assigned Shop Order
(S.O.) number or Circuit Breaker Serial Number.
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K-Line Plus
5
Receiving and Handling
RECEIVING
Before shipment, the switchgear is inspected and marked with its
number and position. The factory ships circuit breakers separately.
Upon receipt of the switchgear, examine the shipment for damage or
loss. Check the contents against the packing list before discarding
any packing material. Notify ABB and the carrier at once of any
discrepancies. If there is damage from improper handling, file a claim
for damages at once with the carrier and notify ABB.
Note: ABB standard shipments are "FOB factory." ABB is not responsible for
damage, after delivery of the equipment to the carrier.
HANDLING
For structural integrity, all doors and panels must be in place and
securely fastened before moving the equipment
Do not move or transport the switchgear with the circuit breakers
installed.
Before energizing the heaters, remove all the packing materials
from the switchgear. Open the circuit breaker or cutout device
that controls the heaters when using a separate power source.
Chapter
3
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6
STORAGE
Leave the equipment on the shipping base.
Store all equipment indoors in a well-ventilated area.
The storage building should have a well-drained paved floor. The
temperature should be above 60ºF. The air should be dry (50%
maximum humidity).
The sections ship wrapped in plastic for protection during shipment
only. Remove the plastic wrap after placing into storage. Cover with
heavy wrapping paper or other moisture barrier. Do not use
materials that would trap moisture inside the unit. Do not cover
louvered or filtered openings.
When storing for a long period of time or in high-humidity, use
heaters to keep the interior dry. Bring the power for the heaters to
the load terminals of the device that controls the heater circuits.
The device must remain open when using a separate power source .
Store circuit breakers upright in their original shipping carton. Do
not stack. Do not store circuit breakers in the switchgear
K-Line Plus
7
Site Preparation
GENERAL
Before installing, consult all drawings furnished for the particular
order. The drawings show top and front views of the switchgear,
primary and secondary connection diagrams, and Bills of Materials.
Study these drawings and the following recommendations before
preparing the site plan drawings.
LOCATION
Locate the switchgear in accordance with local regulations.
Clearances at the front should allow the installation and removal of
the circuit breakers. Allow enough rear clearance to open the rear
doors. Provide rear access for making connections before startup and
for periodic inspections. The recommended minimum clearances
appear on the drawings.
FOUNDATION
The factory supplies floor plan drawings for each installation. The
concrete floor must be straight and level within ¼ inch over the entire
length of the line-up.
The design of the floor may include iron sills in the concrete. The sills
must be straight and level within ¼ inch over their full length, and
correctly spaced. Bolt ties between the sills and shim the lower flange
of each sill to proper height.
Install power and secondary (control) conduits before moving the
switchgear to the site. Available space for the conduits appears on
the floor plans supplied with the switchgear. Conduits should not
extend more than one (1) inch above the station floor level. Plug
conduit openings before pouring concrete.
Chapter
4
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Indoor/ Outdoor Installation
GENERAL
Metal-enclosed switchgear ships in sections. Sections up to 96
inches ship on heavy timber bases or on optional throw away steel
bases
Unload the switchgear as close to the installation site as possible.
Raise the switchgear with jacks and move on rollers with the shipping
bases in place or with an overhead hoist and spreader bar. See pages
15 and 16.
MOVING BY JACKS AND ROLLERS
Use of forklift trucks for jacking or placing the jacks other than as
described may result in stress distortions and irreparable damage
to the switchgear.
Do not remove the shipping bases until the units are set in place.
Moving the units without the shipping base will cause irreparable
damage and a hazardous condition.
Chapter
5
K-Line Plus
10
In many locations the best way of moving the switchgear is with jacks
and rollers.
1. Do not remove the shipping base . Move the unit near the site. Raise
the unit by jacks placed under the front and rear corners. See
Figure 1. Note: Some sections are on throw away steel bases.
Figure 1. Position jacks under the front and rear corners, inside the
shipping base.
K-Line Plus
11
2. Raise the unit enough to position a roller under the shipping base.
Repeat the operation at the other end. See Figure 2
Figure 2. Raise the unit enough to position a roller under the shipping
base.
3. Push the switchgear toward its final position, while another person
puts a third roller under the forward end. Keep moving a roller
from the rear to the front until the unit is in place.
4. For lateral moving, raise the units by jacks as described in step 1.
Place the rollers laterally with steel channels (not furnished) on the
rollers. See Figure 3 and Error! Reference source not found..
Carefully push the unit onto a third roller and move a roller from
the rear to the front until the unit is in place.
K-Line Plus
12
Figure 3. Position rails on rollers as shown for lateral moving.
Figure 4, Carefully push the unit onto a third roller.
5. Locate the units in their final position. Raise the units to clear the
rollers and channels.
K-Line Plus
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RAISING BY SLINGS
1. Attach the optional lifting plates to the 4 holes provided in the top
of the units as shown in Figure 5. They provide a large hole at
each end for attaching a sling and spreader bar assembly.
Figure 5. End view showing extended lifting eye, with optional Drip Proof Roof.
2. Use a spreader bar to keep the legs of the sling vertical.
3. Lift and move the switchgear to it’s final place. Once the unit is set
in place, remove the shipping base as described on page 16.
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