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Document
Revision
2516
G
September 10, 2012
Instruction Manual
Switchgear System
Series 82XSYS
Cooper Industries
Crouse-Hinds Division
Crouse-Hinds Airport
Lighting
1200 Kennedy Road
Windsor, CT 06095
For Parts or Technical Service Call (860) 683-4300
Copyright © 2012 Cooper Technologies Company
Document 2516
Rev. G
Instruction Manual
Switchgear System
Series 82XSYS
Revisions
Revision
Number
A
B
Issue/Reissue
Letter Number
A205-190
A205-285
Description
Released to production, no changes
1.2.1 & 1.2.3.1, Dead-Front Switchboard
was Dead-Front Switchgear; 1.2.3.3,
CCR cabinet wt. was 700 lbs & added
info in regards to “K” option; 1.3 &
2.1.1, added max pad ht.; 2.1.4, left side
rear was left side & 2 Bussman FNQ-R4/10 Fuses was 3; 2.1.5, added info on
magnetic trip adjustment; 2.1.8, added
info on levelers and wheels & max pad
ht.; 2.1.9, added info to complete load
wiring & installation of CCR power
modules from hinge side; 2.1.11.2, added
wire lengths & info to mark with colored
tape and use control wire troughs;
Addendum, added S-1 Cutout 30771 &
related data, Kirk Key Type D, Lock-Out
Bracket KLB-001 & revised Kirk Key
Type F & deleting Superior Interlock;
revised Figure 18 side view; added
photos 6, 7 & 8; dwg 34123 revised to
rev B & dwgs 34126 revised to rev D &
34127 revised to rev C; Figure 15, 27.5
was 26.5, 43.75 was 42.0, 53.5 was 52.6
and added 10" dim note about tangs;
added lift, track extensions and concrete
pad to Figure 13
ii
Checked
05/19/05
08/18/05
Approved
PG
PG
Document 2516
Rev. G
Instruction Manual
Switchgear System
Series 82XSYS
C
A206-107B
D
A206-035
Revised drawings 34122-34125;added
figure 14A; Fig 18, added trough dims;
Fig 14, ¼” bolt torque was 7ft-lbs; Fig
12, added note to use only 4 corner holes
for seismic bolting; Fig 11, added holes
at 9.0 dim; 1.1.1, 2506 was 2512; 2.1.2
added “refer to figure 14A…hardware”;
2.1.4, added factory settings for
thermostat; 2.1.8 added additional
instructions for track extensions; 2.1.9
added 2605 and that door includes main
circuit cards, Addendum parts, added
Microswitch P/N 2DM409 & deleted CH S-1 cutout 30771, Square D indicator
KM38LR & added C-H Kirk key lock
out brkt P/N 34176; added copyright to
cover page
Fig 14A, bolt length was 1-1/4 & added
Belleville washers & deleted 3/8-16 split
lock washer; Fig 13, 50.0 was 44.0 &
60.0 was 54.0; revised 34122, 34126 &
34127; replaced 34123 with 34192;
revised Fig 1-11 & 15-18 pictorials to
agree with 34192; 1.1.1, 2642 was 2605;
1.1, Switchboard was Switchgear; 1.1.2
& 1.2.2, 34192 was 34123; 1.2.3.2,
added “& splice plates are silver plated
copper”; 2.1.9, door panel was door, all
locations & 2642 was 2605 & deleted
“Located near the CCR pwr module
handle on the base of the tolley is a
location # which should match a location
# located above the red display window
on the face of each CCR cabinet door.”;
2.1.10.1 & 2.1.10.2, added “panel”;
3.1.1, added “panels”; 2.1.9, blank door
panel, P/N 34186 was P/N 34189-U
(upper door) or 34189-L (lower door) &
also added does not include “display….
panel cover)” ; 2.1.9, added note to
install panel cover & to flip circuit
breaker plate if req’d
ii.1
4/12/06
PG
10/13/06
PG
Document 2516
Rev. G
Instruction Manual
Switchgear System
Series 82XSYS
E
A208-028
F
A210-201
G
A212-316
1.2.1 & 1.2.3.2, bus stabs were rated
400A; 2.1.6, added note to torque stn stl
hardware; Addendum, Bus Stabs, E10742 was E1016-1621S & E1074-4 was
E1016-1635S & Cooper Interconnect
was Crouse-Hinds Molded products; pg
53, 34192 revision was A
Title page, Copyright 2010 was 2008;
page 22, added optional System Power
Meter info; page 52, revised 34122 to
Rev H; page 55, revised 34125 to Rev G
Title page, Copyright 2012 was 2010;
1.2.3.3 Mechanical, added CCR pagoda
top std and adds 3.0 inches; page 53,
revised 34192 to rev D
ii.2
3/12/2008
PG
10/25/2010
PG
9/10/2012
PG
Document 2516
Rev. G
Instruction Manual
Switchgear System
Series 82XSYS
Limited Product Warranty
The following warranty is exclusive and in lieu of all other warranties, whether express, implied or
statutory, including, but not by way of limitation, any warranty of merchantability or fitness for
any particular purpose.
Crouse-Hinds Airport Lighting Products (the “Company”) warrants each original Buyer of
Products Manufactured by the Company that such Products are, at the time of deliver to the Buyer
free of material and workmanship defects, provided that no warranty is made with respect to:
(a)
any product which has been repaired or altered in such a way, in Company’s
judgement as to affect the Product Adversely;
(b) any Product which has in Company’s judgement, been subject to negligence, accident
or improper storage;
(c)
any Product which has not been operated and maintained in accordance with normal
practice an in conformity with recommendations and published specifications of
company; and,
(d) Any Products, components parts or accessories manufactured by others but supplied
by Company (any claims should be submitted directly to the manufacturer thereof).
Crouse-Hinds Airport Lighting Products’ obligation under this warranty is limited to use
reasonable efforts to repair or, at is option, replace, during normal business hours at any authorized
service facility of Company, any Products which in its judgement proved not to be as warranted
within the applicable warranty period. All cost of transportation of Products claimed not to be as
warranted and of repaired or replacement Products to or from such service facility shall be borne
by Purchaser. Company may require the return of any Product claimed not to be warranted to one
of its facilities as designed by Company, transportation prepaid by Purchaser, to establish a claim
under this warranty. The cost of labor for installing a repaired or replacement product shall be
borne by the Purchaser. Replacement parts provided warranty period of the Products upon which
they are installed to the same extent of such parts were original components thereof. Warranty
services provided under the Agreement not assure uninterrupted operations of Products; Company
does not assume any liability for damages caused by any delays involving warranty service. The
warranty period for the Products is 24 months from date of shipment or 12 months from date of
first uses whichever occurs first.
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Switchgear System
Series 82XSYS
Safety Notices
This equipment is normally used or connected to circuits that may employ voltages which are
dangerous and may be fatal if accidentally contacted by operating or maintenance personnel.
Extreme caution should be exercised when working with this equipment. While practical safety
precautions have been incorporated in this equipment, the following rules must be strictly
observed:
KEEP AWAY FROM LIVE CIRCUITS
Operating and maintenance personnel must at all times observe all safety regulations. DO
NOT PERFORM MAINTENANCE ON INTERNAL COMPONENTS FOR RELAMP WITH POWER ON.
STORED ENERGY
Ensure Capacitors are discharged before working on equipment.
RESUSCITATION
Maintenance personnel should familiarize themselves with the technique for resuscitation
found in widely published manuals of first aid instruction.
See FAA Advisory Circular AC 150/5340-26 for additional information.
i
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Switchgear System
Series 82XSYS
Safety Symbols
DANGER:
DANGER
The hazard or unsafe practice will result in severe injury or death.
WARNING:
WARNING
The hazard or unsafe practice could result in severe injury or death.
CAUTION:
CAUTION
The hazard or unsafe practice could result in severe injury or death.
NOTICE:
NOTICE
Possibly dangerous situation, goods might be damaged.
IMPORTANT:
IMPORTANT
Helpful information.
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Switchgear System
Series 82XSYS
Table of Contents
Title Page ......................................................................................................................................... i
Revisions ......................................................................................................................................... ii
Limited Product Warranty ............................................................................................................. iii
Safety Notices ................................................................................................................................ iv
Safety Symbols ................................................................................................................................v
Table of Contents ........................................................................................................................... vi
Figures....................................................................................................................................... ix
Photos..........................................................................................................................................x
Drawings .....................................................................................................................................x
Section 1. General Information ........................................................................................................1
1.1 Introduction ............................................................................................................................1
1.1.1 Purpose...........................................................................................................................1
1.1.2 Applicability ..................................................................................................................1
1.2 Equipment Description ..........................................................................................................2
1.2.1 Features ..........................................................................................................................2
1.2.2 Options ...........................................................................................................................2
1.2.3 Specifications .................................................................................................................2
1.2.3.1 Compliance ............................................................................................................2
1.2.3.2 Electrical Characteristics .......................................................................................3
1.2.3.3 Physical Characteristics .........................................................................................3
1.3 Installation Requirements ......................................................................................................4
Section 2. Installation.......................................................................................................................5
2.1 Installation..............................................................................................................................5
2.1.1 Location .........................................................................................................................5
2.1.2 Cabinet Installation ........................................................................................................6
2.1.3 Field Load Wiring ..........................................................................................................7
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2.1.4 Fan Operating Control Setting .......................................................................................8
2.1.5 Main Input Power Connections .....................................................................................8
2.1.6 Load Balancing ..............................................................................................................9
2.1.7 Counterbalanced Lift Operation ....................................................................................9
2.1.8 Track Extension Use ....................................................................................................10
2.1.9 CCR Power Module Installation ..................................................................................11
2.1.10 Digitrac and Megatrac Option Installation ................................................................13
2.1.10.1 Digitrac Option Installation ...............................................................................13
2.1.10.2 Megatrac Option Installation .............................................................................13
2.1.11 Control Wiring ...........................................................................................................13
2.1.11.1 Standard CCR Control Wiring ..........................................................................13
2.1.11.2 Digitrac Option Control Wiring Connections ....................................................14
2.1.11.3 Auxiliary Cabinet Option Control Wiring Connections ....................................14
Section 3. Operation.......................................................................................................................15
3.1 Initial System Power-Up ......................................................................................................15
3.1.1 Bus Power Engaged Indicator Light ............................................................................15
3.1.2 CCR Power Module Power-Up ...................................................................................16
3.1.3 Remote Control Wiring Check ....................................................................................16
3.1.3.1 Standard Remote Control Wiring ........................................................................16
3.1.3.2 Digitrac Option Network Wiring .........................................................................17
3.2 Optional Features Operation ................................................................................................17
3.2.1 Megatrac Option Test ..................................................................................................17
3.2.2 S-1 Cutout Auxiliary Cabinet Option ..........................................................................17
3.2.3 L-847 Auxiliary Cabinet Option ..................................................................................17
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Series 82XSYS
Section 4. Periodic Maintenance, Switchgear System ...................................................................18
4.1 Scope of Maintenance ..........................................................................................................18
4.1.1 Cabinet Maintenance ...................................................................................................18
4.1.2 Cabinet Bus and Wiring Connection Maintenance ......................................................18
Section 5. Switchgear Cabinet Addition to System .......................................................................19
5.1 Adding Cabinets...................................................................................................................19
5.1.1 Adding CCR Switchgear Cabinets...............................................................................19
5.1.2 Adding Switchgear System Auxiliary Cabinets ..........................................................19
Section 6. Hot Swapping CCR Power Modules ............................................................................19
6.1 Hot Swapping Procedure .....................................................................................................19
Addendum ......................................................................................................................................21
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Switchgear System
Series 82XSYS
Figures
Figure 1 – Cabinet Installation .......................................................................................................23
Figure 2 – Cabinet Installation .......................................................................................................24
Figure 3 – Cabinet Installation .......................................................................................................25
Figure 4 – Cabinet Installation .......................................................................................................26
Figure 5 – Cabinet Installation .......................................................................................................27
Figure 6 – Cabinet Installation .......................................................................................................28
Figure 7 – Cabinet Installation .......................................................................................................29
Figure 8 – Cabinet Installation .......................................................................................................30
Figure 9 – Cabinet Installation .......................................................................................................31
Figure 10 – Cabinet Installation.....................................................................................................32
Figure 11 – Bottom View, Cabinet Wiring Entrances ...................................................................33
Figure 12 – Seismic Bolting ..........................................................................................................34
Figure 13 – Cabinet Wall Clearances ............................................................................................35
Figure 14 – Bus Splice Installation ................................................................................................36
Figure 14A – Bus Splice Connection Hardware Details ...............................................................37
Figure 15 – Typical CCR Power Modules Installation/Removal – Forklift ..................................38
Figure 16 – Typical CCR Power Module Installation/Removal – Track Extension .....................39
Figure 17 – Recommended Building Ceiling Height ....................................................................40
Figure 18 – Typical Cable Wiring .................................................................................................41
Figure 19 – Optional L-847 Control Wiring Connected to Digitrac .............................................42
Figure 20 – Opt. S-1 Aux. Cab. Intentional Grounded S-1 Cutout Wiring Scheme……………..43
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Switchgear System
Series 82XSYS
Photos
Photo 1 – Lower Track Extension with CCR Power Module ........................................................44
Photo 2 – Lower CCR Power Module Installed in Cabinet ...........................................................45
Photo 3 – Upper Track Extension with CCR Power Module & Counterbalanced Lift .................46
Photo 4 – Upper Track Extension and CCR Power Module .........................................................47
Photo 5 – Upper Track Extension with Upper CCR Power Module Installed ..............................48
Photo 6 – Switchgear Installation on an Elevated Pad ..................................................................49
Photo 7 – Switchgear Cabinet with Fan Option and Doors Opened..............................................50
Photo 8 – Switchgear Cabinet Door with Digitrac and Megatrac Options Installed .....................51
Drawings
Drawing 34122 – Switchgear System Main Input Cabinet ...........................................................52
Drawing 34192 – Switchgear Cabinet – CCR for 2 Power Modules ............................................53
Drawing 34124 – Switchgear System S-1 Cutout Cabinet (Optional) ..........................................54
Drawing 34125 – Switchgear System Auxiliary Cabinet (Optional) ............................................55
Drawing 34126 – Switchgear System (Upper Track Extension) ...................................................56
Drawing 34127 – Switchgear System (Lower Track Extension) ..................................................57
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Switchgear System
Series 82XSYS
1
General Information
1.1 Introduction
Equipment described in this manual is produced for Crouse-Hinds Airport Lighting by EasterOwens Electric to be compliant to UL 891, standard for Dead-Front Switchboard.
1.1.1 Purpose
This instruction manual provides information for installing and maintaining Switchgear
Cabinets for use with FAA Type L-828 Constant Current Power Modules manufactured by
Crouse-Hinds Airport Lighting Products, Windsor, Connecticut 06095, USA.
See manual 2447 and Instruction Sheet 2642 (Door Installation) for information in regards to
the Constant Current Regulator operation and maintenance requirements.
See Manual 10056-1002 for optional Megatrac® operation and maintenance requirements.
See manual VDIV-0001-0-00 for optional Digitrac® operation and maintenance requirements.
See manual 9313 for FAA L-847 Circuit Selector Switch operation and maintenance
requirements if the system was ordered with this optional auxiliary cabinet feature.
See manual 10056-2005 for Logitrac adapter operation and maintenance requirements if the
system was ordered with this optional auxiliary cabinet feature.
1.1.2 Applicability
Only Switchgear Cabinets shown on drawings 34122, 34192, 34124, 34125, 34126, and 34127
are covered by this manual. Drawing 34089 shows the counter balanced lift supplied with the
system for installing the CCR (Constant Current Regulator) power modules. Operation
instructions for the counterbalanced lift are not discussed in this manual, but the use of it is.
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Switchgear System
Series 82XSYS
1.2 Equipment Description
1.2.1 Features
The Switchgear cabinets are designed to provide input power and control and load wiring
cable ways for Crouse-Hinds Airport Lighting CCR power modules. The main input circuit
breaker cabinet is supplied with a circuit breaker rated for 65KAIC. The power bus bars
mounted in the cabinets are rated for 800A, 65KAIC. The ground bus bar is rated for 300A.
the bus stabs are rated for 175A. All line side wiring to the bus stabs are braced for 65 KAIC
and rated for 125A. The CCR power modules when installed in the cabinets are “hot
swappable” when its associated field load has been disconnected and the integral circuit
breaker for the CCR power module is in the off position. The Switchgear cabinets and CCR
power modules are seismic rated to 200% NFPA 500 RRS (Required Response Spectra) and
200% IBC RRS for electrical equipment. The Switchgear cabinets meet the requirements of
NEMA 1. The Switchgear cabinets are compliant to UL 891, standard for Dead-Front
Switchboard. All hinged Switchgear cabinet doors are supplied standard with a 3 point
lockable door handle. The main input circuit breaker is supplied standard with a lockout
device. All Switchgear cabinets are steel painted with a powder coat gray color. All
Switchgear cabinets are supplied with 4 lifting eyebolts. Switchgear CCR power modules
cabinets allow two Crouse-Hinds CCR power modules up to 30kW each (max 20kW each,
50Hz) to be vertically contained and operated in a single cabinet without the use of cabinet
exhaust fans.
1.2.2 Options
The Switchgear cabinets can be supplied with a number of options. Refer to drawing 34122,
34192, 34124, 34125, 34126 and 34127. Switchgear cabinets are custom order and most of
the options listed are factory installed/fabricated only.
1.2.3 Specification
1.2.3.1 Compliance
Switchgear cabinets are compliant with the following specifications:
UL 891, Standard for Dead-Front Switchboard
NEMA Type 1, Indoor Enclosures
Seismic Rated to 200% NFPA 500 RRS (Required Response Spectra) and 200% IBC RRS
for electrical Equipment
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Switchgear System
Series 82XSYS
1.2.3.2 Electrical Characteristics
Primary Power: 480 V, 60Hz, 3 Phase 3 Wire, 800A or 380V, 50 Hz 3 Phase 3 Wire, 800A
when main input circuit breaker cabinet is ordered with maximum circuit breaker size 8. Refer
to drawing 34122 for other available main circuit breaker sizes. Note: CCR Power Modules
must be ordered to match frequency of input power. Maximum bus bar system capacities are
280 kW for 480V input and 220 kW for 380 V input to accommodate a safety margin of 125%
of the rated current for an 800A bus bar system. The horizontal bus bar is rated for 800A
maximum. The ground bus is rated for 300A maximum. The vertical drops to the bus stabs
are rated 125A maximum. The bus stabs are rated 175A maximum. The bracing rating for the
entire Switchgear system is 65KAIC. All power bus bars, ground bus and splice plates are
silver plated copper. Bus stabs and conductor leads are copper.
CCR Power Module Integral Circuit Breaker Sizes. Circuit
breakers provided with the power modules are rated for
65KAIC,
480V, 60Hz
380V, 50HZ
kW Size
CCR Pwr Module CCR Pwr Module
4
15A
20A
7.5
25A
30A
10
30A
40A
15
45A
60A
20
60A
80A
30
90A
Not available
1.2.3.3 Physical Characteristics
Dimensions:
Refer to drawing 34122, 34123. 34124, and 34125. See figure 11 for
additional dimensional information.
Shipping Weights:
Main Input circuit breaker Cabinet
CCR Cabinet (Does not includes power module
weights, CCR power modules shipped separately)
Auxiliary Cabinets, Standard S-1 (Cutouts installed)
Auxiliary Cabinet, L-847 (3 Selector Switches
Installed)
Upper and Lower Track Extensions (combined weight
as shipped)
Counterbalanced lift
3
700 lbs.
1200 lbs.
700 lbs.
700 lbs.
700lbs
5,550 lbs.
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Switchgear System
Series 82XSYS
Mechanical:
Switchgear cabinets are intended for indoor use only and should be stored
in a dry indoor location if being staged for installation. Cabinets are rated
NEMA 1. Cabinets are steel and painted a powder coat gray color.
Standard CCR cabinet tops, bottom section rear and both front door
sections are louvered. All CCR cabinets are supplied with a pagoda top
that adds 3.0 inches to the cabinet overall height. All Switchgear cabinet
hinged doors are supplied with a 3 point lockable door handle. Lockout
devices on all circuit breakers (main system input and CCR power
modules) are standard (padlocks not supplied). Note, option “K”, Kirk
Key Interlock for power module cabinet door and its circuit breaker is key
locked, not padlocked. Side panels are removable and the rear panels are
welded on all Switchgear cabinets. All hinged doors can be removed from
cabinets. Four lifting eyebolts are supplied with each Switchgear cabinet.
Environmental:
Temperature:
-40º C to +55º C
-40º F to +131º F
* 0º C to +55º C
* 32º F to +131º F
* Operating Limits for FAA L-829 Constant Current Regulator
* Operating Limits for LCD Display used with CCR power module
equipped with optional Digitrac or optional Megatrac
Relative Humidity: 10 percent to 95 percent
Altitude:
Zero to 6,600 Feet (2000 M)
1.3 Installation Requirements
The Switchgear Cabinets are shipped from the manufacturer complete (shipped as separate
cabinets, not as a fully assembled system) and ready to install. The agency responsible for
installation must supply all necessary connectors, wire and conduit. Additionally, this same
agency is responsible for off-loading the Switchgear cabinets, CCR power modules and
counterbalanced lift on arrival at the installation or shipping address site. Consult your local
Yellow Pages for riggers in your area. The Switchgear cabinets are intended for indoor
installation only in an area that should be well ventilated or has air conditioning. The floor the
Switchgear cabinets mount on must be level. If mounting to an elevated pad, cabinet fronts
can be no more than 3 inches maximum back from the front face of the elevated pad. Pad
height is limited to 6 inches maximum. This is to accommodate the use of the track extensions
for installing the CCR power modules and height limitations on the counterbalanced lift. Be
sure to order the track extension with the elevated concrete pad dimensional correction.
Switchgear cabinets should be bolted to the floor (this is mandatory to meet seismic rating).
Installation of main input power wires to the main input circuit breaker should be done only by
a qualified electrician. The installation site must have adequate space to maneuver the
counterbalanced lift.
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Switchgear System
Series 82XSYS
2
Installation
WARNING:
WARNING
Installation, Maintenance and Operation should only be performed by
qualified personal
2.1 Installation
Prior to Installation, check all equipment for shipping damage.
NOTICE:
NOTICE
Read all instructions entirely through before proceeding with
installation following the order written when installing.
2.1.1 Location
The Switchgear Cabinets are designed for indoor installation in an environment as specified in
1.2.3.3 having adequate ventilation. Location should also have a minimum ceiling height as
shown in Figure 17. Cabinet rears and side should be at least one foot minimum away from
walls as shown in Figure 13. If Cabinets are to be moved into a structure laying on their sides,
see Figure 8 for height dimension to raise back to vertical. Adequate space should be available
to maneuver the counterbalanced lift to install the CCR power modules once the Switchgear
Cabinets are mounted in place. Refer to Figure 15. Refer to Figure 11 for cabinet wiring
entrances. The slotted hole located at the rear of the cabinet is the best entrance to bring field
load wiring into individual CCR cabinets. If all field load wiring is being brought into an
auxiliary Switchgear cabinet first before being routed to appropriate CCR cabinet CCR Power
Module utilizing the load cable way, use the large “cutout” in the base of the auxiliary cabinet.
The four .625 diameter holes in the corners of each Switchgear cabinet are for bolting the
cabinets to the floor. If mounting to an elevated concrete pad, cabinet front must be flush to 3
inches back maximum from the front face of the elevated concrete pad. Concrete pad can be
no more than 6 inches high maximum.
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Series 82XSYS
2.1.2 Cabinet Installation
Check your drawings for cabinet numbering and match with the appropriate Switchgear
Cabinet to install in the correct sequence. All Switchgear Cabinets should be left bolted to
shipping skids as long as possible to avoid damage when moving. Move cabinet onto its final
installation location and with shipping skid removed set into place. See Figures 1-7 and 9 for
moving suggestions. When moving with a nylon strap, be sure to pad contact points with
cabinet to avoid damaging cabinet. If bolting cabinet to floor, attach hardware but do not
tighten.
IMPORTANT:
IMPORTANT
If Switchgear System was specified to be seismic rated, all
Switchgear Cabinets must be bolted to the floor as shown in Figure
12 as a minimum recommendation.
Level the cabinet. Install the next adjacent cabinet in sequence. If bolting to the floor, attach
hardware but do not tighten. Level the cabinet. Repeat this process until all cabinets are in
place. Once all cabinets are in place, bolt cabinets together with hardware supplied. 8 bolts
connect the cabinets together, 4 in the front vertical side channel and 4 in the rear vertical side
channel. Re-check levelness, see Figure 10. Tighten all floor mounting hardware. Re-check
levelness. Remove the three metal covers in the rear of the CCR cabinets upper section which
cover the bare copper input power Phase A, B, and C horizontal bus bars. Attach the input
power bus bar splices using the hardware provided. Refer to Figure 14A for proper hardware
sequence. Be sure connection areas are free of grease, oils, and burrs. Be sure that the busses
being connected are flat and parallel before torque is applied to hardware. Attach the ground
bus bar splices to the ground bus in the rear bottom section of each Switchgear Cabinet using
the hardware provided. Torque the appropriate size bus hardware on the splices per the table
shown in Figure 14. Re-attach the metal covers previously removed that were covering the
horizontal bus bars.
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Series 82XSYS
2.1.3 Field Load Wiring
If routing from an Auxiliary Cabinet, use field load wiring cable trough to go between
cabinets, see Figure 18. If wiring from floor up to individual CCR Cabinets, use the right side
rear slotted hole in the CCR Cabinet to bring cable into CCR Cabinet. Field load cable ends
should be marked. CCR Power Module field load connections are supplied with a female and
male L-823 primary connector on their connection ends. An L-823 primary connector kit
(male and female; not supplied) should be attached to the field load wire ends to connect to
CCR Power Module L-823 primary connectors. Cables should be routed from the CCR
Cabinet field load-wiring trough right side as follows:
Bottom CCR Cabinet Bay:
Up 22 inches, then forward to cabinet door 30 inches and then
add an extra 48 inches. All cabling (22 & 30 inches) should be
ty-rapped to cabinet interior (use care not to interfere with door
interlock or cabinet latch pin location). The extra 48 inches
should be ty-rapped to itself and L-823 primary connector kits
applied to lead ends.
Upper CCR Cabinet Bay:
Up 22 inches, then through the slotted access hole between the
upper and lower CCR Cabinet bays, the up 48 inches to top of
upper cabinet bay, then forward 30 inches to cabinet door.
Then add an extra 48 inches. All cabling inside cabinet (22,
48, and 30 inches) should be ty-rapped to cabinet interior (use
care not to interfere with door interlock or cabinet latch pin
location). The extra 48 inches should be ty-rapped to itself and
L-823 primary connector kits applied to lead ends.
If installing field load wiring through the bottom of individual CCR cabinets, add 25 inches to
go through the right side rear bottom slot up to the right side trough slot. If installing through
the large “cutout”, add an extra 10 inches to the 25-inch dimension to reach cabling trough.
This will allow the cable to be routed up from the bottom “cutout” behind the bottom bus stab
support and then over to the cabinet right side. Field load cables to be routed behind bus stab
support must not have L-823 primary connector kits attached at this time. See Figure 11. All
load wiring inside the optional S-1 Cutout auxiliary cabinets and the optional L-847 circuit
selector switch auxiliary cabinets should be done at this time.
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Switchgear System
Series 82XSYS
2.1.4 Fan Operating Control Setting
If the CCR Cabinets are installed with the fan option, do the following:
1. Turn the fused disconnect switch to the ON position.
2. Adjust the temperature setting on the fan thermostat. The thermostat can be set between 30
and 140 degrees F. The thermostat is factory set at 100 degrees F.
Controls for the fan option are location in the upper right side rear of the CCR Bay of each
Switchgear Cabinet equipped with this option. Four fans are connected in the top of each CCR
cabinet Bay to the thermostat. The thermostat is connected to a 480/120V step down
transformer.
DANGER:
DANGER
When power is present on transformer, line side of the transformer
has exposed 480V terminals and the load side has exposed 120V
terminals.
The step down transformer is connected to a fused disconnect switch which contains 2
Bussman FNQ-R-4/10 Fuses. The line side of the disconnect switch is connected to the
horizontal input power bus.
2.1.5 Main Input Power Connections
WARNING:
WARNING
Connections to the main input circuit breaker should be done by a
qualified electrician only.
Connect earth ground to the Switchgear system bus ground. The ground conductor should be
copper, 4/0 minimum.
CAUTION:
CAUTION
Do not connect counter poise system to the Switchgear system ground.
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Install input power wires to the line side of the Switchgear main input cabinet circuit breaker.
Be sure the correct input voltage is being applied to the Switchgear System. Wiring is 3 phase,
3 wire. Connection leads should be sized for the full current rating of the main Switchgear
input circuit breaker. Apply input power to the main breaker and switch main circuit breaker
on. The circuit breaker has a yellow push-to-trip button on its front face. Turn breaker OFF.
Lockout breaker in the OFF position. Note, do not move the magnetic trip adjustment. It
should be left at the factory setting which is at the minimal position, unless issues arise once
the complete system is up and running. The adjustment is only to be used to compensate for
large, turn on inrush currents. Basically, this adjustment increases the magnetic trip element
by a factor of 5 to 10%, which in turn increases the breaker’s trip point.
2.1.6 Load Balancing
The stabs in the Switchgear CCR Cabinets are wired for 3 phase (black color stabs) from the
main horizontal bus bars and ground (green color stab) connected to the system ground bus
bar.
All CCR Power Modules are single phase only and are factory wired single phase. The CCR
Power Modules have matting stab connectors on the rear of the trolley, which match its
corresponding stab in the Switchgear CCR Cabinet. All CCR Power Modules have a ground
connected to the green colored stab. CCR Power Module power connections to the black color
trolley stabs are wired with one of the following single-phase connection combinations: Phase
A and B, Phase A and C, or Phase B and C. The factory phase wiring combination was predetermined by selecting the best possible combinations for the CCR Power Modules to have
the load as evenly (or as close as possible) distributed on the three phases based on the
Switchgear system ordered. If you want to change the phasing connections, do so on the CCR
Power Modules prior to installation of the Modules. Note: if factory connections are broken
on CCR Power Module stab connectors, the ½ inch stainless steel hardware must be torqued to
35 foot-pounds maximum after re-connecting.
2.1.7 Counterbalanced Lift Operation
Familiarize yourself with the operation of the counterbalanced lift prior to use in installing the
CCR Power Modules.
IMPORTANT:
IMPORTANT
Contact your local lift truck distributor for narrow aisle
counterbalanced lift training.
It may be necessary to remove counterbalanced lift “backrest” when installing the upper CCR
power module into the Switchgear CCR cabinet if your location has a low ceiling height.
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2.1.8 Track Extension Use
The Switchgear System is provided with an upper and lower track extension for use in
installing or removing CCR Power Modules.
IMPORTANT:
IMPORTANT
Standard track extensions provided with the system do not take into
account if Switchgear System cabinets are mounted on an elevated
pad. Track extensions for use with systems installed on elevated
mounting pads must be ordered prior to manufacture with a
dimensional adjustment for pad height. Pad height maximum is 6
inches.
Lower Track Extension Use:
Open the lower CCR cabinet bay door. Remove the 2 sets of
½ inch hardware (requires a ¾” socket or wrench) located in
the front of the cabinet on the base channel. At initial
installation, test safety hooks in cabinet are in proper
working order by pushing down and then releasing. Spring
attached to hook should allow it to return to it’s normal
upright position. If this does not occur, it may be necessary
to loosen hardware retaining the hook to the cabinet. Insert
the track extension into the cabinet, aligning the extension
track with cabinet track. The front forks on the track
extension engage the safety hooks and push them in a down
position. Install the removed ½ hardware back into the
cabinet front base channel through the slotted holes in the
track extension. Adjust track extension levelers (requires a
15/16” socket or wrench). If equipped, and then screw the
larger wing nuts on the levelers down to tighten. See Figure
16. After use, remove the ½ inch hardware and track
extension. Re-install the ½ inch hardware in the cabinet
from channel. NOTE: Lower track extension wheels are
for moving the structure similar to a wheel barrow.
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Upper Track Extension Use:
Follow the Lower Track Extension procedure except open
the door on the upper CCR cabinet bay. Use the ½ inch
hardware located in the upper bay front channel. When
installing upper track extension, adjust levelers on base of
upper track assembly. It may be easier to adjust the front
levelers (nearest cabinet) and then push extensions structure
into cabinet to engage safety hooks. Install the ½ inch
hardware and then adjust the rear levelers. This method may
allow the use of the rear casters to help move the structure
during the safety hook engagement process. Be sure to
tighten the wing nuts. Track extension must rest on levelers
only before placing the trolley/CCR power module on it.
Track extension wheels will not support the weight of the
trolley/CCR power module. Casters are mounted to plates
attached to the extension structure with wing nuts. The only
time these casters plates need to be removed if you need to
adjust the track extension below its designed height (pad
height). This feature will allow some additional negative
(downward) adjustment.
WARNING:
WARNING
Upper track extensions equipped with wheels are intended to only be
used for installing and removing CCR Power Modules when secured
to the cabinet and resting on extension levelers. Use of the upper or
lower track extension as a cart is not intended and will cause CCR
Power Module to roll off and cause damage, serious injury, or death.
Use the counter balanced lift to remove or install power modules on
the track extensions.
2.1.9 CCR Power Module Installation
WARNING:
WARNING
Be sure Switchgear System main circuit breaker is in the off position
and locked-out during the initial Switchgear System installation.
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When installing CCR Power Modules, always install the lower CCR cabinet bay power
module first before installing the upper CCR cabinet bay power module. Installation of load
wiring into cabinets should be complete prior to installation of CCR power modules.
Inspect the power module prior to installation and check for shipping damage. The door panel,
which includes the main circuit card should be mounted after the CCR power module is
installed in the cabinet. Be sure to mount the door panel shipped with a particular CCR power
modules as settings on the board have been configured and tested with that particular power
module. See instruction sheet 2642 supplied with power module.
Be sure to install the CCR power module in the matching CCR cabinet bay.
Open the CCR cabinet bay door in which the CCR power module is to be installed. Remove
the 2 pins attached with lanyards and their hairpin cotters. See Figures 15 and 16, Photos 1 –
5. Install the track extension. Lift the CCR power module up utilizing the fork lift slots in the
sides of the trolley base using the counterbalanced lift. The forks should extend through the
trolley be about 2 inches. If installing CCR power modules from the hinge side of cabinet, it
will be necessary to remove the door from the cabinet. Door is held to cabinet by 3 pins and 3
retaining rings (Rotor Clip part number SE-21 ST ZD). See figure 15.
NOTICE:
NOTICE
There is a metal plate on the trolley interior which the lift fork must
clear. This plate is to prevent the fork from coming into contact with
the track extension rails preventing removal of the lift fork or
disturbance of the trolley during the fork lift removal.
Place the trolley on top of track extensions aligning the trolley wheel grooves with the track
extension rail grooves. Lower the trolley onto the track extension. Be sure wheels are in the
track extension grooves. Back lift truck out of trolley forklift slots. Attach the field load leads
for the associated CCR power modules to the mating primary connectors on the power
module. Apply a layer of electrical tape around the connection. Push the CCR power module
trolley all the way into the Switchgear CCR cabinet hold the two black handles located at the
trolley front down. Be sure not to pinch field load leads between CCR power module trolley
and cabinet wall. Engage the black handle bosses into their mating bosses located on the CCR
cabinet front rail. Push the black handles up to engage. Re-install the pins and hairpin cotters
into the cabinet through their matching slotted hole in the trolley base. Remove the track
extension. Install the door panel and panel cover onto the cabinet door following the
instructions
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provided with it. Close the cabinet door. Adjust cabinet door panel circuit breaker plate if
required. The panel circuit breaker plate can be flipped 180 degrees to accommodate
installation in either the upper or lower CCR cabinet position. Adjust CCR module circuit
breaker position so actuator handle and lockout brackets protrude through the door. See CCR
Power Module Manual for adjustment screw locations. Be sure CCR power module circuit
breaker and the rotary step selector switch on the door is in the OFF position. Repeat
installation procedure for all CCR power modules until they are all installed.
NOTICE:
NOTICE
If a CCR Cabinet section has no CCR installed, it will not be equipped
with a trolley. Additionally, the door will have blank panel, P/N 34186
installed in place of the standard door panel configuration (does not
include a main circuit card, display circuit card, touch pad, rotary
switch and door panel cover).
2.1.10 Digitrac and Megatrac Option Installation
2.1.10.1 Digitrac Option Installation
If the Digitrac option circuit cards did not come pre-installed from factory, mount on the CCR
cabinet door panel interior per instructions provided with the CCR power module manual
under drawing 828SYS-D. Wire the Digitrac option to the CCR power module main circuit
card on the door per the Digitrac option drawing.
2.1.10.2 Megatrac Option Installation
The Megatrac option high voltage module and current sensing module come pre-installed on
the CCR power module from the factory. If the Megatrac option circuit cards did not come
pre-installed on the CCR cabinet door panel from the factory, mount on the door interior per
instructions provided with the CCR power module manual under drawing 828SYS-M.
2.1.11 Control Wiring
Control wiring to the CCR power modules should be done by utilizing the control wiring
cables troughs provided in the cabinets. See Figure 18. A conduit entrance will need to be cut
into the top of one of the cabinets (first CCR cabinet in line-up is recommended) to allow
control wiring entrance/exit from Switchgear System to a control panel or computer.
2.1.11.1 Standard CCR Control Wiring
Refer to the CCR Power Module manual remote control wiring section for standard
Connections.
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2.1.11.2 Digitrac Option Control Wiring Connections
If CCR’s are to be controlled by means of an optional Digitrac, do not make “standard” remote
control wiring connections as outlined in the CCR Power Module manual. Two #24 AWG
shielded minimum twisted pairs are daisy chained between CCR Power Module Digitrac
control boards. Starting at the first top bay CCR cabinet Digitrac control board, connect one
88 inch long twisted pair to terminals 39 & 40 and the other 88 inch long twisted pair to
terminals 41 & 42 noting the red or black color connection point on each pair. Mark both ends
on twisted pair outer jacket with a colored tape to keep the two sets of twisted pair wires from
being confused. From this top CCR bay Digitrac, connect to the bottom CCR bay Digitrac
control board in the same cabinet. Connect one twisted from the top bay Digitrac board to the
same points (noting color of wires) on the bottom Digitrac board. Repeat this process for the
other twisted pair wires from the top bay Digitrac board to the bottom bay Digitrac board.
From the bottom bay Digitrac board, connect the two twisted pairs – 123 inches long (noting
color and connection points) to the top bay Digitrac board in the next adjacent cabinet. Mark
both ends on twisted pair outer jacket with a colored tape to keep the two sets of twisted pair
wires from being confused. From this top Digitrac board, go to the bottom bay Digitrac board
in its cabinet making the twisted pair wiring connections. Utilize the control wiring troughs to
run all twisted pairs between top and bottom cabinets and to adjacent cabinets. Ty-rap twisted
pairs as necessary to existing cables in cabinet. Repeat this process until all CCR module
Digitrac boards have the twisted pair control wiring installed.
2.1.11.3 L-847 Auxiliary Cabinet Option Control Wiring Connections
Connect control wiring to the L-847 units per its instruction manual. If the L-847 remote
control is to be used with a CCR power module with an optional Digitrac control, do not make
standard remote control wiring connections per the L-847 manual. Instead, refer to Figure 19
for L-847 to CCR power module Digitrac control wiring.
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3
Operation
CAUTION:
CAUTION
Do not megger test the series lighting load while it is connected to the
regulator.
3.1 Initial System Power-Up
All cabinet doors must be closed. Turn the main Switchgear System circuit breaker ON. All
CCR cabinet bays which have an installed CCR power module will now have the red “Bus
Power Engaged” indicator light on the front door illuminated.
3.1.1 Bus Power Engaged Indicator Light
The Red indicator “Bus Power Engaged” light on the front door panels of CCR cabinets
indicates a CCR power module stabs have mated with its cabinet bus stabs and input voltage is
now available at the CCR power module circuit breaker. The main Switchgear circuit breaker
must also be in the on position with power present at its input terminals. If the indicator does
not illuminate, open cabinet door and check for the following:
WARNING:
WARNING
Power is present at the CCR power module circuit breaker line side
terminals even when the breaker is in the OFF position.
Check that the harness connections have been made to the indicator light terminals. Check if
120V is present on the indicator light harness wires, if present the indicator light LED is
defective. IF 120V is not present, attach the track extension and roll CCR power module out
of the cabinet.
WARNING:
WARNING
The cabinet bus stabs have power present in their sockets when the
main Switchgear System circuit breaker is in the on position.
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Check the wiring for any damage or loose connections and also check T8 transformer on the
CCR power module for damage. Refer to CCR Power Module Manual for indicator light
wiring connections.
3.1.2 CCR Power Module Power-Up
Be sure cabinet door is closed. Be sure the rotary selector switch on the CCR bay cabinet door
is in the OFF position. Turn CCR power module circuit breaker on. The red button on the
face of the CCR power module circuit breaker is a push-to-trip button. Observe that thee red
display above the door rotary switch illuminates. Display will briefly show software version
and then change to show output current, which should read 0.00 at this time. If display does
not illuminate, open the cabinet door.
WARNING:
WARNING
Voltage above 1000 volts are present when regulators are operating.
Pull the actuator on the door interlock switch out (door interlock located in each CCR bay
upper right side front corner). If display does not illuminate, go to the troubleshooting section
in the CCR power module manual. If display does illuminate, then interlock switch actuator is
not making contact with door. Shut CCR power module circuit breaker off. Using a pair of
pliers, bend the interlock switch bracket forward. Close door and re-apply power to the CCR
power module circuit breaker. Once display illuminates, push on door to make sure if the door
moves slightly in/out in the closed position there will be no nuisance trips with the door
interlock switch. Turn the rotary switch to the lowest step and observe current reading
changes on the display. Do this for all steps. If regulator (CCR power Module) does not
function correctly, go to the trouble shooting section in the CCR Power Module manual.
Repeat the CCR Power Module power-up process for each power Module in the Switchgear
System.
3.1.3 Remote Control Wiring Check
After the initial CCR Module power-up has been preformed, check the remote control circuit
wiring if installed.
3.1.3.1 Standard Remote Control Wiring
With the CCR Module circuit Breaker on, turn the rotary selector switch on the CCR cabinet
bay from the OFF position to the remote position. Verify remote control works in all steps and
OFF via 2-way communication.
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3.1.3.2 Digitrac Option Network Wiring
The Digitrac option network wiring requires that the wiring be hooked-up to a controlling
computer system with the computer system software programmed for particular Switchgear
System location installation. Be sure to have made prior arrangements with Crouse-Hinds
Airport Solutions Computer Group for the task and final connection/operation scheduling.
3.2 Optional Features Operation
3.2.1 Megatrac Option Test
If the CCR Power Module is installed with an optional Megatrac earth leakage detector, refer
to Megatrac manual for operation.
3.2.2 S-1 Cutout Auxiliary Cabinet Option
To isolate a regulator output from its field load, pull the handle out to is associated S-1 Cutout.
DANGER:
DANGER
Do not pull out or insert S-1 Cutout handle when regulator is in the
ON position. Turn power off at associated regulator (CCR Power
Module) and lock-out breaker.
On optional S-1 Cutout assembly cabinets which utilize an intentional grounding scheme, be
sure to familiarize yourself with its intended function. See Figure 20.
3.2.3 L-847 Auxiliary Cabinet Option
If you have this option installed, refer to the L-847 Instruction Manual for operation. All L847 circuit selector switches obtain their control power from the Switchgear System horizontal
bus bars. A fused disconnect switch containing three Bussman FNQ-R-3/4 fuses is wired to
the L-847’s 480/120V step-down transformer. The fused disconnect switch must be in the ON
position for the L-847 unit to function. The CCR module connected to the particular L-847
unit should have its circuit breaker in the off position to avoid accidental turn-on of the L-847
high voltage switches when the L-847 disconnect switch is turned on.
DANGER:
DANGER
When power is present o the L-847 unit step-down transformer, the
line side of the transformer has exposed 480V terminals and the load
side has exposed 120V terminals.
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NOTICE:
NOTICE
4
Each L-847 unit panel (gold color) ground lug must have #8 AWG
(minimum) ground lead connected to the Switchgear System ground
bus.
Periodic Maintenance, Switchgear System
4.1 Scope of Maintenance
Only maintenance to the Switchgear System Cabinets and bus bars will be discussed. For
maintenance and troubleshooting of the CCR Power Modules, optional Digitrac, optional
Megatrac, and optional L-847 Circuit Selector Switches, refer to their individual manuals.
4.1.1 Cabinet Maintenance
Every 6 months inspect cabinets for rusting metal panels and interior dust build-up. Remove
rust from panels and apply touch-up paint. Turn power off at the main Switchgear System
circuit breaker and lockout.
CAUTION:
CAUTION
Power is present to the line side of the Switchgear System main input
circuit breaker even in the OFF position.
Open the CCR cabinet bay doors and vacuum out any interior dust build-up, in particular
around vent opening and fans if installed.
4.1.2 Cabinet Bus and Wiring Connection Maintenance
Every 2 years, re-torque all bus bar connections and check ALL wiring connections to all
connection points. This maintenance task will require the input power prior to the Switchgear
System main input circuit breaker to be turned off and locked-out. It will also require the
removal of the CCR Power Modules from the CCR Switchgear Cabinets to access the bus
bars.
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5
Switchgear Cabinet Additions to System
5.1 Adding Cabinets
5.1.1 Adding CCR Switchgear Cabinets
Switchgear CCR Cabinets for adding additional power modules to the Switchgear system can
be added after initial installation by following the same steps used for installing the initial
system. The Switchgear System main input circuit breaker must be off and locked-out
when adding cabinets. The only limitations are the capacity of the bus bar and/or the current
rating of the Switchgear System main input circuit breaker. An added Switchgear CCR
Cabinet may only be added to an adjacent first or last CCR Switchgear cabinet in the existing
system because of the required horizontal bus connections.
5.1.2 Adding Switchgear System Auxiliary Cabinets
Switchgear Auxiliary Cabinets can be added to any existing Switchgear System already
installed. Follow the same steps for installing the initial Switchgear cabinets. The
Switchgear System main input circuit breaker must be off and locked-out when adding
cabinets.
6
Hot Swapping CCR Power Modules
6.1 Hot Swapping Procedure
Turn CCR Power Module door rotary switch to OFF position on all units to be moved. Turn
the CCR Power Module circuit breaker OFF on all units to be moved. Install the track
extension. Disconnect field load cables from CCR Power Module. Disconnect the door
harness mating plugs. Remove pin on lanyards and hairpin cotter. Roll the CCR Power
Module out of CCR Cabinet onto the track extension. Lift the CCR Power Module off the
track extension. Move the track extension to CCR cabinet bay in which moved unit will be
installed. This bay should be empty or already had the CCR Power Module from its bay
moved out of the cabinet. Place moved CCR Power Module onto track extension. See manual
section s 2.1.6, 2.17, 2.18, and 2.19. Note: it is recommended that the main control board be
moved with its corresponding CCR Power Module that it was tested with. Check to see if DIP
Switch setting for steps and option on the main control board are correct for the new installed
location.
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DANGER:
DANGER
Power is present on the line side of the CCR Power Module even when
its circuit breaker is in the OFF position.
Never disconnect the field load from the regulator when the power is
in the ON position.
The stabs in the rear of the CCR Cabinet have live voltage present
when the Switchgear System main input circuit breaker is on.
Connect the field load leads to the CCR Power Module. Roll the CCR Power Module into the
cabinet. Re-install all pins and hairpin cotters in cabinet. Remove the track extension. Reconnect the door harness. Close the cabinet door. Turn CCR Power Module circuit breaker
on. Verify local and remote control rotary switch settings function. See manual sections 3.1,
3.1.2, and 3.1.3.
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Addendum
The following is a list of manufacturer’s part number and tools used in the Switchgear System.
Pages following are actual manufacturer’s catalog or data sheets. Copies of these catalog and data
sheets are only included with hard copies at the end of this manual and not with electronic copies.
Switchgear System Main Input Circuit Breaker – Square D part number MHL36300, MHL
36400, MHL 36600, and MHL 36800.
Switchgear System Transient Voltage Surge Suppressor (TVSS), optional – Square D part
number TVS4EBA24A
Switchgear CCR Cabinet Door Interlock Switch – Microswitch Part number 2DM409
Switchgear Disconnect Switch, used with fan option and L-847 Auxiliary Cabinet Option –
Bussman part number OPM-1038RSWC
Switchgear Disconnect fuses used with Bussman disconnect switch – Bussman part number
FQN-R-4/10 (used with fans) or Bussman part number FNQ-R-3/4 (used with L-847)
Switchgear CCR Cabinet fan option stepdown transformer – Acme Electric Corporation part
number TA-2-81213.
Switchgear CCR Cabinet optional fan – EBM-PAPST Inc. part number W2E143-AA15-01
Switchgear CCR Cabinet Fan option thermostat – Hoffman Enclosures Inc., part number ATEMNO
Switchgear CCR Cabinet Bus Stabs – Cooper Interconnect part number E1074-2 (power) and
Cooper interconnect part number E1074-4 (Ground) (no catalog page available).
Switchgear S-1 Cutout auxiliary cabinet S-1 Cutout, optional - Crouse-Hinds Airport Lighting
part number 30775.
L-823 Primary Connector Kits for FAA L-824 Cable - Crouse-Hinds Airport Lighting data
sheet CKP (provided for information only).
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Crimping Tools for Crouse-Hinds Connector Kits - Crouse-Hinds Airport Lighting data sheet
TEK-Tool (provided for information only)
Cable Penciller for preparing ends of L-824 cable for Connector Kits - Crouse-Hinds Airport
Lighting part number 10036-36 (provided for information only).
Counterbalanced Lift for installation of Switchgear CCR Power Modules – Blue Giant
Equipment Corp. part number BGL-22 with optional 36 inch long forged forks.
Key Mechanical Interlock option for Switchgear CCR Cabinet door – Kirk Key Interlock Co.,
part number Type F, 3 inch locking bolt length.
Power Module Circuit Breaker Lock-Out Bracket for use with Kirk Key Type F Interlock –
Crouse-Hinds 34176 (this bracket replaces the normal circuit breaker lock-out
brackets supplied with the power module). Data/catalog sheet not supplied.
Key Mechanical Interlock Option for Switchgear Auxiliary Cabinet hinged box around S-1
Cutout – Kirk Key Interlock Co., part number Type D.
Switchgear System Power Meter, optional – Tyco Electronics Crompton Instruments Integra
Ci3 Digital Metering System.
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3.00" LONG x 1 1/2" WIDE SLOT
TYP (REF)
20.0
10.0
5.0
27.0
36.0
TYP
10.0
TYP
CUTOUT
CUTOUT
CUTOUT
CUTOUT
5.0
15.0
Ø.625 TYP.(6)
PER SECTION
20.0
CABINET WIRING ENTRANCES
33
3.00" LONG x 1 1/2" WIDE SLOT
TYP
16.0
TYP
9.00
12.00
CUTOUT
10.0
38.0
30.0 TYP 42.0
TYP
TYP
12.00
31.0
TYP
1.9
TYP
2.5
TYP
6.0
TYP
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SWITCHGEAR CABINET
2 1/8" MIN
EMBEDMENT
EPOXY RESIN
SEISMIC BOLTING
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INPUT
CABINET
CCR CABINET
FOR 2 POWER
MODULES
BLUE GIANT LIFT
TOP VIEW
TRACK EXTENSION
CABINET WALL CLEARANCES
35
BLUE GIANT LIFT
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BUS HARDWARE
TORQUE SPECIFICATIONS
BUS SPLICE INSTALLATION (DOORS AND PANELS REMOVED FOR CLARITY)
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BUS SPLICE CONNECTION HARDWARE DETAILS
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MAIN
INPUT
CCR CABINET
FOR 2 POWER
MODULES
CCR CABINET
FOR 2 POWER
MODULES
CCR CABINET
FOR 2 POWER
MODULES
CCR CABINET
FOR 2 POWER
MODULES
NOTICE
TYPICAL CCR POWER MODULE INSTALLATION/REMOVAL - FORKLIFT
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NOTICE
IMPORTANT
IMPORTANT
TYPICAL CCR POWER MODULE INSTALLATION/REMOVAL - TRACK EXTENSIONS
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RECOMMENDED BUILDING CEILING HEIGHT
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SIDE VIEW
TYPICAL CABLE WIRING
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OPTIONAL L-847 CONTROL WIRING CONNECTED TO DIGITRAC
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1A
GND
1A
OPTIONAL S-1 CUTOUT AUXILIARY CABINET
INTENTIONAL GROUNDED S-1 CUTOUT WIRING SCHEME
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Lower Track Extension with CCR Power Module
Photo 1
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Lower CCR Power Module Installed in Cabinet
Photo 2
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Document 2516
Rev. F
Upper Track Extension with CCR Power Module and Counterbalanced Lift
Photo 3
46
Document 2516
Rev. F
Upper Track Extension and CCR Power Module
Photo 4
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Document 2516
Rev. F
Upper Track Extension with Upper CCR Power Module Installation
Photo 5
48
Document 2516
Rev. F
Switchgear Installation on an Elevated Pad with Auxiliary Cabinets, Main Input Cabinet
and CCR Cabinets with Fan Option Pagoda Top
Photo 6
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Document 2516
Rev. F
Switchgear CCR Cabinet with Fan Option with Doors Opened and
CCR Power Modules Installed with Digitrac and Megatrac Option
Photo 7
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Document 2516
Rev. F
Switchgear CCR Cabinet Door with Digitrac and Megatrac Option Installed
Photo 8
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Document 2516
Rev. F
EYEBOLTS
98.0
5.0
5.0
10.0
10.0
9.0 TYP
38.0
TYP
30.0
TYP
27.0
42.0
TYP
.63 DIA
(6) PLC'S
2.5 TYP
1.9
TYP
15.0
20.0
6.0
TYP
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Document 2516
Rev. F
EXPANDED METAL TOP STANDARD
OPTION "F CONFIGURATION SHOWN
WITH POGODA TOP REMOVED. NOTE;
THERMOSTAT, TRANSFORMER AND
FUSED DISCONNECT MOUNTED ON A
PLATE ATTACHED NEAR REAR UPPER
RIGHT SIDE OF CABINET INTERIOR.
THE ITEMS MOUNTED ON THIS PLATE
SHOULD ALLOW ACCESS TO THE BUS
FOR INSTALLATION AND MAINTENENCE.
THERMOSTAT TO BE SET AT 100° F.
FANS ON
INTERIOR
3.0
DANGER
HIGH VOLTAGE
INSIDE
OPE N BR EAKER
B EFOR E OP ENING
C ONT R OL DOOR
ON INTERIOR NEAR INTERLOCK SWITCH,
ADD LABEL WITH BLACK LETTERS ON
SMUDGE AND MOISTURE RESISTANT
MATERIAL WITH THE FOLLOWING TEXT:
LIMIT SWITCH ON THIS DOOR DISCONNECTS
POWER TO THE LOAD WHEN THE DOOR
IS OPENED.
"COOPER CROUSE-HINDS" NAME PLATE
PER DRAWING 34129, UPPER DOORS
ONLY.
OPTION "K".
MOUNTING HOLES TO
HAVE PLUGS WHEN
OPTION "K" IS NOT
ORDERED.
OPTION "H"
CONFIGURATION,
HASP & STAPLE.
PADLOCK
NOT SUPPLIED
DANGER
OPE N BR EAKER
B EFOR E OP ENING
C ONT R OL DOOR
T HIS SE CT ION OF
S WITC HGEA R IS
C ONST RUCT ED IN
A CC OR DA NC E TO THE
UL891 S T A NDARD FOR
D EA DFRONT S WITC HGEAR
IN E FFE CT AT THE
T IME ON C ONSTRUCTION
MONTH & Y EAR
98.0
DANGER
DANGER
HIGH VOLTAGE
INSIDE
HIGH VOLTAGE
INSIDE
OPE N BR EAKER
EYEBOLTS
HIGH VOLTAGE
INSIDE
ON CABINET INTERIOR IN MIDDLE OF POWER
STABS, APPLY LABEL "DANGER HIGH VOLTAGE"
EMED CO. P/N SQS30 IN CENTER. STABS TO BE
LABEL LEFT TO RIGHT "PHASE A", "PHASE B" AND
"PHASE C" DEPENDENT ON BUS LEG.
GREEN STAB TO BE LABELED "GND".
OPE N BR EAKER
B EFOR E OP ENING
C ONT R OL DOOR
B EFOR E OP ENING
C ONT R OL DOOR
MAKE LABEL AS SHOWN.
BLACK LETTERS ON SMUDGE
AND MOISTURE RESISTANT
WHITE MATERIAL.
T HIS SE CT ION OF
S WITC HGEA R IS
C ONST RUCT ED IN
A CC OR DA NC E TO THE
UL891 S T A NDARD FOR
D EA DFRONT S WITC HGEAR
IN E FFE CT AT THE
T IME ON C ONSTRUCTION
MONTH & Y EAR
LABEL ON DOOR INTERIOR.
MAKE LABEL AS SHOWN.
BLACK LETTERS ON SMUDGE
AND MOISTURE RESISTANT
WHITE MATERIAL.
10.0
TYP
16.0
TYP
.63 DIA
(6) PLC'S
9.00
9.0 TYP
CUTOUT
PAGODA TOP
STANDARD,
INSTALLED BY
CUSTOMER
"DANGER HIGH VOLTAGE INSIDE"
LABEL, EMED CO. QS423
2.5
TYP
38.0
TYP
12.00
30.0
TYP
42.0
TYP
12.00
31.0
TYP
1.9
TYP
36.0
TYP
6.0
TYP
3.00 LONG x 1.50 WIDE SLOT
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Document 2516
Rev. F
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Document 2516
Rev. F
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Document 2516
Rev. F
CCR CABINET
FOR 2 POWER
MODULES
TOP VIEW
TYPICAL UPPER CCR POWER MODULE INSTALLATION/REMOVAL
DEVICE
FUNCT ION
E NTER
SETUP
CO N TRAST
FRONT VIEW
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Document 2516
Rev. F
CCR CABINET
FOR 2 POWER
MODULES
TOP VIEW
TYPICAL CCR LOWER POWER MODULE INSTALLATION/REMOVAL
DEVICE
FUNCT ION
E NTER
SETUP
CO N TRAST
FRONT VIEW
DETAIL B
57