(106-010)Switchboard_Manual_Vol_1.pdf

FRV40-226-106-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Switchboards, 600 Volt and 480 Volt, Main Ship’s Service, Emergency and Scientific

Volume 1

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

DanLe

REV 1

FRV40-226-106-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Switchboards, 600 Volt and 480 Volt, Main Ship’s Service, Emergency and Scientific

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

PUBLISHED BY DIRECTION OF NOAA

05 JULY 2007

REV 1

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

Rev 1 7/26/04 Made changes per NOAA comments

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-226-106-010

TITLE OF MANUAL: Switchboards, 600 Volt and 480 Volt, Main, Ship’s Service, Emergency and Scientific, APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

50-SPNA-1-00031 FRV40-226 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-226-106-010 to be provided under contract 50-SPNA-1- 00031 has been approved by the approval data shown above.

Date:________________

CHAND LLC

Mathews, LA 70375

CAGE CODE: OD5X4

VALIDATION PERFORMANCE

Title of Publication

Switchboards, 600 Volt and 460 Volt, Main, Ship’s Service, Emergency and Scientific, Volume 1

Contractor Sub-Contractor(If Performing Validation)

Halter Marine Inc. Halter Marine Inc.

Contract No. (s) and Purchase Orders, If Applicable

Chapter Section Paragraph Date Check here if Validation Not validated Completed

Contents of this manual have been validated and certified to be applicable to the equipment furnished under the above procurement as specified for Validation.

Name & Authority of Validating Officer: Signature of Validating Officer:

FOREWORD

This manual is intended to clearly and accurately reflect the actual configuration of the installed equipment described for the FRV40-226 Switchboards, 600 Volt and 480 Volt, Main, Ship’s Service, Emergency and Scientific, Volume 1 . Users are urged to report instances noted wherein the manual does not achieve this objective.

This technical manual provides the instructions necessary to operate, to perform maintenance on and troubleshooting of the Switchboards, 600 Volt and 480 Volt, Main, Ship’s Service, Emergency and Scientific, Volume 1. The text is broken down as follows:

Section 1- 600 Volt Main Switchboard, Installation, Operation and Maintenance

Section 2- 480 Volt Ship Service Switchboard, Installation, Operation and Maintenance

Section 3- 480 Volt Emergency Switchboard, Installation, Operation and Maintenance

Section 4- Crompton Meters and Transducers, Diversified Phase Sequence Monitor, Electroswitch Instrument

Switches

Section 5- Cutler-Hammer Indicating Lights, Push Buttons, Selector Switches, and Relays: Idec Relays and

Sockets, Basler Sync-Check Relays, Voltage Relays, Frequency Relays, Reverse Power Relays

Section 6- Woodward Load Sharing Module and SPM-A Synchronizer, Selco Motorized Potentiometer

Section 7- Micron Control Transformers and Potential Transformers, ITI Current Transformers

Section 8- Cutler-Hammer Magnum DS Breakers, LCL, FCL and LA Current Limiting Breakers and Accessories, N-Frame Breakers and Accessories, L-Frame Breakers and Accessories, KD Breakers and Accessories, FD, ED Breakers and Accessories, HMCP Motor Circuit Protectors, Molded Case Circuit Breakers, Internal and External Accessories

SECTION 1

600 VOLT MAIN SWITCHBOARD

600 Volt Main, 480 Volt Ship Service, and 480 Volt Emergency Switchboards Installation, Operation, Maintenance, and Component Manual

Gulf Coast Power and Control, Inc.

64080 Hwy. 1090

Pearl River, La 70452 Tele: 985-863-2336 Fax: 985-863-2346

VT Halter Marine

NOAA

FRV 40-1 Fisheries

Research Vessel

Gulf Coast Power and Control, Inc.

JOB No. 02S015

NOAA FRV 40-1 Page 1 of 22

FRV 40-1

Fisheries Research Vessel

600Volt Main Switchboard

Installation, Operation, and Maintenance

Gulf Coast Power & Control, Inc.

JOB NO. 02S015

February 7, 2003

NOAA FRV 40-1 Page 2 of 22

This technical manual includes installation, operation, maintenance, and repair instruction, with vendor information for the 600VAC Switchboard. The manual covers the following:

Ch. Title

600Vac Main Switchboard Instructions 1 General Information and Safety Precautions 2 Installation 3 Theory of operation 4 Operating Instructions 5 Maintenance 6 Inspection 7 Performance Verification 8 Disassembly, Repair, Replacement, and Reassembly 9 Preparation For Re-Shipment

10 Troubleshooting Guide 11 Vendor Information

NOAA FRV 40-1 Page 3 of 22

1. CHAPTER 1

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1-1. SAFETY PRECAUTIONS

This manual includes warnings and cautions needed to ensure the safety of personnel and equipment. Before attempting to operate or maintain this equipment, all warnings and cau-tions should be carefully reviewed and under-stood. The following paragraphs define warn-ings, cautions, and notes as they are used in this manual.

WARNING

Identifies an operating or maintenance procedure, practice, condition, or state-ment that, if not strictly followed, could result in death or serious injury to person-nel.

CAUTION

procedure, practice, condition, or statement that, if not strictly followed, could result in damage to or destruction of equipment, or serious impairment of system operation.

NOTE

Highlights an operating or maintenance condition or statement that is essential maintenance, but not known to be hazardous, as indicated by a warning or caution.

1-2. PURPOSE AND FUNCTION

This manual provides operating and maintenance instructions for the 600 Volt Ship Service Switchboard These switchboards consist of a Generator Control Switchboard and Power

Distribution Switcboard. Personnel should thoroughly review and understand the contents of this manual before attempting to operate or maintain this equipment.

1-3. EQUIPMENT DESCRIPTION

The Generator Control Switchboard and Power Distribution Switchboard are lineups consisting of four generator control sections and two power distribution sections. These lineups are mounted side by side and welded to the deck. The paragraphs below describe the use and characteristics of each panel.

Each panel consists of electrical devices, such as contactors, relays, and circuit breakers, enclosed in cabinet made of sheet metal. These devices are wired as needed for their application. Each panel has doors made of sheet metal, mounted on hinges or bolted depending on their application.

1-3.1. Identification

A nameplate that specifies the application identifies each control panel. Each part includes a nameplate or marking with the manufacturer’s part number.

1-3.2. Application

The Switchboard provides control, protection, and primary distribution of all 600 Vac, non-emergency power generated within the vessel.

1-3.3. Power Requirements

During normal operating conditions, the switch-boards receive electrical power from four diesel generators:

• Two 1360 kW, 60 Hz, 600 V ac

• Two 910 kW, 60 Hz, 600 V ac

All generator power cables enter the switchboards from the bottom.

1-4. DIMENSIONS

All dimensions are listed on drawing 02S015- 10010A & B.

NOAA FRV 40-1 Page 4 of 22

1-5. STORAGE

If the equipment is not installed immediately upon receipt, it must be stored properly to pre-vent corrosion and deterioration. Since packing cases do not protect the equipment for outdoor storage, the customer must provide a clean, dry place free of temperature variations, high hu-midity, and dust.

Use the following guidelines when storing the equipment:

1. Place the equipment under adequate cover with the following requirements:

a. Keep the equipment clean and dry, protected from precipitation and flooding.

b. Use only breathable (canvas type) covering material - do not use plastic.

2. Unpack the equipment as described in Chapter 2, and label it.

3. Circuit breakers should be prepared for storage separately. Refer to the appropriate circuit breaker instruction book.

4. Maintain the following environment in the storage enclosure:

a. Ambient storage temperature limits from -20 °C (-4 °F) to 55 °C (131 °F).

b. Surrounding air free of dust and corrosive elements, such as salt spray or chemical and electrically conductive contaminants.

c. Ambient relative humidity from 5 to 95% with provisions to prevent condensation.

d. No rodents.

e. Temperature variations that cause moisture condensation on the equipment.

Moisture on certain internal parts can cause electrical failure.

Condensation occurs with temperature drops of 15 °C (27 °F) at 50% humidity over a 4-hour period, and with smaller temperature variations at higher humidity.

If the storage room temperature varies in such a way, install a reliable heating system that keeps the equipment temperature slightly above that of the ambient air. This can include space heaters (when supplied) inside each enclosure. A 100 watt lamp can sometimes serve as a substitute source of heat.

To prevent fire hazard, remove all carton and other such flammable materials packed inside units before energizing any heaters.

1-6. SAFETY PRACTICES

The following are general guidelines that must be followed when working on electrical equip-ment and systems. They are not a substitute for proper training and awareness of the potential danger to health and life that is posed when op-erating or working on this equipment.

1. When working near electricity, do not use metal rules, flashlights or metallic pencils. Do not wear watch chains, finger rings or other objects having exposed conducting material.

2. Do not operate tagged equipment. These tags are used to indicate that a person’s life may depend on non-operation of the equipment or circuit.

3. Always tag a circuit OUT OF ORDER before working on it. Remove tags when complete.

NOAA FRV 40-1 Page 5 of 22

2. CHAPTER 2

INSTALLATION

2.1 INTRODUCTION

Installation consists of unpacking, permanently setting up the apparatus, and making connections between the various parts in the ship systems.

This chapter provides guidelines, but the actual methods used depend upon local conditions at the installation site.

2-2. UNPACKING AND INSPECTION

The equipment is shipped in an upright position, which should be maintained during all handling.

The equipment includes lifting angles that should not be removed until installation is complete.

When moving the equipment, be sure to observe the center of gravity.

It is good practice not to completely unpack the equipment until it has been placed as near as possible to its permanent location. If equipment has been exposed to low temperatures for an extended period of time, do not unpack it until it has reached room temperature.

A packing list is included in each case to specify the contents of each case shipped. When unpacking, carefully check the contents against the packing list to make sure all equipment is included and to avoid the loss of small parts.

Also, check equipment for any damage sustained during shipping.

Use standard unpacking tools. Carefully move the equipment from its container to avoid damaging or marring the part.

Small parts (such as bolts and screws) are packed in special containers to keep them together.

However, they may become separated. For this reason, carefully inspect packing for loose parts before discarding it.

The apparatus must be cleaned to remove particles of packing material or foreign substances that may have become lodged in or between any of its parts.

2-3. PREPARATION

Before starting installation, consult and study all drawings furnished. These should include arrangement drawings, connection diagrams, elementary diagrams, and a summary of the equipment. When requesting information from the manufacturer on any specific item furnished with the equipment, refer to the item by its specific name and part number whenever possible.

The purchaser must furnish any items external to the switchboard (such as mats, screens, and railings) that may be required to meet any codes.

2-4. INSTALLATION

2-4.1. Mounting

The switchboard floor channels must be level and accurately aligned. Steel shims may be used for exact leveling of the switchboard, if necessary.

When all of the sections of the switchboard are placed and secured on their foundation, they must be bolted together. When bolting together shipping sections, it is imperative that the fronts of all sections of the switchboard are lined-up.

The bus splice bars at the shipping splits are sometimes shipped turned in to reduce the size of the shipping package. These splice bars should be reassembled as required.

2-4.2. Cabling and Wiring

To prevent electrical shock or burn, do not handle or connect any power cables to the

NOAA FRV 40-1 Page 6 of 22 equipment without first checking that power supplies are turned off and no voltage levels are present on the wiring.

In addition to bolting the compartments and rear frames or adjacent sections together, the main bus, ground bus, neutral bus, control cables, and such must be connected.

2-4.2.1. MAIN CONTROL AND POWER

CABLES

All external power inputs are 600 Vac, 3-phase, 60 Hz.

Before connecting any main cables, identify the cables for their correct phase relationship with the equipment connections. The installer should furnish suitable cable supports.

It is important that all cables are adequately supported to take the weight off of the terminals and studs. In all cases, carefully follow the cable manufacturer’s recommendations as well as instructions contained herein.

The torque values for individual cables terminals should be as per the following table:

Wire Size

MCM

Torque*(ft/lbs.)

1,000 33

*These torque values are for non-lubricated threads

2-4.2.2. BUS BAR

Some of the bus is exposed and located within the rear switchboard frame structure. It is accessed through the rear doors. The bus is rigidly supported on polyester glass compound insulating supports, which are resistant to fire and moisture, and have excellent dielectric and mechanical strength.

The bus bracing is designed to withstand the thermal and magnetic stresses caused by an initial short circuit of 85,000 A. The bus is constructed with tin-plated connection joints to provide good electrical contact.

Before bus bar connections are made, wipe clean all tin-plated connections. Do not use sandpaper or any other type of abrasive material.

When bolting together the bus bars, it is imperative that the connections be accurately aligned. Minor adjustments may be made by loosening bars and supports, lining up connections, then retightening.

The torque values for individual bolt sizes should be as per the following table:

Hardware

Size Torque*(ft/lbs.)

Standard Nut with Conical Spring Washer or Lockwasher

¼-20 7-9 3/8-16 25-30 ½-13 35-40

5/8-11 40-45 *These torque values are for non-lubricated threads

2-4.2.3. GROUNDING

It is very important that the switchboard be adequately grounded for safety. The installer must supply a ground connector for connection to the ship’s hull. If the switchboard is welded to the ship’s structure, no separate ground cable is required.

NOAA FRV 40-1 Page 7 of 22

3. CHAPTER 3

THEORY OF OPERATION

3-1. INTRODUCTION

The Main Switchboard provides control and primary distribution of 600 V ac, non-emergency electrical power, generated aboard the vessel. It includes all the necessary instrumentation, protective relays, and local circuit breaker controls for the generator power distribution.

Drawing 02S015-10005A is a one-line schematic diagram of the power distribution system. This schematic shows, in simplified form, the electrical system power circuits and connections.

The following paragraphs provide a detailed description of the switchboard and their functions.

3-2. 600 VAC SWITCHBOARD

FUNCTION

The Switchboard is the link between the source of electrical power and the vessel electrical loads. It provides a central location for distributing and monitoring electrical power to the Ship’s equipment. The following paragraphs describe the various sections of the Switchboard.

Power is normally provided by four main diesel generator sets, connected to a main distribution bus through circuit breakers. The main distribution bus can be divided into four isolated buses by opening Bus Tie A, between buses “A” & “B”, Bus Tie B, between buses “B” & “C”, and Bus Tie C, between buses “C” & “D”.

3-3. GENERATOR CONTROL PANELS

The Switchboard contains four panels with controls and circuit breakers for the Main Diesel Generators. Each main generator is connected to the main bus through an electrically-operated air circuit breaker contained in its generator panel.

An oncoming generator must be synchronized with a live main bus before the circuit breaker can be safely closed.

The Generator Control Panel contains the necessary instrumentation, controls, and circuit breakers for generator operation and monitoring.

Chapter 4 describes operator control devices and their functions.

3-3.1. Fuses

Fuses inside the panels protect instruments, potential transformers, indicating lamps, and circuit breaker operating mechanisms.

3-3.2. Current Transformers

The current transformers step down the line current suitable for use in the Voltage Regulator, Governor, Metering and Power Management systems.

Always short circuit current transformer secondary terminals before disconnecting circuits from current transformers.

3-3.3. Potential Transformers

A potential transformer steps down the primary voltage to a suitable level for use in the Voltage Regulator, Governor, Metering and Power Management systems.

3-3.4. Circuit Breakers

Circuit breakers are used for opening, closing, and protecting power circuits.

Circuit breakers for this switchboard are low voltage power air-circuit breakers, used for main power source connection.

NOAA FRV 40-1 Page 8 of 22

3-3.5. Indicating Lamps

Indicating lamps are used to monitor circuit breaker positions, space heater status, ground faults, and many other functions defined in Chapter 4.

3-3.6. Pushbuttons and Switches

Pushbuttons are used for functions such as testing ground indicators. Switches are used for selecting generators, closing breakers, and synchronizing generators. Chapter 4 defines the pushbuttons and switches.

3-3.7. Control Transformer

A control transformer connects to the generator side on all diesel generator circuit breakers. The transformer provides power for closing the generator circuit breaker on the main generators.

NOAA FRV 40-1 Page 9 of 22

4. CHAPTER 4

OPERATING INSTRUCTIONS

4-1. INTRODUCTION

This chapter describes all the Main Switchboard operating controls and indicators. It includes step-by-step operating procedures for “dead-plant” startup, single generator operation, synchronizing generators, and synchronizing Bus Ties.

Instructions for diesel generators and other related equipment are covered in a separate manual.

4-2.2. Dead Plant Startup

The operator puts the Generator MODE Selector switch in the MANUAL position and starts the engine as described in Engine Manufacture’s Manual.

Before a generator can be connected to a dead bus, the generator voltage should be at 600 Volts and the speed or frequency should be at 60 Hertz. If not, adjust the voltage by turning the voltage adjust potentiometer until the voltmeter reads 600 Volts and adjust the frequency by turning the speed control potentiometer until the frequency meter reads 60 Hertz. The operator should then turn the Generator Sync Switch to the “On” position and close the Circuit Breaker switch. Depending on which generator has been selected, that generator will energize a particular bus (see one-line dwg. 02S015-10005A).

4-2. Synchronizing to an Energized Bus

After the operator has closed the first generator on line as described in 4-1.1., he then can close the appropriate Bus Tie Breaker by placing the Bus Tie Sync Switch in the MANUAL position and actuate the Circuit Breaker Switch to CLOSE position.

Before an Ac generator can be connected to an energized bus, that generator’s voltage and speed must match and be in phase with the bus voltage and speed. The 600 Volt Main Switchboard includes systems that permit manual or automatic synchronizing and paralleling, selected by an operator.

4-2.1. Manual Synchronizing of Generators

The operator puts the Generator MODE Selector switch in the MANUAL position and starts the engine as described in the Engine Manufacture’s Manual. In MANUAL mode, the operator controls synchronizing and paralleling functions using the instruments and controls located on the switchboard’s generator panel. While in this mode the operator must also select the Generator Sync Switch to the “On” Position.

Before a generator can be connected to an energized bus, the generator voltage should be at 600 Volts and the speed or frequency should be at 60 Hertz. If not, adjust the voltage by trimming the voltage adjust rheostat until the voltmeter reads 600 Volts and adjust the frequency by trimming the speed adjust rheostat until the frequency meter reads 60 Hertz The operator should then observe the sync-scope and close the Circuit Breaker when the sync-scope is at 12 o’clock

Although the operator manually adjusts and closes the circuit breaker (using the circuit breaker switch), the switchboard is equipped with a synchronizing check feature. This feature allows the circuit breaker to close only when the generator is in phase with the bus.

4-2.2. Manual Synchronizing of Bus Tie

Breakers

The operator also has the option of closing each generator to its own bus and manually synchronizing across the Bus Tie Breakers. To perform this, the operator must place the Bus Tie Breaker Sync Switch in MANUAL position:

verify proper synchronization by either raising or lowering the speed and the voltage on the generators as described above. The operator should then observe the sync-scope and close the

NOAA FRV 40-1 Page 10 of 22

Bus Tie Circuit Breaker when the sync-scope is at 12 o’clock

4-2.3. Auto Synchronizing of Bus Tie Breakers

The operator also has the option of closing each generator to its own bus and automatically synchronizing across the Bus Tie Breakers. To perform this, the operator must place the Bus Tie Breaker Sync Switch in the AUTO position.

Each Bus Tie Section has a SPM-A synchronizer and will synchronize and close the Bus Tie Breaker automatically.

4-2.4. Power Management

The operator put the Generator MODE Selector switch in the AUTO position to initiate Power Management.

In the POWER MANAGEMENT (PM) position, the control initiation is from the EDI Power Management System. The Power Management System responds to load increases or decreases that require additional generators to be put on the line or taken offline.

NOTE: Reference the EDI Power Management Manual and drawings for more details on automatic controls.

In all the above modes, the switchboard’s synchronizing and paralleling are executed by the LSM (Load Sharing Module) and the SPM-A (Synchronizers) mounted in each section of the switchboard. The Speed Controls (Engine Manufacture furnished) are mounted on the engine.

The system brings the oncoming generator up to rated RPM (Speed Control), then synchronizes it with the bus and closes its circuit breaker (SPM- A). The load is then brought up to match the other generators on line (LSM). The Speed Control and Load Sharing Module adjust the load evenly among the generators for proper parallel operation.

4-3. GROUND DETECTION

The operator uses the GROUND lamps and the GROUND lamp switch to test for ground faults on the 600V main bus. Normally, the three AC ground lamps glow at a reduced and equal brilliance when the GROUND lamp pushbutton is in the NORMAL position (non-pressed). If a ground fault occurs, the lamp on the faulted phase darkens and the other two lamps glow brighter.

To check that no lamp is burned out, the operator pushes the GROUND lamp pushbutton to the TEST position. This opens the ground connection and all three AC lamps glow at a reduced and equal brilliancy. The GROUND lamp pushbutton returns to the NORMAL position when the operator releases it.

4-4. OPERATING CONTROLS AND

INDICATORS

The 600 Volt Main Switchboard contains devices for monitoring and controlling the ship’s electrical power.

4-4.1. Voltmeters

The 600 Volt Main Switchboard includes an ac voltmeter on each Generator Control panel.

These voltmeters indicate voltages supplied by its assigned power source.

4-4.2. Wattmeters

The 600 Volt Main Switchboard includes wattmeters on each Generator Control panel.

These wattmeters indicate the electrical power supplied by the various sources to the main distribution bus

4-4.3. Ammeters

The 600 Volt Main Switchboard includes an ammeter on each Generator Control panel. The meter indicates the current supplied by the various sources of load.

4-4.4. Frequency Meters

The 600 Volt Main Switchboard includes a frequency meter on each Generator Control panel. The frequency meter indicates the cycles/second (Hz) at the 480 V ac distribution bus. Each meter has a range of 55 to 65 Hz. The normal operating frequency is 60 Hz.

4-4.5. Synchroscope

The 600 Volt Main Switchboard includes a synchroscope on the synchronizing panel. The synchroscope is used to check that the generator

NOAA FRV 40-1 Page 11 of 22 voltage is in phase with the bus voltage and that the generator and bus frequencies are the same (see section 4-2 above).

4-4.6. Generator Synchronizing Selector Switch

Each Generator control panel includes a GENERATOR MODE SELECTOR switch. The operator uses it to select the operating mode for Generators 1 thru 4. The operating modes are MANUAL/OFF/AUTO. In MANUAL, the operator manually adjusts and syncs the generators. In AUTO, the Power Management is initiated. (See section 4-2.1. and 4-2.4. for more detail).

4-4.7. Synchronizing ON/OFF Selector Switch

The 600 Volt Main Switchboard includes a Synchronizing On/Off selector switch for each generator. The operator uses it to turn on the sync scope for manual sync functions as well as for starting the switchboard from a dead bus.

4-4.8. Voltmeter Switches

The 600 Volt Main Switchboard includes an ac voltmeter switch on all four Generator Control panels. These switches allow the operator to monitor each phase of the generator and the bus voltage.

4-4.9. Ammeter Switches

The 600 Volt Main Switchboard includes an ammeter switch on each of the four generators.

These switches allow the operator to monitor the current in each phase of the generator.

4-4.10. Circuit Breaker Switch

The circuit breaker switch initiates the electrical closing and opening of the electrically controlled circuit breakers.

4-4.11. Generator Circuit Breakers

Protective circuit breakers are located in each generator panel that connects the generator to the 600 V bus.

4-4.12. Indicating Lamps

Indicating lamps are used to indicate to the operator whether Generator/Bus Tie Circuit Breakers are CLOSED (blue LED bulbs) or OPEN (amber LED bulbs) and grounds in the electrical system (Clear Incandescent bulbs).

4-4.13. Pushbuttons

The operator uses the pushbuttons to test ground indicating lights (see section 4-3).

4-4.14. Generator Heater Lights

Each Generator Control Panel contains an indicator light for the generator space heaters.

4-4.15. Distribution Circuit Breakers

Protective circuit breakers are located on each end sections of the switchboard and connect to the various ship distributions. (See Dwg.

02S015-10005 and 02S015-10010A for size and locations)

NOAA FRV 40-1 Page 12 of 22

5. CHAPTER 5

MAINTENANCE

5-1. SAFETY PRECAUTIONS

To prevent death or injury from electric shock, disconnect all power supplies before performing any maintenance, adjustments, servicing, parts replacement, or any other act requiring physical contact with the electrical working components or wiring of this equipment.

5-1.1. High Voltage Equipment

This equipment uses high voltages. It is important that only experienced and authorized technicians who observe standard safety precautions perform all phases of maintenance.

Before conducting any preventive maintenance, fully deenergize and ground the equipment. Tag the equipment OUT OF SERVICE only after it has been fully deenergized.

5-1.2. Servicing Live Equipment

If it is necessary to service live equipment, the following general instructions must be followed:

shock, use only one hand when servicing live equipment. This prevents an accidental current path being created through the body from one hand to the other.

1. Deenergize the equipment to connect a multimeter. To deenergize any capacitors connected to these terminals, temporarily ground the terminals to be measured.

2. Connect the multimeter to the terminals to be measured, using a range higher than the expected voltage. Make sure that you are not grounded whenever you adjust equipment or use measuring equipment. Do not use test equipment known to be in poor condition.

3. Without touching the meter or test leads, energize the equipment and read the meter.

4. Deenergize the equipment then remove the test equipment and tag the equipment

OUT OF SERVICE.

5-2. PREVENTIVE MAINTENANCE

Preventive maintenance consists of inspections for damage and wear, tests, and cleaning of equipment at scheduled intervals. It helps prevent, detect, and correct conditions that could cause equipment malfunction.

Make sure that inspection does not interfere with presently required on-line operation of equipment. Then remove power as follows:

This equipment contains high voltage. To prevent death or injury from electric shock, only authorized technicians shall perform maintenance. Do not work alone.

1. Deenergize all incoming sources of power, including remote control, and tag

OUT OF SERVICE.

2. Test equipment with multimeter to ensure that power is off. Until this step verifies that power is off, assume that power is on and use applicable precautions.

NOAA FRV 40-1 Page 13 of 22

5-2.1 Preventive Maintenance Schedule

For high service reliability, take equipment out of service periodically for inspection and maintenance. An inspection routine should be established to ensure that each part of the equipment is cleaned and examined at regular intervals. Periodic cleaning is necessary because accumulations of dust, dirt, and corrosion can cause device fault or failure. Periodic examination helps detect defects that could at some time cause the equipment to miss operate.

The schedule for conducting preventive maintenance depends on how much the equipment is used. Table 5-1 lists the preventive maintenance schedule for this equipment. This schedule is based on normal conditions. It should be adjusted for each application as experience requires.

Table 5-1. Preventive Maintenance Schedule

Maintenance Frequency of Equipment Operation Interval

Four or more operations per hour Monthly

Non-automatic operation Quarterly

All others Annually

5-2.2 General Inspection

Inspection of deenergized equipment should include not only visual examination, but also touching and shaking of electrical connections and mechanical parts. This helps determine if connections are tight and if movable parts are free to function.

Do not confine inspection to the switchboard and distribution panels. Also check adjacent installations.

Check that no loose tools or other foreign objects are left in or around the switchboards and distribution panels.

5-2.3. Cabinet Exterior

Inspect the switchboard exterior as follows:

1. Wipe off all dust, moisture, oil and smoke residue and remove corrosion with sandpaper.

2. Remove heavy dust or grease with a wooden scraper.

3. Remove dents.

4. Touch up bare spots with primer and paint.

5. Oil door hinges and latches with machine oil.

6. Replace all missing and damaged hardware, such as lights and controls.

5-2.4. Cabinet Interior

Clean and inspect the switchboard interior as follows:

1. Remove dust and dirt from electrical components using a vacuum cleaner.

2. Pay special attention to contact and magnet face surfaces because dirt particles can interfere with satisfactory operation.

3. Inspect for corrosion of metal parts.

Repair or replace if found.

4. Inspect for worn or broken parts. Repair or replace if found.

5. Inspect for evidence of water or liquids on the enclosure or parts. Check that ventilation openings do not permit water to discharge into electrical equipment. If found, determine the source and fix it.

5-2.5. Wiring and Connections

Loose connections and damaged wiring can be easily fixed, but it requires thorough inspection to detect them. Check wiring and connections as

1. Inspect wiring for wear, fraying, chipping, nicks, and burned or melted wire insulation (caused by overheating).

Repair minor defects with electrical tape, or replace if needed.

NOAA FRV 40-1 Page 14 of 22

2. Inspect for loose electrical and mechanical connections. Replace defective crimp-style lugs. Hand-tighten or replace all loose or missing hardware. Use locking devices, such as check nuts or lock washers, where necessary to keep connections tight.

5-2.6. Bus Bars

1. Clean bus work and creepage surfaces of insulation materials.

2. Check that creepage distances are sufficient.

3. Check the bus work supports. Make sure that the supports prevent striking of bus bars of different polarity and bus bars and grounded parts during periods of shock.

4. Re-torque the bus bar bolt connections every six (6) months. (See torque values in section 2-4.2.2.)

5-2.7. Lights and Fuses

1. Check indicating lights for burned out lamps. Replace as required.

2. Check fuses for correct ratings. Replace if required.

3. Check that fuse clips make firm contact with the fuses, and that lock-in devices (if provided) are properly fitted.

5-2.8. Resistors and Rheostats

1. Check that there is no obstruction to ventilation of rheostats and resistors.

2. To reduce friction and wear, a light coat of GE-D50HD38 (Mobil 28) lubricant can be applied to the rheostat face plate.

5-2.9. Switching Equipment

To prevent hazard of electrical shock or burn, never clean contacts when equipment is energized.

Never use emery or sandpaper or a coarse file to clean contacts.

Switching equipment consists of circuit breakers (also see section 5-2.7), contactors, and relays.

Main contacts in switching equipment should be clean and bright, free from severe pitting or burning, and properly aligned.

1. Remove surface dirt, dust, or grease with a clean cloth. When cleaning and dressing contacts, maintain the original shape of the contact surface and remove as little material as possible.

2. Inspect copper contact surfaces for black copper oxide film, and clean with an ordinary eraser or similar device if required. Severely burned or pitted copper contact surfaces should be dressed with a fine file or crocus cloth.

3. Slight discoloration of solid silver or silver alloy contacts is normal and does no harm, and should not be disturbed. Heavy, black deposits and any high spots caused by burning should be removed with crocus cloth or a fine file.

4. Opening and closing laminated silver plated contacts aids in cleaning. If necessary, use a cloth moistened with a suitable cleaning solution to remove dirt and grease. Do not use a coarse file or sandpaper.

5. Make a contact impression and check spring pressure per the instructions in the applicable technical manual. If information on the correct contact pressure is not available, the contact pressure should be checked with that of similar contacts. When the force is less than the designed value, the contacts either require replacing because they are worn down, or the contact springs should be replaced. Always replace contacts in sets rather than singularly, and replace contact screws at the same time.

6. The function of arcing contacts is not impaired by surface roughness. Remove

NOAA FRV 40-1 Page 15 of 22 excessively rough spots with a fine file.

When arcing contacts have been burned severely and insufficient material remains to permit proper adjustments, replace contacts.

7. Sealing surfaces of switching equipment should be kept clean and free from rust. Rust on the sealing surfaces decreases the contact force and may cause the contact tips to overheat. This condition is sometimes indicated by a loud humming or chattering noise at the contactor or relay. Light machine oil wiped sparingly on the sealing surfaces of the contactor magnet helps prevent rust.

Oil should always be used sparingly on switching equipment, and should not be used at all unless there are specific instructions to do so or if oil holes are provided.

8. If working surfaces or bearings show signs of rust, the device should be disassembled and the rusted surfaces carefully cleaned. Light oil, such as GE- D50-HD38 (Mobil 28) may be wiped on sparingly to prevent further rusting. Oil has a tendency to accumulate dust and grit, which may cause unsatisfactory operation of the device, particularly if the device is delicately balanced.

9. Arc chutes or boxes should be cleaned by a fine wire brush if wiping with a cloth is not sufficient. Replace or provide new linings when broken or burned too deeply. See that arc chutes are securely fastened and that there is sufficient clearance to insure that no interference occurs when the circuit breakers is opened or closed.

10. Shunts and flexible connectors which are flexed by the motion of moving parts should be replaced when worn, broken or frayed.

5-2.10. Circuit Breakers

Before working on a circuit breaker, deenergize all control circuits to which it is connected. Drawout circuit breakers should be racked to the open position and removed before any work is accomplished.

It is good policy to have one or more spare breakers to install in place of breakers requiring maintenance. Keeping a stock of recommended spare parts lessens downtime during maintenance.

Maintain circuit breakers mechanisms as

1. Clean all surfaces, particularly insulation surfaces, with a dry cloth or air hose. Be sure that water is blown out of the air hose, that the air is dry, and that pressure is not over 30 psi before directing on breaker.

2. Check pins, bearings, latches, and all contact and mechanism springs for excessive wear or corrosion and evidence of overheating. Replace parts where necessary.

3. Slowly open and close circuit breakers a few times manually. See that trip shafts, toggle linkages, latches, and all other mechanical parts operate freely and without binding. Make sure that all arcing contacts meet before and break after the main contacts. If poor alignment, sluggishness, or other abnormal conditions are noted, adjust in accordance with the technical manual for circuit breakers.

4. Lubricate bearing points and bearing surfaces, including latches, with a drop or two of light machine oil. Wipe off excess oil.

5. Before returning a circuit breaker to service, inspect all mechanical and electrical connections including mounting bolts and screws, drawout disconnect devices and control wiring. Tighten where necessary.

Give final cleaning with cloth or compressed air. Operate manually to make sure that all moving parts function freely. Check insulation resistance.

5-2.11 Electrical Measuring Instruments

Electrical measuring instruments are of delicate construction and readily affected by exposure to strong magnetic fields and by excessive current flow. The operating forces involved in the instruments are very small and the coils, which

NOAA FRV 40-1 Page 16 of 22 are of limited current-carrying capacity, can easily be burned out by excessive current. To avoid this the following rules should be followed:

1. Make connections only when the circuit is deenergized.

2. Keep all contact surfaces clean.

3. Keep all connections tight.

To ensure accurate readings, observe the following precautions:

1. Check the meters against standards to ensure accuracy. This is particularly important if they have been subjected to overload, misuse, excessive vibration or shock, or if there is any reason to suspect inaccuracy. If an instrument has been exposed to extreme temperature conditions or strong magnetic fields, check it for pivot friction and balance.

2. Never attempt to adjust a meter, except the zero adjustment (see section 5-3.2).

3. Do not attempt to lubricate a meter.

4. Synchroscope calibration may be checked by connecting both circuits to the same source. The pointer should indicate synchronism. If the pointer does not indicate synchronism, it should be shifted to the vertical position.

5-3. CORRECTIVE MAINTENANCE

Corrective maintenance consists of adjustments, repairs, or replacements for defective or malfunctioning equipment. Be sure to observe all safety precautions while performing any corrective maintenance procedures.

5-3.1. Component Replacement

To remove a component from the switchboard for repair or replacement, use the following general rules:

1. Deenergize all incoming sources of power from the switchboard, including remote control, and tag OUT OF SERVICE.

2. Tag any wires so that they can be reconnected correctly, then disconnect wires from the device.

3. Dismount the device by removing the screws that hold it in place.

4. Mount the new or repaired device and secure it with the mounting screws.

5. Reconnect the wires (as tagged) to the new or repaired device.

6. Apply power to the switchboard and operate it. Check for proper functioning of the devices.

7. When the switchboard is operating correctly and repair is completed, remove the OUT OF SERVICE tags.

5-3.2. Electrical Measuring Instruments

Never attempt to adjust a meter, except the zero adjustment.

To make a zero adjustment:

1. Make sure that the instrument is not connected.

2. Check that the pointer does not stick at any point along the scale.

3. Turn the adjustment screw on front of the meter to read zero.

When an ammeter circuit is carrying load, never disconnect any wire of the current transformer

NOAA FRV 40-1 Page 17 of 22

6. CHAPTER 6

INSPECTION

6-1. SCHEDULING

Equipment inspection is part of preventive maintenance, covered in Chapter 5. For scheduling, see 5-2.1.

6-2 DAMAGE AND WEAR

maintenance, covered in Chapter 5.

NOAA FRV 40-1 Page 18 of 22

7. CHAPTER 7

PERFORMANCE VERIFICATION

7-1. GENERAL

Under normal operating conditions, the protective devices do not operate. It is therefore necessary to inspect these devices carefully and verify that they are functioning correctly. If the equipment is in use when performing verification, make sure that the type of service can permit a short interruption. Then test tripping protective devices to observe how the equipment is functioning.

If a device fails to function properly, determine the cause of failure at once and fix it. (For specific information about the maintenance of the various devices refer to the particular instruction book.)

7-2. PROCEDURES

Verification checks whether the equipment operates the way it should. The following sections describe verification tests for the

Care must be exercised during these operating tests not to disrupt any electric power supply vital to the operation of the ship nor to endanger ship’s personnel by inadvertently starting motors, energizing equipment being repaired, or otherwise.

7-2.1. Lights, Switches, and Pushbuttons

For each Generator control panel, verify that all indicating lights are properly lit and that all operator devices function according to their description in Chapter 4.

7-2.2. Circuit Breakers

For manually-operated circuit breakers, open and close the breaker to check mechanical operation.

For electrically-operated circuit breakers, use the operating switch or control to check both mechanical operation and control wiring.

7-2.3. Bus Transfer Equipment

For manual bus transfer equipment, verification test is made by manually transferring a load from one power source to another, and checking mechanical operation and mechanical interlocks.

For semi-automatic equipment, cut off power (open a feeder circuit breaker) to see if any automatic transfer takes place. The precautions given for circuit breaker operating test should be observed when testing bus transfer equipment.

7-2.4. Control Circuits

Check the control circuits to ensure circuit continuity and proper relay and contactor operation. Because of the many types of control circuits installed in the vessels, it is impractical to set up any definite operating test procedures.

When testing circuits, precautions should be observed to guard against damage to the associated equipment.

Protective circuits such as reverse power, or reverse current circuits usually can be verified by actual operation. First, visually check the circuits. Where possible, operate relays manually to make sure that the rest of the protective circuit performs its desired functions.

Extreme care must be taken not to disrupt vital power service or to damage electrical equipment.

7-3. FREQUENCY OF TEST AND

INSPECTIONS

Verification tests should initially be performed after installation. Then, these tests should be conducted at the same time as preventive maintenance procedures (see Chapter 5)

NOAA FRV 40-1 Page 19 of 22

8. CHAPTER 8

DISASSEMBLY, REPAIR, REPLACEMENT, AND REASSEMBLY

Switchboards contain high voltages. To prevent death or injury from electric shock, only authorized personnel shall perform maintenance. Do not work alone.

8-1. COMPONENT REMOVAL,

DISASSEMBLY, AND REPAIR

To remove a component from the switchboard for disassembly and repair, use the following

Disconnect all power supplies before performing any maintenance, servicing, parts replacement, or any other act requiring physical contact with the working components or wiring of this equipment.

from the switchboard and tag OUT OF

SERVICE.

2. Open the switchboard by turning the door handle and pulling the door open.

3. On the component to be removed, tag any wires so that they can be reconnected correctly. Then disconnect the wires from the component.

4. Dismount the component by removing the screws that hold it in place.

1. For disassembly, repair, and reassembly instructions, refer to the component publication.

8-2. COMPONENT REPLACEMENT

To replace a component, use the following general guidelines:

1. Check that all incoming sources of power to the switchboard are turned off and that the equipment is tagged OUT OF SERVICE.

2. Mount the new or repaired component and secure it in place with the mounting screws.

3. Reconnect the wires (as tagged) to the component.

4. Close the switchboard door.

5. Apply power to the switchboard and operate it (see Chapter 4). Check for proper functioning of all switchboard operator devices.

6. When the switchboard is operating

NOAA FRV 40-1 Page 20 of 22

9. CHAPTER 9

PREPARATION FOR RESHIPMENT

Removal of the switchboard panel from lower decks is beyond the scope of this instruction book. For instrumentation, please refer to the vendor publication

NOAA FRV 40-1 Page 21 of 22

10. CHAPTER 10

TROUBLESHOOTING

GENERAL

Troubleshooting of switchgear equipment is simplified by the extensive provisions of signal lights and mechanical indicators, as well as instrumentation. Familiarity with these devices and what they indicate will help to determine whether there is trouble within the switchgear equipment or elsewhere in the system.

Before concluding that trouble exists in the switchgear equipment, make certain that all power and control circuits have continuity, that is, no loose bus or terminal connections and no discontinuous cables or wires

Troubleshooting within the many devices which make up the switchgear equipment is covered in the separate instructions for each device. This type of troubleshooting should be performed after the device has been removed from the switchgear equipment.

DE-ENERGIZE EQUIPMENT COMPLETELY BEFORE DOING MAINTENANCE WORK

ON ANY DEVICES, CONNECTIONS, BUS WORK, BREAKER OR FEEDER CABLE

COMPARTMENTS. THIS INCLUDES DE-ENERGIZING ANY CONNECTIONS TO

OUTSIDE PRIMARY OR SECONDARY SOURCES, SUCH AS TRANSFORMERS, TIE

LINES, ETC.

TROUBLESHOOTING CHART

DEVICE / SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

VOLTMETERS

Incorrect or no reading Voltmeter input wrong Check voltage. If incorrect check fusing for voltmeters.

Voltmeter defective Replace Voltmeter Faulty wiring Check wiring and connections.

Replace or repair as needed.

WATTMETERS

Incorrect or no reading Wattmeter input wrong Check input. If incorrect check fusing for circuit.

Wattmeter defective Replace Wattmeter Faulty wiring Check wiring and connections.

Replace or repair as needed.

AMMETERS

Incorrect or no reading Ammeter input wrong Check input.

Ammeter defective Replace Ammeter Faulty wiring Check wiring and connections.

Replace or repair as needed.

NOAA FRV 40-1 Page 22 of 22

TROUBLESHOOTING CHART (Cont.)

DEVICE / SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

FREQUENCY METER

Incorrect or no reading Frequency meter defective Replace Frequency meter Defective Control Transformer Replace Control Transformer Faulty wiring Check wiring and connections.

Replace or repair as needed.

AUTOMATC FUNCTIONS Governor/Voltage Regulator

Failure See individual manuals

Power Management problems See EDI Management Manual

SECTION 2

480 VOLT SHIP SERVICE

SWITCHBOARD

NOAA FRV 40-1 Page 1 of 23

FRV 40-1

Fisheries Research Vessel

480 Volt Ship Service Switchboard

Installation, Operation, and Maintenance

Gulf Coast Power & Control, Inc.

JOB NO. 02S015

February 7, 2003

NOAA FRV 40-1 Page 2 of 22

This technical manual includes installation, operation, maintenance and repair instruction, with vendor information for the 480VAC Switchboard, as installed. The manual covers the following:

Ch. Title

480Vac Ship Service Switchboard Instructions 1 General Information and Safety Precautions 2 Installation 3 Theory of operation 4 Operating Instructions 5 Maintenance 6 Inspection 7 Performance Verification 8 Disassembly, Repair, Replacement, and Reassembly 9 Preparation for Re-Shipment

10 Troubleshooting Guide 11 Vendor Information

NOAA FRV 40-1

1. CHAPTER 1

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1-1. SAFETY PRECAUTIONS

This manual includes warnings and cautions needed to ensure the safety of personnel and equipment. Before attempting to operate or maintain this equipment, all warnings and cau-tions should be carefully reviewed and under-stood. The following paragraphs define warn-ings, cautions, and notes as they are used in this manual.

procedure, practice, condition, or state-ment that, if not strictly followed, could result in death or serious injury to person-nel.

pro…