Maintaining the Switchboard
 DANGER |
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HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Failure to follow these instructions will result in death or serious injury.
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Periodic maintenance of the switchboard includes cleaning, lubrication, and exercising component parts. The interval between maintenance checks can vary depending upon the amount of usage and environmental conditions of each installation. The maximum recommended inspection interval is one year. This definition for periodic maintenance applies throughout this manual, unless otherwise noted.
Always inspect the switchboard after an external electrical fault. (Refer to Adverse Circumstances). Service bulletins for the various disconnecting and overcurrent devices mounted in the switchboard are available through your local Schneider Electric representative.
General Inspection and Cleaning
- Vacuum the switchboard interior to remove any dirt or dust deposits. Wipe all bus bars, insulators, cables with a clean, dry, lint-free cloth.
- Check the switchboard interior carefully for moisture,
condensation build-up, or signs of any previous wetness. Moisture
can compromise insulation systems and cause rapid oxidation of current-carrying
parts. Inspect all conduit entrances and cracks between the enclosure
panels for dripping leaks. Condensation in conduits can be a source
of moisture and must not be allowed to drip onto live parts or insulating
material. Take the necessary steps to eliminate the moisture and seal
off all leaks.
NOTICE Hazard of CONTAMINATION- Do not use an air hose to blow out the switchboard. Dust can settle inside relays and overcurrent devices, causing overheating and improper operation.
- Do not allow paint, chemicals, or petroleum-based solvents to contact plastics or insulating materials.
Failure to follow these instructions can result in equipment damage. - Inspect the switchboard for any signs of overheating. Discoloration
and flaking of insulation or metal parts are indications of overheating.
If overheating occurs, be sure that all conditions that caused the overheating have been corrected. Loose or contaminated connections can cause overheating.
- Check for signs of rodent nesting in the switchboard. If
required, use a good exterminating technique in the general area of
the switchboard.
Do not place or use exterminating substances and chemicals inside the switchboard. Some products attract rodents.
- Carefully inspect all devices for any visibly worn-out, cracked, or missing parts.
- Manually open and close switches and circuit breakers several times to verify they are working properly.
- Verify that all key interlocks and door interlocking provisions are working properly.
Bus Bar Joints, Lug Terminations, and Insulating Materials
- Bus bar joints are maintenance-free. Do not retighten them
after the
pre-energizing checkout procedure is complete.
NOTICE HAZARD OF PLATING DAMAGE- Do not sand or remove plating on any bus bar, splice bar, or terminal lug.
- Damage to plating can result in overheating. Replace damaged part. Contact Schneider Electric Services at 1-888-778-2733 (US).
Failure to follow these instructions can result in equipment damage. - Check all bus bar joints and terminal lugs for any pitting, corrosion, or discoloration resulting from high temperatures or subjection to high fault conditions. If any damage has occurred, replace the bus bars or lugs. If cleaning is required, use Lectra-Clean®, made by CRC.
- Inspect all insulating materials. Before re-energizing the switchboard, replace insulators with any visible damage.
Circuit Breakers
Schneider Electric circuit breakers are designed and manufactured as sealed units requiring minimal periodic maintenance.
Exercise circuit breakers at least once a year to ensure proper operation. For general maintenance:
Refer to individual circuit breaker instruction manuals shipped with the switchboard for additional maintenance information, such as changing rating plugs, sensor plugs, or adjustable settings and removing circuit breakers. If the instruction manual is not available, refer to Reference Publications for the appropriate number, or contact your local Schneider Electric representative.
I-Line Blank Fillers and Extensions
| Item | Height in. (mm) | Catalog No. | Branch Circuit Side | Circuit Breaker Frame |
|---|---|---|---|---|
| Blank Fillers |
1.50 (38) 4.50 (114) |
Both Sides Both Sides |
Not applicable | |
| Blank Extensions |
1.50 (38) 4.50 (114) 1.50 (38) 4.50 (114) |
Wide Side Wide Side Narrow Side Narrow Side |
All applications except PowerPacT H/J circuit breakers with MicroLogic trip unit 5/6. | |
|
4.50 (114) 4.50 (114) |
Narrow Side Wide Side |
Only PowerPacT H/J circuit breakers with MicroLogic trip unit 5/6. |
- Trip the circuit breaker by pushing the push-to-trip or “Open” button located on the face of the circuit breaker. Refer to the appropriate circuit breaker manual for the specific location of this button.
- Manually open and close the circuit breaker two to three
times.
PowerPacT™ R-Frame Circuit Breaker
NOTE: Schneider Electric instruction bulletin 0600IB1201, Field Testing and Maintenance Guide for Thermal-Magnetic and MicroLogic™ Electronic Trip Molded Case Circuit Breakers, provides more in-depth information. DANGERHAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH- If adjusting circuit breaker settings, do not set the long-time trip rating at a higher ampacity than the rating of the bus bar or load cables it supplies; overheating can occur.
- Before energizing the switchboard, fill all unused I-Line circuit breaker mounting spaces with blank fillers and/or extensions as listed in Table 2.
Failure to follow these instructions will result in death or serious injury.NOTICE HAZARD OF PLUG-ON CONNECTOR DAMAGE- Do not remove the protective lubricant on the plug-on connectors.
- If additional lubrication is required, apply a coating of electrical joint compound, catalog number PJC7201, to the contact surfaces of the plug-on connector.
Failure to follow these instructions can result in equipment damage. - A full function test kit, catalog number FFTK, is available
from Schneider Electric to test PowerPacT M, P, and R circuit breakers
equipped with MicroLogic trip units. It runs trip unit tests automatically,
with prompts to the user for initial information. Test modules for
each circuit breaker frame are used to store data necessary for automatic
tests. Series B MicroLogic trip units require test module CBTMB, which
is included in UTS3.
A pocket tester, catalog number S434206, or UTA tester, catalog number STRV00910, are available from Schneider Electric to test PowerPacT H, J, and L circuit breakers with MicroLogic trip units. These testers supply power to the MicroLogic trip units and allow for settings to be adjusted through the keypad located on the circuit breaker or through a PC using the USB interface.
To test MasterPact NW circuit breakers with MicroLogic trip units, use the full-function test set, catalog number S33595, or the hand-held test set, catalog number S33594, which are available from Schneider Electric.
Plug-on Neutrals
Plug-on neutrals are used with three- phase four-wire FlexSeT switchboards only. For installation, maintenance, or other information on plug-on neutrals, please refer to instruction bulletin NNZ9919501, FLEXPON 570/1200/1200S Plug-on Neutrals.
Ground Fault Protection Systems
Check the terminal connections on the ground fault protection system at least once a year for tightness and corrosion. If the system can be tested without tripping the main or branch device, directions for testing the system are in the device manual. Otherwise, testing the ground fault protection system will trip the main or branch device to which it is connected. If the ground fault sensor or relay is physically or electrically damaged, replace it.
If the ground fault protection system does not operate properly and additional equipment has been connected to the installation since the last maintenance test/check, de-energize the entire system, and check for grounds on the neutral downstream from the main bonding jumper. If no downstream grounds are detected and the ground fault system is not operating properly, contact Schneider Electric Services at 1-888-778-2733 (US).
If no additions have been made to the installation and the ground fault protection system does not operate properly, contact Schneider Electric Services at 1-888-778-2733 (US).
Refer to the ground fault field test instruction manual for additional testing information. If the manual is not available, refer toReference Publications to obtain the appropriate number. Contact your local Schneider Electric representative to obtain this manual.