Maintaining the Switchboard

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E or CSA Z462 or local equivalent. This equipment must be installed and serviced only by qualified personnel. Perform such work only after reading and understanding all of the instructions contained in this bulletin. Turn off all power supplying this equipment before working on or inside equipment. Before performing visual inspections, tests, or maintenance on this equipment, disconnect all sources of electric power. Assume all circuits are live until they are de-energized, tested, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding. Always use a properly rated voltage sensing device to confirm power is off. Handle this equipment carefully and install, operate, and maintain it correctly for it to function properly. Carefully inspect the work area and remove any tools and objects left inside the equipment. Replace all devices, doors, and covers before turning on power to this equipment. All instructions in this manual assume that the customer has taken these measures. Failure to follow these instructions will result in death or serious injury.

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E or CSA Z462 or local equivalent.
This equipment must be installed and serviced only by qualified personnel.
Perform such work only after reading and understanding all of the instructions contained in this bulletin.
Turn off all power supplying this equipment before working on or inside equipment.
Before performing visual inspections, tests, or maintenance on this equipment, disconnect all sources of electric power. Assume all circuits are live until they are de-energized, tested, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding.
Always use a properly rated voltage sensing device to confirm power is off.
Handle this equipment carefully and install, operate, and maintain it correctly for it to function properly.
Carefully inspect the work area and remove any tools and objects left inside the equipment.
Replace all devices, doors, and covers before turning on power to this equipment.
All instructions in this manual assume that the customer has taken these measures.

Failure to follow these instructions will result in death or serious injury.

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 a 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.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH 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 will result in death or serious injury.

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.
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 a 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)	HNM1BL HNM4BL	Both Sides Both Sides	Not applicable
Blank Extensions	1.50 (38) 4.50 (114) 1.50 (38) 4.50 (114)	HLW1BL HLW4BL HLN1BL HLN4BL	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)	HLN4EBL HLW4EBL	Narrow Side Wide Side	Only PowerPacT H/J circuit breakers with MicroLogic trip unit 5/6.

Item

Height in. (mm)

Catalog No.

Branch Circuit Side

Circuit Breaker Frame

Blank Fillers

1.50 (38)
4.50 (114)

HNM1BL
HNM4BL

Both Sides
Both Sides

Not applicable

Blank Extensions

1.50 (38)
4.50 (114)
1.50 (38)
4.50 (114)

HLW1BL
HLW4BL
HLN1BL
HLN4BL

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)

HLN4EBL
HLW4EBL

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.

0100CT1901

DANGER
HAZARD 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 I-Line Blank Fillers and Extensions. Failure to follow these instructions will result in death or serious injury.

DANGER

HAZARD 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 I-Line Blank Fillers and Extensions.

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.

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

NOTE: The ground fault test log card is in the data pocket behind the I-Line section dead front.

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 a local Schneider Electric representative to obtain this manual.