The Panama Canal: Third Set of Locks Project

THE PANAMA CANAL
THIRD SET OF LOCKS PROJECT
MAINTENANCE AND OPERATION MANUAL

LOW VOLTAGE SYSTEM
PANELBOARDS
DOCUMENT No.:
G91/ETNMAN1010
VERIF. APPROV.
REV. DATE PREP. APPROV. DESCRIPTION
GUPC GUPC
PA 11/11/14 Alejandro Martinez Marco Astua Erick Brieño Sergi Ametller First Issue
Contract No. CMC-221427, Design and Construction of the Third Set of Locks
MAINTENANCE AND OPERATION MANUAL Date: 11/11/14
Doc. No.: LOW VOLTAGE SYSTEM
G91/ETNMAN1010-PA PANELBOARDS Page: 2 of 33
TABLE OF CONTENTS
1.0 SCOPE OF WORK ................................................................................................................. 4

1.1 INTRODUCTION TO THE PROJECT ................................................................... 4
1.2 SCOPE OF THIS DOCUMENT ................................................................................ 4
2.0 REFERENCES ........................................................................................................................ 4
2.1 EMPLOYER’S REQUIREMENTS........................................................................... 4
2.2 INTERNATIONAL CODES AND STANDARDS ................................................... 4
2.3 STANDARDS COMPLIANCE (IEEE/ANSI) .......................................................... 5
2.4 GUPC DOCUMENTATION ...................................................................................... 6
2.5 SUBCONTRACTOR’S DOCUMENTATION ......................................................... 6
3.0 REFERENCE DOCUMENTS................................................................................................ 6
3.1 DESIGN BASIS DOCUMENTS ................................................................................... 6
4.0 SYSTEM DESCRIPTION ...................................................................................................... 7
4.1 REFERENCE DOCUMENTS ...................................................................................... 7
4.2 SUB-SYSTEM DESCRIPTION ................................................................................... 7
4.3 COMPONENT DESCRIPTION .................................................................................. 8
5.0 SYSTEM OPERATIONS MANUAL .................................................................................... 9
5.1 ENVIRONMENTAL CONDITIONS .......................................................................... 9
5.2 SAFETY PRECAUTIONS .......................................................................................... 10
5.3 OPERATOR PRE-START PROCEDURES ............................................................. 10
5.4 STARTUP PROCEDURES ........................................................................................ 11
5.5 NORMAL OPERATIONS .......................................................................................... 11
5.6 SPECIAL OPERATIONS ........................................................................................... 12
6.0 ADDITIONAL OPERATIONS DATA .................................................................................. 12
6.1 REFERENCE DOCUMENTS .................................................................................... 12
TABLE OF CONTENTS (cont’d)
6.2 PRODUCT SUBMITTAL DATA (SUCH AS DESIGN CRITERIA, DISASTER

PREVENTION AND RECOVERY PLANS, ETC.) ................................................. 12
6.3 ENVIRONMENTAL IMPACT .................................................................................. 13
7.0 MAINTENANCE MASTER MANUAL ................................................................................ 13
7.1 REFERENCE DOCUMENTS .................................................................................... 13
7.2 INSPECTIONS ............................................................................................................ 13
7.3 PERIODIC MAINTENANCE TASKS ...................................................................... 14
7.4 MAINTENANCE TASKS ........................................................................................... 14
7.5 LUBRICATION DATA............................................................................................... 15
7.6 CORRECTIVE MAINTENANCE MANUAL .......................................................... 16
7.7 MANUFACTURER CONTACT INFORMATION ................................................. 16
7.8 TECHNICAL DATA FOR MAINTENANCE INSTRUCTIONS .......................... 16
1.0 SCOPE OF WORK
1.1 INTRODUCTION TO THE PROJECT
The Eaton Corporation has been awarded the subcontract for the Engineering,
Manufacturing, Shipment, Commissioning and Start-up of the Low Voltage System
Panelboards for the Project “The Panama Canal – Third Set of Locks”.
1.2 SCOPE OF THIS DOCUMENT
This document covers the Maintenance and Operation Manual related to the Low Voltage
System Panelboards scope.
2.0 REFERENCES
2.1 EMPLOYER'S REQUIREMENTS
The following Sections are applicable:
• SECTION 01 33 00 - Submittal Procedures
• SECTION 01 40 00 - Quality Requirements
• SECTION 26 20 00 – Electrical Low Voltage Distribution Work
• SECTION 01 32 00 - Project Communications and Document Management
• SECTION 01 31 00 - Project Management and Coordination
2.2 INTERNATIONAL CODES AND STANDARDS
• American Institute of Steel Construction (AISC)

• American National Standard Institute (ANSI)
• American Society of Mechanical Engineers (ASME)
• American Society for Non-destructive Testing (ASNT)
• American Welding Society (AWS)

• National Association of Corrosion Engineers (NACE)
• Society for Protective Coatings (SSPC)
• Occupational Safety and Health Administration (OSHA)
• International Organization for Standardization (ISO)
• Institute of Electrical and Electronics Engineers (IEEE)
• American Society for Testing and Materials (ASTM)
• Underwriters Laboratories Inc. (UL)
• National Electrical Code (NEC)
• National Electrical Manufacturers Association (NEMA)
• National Electrical Safety Code (NESC)
• National Fire Protection Association (NFPA)
2.3 STANDARDS COMPLIANCE (IEEE/ANSI)
• UL 50 - Enclosures for Electrical Equipment

• UL 67 – Standard for Panelboards
• UL 489 – Standard for Molded Case Circuit Breakers, Molded Case Switches and
Circuit-Breaker Enclosures.
• NEMA PB-1.1
• ANSI C37.81 Seismic Qualified
• Federal Specification Classification W-C-375b
• NFPA 70 – National Electrical Code
2.4 GUPC DOCUMENTATION
• G00/CICTSP-E0003 General Electrical Requirements

• G00/UPCMGP0005 Definition & Application of Quality Levels
• G00/UPCMGP0016 Material Receiving Inspection, Handling and Storage
• G00/UPCMGP-0002 Coding of Documents
• G00/UPCQMM0001 Quality Management Manual
• G00/UPCWPR0015 Shipping of Electromechanical Permanent Plant Material and
Equipment
• G80/CICDSR-E0001 PD Integration Management Plan
• G80/CICTSP-E0224 Electrical Systems Integration
• P00-UPCSCP0001 Pacific Security Plan
2.5 SUBCONTRACTOR'S DOCUMENTATION
• G91/ETNITP1011 Inspection & Test Plan

• G91/ETNMQP1010 Manufacturing Quality Plan
• G91/ETNMGP1001 External Audit Procedure
• G91/ETNMGP1002 Internal Audit Procedure
• G91/ETNQPN1011 Quality Plan
• G91/ETNWPR1010 Work Procedures
3.0 REFERENCE DOCUMENTS
3.1 DESIGN BASIS DOCUMENTS
• Drawings
• Wiring Diagrams
• Certified Test Reports
• Certifications: ISO, Seismic UL.
4.0 SYSTEM DESCRIPTION
Eaton´s assembled panelboards are designed for sequence phase connection of branch circuit
devices. This allows complete flexibility of circuit arrangement (single-two or three-pole) to allow
balance of the electrical load on each phase.
• G91/ETNDAT1001
4.2 SUB-SYSTEM DESCRIPTION
ENCLOSURES
Boxes are code-gauge galvanized steel, which include a painted box finished in ANSI-621
light gray to match the trim.
standard panelboard cabinets are designed for indoor use. Alternate types are available for
indoor and special purpose applications.
All enclosures are furnished in accordance with Underwriters Laboratories standards and
include wiring gutter with proper wire bending space.
Standard panelboards boxes are supplied without knockouts (blank endwalls).
FRONTS
Fronts (trims) for all panelboards are made of code-gauge steel and have a high durability
ANSI-61 light gray finish applied by a baked-on polyester powder coating paint system.
The fronts for lighting and appliance branch circuit panelboards and small power
distribution panelboards include a door with rounded corners and concealed hinges. A
flush-type latch and lock assembly is included.
Fronts for power distribution panelboards utilize a unique breaker front cover design in
which each device has a dedicated bolt-on steel cover.
4.3 COMPONENT DESCRIPTION
SPD Surge Protection Device:

The Eaton SPD Series protects critical electrical and electronic equipment from damage by
power surges. This is done by shunting high energy lightning surges (and other transient
disturbances) away from the equipment being protected. It does this in nanoseconds by
providing a low impedance surge path to ground while supporting power frequency voltage.
Eaton´s SPD Series are the latest and most advanced UL 1449 3rd Edition certified surge
protectors. Units are available integrated within Eaton electrical assemblies, including
panelboards, switchboards, motor control centers, switchgear, and bus plugs. Application of
SPD Series units throughout a facility will ensure that equipment is protected with the
safest and most reliable surge protective devices available.
SPD Series units are available in all common voltages and configurations and also a variety
of surge current capacity ratings from 50 through 400 kA.
CAN:
The can, also called the box, is typically constructed of galvanized steel. It houses the other
components. It is designed to provide component and personnel protection. Removable
blank end panels allow the user to cut conduit holes as necessary. Pre-stamped knockouts
are available as an option.
INTERIOR:
The interior consists of several components, including overcurrent protection devices, bus
bars and insulated neutral bars.
BUS BARS:
The centerpiece is the set of bus bars. A bus bar is a conductor that serves as a common
connection for two or more circuits. Bus bars are usually aluminum, but can also be copper.
They provide a mechanical means of affixing branch circuit breakers. The bus bars are
mounted on the interior, which is mounted on studs in the box.
NEUTRAL BAR:
The neutral bar provides the termination point for the neutral wires from both the incoming
service and the load circuits. The neutral bar can be mounted on studs in the back of the
box, or on the panelboard interior.
CIRCUIT PROTECTION DEVICES:

The circuit protection devices are usually circuit breakers. They are mounted directly to the
bus bars.
LABEL: The label identifies the panelboard´s voltage rating and ampacity.
DEAD FRONT and TRIM:

These are the front surfaces of the panelboard that cover the interior. The trim includes an
access door. These components provide access to the circuit breakers while sealing off the
bus bars and internal wiring from contact.
FILLER PLATES:
Filler plates are used to cover any unused pole spaces not used by a circuit breaker.
5.0 SYSTEM OPERATIONS MANUAL
5.1 ENVIRONMENTAL CONDITIONS
The primary function of an overcurrent device is to protect the conductor and its insulation
against overheating. In selecting the size of the devices and conductors, consideration
should be given to the ambient temperature surrounding the conductors within and external
to the panelboard. Cumulative heating within the panelboard may cause premature
operation of the overcurrent protective devices.
Do not locate the cabinet where it will be exposed to ambient temperatures above 40°C
(140°F), corrosive or explosive fumes, dust, vapors, dripping or standing water, abnormal
vibration, mechanical shock, high humidity, tilting, or unusual operating conditions unless
the cabinet/panelboard combination has been designed and so identified by the
manufacturer for these conditions.
Locate or shield the cabinet so as to prevent moisture and water from entering and
accumulating therein. Mount the cabinet so that there is at least ¼ inch of air space between
the cabinet and the wall or other supporting surface.
5.2 SAFETY PRECAUTIONS
The successful operation of panelboards is dependent upon proper installation, operation,

and maintenance. Neglecting fundamental installation and maintenance requirements may
lead to personal injury, death or damage to electrical equipment or other property.
WARNING
Hazardous voltages in electrical equipment can cause severe personal injury or death.
Unless otherwise specified, inspection and maintenance should only be performed on
panelboards and equipment to which power has been turned off, disconnected and
electrically isolated so that no accidental contract can be made with energized parts.
CAUTION
Hydrocarbon spray propellants and hydrocarbon based sprays or compounds will cause
degradation of certain plastics. Contact the manufacturer before using these products to
clean, dry or lubricate components during installation or maintenance.
5.3 OPERATOR PRE-START PROCEDURES
Tighten all accessible electrical connections to the manufacturer´s torque specifications. If

such information is not provided with the equipment, consult the manufacturer.
Make certain that all blocks and packing materials used for shipment have been removed
from all component devices and the panelboard.
Manually exercise all switches, circuit breakers, and other operating mechanisms to make
certain they operate freely.
To make sure that the system is free from short circuits and grounds, conduct an insulation
resistance test phase to ground and phase to phase with the switches or circuit breakers in
both the open and closed positions. If the resistance reads less than 1 megaohm while
testing with the branch circuit devices in the open position, the system may be unsafe and
should be investigated. If after investigation and possible correction, low readings are still
observed, the manufacturer should be contacted.
Test the ground fault protection system (if furnished).
Set any adjustable tie current trip device settings to the proper values. Experience has
indicated that damage from overcurrent can be reduced if the devices used for overload and
short-circuit protection are set to operate instantaneously (that is, without intentional time
delay) at 115 percent of the highest value of phase current which is likely to occur as the
result of any anticipated motor stating or welding currents.
Check to determine that all grounding connections are properly made. If the panelboard is
used as service equipment, make certain that the neutral, if present, is properly bonded to
the cabinet.
Remove all foreign material from the panelboard and cabinet before installing the cabinet
front. Make certain that all deadfront shields are properly aligned and tightened.
5.4 STARTUP PROCEDURES
Qualified personnel should be present when the equipment is energized for the first time. If
short circuit conditions caused by damage or poor installation practices have not been
detected, serious personal injury and damage can occur when the power is turned on.
There should be no load on the panelboard when it is energized. Turn off all of the
downstream loads.
The equipment should be energized in sequence by starting at the source end of the system
and working towards the load end. In other words, energize the main devices, then the
feeder devices, and then the branch-circuit devices. Turn the devices on with a firm
positive motion.
After all main, feeder, and branch circuit devices have been closed, loads such as lighting
circuits, contractors, heaters, and motors may be turned on.
5.5 NORMAL OPERATIONS
In compliance with the National Electrical Code, the loads of panelboard circuits should be
not more than 80 percent of the rating of the overcurrent protective device, unless the
marking of the device indicates that it is suitable for continuous duty at 100 percent of its
rating.
Some types of electrical equipment cause harmonics in the electrical system which may
result in overheating. This condition should be considered when determining panelboard
loading.
5.6 SPECIAL OPERATIONS
Standard panelboards, assembled with standard components, are adequate for most
applications. However, special consideration should be given to those required for
application under special conditions such as:
• Excessive vibration or shock

• Frequencies above 60 cycles.
• Altitudes above 6600 feet (2011.7m)
• Damp environment (possible fungus growth).
• Compliance with federal, state and municipal electrical codes and standards.
6.0 ADDITIONAL OPERATIONS DATA
Refer to documents:
- G91/ETNCRT1010 UL Certification
- G91/ETNCRT1011 ISO Certification
- G91/ETNCRT1012 Seismic Certification
6.2 PRODUCT SUBMITTAL DATA (SUCH AS DESIGN CRITERIA,

DISASTER PREVENTION AND RECOVERY PLANS, ETC.)
The short-circuit rating of Eaton´s assembled panelboards are test verified by, and listed
with, Underwriters Laboratories (UL). Generally, these ratings are that of the lowest
interrupting rated device in the panel.
Eaton´s panelboards are designed to meet the following applicable industry standards,
except where noted:
Underwriters Laboratories:
-Panelboards: UL 67
-Cabinets and Boxes: UL 50
Federal Specification W-P-115c:

-Circuit Breakers - Type I Class I
-Fusible Switch - Type II Class I
National Electrical Code

NEMA Standards: PB 1
All Eaton panelboards are seismic qualified at the highest possible level, and have been
tested in accordance with ANSI C37.81. This standard quantifies actual earthquake
conditions, as well as equipment seismic capability.
6.3 PERSONNEL TRAINING REQUIREMENTS
Installation, operation, and maintenance of panelboards should be conducted only by

qualified personnel.
A qualified person is one who is familiar with the installation, construction, and operation
of the equipment and hazards involved.
A person with knowledge of the requirements of the National Electrical Code and of all
other applicable codes, laws, and standards.
Trained an authorized to test, energize, clear, ground, tag, and lockout circuits and
equipment in accordance with established safety practices.
Trained in the proper care and use of protective equipment such as rubber gloves, hard hat,
safety glasses or face shields, and flash resistant clothing.
7.0 MAINTENANCE MASTER MANUAL
APPENDIX 1
7.2 INSPECTIONS
A panelboard which has been carrying its regular load for at least 3 hours just prior to
inspection should be field tested by feeling the deadfront surfaces of circuit breakers,
switches, interior trims doors, and enclosure sides with the palm of the hand. If the
temperature of these surfaces does not permit you to maintain contact for at least 3 seconds,
this may be an indication of trouble and investigation is necessary.
7.3 PERIODIC MAINTENANCE TASKS
A maintenance program for panelboards should be conducted on a regularly scheduled

basis .
7.4 MAINTENANCE TASKS
Inspect the panelboard once each year or after any severe short circuit.
If there is an accumulation if dust and dirt, clean out the panelboard by using a brush,
vacuum cleaner, or clean lint-free rags. Avoid blowing dust into circuit breakers or other
components. Do no use a blower or compressed air.
Carefully inspect all visible electrical joints and terminals in the bus and wiring system.
Visually check all conductors and connections to be certain that they are clean and secure.
Loose and/or contaminated connections increase electrical resistance which can cause
overheating. Such overheating is indicated by discoloration or flacking of insulation and/or
metal parts. Pitting or melting of connecting surfaces is a sign of arcing due to a loose, or
otherwise poor connection. Parts which show evidence of overheating or looseness should
be cleaned and re-torqued or replaced if damaged. Tighten bolts and nuts at bus joints to
manufacturers torque specifications.
Examine fuse clip contact pressure and contact means. If there is any sign of overheating or
looseness follow the manufacturer´s maintenance instructions or replace the fuse clips.
Loose fuse clips can result in overheating.
Re-tighten plug fuses.
Be sure that all conditions which caused the overheating have been corrected.
Check circuit breakers, switches, and fuses to ensure they have the proper ampere, voltage
and interrupting ratings. Ensure that non-current-limiting devices are not used as
replacements for current-limiting devices never attempt to defeat rejection mechanisms
which are provided to prevent the installation of the incorrect class of fuse.
Operate each switch or circuit breaker several times to ensure that all mechanisms are free
and in proper working order. Replace as required.
Check the operation of all mechanical components. Replace as required.

Exercise switch operating mechanisms and external operators for circuit breakers to
determine that they operate freely to their full on and off positions.
Check the integrity of all electrical and mechanical interlocks and padlocking mechanisms.
Whenever practical, check all devices for missing or broken parts, proper spring tension,
free movement corrosion dirt, and excessive wear.
Clean and dress readily accessible copper electrical contacts, blades, and jaws according to
the instructions when inspection indicates the need.
Look for and replace deteriorated insulating material and assemblies where sealing
compounds have melted.
Look for any moisture or signs of previous wetness or dripping inside the cabinet.
Condensation in conduits or dripping from outside sources in one known cause of
panelboards malfunction.
Seal off any conduits which have dripped condensate, and provide means for further
condensate to drain away from the panelboard.
Seal off any cracks or openings which have allowed moisture to enter the enclosure.
Eliminate the source of any dripping on the enclosure and any other source of moisture.
Replace or thoroughly dry and clean any insulating material which is damp or wet or shows
an accumulation of deposited material from previous wettings.
Inspect all component devices. Replace any component device which shows evidence of
moisture damage or has been subjected to water damage or flooding.
7.5 LUBRICATION DATA
- Adjust, clean and lubricate or replace parts according to the instructions.
- Use clean nonmetallic light grease or oil as instructed.
- Do not oil or grease parts of molded case circuit breakers.
- If no instructions are given on the devices, sliding copper contacts, operating mechanisms,
and interlocks may be lubricated with clean, light grease.
- Wipe off excess lubrication to avoid contamination.

7.6 CORRECTIVE MAINTENANCE MANUAL
If a severe electrical short circuit has occurred, the excessive currents may have resulted in
structural component and/or bus and conductor damage due to mechanical distortion,
thermal damage, metal deposits, or smoke. Examine all devices and bus supports for cracks
or breakage.
Check insulation resistance under any of the following conditions:
• Is a severe short circuit has occurred.

• If it has been necessary to replace parts or clean insulating surfaces.
• If the panelboard has been exposed to high humidity, condensation, or dripping
moisture.
7.7 MANUFACTURER CONTACT INFORMATION
For a complete list of Instruction Leaflets (IL´s) and Instruction Bulletins (IB´s), access the
Cutler-Hammer website at www.eatonelectrical.com or www.cutlerhammer.eaton.com.
You can also contact Cutler-Hammer using the Fax Retrieval of Engineering Documents
(FRED) by calling (412)937-6400 and following the operator´s instructions.
7.8 TECHNICAL DATA FOR MAINTENANCE INSTRUCTIONS
APPENDIX 1.
APPENDIX 1
POW-R-LINE PANELBOARDS
INSTALLATION,
MAINTENANCE AND
OPERATION MANUAL

The Panama Canal: Third Set of Locks Project

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THE PANAMA CANAL

THIRD SET OF LOCKS PROJECT

MAINTENANCE AND OPERATION MANUAL

1.0 SCOPE OF WORK ................................................................................................................. 4

TABLE OF CONTENTS (cont’d)

6.2 PRODUCT SUBMITTAL DATA (SUCH AS DESIGN CRITERIA, DISASTER

1.0 SCOPE OF WORK

1.1 INTRODUCTION TO THE PROJECT

1.2 SCOPE OF THIS DOCUMENT

2.1 EMPLOYER'S REQUIREMENTS

The following Sections are applicable:

• SECTION 01 33 00 - Submittal Procedures

• SECTION 01 40 00 - Quality Requirements

• SECTION 26 20 00 – Electrical Low Voltage Distribution Work

• SECTION 01 32 00 - Project Communications and Document Management

• SECTION 01 31 00 - Project Management and Coordination

2.2 INTERNATIONAL CODES AND STANDARDS

• American Institute of Steel Construction (AISC)

• American Welding Society (AWS)

2.3 STANDARDS COMPLIANCE (IEEE/ANSI)

• UL 50 - Enclosures for Electrical Equipment

2.4 GUPC DOCUMENTATION

• G00/CICTSP-E0003 General Electrical Requirements

2.5 SUBCONTRACTOR'S DOCUMENTATION

• G91/ETNITP1011 Inspection & Test Plan

3.0 REFERENCE DOCUMENTS

3.1 DESIGN BASIS DOCUMENTS

• Certified Test Reports

• Certifications: ISO, Seismic UL.

4.0 SYSTEM DESCRIPTION

4.1 REFERENCE DOCUMENTS

4.2 SUB-SYSTEM DESCRIPTION

Standard panelboards boxes are supplied without knockouts (blank endwalls).

4.3 COMPONENT DESCRIPTION

SPD Surge Protection Device:

CIRCUIT PROTECTION DEVICES:

DEAD FRONT and TRIM:

5.0 SYSTEM OPERATIONS MANUAL

5.1 ENVIRONMENTAL CONDITIONS

5.2 SAFETY PRECAUTIONS

The successful operation of panelboards is dependent upon proper installation, operation,

5.3 OPERATOR PRE-START PROCEDURES

Tighten all accessible electrical connections to the manufacturer´s torque specifications. If

Test the ground fault protection system (if furnished).

5.4 STARTUP PROCEDURES

5.5 NORMAL OPERATIONS

5.6 SPECIAL OPERATIONS

• Excessive vibration or shock

6.0 ADDITIONAL OPERATIONS DATA

6.1 REFERENCE DOCUMENTS

6.2 PRODUCT SUBMITTAL DATA (SUCH AS DESIGN CRITERIA,

Federal Specification W-P-115c:

National Electrical Code

6.3 PERSONNEL TRAINING REQUIREMENTS

Installation, operation, and maintenance of panelboards should be conducted only by

7.0 MAINTENANCE MASTER MANUAL

7.1 REFERENCE DOCUMENTS

7.3 PERIODIC MAINTENANCE TASKS

A maintenance program for panelboards should be conducted on a regularly scheduled

7.4 MAINTENANCE TASKS

Re-tighten plug fuses.

Check the operation of all mechanical components. Replace as required.