SDC 8X60Amp 4X100Amp 150KVA (MAY2002) PDF

USAF TO 35CA2-2-14-1
USA TM 9-6115-485-14&P
RADIAN CTM 01646.1R0256
COMMERCIAL TECHNICAL MANUAL

SECONDARY DISTRIBUTION CENTER
(SDC)
150KVA
8 EACH 60 AMPERE / 4 EACH 100 AMPERE
COMMERCIAL CONNECTORS
NSN XXXX-XX-XXX-XXXX
RADIAN PART NUMBER 1R0256
COPYRIGHT 2001 RADIAN INC.

5845 RICHMOND HWY., SUITE 725 ALEXANDRIA, VIRGINIA 22303-1873
MAY 17, 2002
DISTRIBUTION STATEMENT: Approved for public release; distribution is unlimited. Questions pertaining to technical
content shall be referred to WR-ALC/LES, Robins AFB, GA 31098. Other requests for this document shall be referred to
WR-ALC/LKCB, Robins AFB, GA 31098.
MAY 17, 2002
SDC 8/60 4/100 COMM
USA TM 9-6115-485-14&P
SAFETY PRECAUTIONS
READ THIS NOTICE
BEFORE INSTALLING, OPERATING OR MAINTAINING
SECONDARY DISTRIBUTION CENTER (SDC) 150KVA
RADIAN PART NUMBER 1R0256
The Secondary Distribution Center (SDC) equipment as described in this Commercial Technical
Manual (CTM) must be installed, operated, and maintained by qualified persons who are
knowledgeable in the installation, operation, and maintenance of electric power distribution
equipment and their associated hazards.
A qualified person is one who is trained and competent in:
(1) The skills and techniques necessary to distinguish exposed lived parts from non-live parts
of electronic and electrical equipment.
(2) The skills and techniques necessary to determine the proper approach distances
corresponding to the voltages that the qualified person will be exposed.
(3) The proper use of the special precautionary techniques, personal protective equipment,
insulating and shielding materials, and insulated tools for working on or near exposed
energized parts of electronic or electrical equipment.
The information, instructions and data of this manual is provided only for such qualified persons.
They are not intended to be a substitute for adequate training and experience in safety, operations
and maintenance procedures for this equipment.
The Secondary Distribution Center (SDC) must be selected and used for a specific application.
The application must be within the ratings of the SDC. Ratings for this equipment are listed on
the Radian Nomenclature Plate, which is attached to the SDC.
MAY 17, 2002
SDC 8/60 4/100 COMM
USA TM 9-6115-485-14&P
SAFETY PRECAUTIONS (CONTINUED)
WARNING
DEATH OR SERIOUS PERSONAL INJURY MAY RESULT IF YOU FAIL TO OBSERVE
SAFETY PRECAUTIONS.
WARNING
NEVER WORK ON ELECTRICAL EQUIPMENT UNLESS THERE IS ANOTHER
PERSON NEARBY WHO IS FAMILIAR WITH THE OPERATION AND HAZARDS OF
THE EQUIPMENT AND WHO IS COMPETENT IN ADMINISTERING FIRST AID.
WHEN OPERATORS AID THE TECHNICIAN, THEY MUST BE WARNED ABOUT
DANGEROUS AREAS.
WARNING
THE INPUT POWER SUPPLY TO THE EQUIPMENT MUST BE SHUT OFF AND
DISCONNECTED BEFORE BEGINNING WORK ON THE EQUIPMENT.
WARNING
WHENEVER THE NATURE OF THE OPERATION PERMITS, KEEP ONE HAND
AWAY FROM THE EQUIPMENT TO REDUCE THE HAZARD OF CURRENT
FLOWING THROUGH VITAL ORGANS OF THE BODY. REMOVE ALL JEWELRY
BEFORE WORKING ON EQUIPMENT.
WARNING
ALWAYS VERIFY THAT POWER IS SHUT OFF BEFORE MATING OR DE-MATING
CONNECTORS.
WARNING
NEVER ATTEMPT TO BYPASS INTERLOCKS OR REMOVE GUARDS.
WARNING
NEVER REMOVE LOCKS FROM ELECTRICAL EQUIPMENT WITHOUT PROPER
AUTHORITY.
AUTHORIZED MAINTENANCE PERSONNEL SHALL HAVE
POSSESSION OF KEYS FOR THIS EQUIPMENT.
WARNING
DO NOT ATTEMPT TO LOCK CIRCUIT BREAKERS IN THE CLOSED POSITION.
MAY 17, 2002
SDC 8/60 4/100 COMM
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WARNING
OBSERVE ALL SAFETY REGULATIONS AT ALL TIMES. DO NOT REPLACE
COMPONENTS OR MAKE ADJUSTMENTS INSIDE THE EQUIPMENT WITH THE
VOLTAGE SOURCES CONNECTED. UNDER CERTAIN CONDITIONS, DANGEROUS
POTENTIALS MAY EXIST WHEN THE ISOLATION SWITCHES ARE TURNED OFF
AS A RESULT OF VOLTAGE BACK-FEEDING TO THE CONTACTORS FROM THE
LOADS. ALWAYS REMOVE POWER, DISCHARGE, AND GROUND A CIRCUIT
BEFORE TOUCHING.
WARNING
LOW VOLTAGE (120VAC & 208VAC) CIRCUITS CAN BE AS LETHAL AS HIGH
VOLTAGE CIRCUITS.
WARNING
PERSONNEL SHOULD WORK IN PAIRS WITH EACH HAVING RESPONSIBILITY
FOR THE SAFETY OF THE OTHER.
WARNING
INSTALL GROUND ROD AND WIRE CAREFULLY. FAILURE TO ACHIEVE A GOOD
GROUND CAN RESULT IN LOSS OF LIFE AND MAJOR DAMAGE TO EQUIPMENT.
WARNING
BE SURE ALL POWER IS REMOVED FROM THE PRIMARY POWER CABLES
BEFORE ATTEMPTING TO ATTACH OR DETACH THE LOADBREAK ELBOWS.
DISCONNECT CABLES AT SOURCE IF NOT ALREADY DISCONNECTED. LETHAL
VOLTAGES ARE PRESENT.
PULLING THE CENTER EFD WILL NOT DE-ENERGIZE ANY CABLE
INTERCONNECTING SDCs IN THE CIRCUIT. THIS WILL ONLY DE-ENERGIZE THE
TRANSFORMER ON THE SDC FROM WHICH THE EFD WAS REMOVED.
DO NOT APPLY PRIMARY POWER TO THE SDC UNTIL ALL POST-INSTALLATION
CHECKS HAVE BEEN SATISFACTORILY COMPLETED.
BE SURE TO OBSERVE COLOR-CODING PER TABLE 4.14.2-1 FOR CORRECT
PHASE ROTATION IN ALL PRIMARY CABLE INSTALLATIONS.
FAILURE TO COMPLETE THESE CHECKS MAY RESULT IN DANGER TO
OPERATING PERSONNEL AND/OR SERIOUS DAMAGE TO THE EQUIPMENT.
MAY 17, 2002
SDC 8/60 4/100 COMM
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WARNING
MAIN CIRCUIT BREAKER AND MISSION ESSENTIAL BREAKERS HAVE AN
INTERLOCKING DEVICE TO PREVENT BOTH BREAKERS BEING ENERGIZED
SIMULTANEOUSLY.
ENSURE INTERLOCKING DEVICE IS FUNCTIONAL TO
PREVENT POSSIBLE BACKFEED CONDITION.
WARNING
ENSURE BOTH PRIMARY AND MISSION ESSENTIAL POWER SOURCES ARE
DISCONNECTED BEFORE ATTEMPTING TO REPAIR, REMOVE, OR REPLACE ANY
ELECTRICAL COMPONENTS.
FAILURE TO DISCONNECT MAY RESULT IN
PERSONAL INJURY, DEATH OR DAMAGE TO EQUIPMENT.
WARNING
GROUND PRIMARY AND SECONDARY TERMINALS PRIOR TO HANDLING.
FAILURE TO GROUND SECONDARY WINDINGS MAY RESULT IN PERSONAL
INJURY, DEATH OR DAMAGE TO EQUIPMENT.
WARNING
LOCK HIGH VOLTAGE COMPARTMENT DOORS. ANY ELECTRICAL SOURCE
APPLIED TO SECONDARY TERMINALS WILL MULTIPLY THAT VOLTAGE BY 20
TIMES ON THE HIGH VOLTAGE TERMINALS.
WARNING
ONLY QUALIFIED PERSONNEL SHOULD BE INVOLVED IN THE TRANSFORMER
TESTING TO AVOID POSSIBLE MISAPPLICATION OF TEST THAT CAN RESULT IN
PERSONAL INJURY.
YOU MUST FOLLOW THE TEST EQUIPMENT
MANUFACTURERS PROCEDURES FOR THE FOLLOWING TESTS. THE LISTED
PROCEDURES ARE FOR EXAMPLE ONLY.
WARNING
TRANSFORMER IS HEAVY. LIFTING DEVICE CAPABLE OF LIFTING 1500 POUNDS
IS REQUIRED.
MAY 17, 2002
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WARNING
SOLVENTS USED TO CLEAN CAN BE FLAMMABLE AND THEIR VAPORS CAN BE
EXPLOSIVE. REPEATED OR PROLONGED SKIN CONTACT OR INHALATION OF
VAPORS CAN BE TOXIC. USE A WELL-VENTILATED AREA, WEAR RUBBER
GLOVES, AND KEEP AWAY FROM SPARKS OR FLAME.
PAINTS ARE
FLAMMABLE AND PROLONGED BREATHING OF VAPORS CAN BE HARMFUL.
USE IN WELL-VENTILATED AREA. DO NOT USE NEAR HEAT SOURCE OR OPEN
FLAME.
WARNING
SOLVENTS USED TO REMOVE GASKETS AND INSULATION CAN BE
FLAMMABLE, AND THEIR VAPORS CAN BE EXPLOSIVE.
REPEATED OR
PROLONGED SKIN CONTACT OR INHALATION OF VAPORS CAN BE TOXIC. USE
A WELL-VENTILATED AREA, WEAR GLOVES, AND KEEP AWAY FROM SPARKS
OR FLAME.
CAUTION
PERSONNEL ASSIGNED TO DEPLOY, OPERATE, STRIKE, OR PERFORM
MAINTENANCE ON ELECTRICAL EQUIPMENT SHALL BE FAMILIAR WITH THE
ELECTRICAL EQUIPMENT, THE SYSTEM, AND FIRST AID PROCEDURES.
CAUTION
BE SURE ADEQUATE FIRE FIGHTING DEVICES AND FIRST AID EQUIPMENT ARE
AVAILABLE AND PROPERLY MAINTAINED.
PERSONNEL SHOULD BE
PROFICIENT IN FIRST AID INCLUDING APPROVED ARTIFICIAL RESPIRATION
TECHNIQUES.
CAUTION
USE CARE IN HANDLING TO AVOID DAMAGE TO THE SDC. IF AN OVERHEAD
LIFTING DEVICE MUST BE USED, USE AN APPROPRIATE SLING SO THAT THE
WEIGHT OF THE UNIT IS BORNE BY THE LIFTING RINGS. SO THAT THE UNIT IS
PROTECTED, IT SHOULD BE LEFT CRATED UNTIL MOVED TO THE LOCATION
WHERE IT IS TO BE INSTALLED.
CAUTION
DO NOT REMOVE TAGS, IF INSTALLED, FROM THE EQUIPMENT UNTIL THEIR
INSTRUCTIONS HAVE BEEN FOLLOWED.
FAILURE TO FOLLOW THESE
INSTRUCTIONS CAN RESULT IN SERIOUS DAMAGE TO THE EQUIPMENT.
MAY 17, 2002
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CAUTION
FORKLIFT FROM EITHER SIDE TO PREVENT DAMAGE. DO NOT FORKLIFT FROM
EITHER THE HIGH VOLTAGE OR LOW VOLTAGE COMPARTMENT ENDS.
CAUTION
ENSURE THAT THE REPLACEMENT LOADBREAK ELBOW. IS CORRECT FOR THE
CABLE SIZE. CABLES ARE MARKED APPROXIMATELY EVERY 6 FEET WITH
CONDUCTOR SIZE. YOU MUST USE THE MANUFACTURERS INSTRUCTIONS
PROVIDED WITH THE LOADBREAK ELBOWS. FAILURE TO DO SO COULD
RESULT IN A DEFECTIVE CONNECTION WITH THE PRIMARY CABLE.
MAY 17, 2002
SDC 8/60 4/100 COMM
USA TM 9-6115-485-14&P
COMMERCIAL TECHNICAL MANUAL (CTM) 01646.1R0256
SECONDARY DISTRIBUTION CENTER (SDC) 150kVA
Commercial Connectors
This manual has been prepared in accordance with the requirements of Contract
FO08626-97-C-0236, Deployable Power Generation and Distribution System
(DPGDS).
The following data rights are specified in accordance with Defense Federal
Acquisition Regulation Supplement (DFARS), paragraph 227-7102.
This
Commercial Technical Manual (CTM) is copyrighted by Radian Inc. in accordance
with DFARS paragraphs 227-7103, 7105, and 7106. Due to this copyright as well
as the use of proprietary data and procedures, Radian Inc. proposes Government
Purpose License Rights (GPLR) only.
MAY 17, 2002
SDC 8/60 4/100 COMM
USA TM 9-6115-485-14&P
CHANGE RECORD
REVISION
TITLE
DATE
Date of Issue
MAY 17, 2002
5/17/02
SDC 8/60 4/100 COMM
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THIS PAGE IS INTENTIONALLY BLANK
MAY 17, 2002
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TABLE OF CONTENTS
SECTION
TITLE
PAGE
COVER SHEET1
SAFETY PRECAUTIONS
COMMERCIAL TECHNICAL MANUAL (CTM) 01646.1R0256
CHANGE RECORD
TABLE OF CONTENTS
11
LIST OF APPENDICES
15
LIST OF TABLES
16
LIST OF FIGURES
19
CHAPTER 1.0 INTRODUCTION
21
1.1
SCOPE
21
1.2
REPORTING MANUAL/EQUIPMENT IMPROVEMENT RECOMMENDATIONS
21
1.3
ACRONYMS/ABBREVIATIONS
21
1.4
CONFIGURATION MANAGEMENT
22
1.5
EQUIPMENT DESCRIPTION AND DATA
22
1.5.1
PURPOSE, CAPABILITIES AND FEATURES
22
1.5.2
LOCATION OF MAJOR COMPONENTS
22
1.5.3
SDC DIMENSIONS, WEIGHTS AND POWER REQUIREMENTS
26
1.6
PRINCIPLES OF OPERATION
29
1.6.1
GENERAL DESCRIPTION
29
1.6.2
SDC INPUTS
29
1.6.3
SDC OUTPUTS
30
1.7
MODES OF OPERATION
32
CHAPTER 2.0 ASSEMBLY AND INSTALLATION
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11
33
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2.1
UNLOADING AND INSPECTION UPON RECEIPT
33
2.2
SITE PREPARATION
34
2.3
GROUND ROD INSTALLATION
34
2.4
CONNECTING CABLES TO SDC
36
2.4.1
HIGH VOLTAGE SIDE
36
2.5
INTERCONNECTING SDCS
38
2.5.1
HIGH VOLTAGE SIDE
38
2.5.2
LOW VOLTAGE SIDE
39
2.6
MISSION ESSENTIAL POWER CONNECTIONS
39
2.7
POST-INSTALLATION CHECKS
41
2.8
PRE-ENERGIZATION CHECKS
41
2.8.1
PRIMARY POWER MODE CHECKS
41
2.8.2
MISSION ESSENTIAL MODE CHECKS
42
2.9
PREPARATION FOR MOVEMENT
43
2.10
STORAGE
44
2.10.1
SHORT TERM STORAGE
44
2.10.2
LONG TERM STORAGE
44
2.11
SHIPPING
44
2.11.1
AIR TRANSPORT
44
2.11.2
GROUND TRANSPORT
44
CHAPTER 3.0 OPERATIONS
45
3.1
OPERATORS CONTROLS AND INDICATORS
45
3.2
OPERATIONAL CHECKS AND PROCEDURES
45
3.3
MISSION ESSENTIAL POWER MODE
48
3.3.1
GENERAL
48
3.3.2
MEP MODE SHUTDOWN
49
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3.4
OPERATING IN EMERGENCY CONDITIONS
49
3.5
OPERATING IN UNUSUAL CLIMATIC CONDITIONS
49
CHAPTER 4.0 MAINTENANCE
51
4.1
PARTS
51
4.2
COMMON TOOLS
51
4.3
SPECIAL TOOLS
51
4.4
LUBRICATION
51
4.5
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
51
4.6
TROUBLESHOOTING PROCEDURES
56
4.7
GENERAL WIRE AND CABLE REPAIR
59
4.8
GENERAL ENCLOSURE REPAIR
60
4.8.1
TASK REQUIREMENTS
60
4.8.2
TASK ACTIVITIES
60
4.9
AIR FILTERS
62
4.9.1
TASK REQUIREMENTS
62
4.9.2
TASK ACTIVITIES
62
4.10
GASKETS, INSULATION, AND INFORMATION PLATES
63
4.10.1
TASK REQUIREMENTS
63
4.10.2
TASK ACTIVITIES
64
4.11
CIRCUIT BREAKERS
66
4.11.1
TASK REQUIREMENTS
66
4.11.2
TASK ACTIVITIES
66
4.12
FUSES
68
4.12.1
LOW VOLTAGE FUSES
68
4.12.1.1
TASK REQUIREMENTS
68
4.12.1.2
TASK ACTIVITIES
68
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4.12.2
HIGH VOLTAGE FUSES
69
4.12.2.1
TASK REQUIREMENTS
69
4.12.2.2
TASK ACTIVITIES
70
4.13
INDICATOR LIGHTS
71
4.13.1
TASK REQUIREMENTS
71
4.13.2
TASK ACTIVITIES
71
4.14
LOADBREAK ELBOWS
72
4.14.1
TASK REQUIREMENTS
72
4.14.2
TASK ACTIVITIES
72
4.15
TRANSFORMER
74
4.15.1
TASK REQUIREMENTS
74
4.15.2
TASK ACTIVITIES
76
4.15.2.1
TRANSFORMER VISUAL AND MECHANICAL INSPECTION
76
4.15.2.2
TRANSFORMER TAP CONNECTIONS
77
4.15.2.3
TRANSFORMER TESTS
79
4.15.2.3.1
INSULATION RESISTANCE TESTING
79
4.15.2.3.2
TRANSFORMER TURNS RATIO (TTR) TEST
83
4.15.3
REMOVAL/REPLACEMENT
85
4.16
CONNECTORS
86
4.16.1
TASK REQUIREMENTS
86
4.16.2
TASK ACTIVITIES
87
A.1
PARTS
89
A.2
OTHER SDC ITEMS
102
B.1
SUPPLIES AND MATERIALS
103
B.2
SPECIAL TOOLS LIST
104
C.1
SCHEMATIC DIAGRAM
107
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LIST OF APPENDICES
APPENDIX
TITLE
APPENDIX A
SECONDARY DISTRIBUTION CENTER (SDC) COMPONENTS/PARTS LIST
89
A.1
PARTS
89
A.2
OTHER SDC ITEMS
102
APPENDIX B
EXPENDABLE SUPPLIES, MATERIALS, AND SPECIAL TOOLS LIST
101
B.1
103
B.2
SPECIAL TOOLS LIST
104
APPENDIX C
SCHEMATIC DIAGRAM
107
C.1
SCHEMATIC DIAGRAM
109
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LIST OF TABLES
TABLE
TITLE
TABLE 1.5.3-1
SDC GENERAL EQUIPMENT DATA
26
TABLE 1.5.3-2
SDC POWER REQUIREMENTS
26
TABLE 1.5.3-3
SDC CIRCUIT BREAKER CHARACTERISTICS
27
TABLE 1.5.3-4
SDC TRANSFORMER CHARACTERISTICS
28
TABLE 1.6.3-1
SDC CONNECTIONS
31
TABLE 1.7-1
SDC OPERATING MODES AND OPERATING CONDITIONS
32
TABLE 2.1-1
SDC UNLOADING/INSPECTION
33
TABLE 2.3-1
GROUND ROD INSTALLATION PROCEDURES
35
TABLE 2.4.1-1
HIGH VOLTAGE SIDE CONNECTIONS
36
TABLE 2.4.1-1
HIGH VOLTAGE SIDE CONNECTIONS (CONT)
37
TABLE 2.5.1-1
INTERCONNECTING SDCS - HIGH VOLTAGE SIDE CONNECTIONS
38
TABLE 2.5.1-1
INTERCONNECTING SDCS - HIGH VOLTAGE SIDE CONNECTIONS (CONT)

39
TABLE 2.5.2-1
CONNECTING OUTPUT CABLES TO SDC - LOW VOLTAGE SIDE

CONNECTIONS
39
TABLE 2.6-1
COLOR CODES FOR MEP AUXILIARY CABLES
39
TABLE 2.6-2
40
TABLE 2.8.1-1
41
TABLE 2.8.2-1
42
TABLE 2.9-1
PROCEDURES FOR PREPARING THE SDC FOR MOVEMENT
43
TABLE 3.1-1
SDC MAJOR COMPONENTS DESCRIPTIONS
46
TABLE 3.2-1
SDC INITIAL OPERATIONAL CHECKS
47
TABLE 3.3.1-1
MEP MODE OPERATIONAL CHECKS
48
TABLE 3.3.2-1
MEP MODE SHUTDOWN ACTIONS
49
TABLE 3.4-1
49
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TABLE 4.5-1
SDC PREVENTIVE MAINTENANCE CHECKS AND SERVICES
52
TABLE 4.5-1
SDC PREVENTIVE MAINTENANCE CHECKS AND SERVICES (CONT)
53
TABLE 4.5-1
54
TABLE 4.5-1
55
TABLE 4.6-1
MALFUNCTIONS AND TROUBLESHOOTING PROCEDURES
56
TABLE 4.6-1
MALFUNCTIONS AND TROUBLESHOOTING PROCEDURES (CONT)
57
TABLE 4.6-1
58
TABLE 4.7-1
GENERAL WIRE AND CABLE REPAIR ACTIONS
59
TABLE 4.8-1
GENERAL ENCLOSURE REPAIR TASK REQUIREMENTS
60
TABLE 4.8.2-1
GENERAL ENCLOSURE REPAIR TASKS
61
TABLE 4.9.1-1
AIR FILTER TASK REQUIREMENTS
62
TABLE 4.9.2-1
AIR FILTER REPAIR TASKS
63
TABLE 4.10.1-1
GASKET, INSULATION, AND INFORMATION PLATES TASK

REQUIREMENTS
63
TABLE 4.10.2-1
GASKETS, INSULATION AND INFORMATION PLATES REPAIR TASKS 65
TABLE 4.11.1-1
CIRCUIT BREAKERS TASK REQUIREMENTS
66
TABLE 4.11.2-1
CIRCUIT BREAKERS REPAIR TASKS
67
TABLE 4.12.1.1-1
LOW VOLTAGE FUSE TASK REQUIREMENTS
68
TABLE 4.12.1.2-1
LOW VOLTAGE FUSE REPAIR TASKS
68
TABLE 4.12.2.1-1
HIGH VOLTAGE FUSE TASK REQUIREMENTS
69
TABLE 4.12.2.2-1
HIGH VOLTAGE FUSE REPAIR TASKS
70
TABLE 4.12.2.2-1
HIGH VOLTAGE FUSE REPAIR TASKS (CONT)
71
TABLE 4.13.1-1
INDICATOR LIGHT TASK REQUIREMENTS
71
TABLE 4.13.2-1
INDICATOR LIGHT REPAIR TASKS
71
TABLE 4.14.1-1
LOADBREAK ELBOW TASK REQUIREMENTS
72
TABLE 4.14.2-1
LOADBREAK ELBOW REPAIR TASKS
73
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TABLE 4.14.2-2
COLOR CODES FOR PRIMARY POWER CABLES
74
TABLE 4.14.2-3
INSPECT PRIMARY POWER CABLES
74
TABLE 4.15.1-1
TRANSFORMER TASK REQUIREMENTS
74
TABLE 4.15.2.1-1
TRANSFORMER VISUAL AND MECHANICAL INSPECTION TASKS
76
TABLE 4.15.2.3.1-1
SET-UP PROCEDURES FOR TRANSFORMER TESTING
80
TABLE 4.15.2.3.1-2
PROCEDURES FOR TRANSFORMER INSULATION RESISTANCE TESTING

82
TABLE 4.15.2.3.1-3
INSULATION RESISTANCE CONVERSION FACTORS
83
TABLE 4.15.3-1
TRANSFORMER REMOVAL/REPLACEMENT PROCEDURES
85
TABLE 4.16.1-1
CONNECTOR TASK REQUIREMENTS
86
TABLE 4.16.2-1
SDC CONNECTOR INSPECTION AND REPAIR TAS
87
TABLE 4.16.2-1
SDC CONNECTOR INSPECTION AND REPAIR TASKS (CONT)
88
TABLE A.1-1
SECONDARY DISTRIBUTION CENTER (SDC) PARTS
89
TABLE A.1-1
SECONDARY DISTRIBUTION CENTER (SDC) PARTS (CONT)
90
TABLE A.1-1
91
TABLE A.1-1
92
TABLE A.1-1
93
TABLE A.1-1
94
TABLE A.2-1
OTHER SDC ITEMS
102
TABLE B.1-1
EXPENDABLE SUPPLIES AND MATERIALS LIST
103
TABLE B.2-1
SPECIAL TOOLS LIST
104
TABLE B.2-2
CRIMPING TOOL AND DIE PART NUMBERS
105
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LIST OF FIGURES
TABLE
TITLE
FIGURE 1.5.2-1
HIGH VOLTAGE (LINE SIDE) COMPARTMENT
23
FIGURE 1.5.2-2
SDC SIDE VIEW (SIDE PANEL NOT SHOWN)
24
FIGURE 1.5.2-3
LOW VOLTAGE (LOAD SIDE) COMPARTMENT
25
FIGURE 1.6.2-1
SDC INPUTS
30
FIGURE 2.3-1
GROUND ROD STORAGE
34
FIGURE 2.3-2
GROUND ROD ASSEMBLY
35
FIGURE 2.4.1-1
FUSIBLE (EFD) AND NON-FUSIBLE DISCONNECTS
37
FIGURE 2.4.1-2
SCHEMATIC OF FUSIBLE AND NON-FUSIBLE DISCONNECT SWITCHES

38
FIGURE 2.6-1
AUXILIARY CABLE FOR OTHER THAN TQG POWER SOURCE
40
FIGURE 2.11.2-1
SDC TIE DOWNS, LIFTING POINTS, AND FORKLIFT CHANNELS
44
FIGURE 3.1-1
SDC INDICATOR LIGHTS, TOGGLE SWITCH AND CIRCUIT BREAKERS 45
FIGURE 4.9.2-1
SDC AIR FILTER LOCATIONS
62
FIGURE 4.10.2-1
SDC PLATE LOCATIONS
64
FIGURE 4.11.2-1
SDC CIRCUIT BREAKER LOCATIONS
66
FIGURE 4.12.1.2-1
SDC LOW VOLTAGE FUSES AND INDICATOR LIGHTS
69
FIGURE 4.14.2-1
PARKING STAND AND CABLE FEED THROUGH POINTS
72
FIGURE 4.15.1-1
SDC TRANSFORMER SIDE VIEW
75
FIGURE 4.15.2.2-1
77
FIGURE 4.15.2.2-2
4056 V TAP CONNECTION
77
FIGURE 4.15.2.2-3
78
FIGURE 4.15.2.2-4
78
FIGURE 4.15.2.3.1-1
INSULATION RESISTANCE TESTING, HIGH TO LOW AND GROUND
81
FIGURE 4.16.1-1
SDC CONNECTOR POSITIONS
86
FIGURE 4.16.1-2
SDC CONNECTOR PIN ASSIGNMENTS
88
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FIGURE A.1-1A
SDC LOW VOLTAGE
95
FIGURE A.1-1B
SDC LOW VOLTAGE
96
FIGURE A.1-2
SDC HIGH VOLTAGE (HV) VIEW
97
FIGURE A.1-3
SDC PLAN VIEW
98
FIGURE A.1-4
END SECTION VIEW
99
FIGURE A.1-5A
SDC LOW VOLTAGE LABELS
100
FIGURE A.1-5B
SDC HIGH VOLTAGE LABELS
101
FIGURE C.1-1
SDC SCHEMATIC DIAGRAM
109
MAY 17, 2002
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CHAPTER 1
1.0
INTRODUCTION
1.1
SCOPE
This manual is a Commercial Technical Manual (CTM) for the operation and maintenance of the 150kVA
Secondary Distribution Center (SDC), Radian Part Number 1R0256, for the Deployable Power
Generation and Distribution System (DPGDS). The SDC features 8 each 60 Ampere and 4 each 100
Ampere Commercial Connectors.
The SDC transforms three-phase primary power, 3800/4160VAC, 50/60Hz to 120/208VAC power for
distribution throughout the secondary power system.
1.2
REPORTING MANUAL/EQUIPMENT IMPROVEMENT RECOMMENDATIONS
If you find any mistakes in the manual, know a way to improve the procedures, or have suggestions that
will improve the equipment, please let us know. Write a letter and mail it to; Radian Inc., Attn.: Power
Generation Program Manager, 5845 Richmond Highway, Alexandria, VA 22303-1865.
1.3
ACRONYMS/ABBREVIATIONS
The following is a list of acronyms of components, terms, and organizations associated with the SDC:
A
AWG
C
CTM
DLRO
DPGDS
EFD
EA
F
FCAN
FCBN
GFCI
G
HV
Hz
IAW
IEC
Ampere
American Wire Gauge
Centigrade
Commercial Technical Manual
Digital Low Resistance Ohmmeter
Deployable Power Generation and
Distribution System
Electric Fusible Disconnect
Each
Fahrenheit
Full Capacity Above Normal
Full Capacity Below Normal
Ground Fault Circuit Interrupter
Ground
High Voltage
Hertz
In Accordance With
International Electrical Code
MAY 17, 2002
IEEE
IN
LB
LV
kV
kVA
MEP
N
NEC
NEMA
Ph
SDC
SW
TTR
TQG
VAC
21
Institute of Electrical & Electronic

Engineers
Inch
Pounds
Low Voltage
kilovolts
kilovolt Amperes
Mission Essential Power
Neutral
National Electric Code
National Electrical Manufacturers
Association
Phase
Secondary Distribution Center
Switch
Transformer Turns Ratio
Tactical Quiet Generator
Volts Alternating Current
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1.4
CONFIGURATION MANAGEMENT
Radian Inc. provides configuration management for both the Secondary Distribution Center (SDC)
equipment as well as its technical documentation. Accordingly, change pages and change record
advisories regarding changes to the equipment and technical documentation will be developed and
implemented. Serial number effectively will be stated for all changes/revisions.
1.5
EQUIPMENT DESCRIPTION AND DATA
1.5.1
PURPOSE, CAPABILITIES AND FEATURES
The function of the Secondary Distribution Center (SDC) is to accept primary power and reduce the
voltage for distribution. Primary power can be either from a commercial power plant, diesel engine driven
prime power generator sets, or from another SDC.
The SDC is designed to accept primary power at 4160VAC, 60Hz, or 3800VAC, 50Hz, 3-phase from any
source utilizing Loadbreak Elbows and reduce the voltage (by a 150kVA transformer) to 120/208VAC,
60or 50Hz, 3-phase for distribution.
The SDC is used to provide power for equipment requiring 120/208VAC electrical power. The SDC is
also equipped with two (2) additional sets of Medium Voltage Output Loadbreak Elbow connections
(bushing wells). These connections are used for parallel operations with additional SDCs, forming a
common bus.
The SDC can also accept secondary power from an emergency power generator; called a Mission
Essential Power (MEP) generator set. MEP generators feed through a circuit breaker to the secondary
bus. The breaker is interlocked to prevent inadvertently feeding the secondary bus from two power
sources.
Electrical power distribution consists of circuit breakers feeding pin and sleeve type connectors which
permit connecting the secondary cable feeders which in turn feed out to the load centers. The pin and
sleeve connectors are designed to meet IEC 6039-1 and IEC 60309-2309-2 specifications. The
arrangement of pins, sleeves, and keys in these connectors is such that the device cannot be mated with
an IEC device of a different voltage, current, or system rating.
The equipment is designed for safe operation and it conforms to the National Electric Code (NEC) for
outdoor use. The phase rotation is A, B, C for the Secondary Output Circuit. See Appendix C for a
schematic diagram of the SDC electrical system.
See Appendix A for listing of components supplied with the SDC. Auxiliary cable assemblies, primary
cables, secondary cables, and Loadbreak elbows, are not supplied with the SDC.
1.5.2
LOCATION OF MAJOR COMPONENTS
The major components of the Secondary Distribution Center (SDC) are illustrated in Figures 1.5.2-1,
1.5.2-2, and 1.5.2-3. These Figures present both internal and external components as well as both high
and low voltage sides of the SDC.
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1
2
3
POWER INPUT, 4160 VAC, 200 AMP,

LOADBREAK ELBOW
CONNECTIONS. (PHASES A, B, C)
PARKING STAND BRACKETS
FUSIBLE AND NON-FUSIBLE
DISCONNECTS
FIGURE 1.5.2-1
4
5
6
POWER OUTPUT, 4160 VAC, 200 AMP,

LOADBREAK ELBOW CONNECTIONS.
(PHASES A, B, C)
GROUND BUS BAR
CABLE FEED THROUGH POINTS
HIGH VOLTAGE (LINE SIDE) COMPARTMENT

(DOORS NOT SHOWN)
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LIFTING
RINGS
(4 PLACES)
TIE DOWN
(4 PLACES
FIGURE 1.5.2-2
MAY 17, 2002
FUSIBLE AND NON-FUSIBLE

DISCONNECTS
LOADBREAK ELBOW
FOR INPUT POWER
(NOT PART OF SDC)
FORKLIFT PROVISIONS
TRANSFORMER
SDC SIDE VIEW (SIDE PANEL NOT SHOWN)
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1
2
3
4
5
60A OUTPUT RECEPTACLES (8 PLACES)

CIRCUIT BREAKER PANEL
GFCI OUTPUT CIRCUIT BREAKERS (2 PLACES)
OUTPUT CIRCUIT BREAKERS (12 PLACES)
INTERLOCK BAR
FIGURE 1.5.2-3
6
7
8
9
10
MAIN CIRCUIT BREAKER

200A INPUT RECEPTACLE (MEP INPUT)
100A OUTPUT RECEPTACLES (4 PLACES)
120-VOLT OUTPUT CONVENIENCE RECEPTACLES
MISSION ESSENTIAL POWER (MEP) CIRCUIT BREAKER
LOW VOLTAGE (LOAD SIDE) COMPARTMENT

(DOOR NOT SHOWN)
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1.5.3
SDC DIMENSIONS, WEIGHTS AND POWER REQUIREMENTS
Table 1.5.3-1 presents SDC general equipment information.

TABLE 1.5.3-1
SDC GENERAL EQUIPMENT DATA

MANUFACTURER
Part number
RADIAN, INC.
1R0256
Operating Temperature range
-25 F to +125 F
Storage Temperature range
-65 F to +150 F
Weight
2,070LB
Overall Length
60.56 IN
Overall Width
47.63 IN
Overall Height
71.88 IN (76.16 with lifting rings)
Table 1.5.3-2 presents the SDC power requirements.

TABLE 1.5.3-2
INPUT
OUTPUT
SDC POWER REQUIREMENTS
Voltage/Phase/Hertz
4160VAC/3-Phase/60Hz or 3800VAC/3-Phase/50Hz
Mission Essential Power
208VAC/3-Phase/60Hz
Voltage/Phase/Hertz
120/208VAC/3-Phase/60or 50Hz 3-wire or

120/208VAC/3-Phase/60 or 50Hz 4-wire
Total Power Rating
150kVA
Current
416A
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Table 1.5.3-3 presents SDC circuit breaker characteristics.
TABLE 1.5.3-3
SDC CIRCUIT BREAKER CHARACTERISTICS
INPUT CIRCUIT
BREAKERS
Main (1 EA) magnetic trip - 600A, 600VAC

Mission Essential (1 EA) magnetic trip - 250A, 600VAC
OUTPUT
J1 and J2 (GFCI) (2 EA) - 20A, 120VAC
CIRCUIT
J3 through J10 (8 EA) - 60A, 208VAC
BREAKERS
J11 through J14 (4 EA - 100A, 208VAC
INPUT
CONNECTORS
Bushing wells
OUTPUT
CONNECTORS
Loadbreak receptacles (3 EA) - 200A IAW IEEE Standards 386-1995

Bushing wells
Loadbreak receptacles (6 EA) - 200A IAW IEEE Standards 386-1995
J1 and J2 (2 EA) - 15A (Convenience Receptacles)
Voltage - 125VAC 50/60Hz
RECEPTACLES
Phase - Single
Type - NEMA 5-15
J3 through J10 (8 EA) - 60A, IEC 309-1 and 309-2
J11 through J14 (4 EA) - 100A, IEC 309-1and 309-2
200A (1 each)
MEP
Voltage - 120/208VAC 50/60Hz

Phase - 3
Configuration - 5-wire, with coupling nut
Class - L type
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Table 1.5.3-4 presents SDC transformer characteristics.
TABLE 1.5.3-4
SDC TRANSFORMER CHARACTERISTICS
CHARACTERISTIC
VALUE
Size
150kVA
Type
Dry
Class
AA
Weight
1128 pounds
Insulation Cooling
Self Cooling
Temperature Rise
150 C maximum above ambient
Design Impedance
6.5%
Voltage (Nominal Rating)

Current
Primary - 4160VAC/3800 +/- 5%

Secondary - 120/208VAC
Primary (full load) - 20.8A at 4160VAC
Secondary (full load) - 416.3A at 208VAC
Frequency
50/60Hz
Duty
Continuous
Taps (Primary)
(2) 2.5 % FCAN (4) 2.5% FCBN
High Voltage Tap Connects
See paragraph 4.15.2.2
Losses (170 C)
4760 watts maximum
Polarity
Additive
Efficiency at 100 % load
(120 C) 97.27%
Nameplate Voltage Ratio
4160/3800VAC + to 120/208VAC Y
Insulation
Class R, 220 C
Thermostat
200C with normally open contacts in each coil
Hi Pot Test (100% tested)
MAY 17, 2002
KV-Low Voltage-Ground - 12 KV
Low voltage-Neutral-Ground - 2.5 KV
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1.6
PRINCIPLES OF OPERATION
1.6.1
GENERAL DESCRIPTION
The function of the SECONDARY DISTRIBUTION CENTER (SDC) is to accept primary power and
reduce the voltage for distribution. Primary power can be either from a commercial power plant, diesel
engine driven prime power generator sets, or from another SDC. The SDC is designed to accept primary
power at 4160VAC, 60Hz, or 3800VAC, 50Hz, 3-phase from any source utilizing Loadbreak Elbows and
reduce the voltage (by a 150kVA transformer) to 120/208VAC, 50/60Hz, 3-phase for distribution. The
SDC is used to provide power for equipment such as airfield lighting, shelters, hangers, remote area
lighting systems and other related equipment requiring 120/208VAC electrical power.
The SDC is used to provide power for equipment requiring 120/208VAC electrical power. The SDC is
also equipped with two (2) additional sets of Medium Voltage Output Loadbreak Elbow connections
(bushing wells). These connections are used for parallel operations with additional SDCs, forming a
common bus.
In the event of loss of 4160 or 3800 volts primary power, the SDC can accept secondary power from an
emergency power generator; called a Mission Essential Power (MEP) generator set. MEP generators
feed through a circuit breaker to the secondary bus. The breaker is interlocked to prevent inadvertently
feeding the secondary bus from two power sources.
Electrical power distribution consists of circuit breakers feeding pin and sleeve type connectors which
permit connecting the secondary cable feeders which in turn feed out to the load centers. The pin and
sleeve connectors are designed to meet IEC 6039-1 and IEC 60309-2309-2 specifications. The
arrangement of pins, sleeves, and keys in these connectors is such that the device cannot be mated with
an IEC device of a different voltage and current.
The equipment is designed for safe operation and it conforms to the National Electric Code (NEC) for
outdoor use. The phase rotation is A, B, C. See Appendix C for a schematic diagram of the SDC
electrical system.
1.6.2
SDC INPUTS
Figure 1.6.2-1 illustrates the sources of input power to the SDC. Primary power (4160VAC, 60Hz, or
3800VAC, 50Hz, 3-phase, 3 wire) is supplied to the SDC via three primary cables. A primary power
connection is accomplished with three Loadbreak elbow connectors and the SDCs bushing wells. The
bushing wells then feed to the primary bus in the high voltage compartment. For protection of the
transformer, primary power goes through fuses (EFD) between the bushing wells and the transformer.
Taps are provided on the transformer primary windings for accepting a range of primary voltages and
converting to 120/208VAC.
In the event of loss of primary power, the SDC will also accept secondary power (Mission Essential
Power (MEP) from an auxiliary generator set, (such as the Tactical Quiet Generator (TQG)) at
120/208VAC, 60Hz, 3-phase. MEP power, in lieu of high voltage power, is fed into the SDC through a
circuit
breaker.
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PRIME
POWER
SOURCE
PRIMARY POWER CABLES

(3 INDIVIDUAL CABLES,
ONE PER PHASE
SECONDARY
DISTRIBUTION
CENTER
(SDC)
SECONDARY
DISTRIBUTION
CENTER
(SDC)
PRIMARY POWER CABLES

(INDIVIDUAL CABLES,
ONE PER PHASE PER SDC)
AUXILIARY CABLE
ASSEMBLY
FIGURE 1.6.2-1
1.6.3
MISSION
ESSENTIAL
POWER
(MEP)
SDC INPUTS
SDC OUTPUTS
SDC output connections are shown in Table 1.6.3-1 and illustrated in Figure 1.6.3-1.
Each SDC has 2 high voltage and 14 low voltage output circuits. There are two sets of Loadbreak elbow
connections for feed through capabilities to additional SDCs. A maximum of five SDCs can be supported
from point of origin (power source).
Two 15A, 120VAC, single-phase, 50/60Hz, NEMA 5-15, GFCI-protected convenience receptacles (J1
and J2) are provided for general use.
Eight (8) 60A magnetic-only circuit breakers to eight (8) 60A IEC output receptacles (J3 through J10); and
Four (4) 100A magnetic-only circuit breakers to four (4) 100A IEC, outlet receptacles (j11 through J14)
Low voltage secondary power (120/208VAC) is distributed through five-wire, wye configuration cables;
three wires are for the 3-phases (A, B, & C), with a fourth for neutral, and a ground wire (5-wire system).
Output is through:
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TABLE 1.6.3-1
SDC CONNECTIONS
PARAMETER/CONNECTION
VALUE
SDC Power Rating
150kVA
Number of 100A output receptacles
Number of 60A output receptacles
Number of 20A output convenience receptacles
Number of MEP input connectors
Number of Loadbreak Elbow receptacles
9 (3 of these are for power input to the SDC,

the others are feed through to other SDCs)
PRIME POWER UNIT

3800/4160 VAC, 3 PH 50/60 HZ,
3- WIRE WITH GROUND
OTHER
SDCS
(IF
CONNECTED)
WATER DISTRIBUTION
SECONDARY
DISTRIBUTION
CENTER
(SDC)
REMOTE AREA LIGHTING SYSTEM
SHELTERS
AIR CONDITIONING
MISSION
ESSENTIAL
POWER (MEP)
208 VAC, 3 PH
HEATERS
AIR CONDITIONING
HANGERS
FIGURE 1.6.3-1
MAY 17, 2002
SDC LOW VOLTAGE SYSTEM COMPONENTS AND TYPICAL INTERFACES

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1.7
MODES OF OPERATION
Table 1.7-1 presents the modes of SDC operation and the operating conditions. Appendix C contains
SDC wiring diagrams for complete circuit description.
TABLE 1.7-1
SDC OPERATING MODES AND OPERATING CONDITIONS
OPERATING MODE
Under normal operation
these conditions exist:
SDC EQUIPMENT STATUS/CONDITIONS

The MAIN CIRCUIT BREAKER (3ACB) contacts are closed.
PHASE INDICATOR LIGHTS (1WIL, 2WIL & 3WIL) are illuminated.
The TRANSFORMER HIGH TEMPERATURE LIGHT (4AIL) is not
illuminated.
The transformer winding temperature sensor contacts (49TT) are
open.
The transformer TEMPERATURE OVERRIDE SWITCH (SW) is in the
closed (NORMAL) position.
The MAIN CIRCUIT BREAKER shunt trip coil (52TC) is not energized.
Immediately after the

At least one of the transformer winding temperature sensor contacts is
transformer has overheated,
closed.
these conditions exist:
The MAIN CIRCUIT BREAKER shunt trip coil is energized, tripping the
circuit breaker.
The MAIN CIRCUIT BREAKER contacts open.
PHASE INDICATOR LIGHTS go out.
The TRANSFORMER HIGH TEMPERATURE LIGHT is illuminated.
The transformer HIGH TEMPERATURE OVERRIDE SWITCH is in the
closed (NORMAL) position.
During emergencies
(e.g. battle-short), it may be
necessary to switch the
HIGH TEMPERATURE
OVERRIDE SWITCH to the
OVERRIDE position and
manually reset the MAIN
CIRCUIT BREAKER.
These conditions exist:
The MAIN CIRCUIT BREAKER contacts are closed.

PHASE INDICATOR LIGHTS are illuminated.
The transformer HIGH TEMPERATURE LIGHT remains illuminated.
At least one of the transformer winding temperature sensor contacts is
closed.
The transformer HIGH TEMPERATURE OVERRIDE SWITCH is in the
opened (OVERRIDE) position.
The MAIN CIRCUIT BREAKER shunt trip coil is de-energized so that it
will not re-open the MAIN CIRCUIT BREAKER.
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CHAPTER 2
2.0
ASSEMBLY AND INSTALLATION
2.1
UNLOADING AND INSPECTION UPON RECEIPT
The SDC is designed for shipment and handling with the cabinet in an upright position. The base of the
SDC is constructed as a shipping pallet with provisions for the insertion of the forks on material handling
equipment. Lifting provisions are built into the top (lifting eyes) and bottom (tie downs). Table 2.1-1
identifies the safety precautions and steps required to unload the SDC.
CAUTION
USE CARE IN HANDLING TO AVOID DAMAGE TO THE SDC. IF AN OVERHEAD
LIFTING DEVICE MUST BE USED, USE AN APPROPRIATE SLING SO THAT THE
WEIGHT OF THE UNIT IS BORNE BY THE LIFTING RINGS. SO THAT THE UNIT IS
PROTECTED, IT SHOULD BE LEFT CRATED UNTIL MOVED TO THE LOCATION
WHERE IT IS TO BE INSTALLED.
CAUTION
DO NOT REMOVE TAGS, IF INSTALLED, FROM THE EQUIPMENT UNTIL THEIR
INSTRUCTIONS HAVE BEEN FOLLOWED.
FAILURE TO FOLLOW THESE
INSTRUCTIONS CAN RESULT IN SERIOUS DAMAGE TO THE EQUIPMENT.
TABLE 2.1-1
SDC UNLOADING/INSPECTION
STEP
ACTION
REFERENCE DONE
Remove all blocking and tiedowns that may have been used to secure
the container to the carrier.
Use a forklift truck, overhead hoist, or other suitable material handling

equipment to remove the packaging unit from the carrier (truck, flatbed,
etc.), if applicable.
Inspect the equipment for damage incurred during shipment. If the

equipment has been damaged, report damage on appropriate forms and
promptly notify the carrier for damage claim.
Check the equipment against the Other SDC Items in Appendix A to

see if the shipment is complete.
Report any discrepancies.
If equipment is accepted with discrepancies, repair or correct as

necessary before use.
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2.2
SITE PREPARATION
The following general guidelines for installation site preparation apply:
A relatively level surface capable of bearing the weight of the SDC is required.
The site should be cleared of brush, large rocks and other items, which might interfere with the
operation, maintenance, access to, or stability of the unit.
Ensure area is free from potential floods or washout from rains.
Ensure that there is an unobstructed flow of air to the outside vents to allow cooling of the
transformer. Clear within six feet above and ten feet on the sides of the unit.
Access to all removable outside panels and door openings should be considered.
If possible, make use of terrain features to minimize the heat loads on the SDC by placing the
unit in shady areas.
2.3
GROUND ROD INSTALLATION
One ground rod (in two 4-foot sections) and six feet of #6 AWG, bare, stranded copper wire is shipped
with each SDC. The ground rod is stored in the high voltage compartment door, as indicated in Figure
2.3-1.
GROUND ROD STORAGE

(INSIDE HIGH VOLTAGE
COMPARTMENT DOOR)
FIGURE 2.3-1
MAY 17, 2002
GROUND ROD STORAGE
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Table 2.3-1 provides the procedure for installation of the ground rod.
WARNING
INSTALL GROUND ROD AND WIRE CAREFULLY. FAILURE TO ACHIEVE A GOOD
GROUND CAN RESULT IN LOSS OF LIFE AND MAJOR DAMAGE TO EQUIPMENT.
NOTE
If you repeatedly encounter rock before the ground rod has reached the correct depth,
and the rod cannot be driven further, extract the rod and bury it horizontally (see Step 3).
Or else use plate electrodes one foot square in area, 0.25 inches thick of a ferrous metal,
or 0.06 inches thick of a nonferrous metal buried in a horizontal orientation 18 IN in the
ground.
TABLE 2.3-1
GROUND ROD INSTALLATION PROCEDURES
STEP
ACTION
REFERENCE DONE
Remove ground rod from high voltage compartment door.
Emplace the ground rod on high voltage side of the SDC within 5 feet.
Locate the section that has threads on one end and is pointed on the
other. Attach the other section to the first with a coupling. Drive the
assembly into the ground, pointed end first, until approximately four to
six inches is still above ground. When necessary to bury the ground rod
horizontally, attach wire and clamp before burying it. Bury it below the
frost level or in a trench 18 IN deep, backfill with dirt (no rocks), and
tamp material. If necessary, use water to compact the ground around
the buried rod.
After driving the ground rod into place, attach the copper wire to its
exposed end, and secure the wire with the ground rod clamp provided.
Test the ground rod resistance IAW the instructions in Chapter 10,
Section III of the Facilities Engineering Technical Manual
(Air Force AFJMAN 32-1082 or Army TM5-684).
If the resistance is not within tolerance, drive an additional rod or rods

near the first rod and connect in parallel as necessary to obtain an
acceptable measurement or follow alternative methods of reducing
ground resistance as outlined in Chapter 10-9 of the Facilities
Engineering Technical Manual.
Attach the loose end of the ground wire to the SDC external ground lug.
PO INTED G R O U ND RO D
CO U PLING
Figure 2.3-2
G R O UN D RO D C LAM P
G R O U ND RO D
FIGURE 2.3-2
MAY 17, 2002
GROUND ROD ASSEMBLY
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2.4
CONNECTING CABLES TO SDC
Loadbreak elbows and primary cables are not supplied with the SDC. See paragraph 4.14 for installing
loadbreak elbows on to high voltage cables and connecting to the SDC parking stands.
2.4.1
HIGH VOLTAGE SIDE
Primary power cables are connected to the SDC in accordance with the procedures of Table 2.4.1-1.
WARNING
PULLING THE CENTER EFD WILL NOT DE-ENERGIZE ANY CABLE
DO NOT APPLY PRIMARY POWER TO THE SDC UNTIL ALL POST-INSTALLATION
OPERATING PERSONNEL AND/OR SERIOUS DAMAGE TO THE EQUIPMENT.
TABLE 2.4.1-1
STEP
HIGH VOLTAGE SIDE CONNECTIONS

ACTION
REFERENCE DONE
Remove the center pole of each of the three input EFD units by sliding
them out of the enclosure using a Hot Line Stick and lineman gloves.
Figure 2.4.11
Remove the caps from the three fuse sections by removing the nylon
screws at the top and bottom. Verify fuses are correct per the Parts List.
Verify that all fuses are firmly in place in the fuse clips. Reinstall the fuse
section caps, and install the center pole sections in the EFD units.
Appendix A
Remove (red) loadbreak protective shipping caps on input connectors.

Wipe connectors clean with rag. Save all shipping caps for later use.
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TABLE 2.4.1-1 HIGH VOLTAGE SIDE CONNECTIONS (CONT)
STEP
4
ACTION
REFERENCE DONE
Connect primary power cables to the corresponding input connector for

correct color band/phase as follows:
Table
4.14.2-1
4.1 Lightly coat the bushing well insert and loadbreak elbow with
dielectric silicone grease.
4.2 Using a Hot Line Stick and lineman gloves, carefully remove
loadbreak elbow from the parking stand.
Appendix B
4.3 Position tip of the loadbreak elbow probe into eye of the input
connector (bushing well).
4.4 Turn around so that your back is towards the bushing and loadbreak
elbow, and firmly grasp the Hot Stick with both hands.
4.5 Now, positively shove the loadbreak elbow the rest of the way onto
the bushing, maintaining a firm grasp on the Hot Stick.
4.6 Push again on the loadbreak elbow with the hot stick and then pull
gently to make sure that it is securely seated.
4.7 Repeat (4.1 through 4.6) for the other two phases.
4.8 Cover any exposed, energized bushings with the 15kV protective
covers prior to energizing.
4.9 Connect concentric grounds to the ground bus bar.
PHASE A
(Black)
PHASE B
(Red)
PHASE C
(Blue)
OUTLET 1
TRANSFORMER
OUTLET 2
FIGURE 2.4.1-1
MAY 17, 2002
FUSIBLE (EFD) AND NON-FUSIBLE DISCONNECTS
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UT
TP
OU
2
UT
NP
CI
R
ME
OR
SF
AN
TR
UT
TP
OU
UT
TP
OU
UT
NP
BI
R
ME
OR
SF
AN
TR
UT
TP
OU
2.5
2
UT
TP
OU
UT
NP
AI
ME
OR
SF
AN
TR
1
UT
TP
OU
FIGURE 2.4.1-2
SCHEMATIC OF FUSIBLE AND NON-FUSIBLE DISCONNECT SWITCHES
INTERCONNECTING SDCS
The procedures for interconnecting SDCs are presented in the following Sections.
2.5.1
HIGH VOLTAGE SIDE
Table 2.5.1-1 presents the procedures for interconnecting SDCs from the High Voltage Side.
WARNING
BE SURE ALL POWER IS REMOVED FROM THE CABLES BEFORE ATTEMPTING
TO ATTACH THE LOADBREAK ELBOWS. LETHAL VOLTAGES ARE PRESENT.
DO NOT APPLY PRIMARY POWER TO THE SDC UNTIL ALL POST INSTALLATION
CHECKS HAVE BEEN SATISFACTORILY COMPLETED. FAILURE TO COMPLETE
THESE CHECKS MAY RESULT IN DANGER TO OPERATING PERSONNEL.
TABLE 2.5.1-1
STEP
1
INTERCONNECTING SDCS - HIGH VOLTAGE SIDE CONNECTIONS

ACTION
REFERENCE DONE
For each SDC to be connected, check their respective EFDs:
1.1 Remove the center pole from each of the three EFDs by sliding it out
of the enclosure using a hot line stick and gloves.
Figure
2.4.1-1
1.2 Remove the caps of the three fuse sections by removing the nylon
screws at the top and bottom. Verify that a fuse is firmly in place in
the fuse clips. Verify fuse is correct per Parts List. Reinstall the
fuse section caps; then install center pole sections in the EFD units.
Appendix A
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TABLE 2.5.1-1
INTERCONNECTING SDCS - HIGH VOLTAGE SIDE CONNECTIONS (CONT)
STEP
ACTION
REFERENCE DONE
Connect concentric grounds to the ground bus bar.
Connect primary cables between SDCs on the output connector,

bushing well of the source SDC and the input connector, bushing wells
of the second SDC.
Reinstall the center poles in the EFD compartment.
2.5.2
Figure
1.5.2-1
LOW VOLTAGE SIDE
Table 2.5.2-1 presents the procedures for connecting output cables to the SDC Low Voltage Side.
WARNING
THESE CHECKS MAY RESULT IN DANGER TO OPERATING PERSONNEL.
TABLE 2.5.2-1 CONNECTING OUTPUT CABLES TO SDC - LOW VOLTAGE SIDE CONNECTIONS
STEP
ACTION
Check to see that the circuit breaker is OFF for each output connector.
Twist the outer ring of receptacle caps and remove. Connect the output
cables as required.
Check to see that the circuit breaker is ON for each output connector.
2.6
REFERENCE DONE
Table 2.6-2 presents the procedures for the connection of Mission Essential Power (MEP) power source
producing 120/208VAC, 60Hz. Color coding for cables are provided in Table 2.6.1 and construction is
depicted in Figure 2.6-1.
TABLE 2.6-1
PHASE
COLOR CODES FOR MEP AUXILIARY CABLES

COLOR CODE BAND
(OPTIONAL)
TERMINAL
(J15)
LINE
Black
L1
Red
L2
Blue
L3
Neutral
White
Ground
Green
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TO SDC
CONNECTOR, PLUG
MS90557C52412S
FIGURE 2.6-1
CABLE (5 WIRE), SIZE TO HANDLE MAX.

AMPERAGE OF POWER SOURCE
TO POWER
SOURCE
AUXILIARY CABLE FOR OTHER THAN TQG POWER SOURCE

WARNING
THESE CHECKS MAY RESULT IN DANGER OF OPERATING PERSONNEL.
TABLE 2.6-2
STEP
1

ACTION
REFERENCE DONE
If using a TQG for Mission Essential Power, connect as follows:

1.1 Check to see that the TQG has been modified with a connector kit
(not part of the SDC).
1.2 Ensure TQG is not operating and the J15 Circuit Breaker is in the
OFF position.
1.3 Connect one end of the Auxiliary Power Cable Assembly
(not part of the SDC) to the connector on the TQG generator.
Figure 2.6-1
1.4 Connect the other end of the Auxiliary Power Cable Assembly to
receptacle J15 on the SDC.
2
If using a power source other than a TQG, connect as follows:
2.1 Ensure that the auxiliary power source is not operating

2.2 Check that the SDCs J15 Circuit Breaker is in the OFF position.
2.3 Fabricate an auxiliary cable with an MS90557C52412S connector
that mates with the SDC receptacle J15 in accordance with Figure
2.6-1.
Figure 2.6-1
2.4 Attach the auxiliary cable to the auxiliary power source.

2.5 Check phase rotation to be ABC and again ensure that the auxiliary
power source is not operating.
2.6 Connect the other end to the receptacle, J15, on the SDC.
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2.7
POST-INSTALLATION CHECKS
After completing installation of the SDC, and before energizing the equipment, ensure that the conditions
contained in the following warning are implemented.
WARNING
DO NOT CONNECT THE PRIMARY POWER BEFORE OR DURING THESE CHECKS.
CONNECTING PRIMARY POWER MAY CREATE A HAZARD TO INSPECTING
PERSONNEL.
TO PROTECT PERSONNEL FROM INJURY, BE SURE THAT
MISSION ESSENTIAL POWER IS PROPERLY GROUNDED, IF USED.
2.8
PRE-ENERGIZATION CHECKS
2.8.1
Table 2.8.1-1 presents the checks that must be made before applying primary power to the SDC.
WARNING
IF THE LOADBREAK CONNECTORS OF THE PRIMARY CABLES ARE ON THE
PARKING STANDS, BE SURE THE PRIMARY POWER IS NOT ENERGIZING THE
CABLES BEFORE MAKING THE CONNECTIONS. ENERGIZED PRIMARY POWER
CABLES ARE A LETHAL SHOCK HAZARD.
TABLE 2.8.1-1
STEP

ACTION
REFERENCE DONE
Check that the SDC ground rod is in place and properly connected.
Paragraph 2.3
Check that output connectors to the loads on the SDC are firmly in
place.
Check that all J1 through J14 load circuit breakers are OFF .
Check that the MAIN and J15 Circuit Breakers are both OFF .
Check that the loadbreak elbows are in place in their bushing wells and
15 kV protective covers all unused bushing wells.
Ensure that the primary power cable concentric grounds are all
connected to the ground bus.
Close and lock the high voltage compartment access doors.
Ensure that the HIGH TEMPERATURE OVERRIDE SWITCH is in the

NORMAL position.
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2.8.2
Table 2.8.2-1 presents the checks that must be made before energizing the SDC when it is necessary
that certain equipment be used before primary power is available, or when primary power is missing and
auxiliary power has been connected.
TABLE 2.8.2-1
STEP

ACTION
REFERENCE DONE
Ensure all load circuit breakers are OFF .
Check that the J15 Circuit Breaker is OFF .
Check that the MAIN CIRCUIT BREAKER is OFF .
Ensure that the SDC is properly grounded.
Check that the mission essential power source is properly grounded.
Check that the mission essential power source connector is firmly in

place in the receptacle, J15.
Check that output connectors to the loads on the SDC are firmly in
place in the load receptacles.
Paragraph 2.3
The Secondary Distribution Center (SDC) system is now ready for operations. Chapter 3 of this manual
contains SDC Operating Instructions.
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2.9
PREPARATION FOR MOVEMENT
Table 2.9-1 presents the procedures for preparing the SDC for movement.
WARNING
BE SURE THE PRIMARY POWER IS NOT ENERGIZING THE CABLES BEFORE
DISCONNECTING. ENERGIZED PRIMARY POWER CABLES ARE A LETHAL
SHOCK HAZARD.
TABLE 2.9-1
PROCEDURES FOR PREPARING THE SDC FOR MOVEMENT
STEP
ACTION
DONE
Shut down individual loads by setting the load circuit breakers to OFF .
Set the MAIN CIRCUIT BREAKER and the J15 Circuit Breaker to OFF . Check that the
three PHASE INDICATOR LIGHTS on the SDC are not illuminated.
Open (trip) circuit breaker at primary power source.
Disconnect primary power cables at source.
Unlock high voltage doors on SDC.
If supplied, remove protective caps from parking stands, otherwise clean parking stands
with wiping rag (Appendix B).
Securely fasten a hot line stick to the loadbreak elbow eye.
Without exerting any pulling force, slightly rotate the loadbreak elbow in order to break
surface friction between the loadbreak elbow and the bushing.
Withdraw the loadbreak elbow from the bushing with a fast, firm, straight motion, being
careful not to place the loadbreak elbow near a ground plane. Be careful as loadbreak
elbow may require a strong force then may release suddenly.
10
Place the elbow on the corresponding parking stand.
11
Repeat until all primary power cables are disconnected and on parking stands.
12
Disconnect all concentric grounds.
13
If available, place protective cover on bushing wells.
14
Cover loadbreak elbows to prevent dirt and moisture from entering.
15
Remove all primary cables from enclosure. Be careful not to drop the cable and
damage the porcelain probe tip inside the loadbreak elbow. Carefully package the
loadbreak elbows to prevent damage.
16
If connected, disconnect MEP and screw cap back on connector.
17
Disconnect and cap all output cable (low voltage) connectors.
18
Retrieve ground rod and wire and store in SDC high voltage compartment door.
19
Ensure doors are securely closed and fastened. The SDC is ready for movement.
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2.10
STORAGE
2.10.1
SHORT TERM STORAGE
Short-term storage is storage of less than 180 days. No special handling is required. Placing the SDC in
a dry, covered area minimizes exposure to the elements.
2.10.2
LONG TERM STORAGE
There is no time limit for this type of storage. If possible, locate SDC in a dry, covered area. Wrap the
SDC with protective materials.
2.11
SHIPPING
2.11.1
AIR TRANSPORT
SDCs are air transportable in C-130, C-141, C5A, and C-17A cargo aircraft and do not require a pallet for
transport. The SDC can be placed and tied down on a 463L pallet if required for transport. Individual
units are also capable of being moved by helicopter.
2.11.2
GROUND TRANSPORT
The units are truck and trailer transportable. They are equipped with forklift pockets to accommodate the
tines of a 10,000-pound capacity forklift. Attachment points are provided for towing, tiedown, and lifting
individual units, as show in Figure 2.11.2-1.
CAUTION
FORKLIFT FROM EITHER SIDE TO PREVENT DAMAGE. DO NOT FORKLIFT FROM
EITHER THE HIGH VOLTAGE OR LOW VOLTAGE COMPARTMENT ENDS.
LIFTING RING
10,000 LB RATING
(4 PLACES)
TIE DOWN HOLE

_10,000 LB RATING
(4 PLACES)
FIGURE 2.11.2-1
MAY 17, 2002
FORKLIFT
PROVISIONS
SDC TIE DOWNS, LIFTING POINTS, AND FORKLIFT CHANNELS
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CHAPTER 3
3.0
OPERATIONS
3.1
OPERATORS CONTROLS AND INDICATORS
All controls and indicators are located on the circuit breaker panel in the low voltage compartment. No
controls or indicators are located inside the high voltage compartment.
Figure 3.1-1 illustrates the SDC phase indicator lights, transformer high temperature indicator light and
override toggle switch and output and input circuit breakers.
6 BRANCH CIRCUIT
BREAKER
5 TEMP
OVERRIDE
SWITCH
4 HIGH TEMP LIGHT

3 PH INDICATOR LIGHTS
2 MEP (J15)
CIRCUIT
BREAKER
7 FUSES
1 MAIN CIRCUIT BREAKER

FIGURE 3.1-1
SDC INDICATOR LIGHTS, TOGGLE SWITCH AND CIRCUIT BREAKERS
Table 3.1-1 identifies each circuit element and describes its functions.
3.2
OPERATIONAL CHECKS AND PROCEDURES
Operations include the following checks and procedures as described in Table 3.2-1.
Initial Operational Checks,
Initial Voltage Check,
Normal Operations and Shutdown Procedures, and Transformer Overheat.
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TABLE 3.1-1
SDC MAJOR COMPONENTS DESCRIPTIONS
ITEM
DESCRIPTION
MAIN CIRCUIT BREAKER (4ACB)- The Main Circuit Breaker connects 208VAC power to
the panel board bus. Setting the circuit breaker to the ON position readies the SDC to
deliver power to all loads connected to it.
The Main Circuit Breaker is designed to provide overload and over current protection. In the
event of excessively high transformer temperatures, the shunt trip is energized tripping the
circuit breaker. The circuit breaker must be manually reset. If the circuit breaker is in the
tripped position, it indicates that the breaker has been subjected to an over current or high
transformer temperature condition. Locate cause and correct before proceeding.
To reset breaker, it must be pushed to OFF position before turning ON . If it trips again
after resetting, push to the OFF position and troubleshoot.
MISSION ESSENTIAL CIRCUIT BREAKER (3ACB)- The mission essential circuit breaker
located just above the Main Circuit Breaker, at the bottom of the circuit breaker panel applies
208VAC power from a secondary generator input to the panel board bus. An interlock is
designed to prevent the simultaneous use of both the MAIN and J15 Circuit Breakers.
A, B, AND C PHASE INDICATING LIGHTS - Bus indicating lights for phases A, B, and C,
located on the indicator panel, illuminate when the designated phase is energized.
TRANSFORMER HIGH TEMPERATURE LIGHT - This indicator light, located at the top of
the indicator panel, illuminates at excessively high transformer temperatures. During normal
operation, this light will remain unlit. To test, press bulb lens and lamp should light.
TRANSFORMER HIGH TEMPERATURE OVERRIDE SWITCH - This two-position toggle

switch is located on the indicator panel. During normal operation conditions, the override
switch shall be maintained in the NORMAL position. In the OVERRIDE (battle-short)
position, it permits closing the Main Circuit Breaker to apply 120/208VAC power to the
branch circuit breakers after the Main Circuit Breaker has been tripped due to excessive
transformer temperature.
BRANCH CIRCUIT BREAKERS - The fourteen branch circuit breakers running up the left
and right hand sides of the circuit breaker panel control the application of secondary power to
the eight feeder receptacles for distribution to connected loads. Twelve circuit breakers feed
120/208VAC, 3-Phase, and two circuit breakers feed 120VAC, single-phase, ground fault
power.
If a circuit breaker is in the tripped position, it indicates that the breaker has been subjected
to an overload condition. To reset breaker, it must be pushed to OFF position before
turning ON . If it trips again after resetting, push to the OFF position and troubleshoot.
FUSES - Three, 1A time delay fuses (1FU1 through 1FU3) located on the indicator panel
protect each phase indicator lamp. A fourth fuse (10A time delay, 2FU1) also located on the
indicator panel is in series with the transformer winding temperature sensors.
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TABLE 3.2-1
CHECK
Initial
Operational
Check
SDC INITIAL OPERATIONAL CHECKS

STEP
ACTION
DONE
Check that all circuit breakers in the SDC are set to OFF .
Ensure that the TRANSFORMER HIGH TEMPERATURE OVERRIDE

SWITCH is set to NORMAL .
Slide the mechanical interlock bar and set the MAIN CIRCUIT
BREAKER to ON . The A, B, and C Phase indicator lights will
illuminate. If one or more of the PHASE INDICATOR LIGHTS do not
illuminate, return the MAIN CIRCUIT BREAKER to OFF , and
troubleshoot per Chapter 4.
Test Transformer High Temp indicator light by pressing the lens. Light
should illuminate when pressed.
With the MAIN CIRCUIT BREAKER in the ON position and the PHASE
INDICATOR LIGHTS lit, press the red test button on the GFIC breakers.
Reset the GFIC breakers
Initial Voltage
Check
Set one OUTPUT CIRCUIT BREAKER to ON . Check low voltage

output. If output voltage is not 120/208VAC then troubleshoot IAW
paragraph 4.6, step 6.
Normal
Operation
Check phase rotation. Phase rotation is important for some equipment,

such as fans and air conditioning, in order for them to function correctly.
If phase rotation is wrong, check that the primary cables are marked
and connected correctly. If correct, exchange two cables at source.
The SDC is ready to deliver power to any or all loads connected to the
SDC through the (output) receptacles up to a total load of 150kVA. To
apply power to the loads, set the appropriate OUTPUT CIRCUIT
BREAKER(s) to ON . The SDC is now fully operational and requires
no further attention.
Individual Loads: To shut down an individual load, it is only necessary

to set the particular OUTPUT CIRCUIT BREAKER to OFF.
Output: To isolate the low voltage output of the SDC, set the MAIN
CIRCUIT BREAKER to OFF.
Shut down the output circuit breakers and set the MAIN CIRCUIT
BREAKER to OFF.
Notify maintenance and do not operate the unit until the problem has
been corrected.
Normal
Shutdown
Transformer
Overheat
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3.3
MISSION ESSENTIAL POWER MODE
3.3.1
GENERAL
The SDC can also be connected to an auxiliary power input source called a Mission Essential Power
(MEP) generator set. Power input is 208VAC, 3-Phase, 50/60Hz with a maximum of 200 amperes per
phase. Power is supplied through a cable connected between the generator output and the SDCs 200A
receptacle, J15. Table 3.3.1-1 presents the procedures to provide low voltage power (120/208VAC, 3phase) to equipment when using an auxiliary power input source.
WARNING
MAIN CIRCUIT BREAKER AND MISSION ESSENTIAL BREAKERS HAVE AN
INTERLOCKING DEVICE TO PREVENT BOTH BREAKERS BEING ENERGIZED
SIMULTANEOUSLY.
ENSURE INTERLOCKING DEVICE IS FUNCTIONAL TO
PREVENT POSSIBLE BACKFEED CONDITION.
TABLE 3.3.1-1
MEP MODE OPERATIONAL CHECKS
STEP
ACTION
Check that all circuit breakers in the SDC are set to OFF, including
the MAIN CIRCUIT BREAKER and J15 CIRCUIT BREAKER.
Ensure that the auxiliary cable is connected between the auxiliary

power source and the SDC (see paragraph 2.6, Mission Essential
Power Connections).
Check to be sure that the post-installation checks for the auxiliary

power source are completed (see paragraph 2-7).
Start auxiliary power source in accordance with its manual.
Close the output contactor on MEP.
Slide the mechanical interlock and set the J15 CIRCUIT BREAKER
to ON. The A, B, and C PHASE INDICATOR LIGHTS will come on.
If one or more of the PHASE INDICATOR LIGHTS does not come
on, return the J15 CIRCUIT BREAKER to OFF, and check the
fuse(s) and lamps for the phase whose indicator(s) did not light (see
paragraph 4.13).
With the J15 Circuit Breaker in the ON position and the PHASE
INDICATOR LIGHTS lit, the SDC is ready to deliver power to any or
all loads connected to the SDC through the (output) receptacles up
to a total of 72 kVA. To apply power to the loads, set the appropriate
OUTPUT CIRCUIT BREAKER(s) to ON. The SDC is now fully
operational and requires no further attention.
MAY 17, 2002
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REFERENCE DONE
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3.3.2
MEP MODE SHUTDOWN
Table 3.3.2-1 presents the actions to be taken to shutdown operations in the MEP mode.
TABLE 3.3.2-1
MEP MODE SHUTDOWN ACTIONS
MODE
SHUTDOWN ACTION
Individual Loads
To shut down an individual load, set the particular OUTPUT CIRCUIT BREAKER
to OFF.
Output
To isolate the low voltage output of the SDC, set the J15 CIRCUIT BREAKER to
OFF.
3.4
It is possible to operate the SDC in emergency conditions should it shut down due to transformer
overheating.
The transformer HIGH TEMPERATURE OVERRIDE SWITCH is for EMERGENCY use only. It allows
operation with excessively high transformer temperature. Operations in this situation may permanently
damage the transformer, and will void the warranty. Table 3.4-1 identifies the steps required to conduct
emergency operations.
TABLE 3.4-1
STEP
ACTION
Set to OFF those output receptacle circuit breakers for loads that are not absolutely
required.
Place the HIGH TEMPERATURE OVERRIDE SWITCH in the OVERRIDE position.
Set the MAIN CIRCUIT BREAKER to ON.
The TRANSFORMER HIGH TEMPERATURE INDICATOR LIGHT will stay

illuminated until the transformer cools down.
3.5
DONE
OPERATING IN UNUSUAL CLIMATIC CONDITIONS
Precipitation and dust can degrade the performance of the SDC and can result in hazardous conditions.
The following practices are recommended:
Do not allow the SDC cables to become submerged in water. Death or injury may result.
Corroded terminals and connections develop their own high resistance.
Frequent, regular inspections, maintenance and treatment of connections can reduce this
corrosion.
Cap unused connectors and keep doors closed to protect against sand, dirt and water.
Check and clean ventilation filters as required by conditions.
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MAY 17, 2002
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CHAPTER 4
4.0
MAINTENANCE
4.1
PARTS
Parts are listed in Appendix A of this manual and are available from Radian Inc.
4.2
COMMON TOOLS
Standard industrial tool kits contain the common tools needed for maintenance.
4.3
SPECIAL TOOLS
Special tools and test equipment that are needed to maintain the Secondary Distribution Center (SDC)
are listed in Appendix B.
4.4
LUBRICATION
All bushing wells and parking stands should be lubricated with silicon grease.
WARNING
ENSURE BOTH PRIMARY AND EMERGENCY POWER SOURCES
DISCONNECTED BEFORE ATTEMPTING TO LUBRICATE BUSHING WELLS.
ARE
Door hinges and door handles/locks should be lubricated as required to relieve stiffness or binding. To
lubricate, sparingly apply lubricating oil and work it into the joints or pivots involved. Blot up all excess oil.
Report stiffness or binding of all other operational controls or moving parts.
4.5
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Systematic, periodic, Preventive Maintenance Checks And Services (PMCS) are essential to ensure that
the SDC is ready for operation at all times. The purpose of a preventative maintenance program is to find
and correct defects and deficiencies before they can cause serious damage or complete failure of the
equipment.
Table 4.5-1 lists the inspections for the equipment required to keep it in good condition. All CAUTIONS
and WARNINGS should be reviewed prior to performing any of the PMCS functions.
WARNING
ENSURE BOTH PRIMARY AND EMERGENCY POWER SOURCES ARE
DISCONNECTED BEFORE ATTEMPTING TO REPAIR, REMOVE OR REPLACE ANY
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TABLE 4.5-1
NO.
SDC PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FREQUENCY
INSPECTED
ITEM
INSPECTION
PROCESS
ACTION
Before
Use
After
Use
As
Require
d
Enclosure
Inspect doors, latches,

and door handles for
stiffness or binding
Lubricate as
required
Before
Use
After
Use
Enclosure
Check vents for

restrictions. Check all
air filters for airflow
blockage. Check
monthly in sandy or
dusty conditions.
Clear any
debris blocking
vents or air
filters, see
para. 4.9.
Enclosure
Inspect doors seals

are firmly attached
and in good condition.
Replace as
required, see
para. 4.10.
After
Use
After
Use
As
Require
d
Enclosure
Inspect cabinet and

doors for damage,
corrosion, and
condition of paint.
Repair damage,
clean corrosion
and repaint as
required, see
para. 4.8.
After
Use
As
Require
d
Enclosure
Inspect cabinet and

doors for missing
components including
information plates.
Replace missing
components
Before
Use
After
Use
As
Require
d
Enclosure
Inspect cabinet for

dirt, oil or other
contaminates.
Clean cabinet.
Before
Use
After
Use
As
Require
d
Electrical
Inspect output
receptacles for
electrical contacts
condition, bent pins,
cap (covers) in good
condition and still
attached. Inspect for
corrosion.
Replace any
defective
receptacles or
missing covers.
Before
Use
After
Use
As
Require
d
Electrical
Inspect circuit
breakers for condition,
operation and
mounting.
Exercise all
breakers to
ensure
mechanical
operation.
Tighten loose
mounting.
Replace circuit
breakers.
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TABLE 4.5-1
NO.

FREQUENCY
INSPECTED
ITEM
INSPECTION
PROCESS
ACTION
Before
Use
After
Use
As
Require
d
Electrical
Inspect indicator
lamps and lenses.
Replace
cracked, broken
or missing
lamps or lenses,
see para. 4.13.
10
Before
Use
After
Use
As
Require
d
Electrical
Inspect fuses and

EFDs.
Replace blown
or missing
fuse(s). Use the
hot stick to
remove EFD.
Replace blown
fuses.
11
Before
Use
After
Use
As
Require
d
Electrical
Inspect bushing wells

for corrosion and
condition. Lubricate
bushing well inserts
with dielectric grease.
Clean bushing
wells as
required.
Lubricate as
required.
12
Before
Use
After
Use
Transforme
r
Inspect transformer
compartment for dirt
or other debris.
Clean
transformer
compartment.
13
Before
Use
After
Use
Transforme
r
Inspect transformer
windings for
accumulation of dirt
or discoloration due
to overheating.
Vacuum dirt or
dust from
transformer.
14
Before
Use
After
Use
Transforme
r
Inspect transformer
power connections,
taps and bushings for
good connections.
Check for corroded or
broken ground
connections.
Clean and
tighten
connections.
15
Before
Use
After
Use
Transforme
r
Check internal wiring

for secure
connections. Look for
burnt insulation and
signs of overheating.
Tighten or
replace
connector ends.
Replace burnt or
overheated
wires.
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TABLE 4.5-1
NO.

FREQUENCY
INSPECTED
ITEM
INSPECTION
PROCESS
ACTION
16
Before
Use
After
Use
Transforme
r
Check transformer
bushing insulating
surfaces for tracking
cracks or chipped
surfaces. Inspect
bushing gasket bases
for hardening.
Replace
transformer if
bushing is
broken, cracked
or chipped.
17
Before
Use
After
Use
Transforme
r
Check bolted
connections on
transformer.
Tighten bolted
connections to
30 foot pounds
using calibrated
torque wrench.
18
Yearly
Transforme
r
Test transformer
insulation (megger)
annually. See test
procedures in
paragraph 4-15.
Replace any
defective
transformer that
fails to meet 500
megohms after
temperature
corrected.
19
Yearly
Transforme
r
Test Transformer
Turns Ratio (TTR)
annually. See
procedures in
paragraph 4.15.
Replace any
defective
transformer with
results that
deviate more
than one-half
(1/2%) percent
from either
adjacent coil.
Transforme
r
Verify that the tap

connections are as
shown on wiring
schematic, Appendix
C.
Correct tap
connections if
different from
schematic.
Power On
Checks and
Tests
Check phase rotation

at each connector.
If all connectors
are wrong,
switch at source,
if one or more
connectors
switch at
connector.
20
Before
Use
21
MAY 17, 2002
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Use
As
Require
d
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TABLE 4.5-1
NO.

FREQUENCY
INSPECTED
ITEM
INSPECTION
PROCESS
22
As
Require
d
Power On
Checks and
Tests
Check secondary
voltage at each
connector.
If voltage is low,
verify taps on
transformer.
Perform TTR
test (para. 4-15).
Change taps as
required.
23
As
Require
d
Power On
Checks and
Tests
Test and reset GFCI

circuit breaker.
Push the red

button to test
then reset. If
circuit breaker
fails to trip or
reset, replace.
24
As
Require
d
Power On
Checks and
Tests
Test push to test

transformer high
temperature indicator
light.
If light fails to
light, check fuse.
If fuse is good,
check bulb. See
Figure C.1-1, for
circuit schematic
diagram.
25
As
Require
d
Power On
Checks and
Tests
When power is
applied to secondary
load circuit breakers,
inspect PHASE
INDICATOR LIGHTS
for illumination. (See
Figure 3.1-1 for
location.)
Inspect and
repair as
necessary, see
para. 4.13.
MAY 17, 2002
55
ACTION
SDC 8/60 4/100 COMM
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4.6
TROUBLESHOOTING PROCEDURES
Table 4.6-1 presents malfunctions that may occur during operations of the Secondary Distribution Center
(SDC), as well as the tests and corrective action for each malfunction. The best practices to be observed
when conducting maintenance/troubleshooting the Secondary Distribution Center (SDC) include:
Making only one change at a time.
Testing the system after each repair to determine if the problem was eliminated.
Checking electrical problems with power disconnected.
Checking circuits and components with multi-meter.
Checking electrical properties of potentially defective component prior to removal.
Checking all mechanical functions prior to removal of parts.

WARNING
BE SURE ALL POWER IS REMOVED FROM THE PRIMARY INPUT POWER CABLES
LETHAL VOLTAGES ARE PRESENT.
WARNING
PERSONAL INJURY, DEATH, OR DAMAGE TO EQUIPMENT.
TABLE 4.6-1
NO.
1
MALFUNCTIONS AND TROUBLESHOOTING PROCEDURES

MALFUNCTION
No primary input
power to SDC
transformer.
TEST OR INSPECTION
CORRECTIVE ACTION
A. Check for source failure.
Check that upstream power source

is operating and producing primary
power.
B. Check for primary power

cable connection failure.
1. Check that loadbreak elbows are

not in parking stands.
2. Use a hot stick and lineman
gloves (Appendix B); check that
Loadbreak elbow connections
are completely pushed onto the
bushings.
C. Check EFD fuse(s)

missing or blown.
MAY 17, 2002
56
Check, using a hot stick and

lineman gloves (Appendix B), that
the EFD fuse(s) are in place and not
blown (see paragraph 2.4.1).
SDC 8/60 4/100 COMM
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TABLE 4.6-1
NO.
MALFUNCTION
Primary input power

available but no
208VAC secondary
power.
TEST OR INSPECTION
A. Check for tripped or
OFF MAIN CIRCUIT
BREAKER.
CORRECTIVE ACTION
1. If tripped, turn OFF all load circuit
breakers.
2. Set or reset MAIN CIRCUIT
BREAKER to ON. If circuit
breaker trips, check for short or
overload before resetting
breaker. If no fault is detected,
check or replace breaker. Turn
load circuit breakers ON.
3. If not tripped, check fuses and
indicator lights.
4. If no indicator lights, transformer
has failed. Check transformer
wiring and connections IAW
wiring diagram, Appendix C.
5. Test transformer (see paragraph
4-15). If defective, replace
transformer.
B. If 208VAC is missing on
some but not all loads,
check for tripped or
OFF load circuit
breakers.
1. Set or reset load circuit breakers

to ON.
2. If circuit breakers trip, check for
short or overload before
resetting breaker.
3. If no fault is detected, check or
replace breaker.
C. Check for
TRANSFORMER HIGH
TEMPERATURE
indicator light ON.
1. If light is ON, allow transformer

to cool.
2. Correct causes for overheat
condition before resetting MAIN
breaker.
3. Set or reset MAIN CIRCUIT
BREAKER to ON.
1. If no light, press to test bulb.
2. If bulb fails to light, check fuse
and replace blown fuse.
3. If fuse OK, check bulb and
replace if defective.
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TABLE 4.6-1
NO.
MALFUNCTION
TEST OR INSPECTION
Loss of single-phase
indication
A. Check for blown

indicator light fuse(s) in
all phases,1FU1, 1FU2
and 1FU3.
Replace any blown fuse. (see

paragraph 4.12)
B. Check for burned out

bulb(s) 1WIL, 2WIL and
3WIL.
Replace any burned out bulbs. (see

paragraph 4.13)
C. Check transformer
output by checking
208VAC output at
receptacles.
If phase is missing, check

transformer input.
D. Check transformer input
See number 1 above.
E. Check leads between

EFD disconnects and
transformer
If wire leads are broken, replace

broken wire or terminal.
F. Test transformer
If transformer is defective, replace

transformer.
Check for tripped or OFF

GFCI circuit breaker.
1. Set or reset GFCI circuit breaker

to ON. If circuit breaker trips,
check for shorts or overloads
before resetting breaker.
Secondary 120VAC
missing from
convenience
receptacle(s).
CORRECTIVE ACTION
2. If no fault is detected, check or

replace circuit breaker.
5
Repeated Blown
Indicator Light Fuse.
Low or high output

voltage.
Check for short in wiring.
Correct short and replace fuse.

(see paragraph 4.12)
Check input voltage at

source.
1. Correct source voltage.

2. If source is correct, verify tap
setting on transformer (see
paragraph 4.15.). Check wiring
of transformer and correct as
needed.
3. If taps are set correctly, test
transformer IAW paragraph 415. If transformer is good,
change taps to provide an output
of 120/208VAC (see paragraph
4.15).
MAY 17, 2002
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4.7
GENERAL WIRE AND CABLE REPAIR
Before replacing a harness, it must be determined if a repair is possible. If it can be repaired, then it
consists of isolating the defective wire, removal of the individual wire(s), inserting the new wire(s), and
making the appropriate connections. Preferred repair methods consist of replacing wires, terminals,
connectors, etc., rather than splicing wires, bending ends to form terminals and other makeshift
procedures. Use the proper size and length of wire, cable connector or terminal in any repair. Table 4.71 presents wire and cable repair actions by connector/connection type.
WARNING
TABLE 4.7-1
GENERAL WIRE AND CABLE REPAIR ACTIONS
CONNECTION
ACTION
Solder connections
Whenever possible, make a mechanical connection before soldering. Make sure

all components are clean before soldering. Use an approved flux. Excessive
buildup of solder gobs on the joint should be avoided or removed.
Insulation joints
Use heat shrink tubing to insulate any joint whenever possible. Use the correct
diameter and length to completely cover the joint. After the joint is made, slide
the tubing so that it covers the joint, and shrink in place with moderate heat.
Crimping terminals
To install a terminal on the end of a wire, strip enough insulation to ensure that
enough wire will extend into the barrel of the terminal yet not to extend into the
mating part of the terminal. Crimp terminal barrel with crimping tool. Pull on wire
to ensure wire is secured in wire barrel. Use heat shrink if the terminal is uninsulated.
Output receptacles
To install a connector on the end of a wire, strip 13/16 inches of insulation to

ensure that enough wire will extend into the barrel of the connector.
60A (J3 J10)

100A (J11 - J14)
MAY 17, 2002
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4.8
GENERAL ENCLOSURE REPAIR
4.8.1
TASK REQUIREMENTS
Table 4.8-1 lists the repair requirements for general enclosure repair.
TABLE 4.8-1
GENERAL ENCLOSURE REPAIR TASK REQUIREMENTS

a. Inspection
TASK COVERAGE
b. Service
c. Repair
Protective clothing and equipment such as rubber gloves, face and eye
shields, respiratory devices, booths, and a fire extinguisher.
SPECIAL
EQUIPMENT
Other items that may be needed are welder and paint brush.
MATERIAL PARTS
NEEDED FOR
REPLACEMENT
Sandpaper, dry cleaning solvent, primer, and paint. (See Appendix B)
DATA NEEDED
None
4.8.2
TASK ACTIVITIES
Table 4.8.2-1 presents the General Enclosure Repair tasks.

WARNING
SOLVENTS USED TO CLEAN CAN BE FLAMMABLE AND THEIR VAPORS CAN BE
EXPLOSIVE. REPEATED OR PROLONGED SKIN CONTACT OR INHALATION OF
VAPORS CAN BE TOXIC. USE A WELL-VENTILATED AREA, WEAR RUBBER
GLOVES, AND KEEP AWAY FROM SPARKS OR FLAME.
PAINTS ARE
FLAMMABLE AND PROLONGED BREATHING OF VAPORS CAN BE HARMFUL.
USE IN WELL-VENTILATED AREA. DO NOT USE NEAR HEAT SOURCE OR OPEN
FLAME.
MAY 17, 2002
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TABLE 4.8.2-1
GENERAL ENCLOSURE REPAIR TASKS
TASK
ACTION
COMMENT
Inspection
Inspect
enclosure, covers
and doors for
damage.
Service
Brush off loose

dirt or foreign
matter.
Wipe enclosure
with a cloth
dampened with
dry cleaning
solvent
Repair
Corrosion control
Control of corrosion is a multi-step function.

Prevention is the first step in the process. The SDC is
manufactured with various protective coatings that may get
damaged or removed which subject the material to corrosion
(including rust).
Whenever corrosion is detected:
remove corrosion (scraper, wire brush, etc.)
carefully clean local areas (soap & water, brush, sand paper,
vacuum cleaner, etc.).
remove all dust or cleaning residue.
Apply a suitable replacement protective coating.
Other
Straighten all dents and weld as required.

Replace panels too damaged to be straightened.
Repainting
Before painting, treat area for corrosion. Do not paint over warning
or schematic plates, component identification markings, air filters,
wires, connectors or any electrical component. Mask off before
painting.
Paint using primers and topcoats IAW Appendix B.
Paint topcoat color using matching color paint; see Appendix B for
specific color identification.
MAY 17, 2002
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4.9
AIR FILTERS
4.9.1
TASK REQUIREMENTS
Table 4.9.1-1 presents the task requirements for air filters.

TABLE 4.9.1-1
AIR FILTER TASK REQUIREMENTS

a. Inspection
TASK COVERAGE
b. Service
SPECIAL EQUIPMENT
None
MATERIAL PARTS NEEDED FOR

REPLACEMENT
Filters (if needed). (See Appendix A)
DATA NEEDED
None
4.9.2
TASK ACTIVITIES
Table 4.9.2-1 presents the air filter repair tasks. Figure 4.9.2-1 illustrates the location of the air filters.
The air filters are located in the same positions on both the left and right hand sides of the SDC.
LARGE
SIDE
PANEL
AIR FILTERS
FIGURE 4.9.2-1
MAY 17, 2002
SDC AIR FILTER LOCATIONS
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WARNING
AIR FILTER. FAILURE TO TURN POWER OFF MAY RESULT IN PERSONAL
TABLE 4.9.2-1
AIR FILTER REPAIR TASKS
TASK
STEP
Inspection
Remove large cabinet side panels
Remove retaining screws from bottom filter retainers
Slip all filters out and inspect louvers for obstructions.
Inspect all filters for serviceability.
Clean filter or replace as required.
Reinstall filters. Retain with screws if applicable.
Reinstall large side panels.
Service
ACTION
DONE
4.10
GASKETS, INSULATION, AND INFORMATION PLATES
4.10.1
TASK REQUIREMENTS
Table 4.10.1-1 presents the task requirements for Gaskets, Insulation and Information Plates.
TABLE 4.10.1-1
GASKET, INSULATION, AND INFORMATION PLATES TASK REQUIREMENTS

a. Removal - gasket or insulation
TASK COVERAGE
b. Installation - gasket
c. Installation - insulation
d. Replacement - Information plates
SPECIAL
EQUIPMENT
None
MATERIAL PARTS
NEEDED FOR
REPLACEMENT
Dry cleaning solvent, gaskets, insulation, information plates, rivets as required.

(See Appendix B.)
DATA NEEDED
None
MAY 17, 2002
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4.10.2
TASK ACTIVITIES
Table 4.10.2-1 presents the Gaskets, Insulation and Information Plate repair Tasks. Figure 4.10.2-1
illustrates the location of the plate.
WARNING DECALS
(TYPICAL)
IDENTIFICATION
PLATE
FIGURE 4.10.2-1
WIRING DIAGRAM
PLATE (INSIDE DOOR)
SDC PLATE LOCATIONS

WARNING
SOLVENTS USED TO REMOVE GASKETS AND INSULATION CAN BE

FLAMMABLE, AND THEIR VAPORS CAN BE EXPLOSIVE.
REPEATED OR
PROLONGED SKIN CONTACT OR INHALATION OF VAPORS CAN BE TOXIC. USE
A WELL-VENTILATED AREA, WEAR GLOVES, AND KEEP AWAY FROM SPARKS
OR FLAME.
MAY 17, 2002
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TABLE 4.10.2-1
GASKETS, INSULATION AND INFORMATION PLATES REPAIR TASKS
TASK
STEP
Gasket or
Insulation Removal
Prior to removal of old gaskets material or insulation cut the

new replacement material to size using the old item as a
sample if possible.
Remove as much old gasket or insulation material as possible

by pulling or scraping it away from the metal surface.
Soften and remove old adhesive and gasket residue, using

approved solvent.
Cut gasket to size
Be sure that the surface to which gasket is to be applied is

clean and free of old adhesive material.
Use applicable adhesive to secure gaskets to unit.
Use scraper or other similar tool to remove old warning decals
Soften and remove old adhesive and decal residue, using

approved solvent. Be sure that the surface to which decal is to
be applied is clean and free of old adhesive material.
3
1
Apply new warning decal to panel.

Drill out rivets of defective plate and remove.
Rivet new schematic plate with rivets using the old rivet holes
unless old holes are too large. If holes are too large, locate
new holes close to the old holes and fill old exposed holes
with rivets.
Gasket Installation
Warning Decal
Replacement
Schematic or
identification plate
Replacement
MAY 17, 2002
ACTION
65
DONE
SDC 8/60 4/100 COMM
USA TM 9-6115-485-14&P
4.11
CIRCUIT BREAKERS
4.11.1
TASK REQUIREMENTS
Table 4.11.1-1 presents the task requirements for Circuit Breakers.

TABLE 4.11.1-1
CIRCUIT BREAKERS TASK REQUIREMENTS

a. Inspection
TASK COVERAGE
b. Replacement - Main Circuit Breaker

c. Replacement - Mission Essential Circuit Breaker
d. Replacement - Load Circuit Breakers
SPECIAL EQUIPMENT
Low resistance ohmmeter (DLRO) (Appendix B)
MATERIAL PARTS NEEDED

FOR REPLACEMENT
Circuit breakers as required (Appendix A)
DATA NEEDED
Wiring diagram (Appendix C)
4.11.2
TASK ACTIVITIES
Table 4.11.2-1 presents the Circuit Breakers repair tasks. Figure 4.11.2-1 identifies the location of the
SDC Circuit Breakers.
J1 AND J2 GFCI
OUTPUT CIRCUIT
BREAKERS
MEP
CIRCUIT
BREAKER
J3 THROUGH J14
OUTPUT CIRCUIT
BREAKERS
MAIN
CIRCUIT
BREAKER
FIGURE 4.11.2-1
SDC CIRCUIT BREAKER LOCATIONS
(DOOR AND PANEL REMOVED FOR CLARITY)
MAY 17, 2002
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WARNING
TABLE 4.11.2-1
CIRCUIT BREAKERS REPAIR TASKS
TASK
STEP
Inspection
Open low voltage door.
Remove circuit breaker cover panel.
Inspect circuit breakers for correct mounting.
Operate circuit breakers to ensure smooth operation.
Inspect cases for cracks or other defects.
Replacement
MAY 17, 2002
ACTION
STEP
DONE
ACTION
DONE
Tag and remove wires.
Loosen screws securing circuit breaker to bus bar

assembly.
Tilt or slide circuit breaker away from bus bar assembly

and remove circuit breaker.
Hook or slide new circuit breaker on support rail and

secure with screws.
Connect wire to circuit breaker lug and remove tag.
Torque circuit breaker wire lug to the value shown on the

circuit breaker
Replace circuit breaker cover panel and low voltage door.
67
SDC 8/60 4/100 COMM
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4.12
FUSES
4.12.1
LOW VOLTAGE FUSES
4.12.1.1
TASK REQUIREMENTS
Table 4.12.1.1-1 presents low voltage Fuse task requirements.

TABLE 4.12.1.1-1
TASK COVERAGE
LOW VOLTAGE FUSE TASK REQUIREMENTS

a. Inspection
b. Test
c. Replacement
SPECIAL EQUIPMENT
Low resistance ohmmeter (DLRO) (see Appendix

B)

REPLACEMENT
Fuses as required (Appendix A)
DATA NEEDED
None
4.12.1.2
TASK ACTIVITIES
Table 4.12.1.2-1 presents the low voltage Fuse repair tasks. Figure 4.12.1.2-1 illustrates SDC low
voltage fuses and indicator lights.
TABLE 4.12.1.2-1
TASK
Inspection
Test
Replacement
LOW VOLTAGE FUSE REPAIR TASKS

STEP
1
ACTIVITY
DONE
Inspect fuse for proper installation.
Inspect case for cracks or other defects.
Inspect all electrical connections for high resistance to

ground using a low resistance ohmmeter (DLRO).
Pop out fuse and test for continuity with low resistance ohmmeter.
Replace fuse with same rated fuse (Appendix A)
Note: The fuse for the high temperature light is not the same as the phase
indicator light fuses.
MAY 17, 2002
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SDC 8/60 4/100 COMM
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INDICATOR
LIGHTS
FUSES
FIGURE 4.12.1.2-1 SDC LOW VOLTAGE FUSES AND INDICATOR LIGHTS
4.12.2
HIGH VOLTAGE FUSES
4.12.2.1
TASK REQUIREMENTS
Table 4.12.2.1-1 presents the High Voltage Fuse task requirements.

TABLE 4.12.2.1-1
TASK COVERAGE
HIGH VOLTAGE FUSE TASK REQUIREMENTS

a. Inspection
b. Test
c. Replacement
SPECIAL EQUIPMENT
Hot Line Stick, Lineman Gloves, Low Resistance Ohmmeter (DLRO)

(see Appendix B)
MATERIAL PARTS
NEEDED FOR
REPLACEMENT
Fuses as required (see Appendix A)
DATA NEEDED
None
MAY 17, 2002
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4.12.2.2
TASK ACTIVITIES
Table 4.12.2.2-1 presents the High Voltage repair task. Figure 4.12.2.2-1 illustrates the SDC high voltage
fuses.
WARNING
WARNING
BEFORE ATTEMPTING TO ATTACH OR DETACH THE LOAD BREAK ELBOWS.
PULLING THE CENTER EFDC WILL NOT DE-ENGERGIZE ANY CABLE
DO NOT APPLY PRIMARY POWER TO THE SDC UNITL ALL POST-INSTALLATION
OPERATING PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT.
TABLE 4.12.2.2-1
TASK
Inspection
HIGH VOLTAGE FUSE REPAIR TASKS

STEP
ACTION
1
2
3
4
5
MAY 17, 2002
DONE
Using a Hot Line Stick and lineman Gloves, detach all primary
power cables from their bushing well inserts and attach the
cables to the adjacent corresponding parking stands.
Disconnect the Mission Essential Power generator input cable
from connector J15. NOTE: When primary power cables
are removed, all SDCs interconnected on the circuit are
disconnected.
Using a Hot Line Stick and lineman Gloves, remove the center
pole of each of the three EFD units by sliding them out of the
enclosure
Remove the caps from the three EFD center pole sections by
removing the nylon screws at the top and bottom.
Verify the fuses are correct per the Parts List (see Appendix
A)
Inspect the fuses for signs of physical damage, over-heating,
or looseness of attaching hardware. Tighten loose hardware.
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SDC 8/60 4/100 COMM
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TABLE 4.12.2.2-1
TASK
HIGH VOLTAGE FUSE REPAIR TASKS (CONT)

STEP
ACTION
Test
Replacement
2
3
4
DONE
Test the fuses for continuity using a multimeter. (see

Appendix B)
Replace incorrect fuses, fuses showing signs of physical
damage or overheating, or fuses showing other than 0 ohms
internal resistance, with rated fuses per the Parts List. (see
Appendix A)
Re-install the caps on the three EFD center pole sections.
Using a Hot Line Stick and lineman Gloves, replace the three
EFD center pole sections in the EFD units.
Using a Hot Line Stick and lineman Gloves, attach all primary
power cables to their bushing well inserts and reconnect the
Mission Essential Power generator input cable to connector
J15
4.13
INDICATOR LIGHTS
4.13.1
TASK REQUIREMENTS
Table 4.13.1-1 presents Indicator Lights task requirements.

TABLE 4.13.1-1
TASK COVERAGE
INDICATOR LIGHT TASK REQUIREMENTS

a. Inspection
b. Replacement
SPECIAL EQUIPMENT
None

REPLACEMENT
Indicating lights as required (Appendix A)

See Figure 4.12.1.2-1 for location of lights.
DATA NEEDED
None
4.13.2
TASK ACTIVITIES
Table 4.13.2-1 presents Indicator Lights repair tasks.

TABLE 4.13.2-1
INDICATOR LIGHT REPAIR TASKS
TASK
STEP
ACTIVITY
Inspection
Inspect indicating light enclosure for correct mounting or

defects.
Inspect for cracks or other defects in the lens.
Unscrew lens and remove lens and bulb.
Replace indicating light(s) with same. (see Appendix A)
Replacement
MAY 17, 2002
71
DONE
SDC 8/60 4/100 COMM
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4.14
LOADBREAK ELBOWS
Loadbreak elbows are NOT supplied with the SDC. These instructions are for information only.
4.14.1
TASK REQUIREMENTS
Table 4.14.1-1 presents Loadbreak Elbow task requirements.

TABLE 4.14.1-1
TASK COVERAGE
LOADBREAK ELBOW TASK REQUIREMENTS

Inspection and replacement.
TOOLS NEEDED FOR

ASSEMBLY
Tape measure, wire brush, knife, cable stripping tool, crimping tool,
cable cleaner, cable cutter, and emery cloth.
SPECIAL EQUIPMENT
Crimper (see Appendix B).
MATERIAL PARTS
NEEDED FOR
REPLACEMENT
200A Loadbreak elbow kit (that must fit both cable conductor and
outside diameter), an adapter kit is required for smaller diameter cable,
colored tape, #4 AWG 5kV cable, and silicone lubricant.
DATA NEEDED
Manufacturers Loadbreak elbow installation instructions.
4.14.2
TASK ACTIVITIES
Table 4.14.2-1 presents Loadbreak Elbow inspection and replacement tasks. Figure 4.14.2-1 illustrates
the position of the parking stands as well as the feed-through points for loadbreak cables into the SDC.
PARKING STAND
FEED CABLES
FROM BELOW
FIGURE 4.14.2-1
PARKING STAND AND CABLE FEED THROUGH POINTS
Table 4.14.2-2 presents the color codes for the three phases of the primary power cables.
MAY 17, 2002
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WARNING
ENSURE BOTH PRIMARY AND MISSION ESSENTIAL POWER SOURCES ARE
CAUTION
ENSURE THAT THE REPLACEMENT LOADBREAK ELBOW IS CORRECT FOR THE
CABLE SIZE. CABLES ARE MARKED APPROXIMATELY EVERY 6 FEET WITH
CONDUCTOR SIZE. YOU MUST USE THE MANUFACTURERS INSTRUCTIONS
PROVIDED WITH THE LOADBREAK ELBOWS. FAILURE TO DO SO COULD
RESULT IN A DEFECTIVE CONNECTION WITH THE PRIMARY CABLE.
TABLE 4.14.2-1
LOADBREAK ELBOW REPAIR TASKS
TASK
STEP
Replacemen
t
Layout cables from the prime power source to the SDC.
The end of the cable should be approximately the same as the

centerline of the mating bushing centerline.
Allow for loadbreak elbows to reach when placed on bushing well or

parking stands.
Cut cables to length.
Ensure cable ends are cut squarely.
Using colored tape, color code the cables per the Table 4.14.2-2
below. The tape should be within eighteen (18) inches but not less
than twelve (12) inches from each end of the cable.
Train the cable so that it is located in the final assembled position with
a two inch offset to provide adequate clearance for disconnecting
elbows when placing on parking stands.
Prepare cable IAW Loadbreak elbow manufacturers instructions

utilizing adapter if needed for smaller diameter.
Feed the cable through the bottom of the SDC, into the high voltage
compartment. Place cable loadbreak elbow in their respective phase
parking stands. Check that the color band matches the phase label for
the corresponding bushing well.
10
Twist concentric neutral wires below loadbreak elbow into a pigtail.

Make jumpers from excess cable wires that are long enough to reach
the ground bus. A single jumper can be attached to all three-cable
pigtails. Use an appropriate clamp to connect pigtails to the jumper
and attach to the ground bus.
11
If additional SDCs are to be interconnected, prepare the cables by

repeating steps 1 through 10 for each SDC.
MAY 17, 2002
ACTION
73
DONE
SDC 8/60 4/100 COMM
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TABLE 4.14.2-2
COLOR CODES FOR PRIMARY POWER CABLES
PHASE
COLOR CODE BAND
Black
Red
Blue
TABLE 4.14.2-3
INSPECT PRIMARY POWER CABLES
TASK
STEP
ACTION
Inspection
Using a Hot Line Stick and Lineman Gloves, detach all primary power
cables from their bushing well inserts and attach the cables to the
adjacent corresponding parking stands. Disconnect the Mission
Essential; Power generator input cable from SDC connector J15.
Detach each loadbreak elbow, one at a time, from its parking stand and
inspect interior and exterior for signs of physical damage, deterioration,
overheating, or looseness of the center probe. Replace any loadbreak
elbow with any of these conditions. Attach each usable loadbreak to its
corresponding parking stand.
4.15
TRANSFORMER
4.15.1
TASK REQUIREMENTS
DONE
Table 4.15.1-1 presents Transformer task requirements. Figure 4.15.1-1 illustrates the SDC transformer.
WARNING
THE TRANSFORMER IS HEAVY. LIFTING DEVICE CAPABLE OF LIFTING 1500
POUNDS IS REQUIRED.
TABLE 4.15.1-1
TASK COVERAGE
TRANSFORMER TASK REQUIREMENTS

a. Visual and mechanical Inspection
b. Test
c. Removal/Replacement
SPECIAL EQUIPMENT
Multi-meter, Transformer Turns Ratio (TTR) test set, megohmmeter

(megger), low-resistance ohmmeter (DLRO), and lifting device. (see
Appendix B)
MATERIALS/PARTS
NEEDED FOR
REPLACEMENT
Transformer as required. (see Appendix A)
DATA NEEDED
None
MAY 17, 2002
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INSULATOR
BUSHING
TRANSFOMER
FIGURE 4.15.1-1
SDC TRANSFORMER SIDE VIEW
(PANEL REMOVED)
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4.15.2
TASK ACTIVITIES
4.15.2.1
TRANSFORMER VISUAL AND MECHANICAL INSPECTION
Table 4.15.2.1-1 presents visual and mechanical inspection tasks for the transformer.
WARNING
GROUND PRIMARY AND SECONDARY TERMINALS PRIOR TO HANDLING.
FAILURE TO GROUND SECONDARY WINDINGS MAY RESULT IN PERSONAL
LOCK HIGH VOLTAGE COMPARTMENT DOORS. ANY ELECTRICAL SOURCE
APPLIED TO SECONDARY TERMINALS WILL MULTIPLY THAT VOLTAGE BY 20
TIMES ON THE HIGH VOLTAGE TERMINALS.
TABLE 4.15.2.1-1
STEP
TRANSFORMER VISUAL AND MECHANICAL INSPECTION TASKS

ACTION
FIGURE
De-energize and disconnect primary power at source (see paragraph

2.9, steps 1 through 12).
Ensure SDC is electrically isolated.
Disconnect Loadbreak elbows and place them on the parking stands.
Close and lock high voltage compartment doors.
Remove both large SDC side access panels.
Inspect physical and mechanical condition of transformer.
Clean transformer prior to testing.
Inspect all wires and terminals for discoloration due to overheating.
Inspect tap connections and compare them to Figure 4.15.2.2-1
10
Inspect all bolted electrical connections for high resistance using one of
the following methods:
4.15.2.21
-
(a) Use of low-resistance ohmmeter (DLRO) in accordance with

ohmmeters manual.
(b) Verify tightness of accessible bolted electrical connections by
calibrated torque-wrench method to 30 foot-pounds.
MAY 17, 2002
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4.15.2.2
The transformer tap connections, shown in Figure 4.15.2.2-1, are factory set for a 4160VAC primary input
to produce a 208VAC secondary output.
FIGURE 4.15.2.2-1 TRANSFORMER TAP CONNECTIONS

Figures 4.15.2.2-2 and 4.15.2.2-3 show typical 60 hertz connections where the input voltage range is
3952 to 4368VAC.
FIGURE 4.15.2.2-2 4056 V TAP CONNECTION
MAY 17, 2002
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Changing the high voltage transformer taps changes the primary to secondary turns ratio. These tap
changes are done to keep the secondary output voltage constant, when the input voltage varies 5%
above or below 4160VAC at 60 hertz, or at 50 hertz, 5% above or below 3810VAC.
For each 2.5 % voltage range above or below 4160VAC, or for 50 hertz 3810VAC, there is a specific HV
TAP setting, as shown to the left of the input VOLTS in each table. The CONNECT tap settings, as
shown in the right hand column of each table, remain the same for all of the voltage ranges in that
specific table. Figures 4.15.2.2-4 and 4.15.2.2-5 show typical 50 hertz connections where the input
voltage range is 3604 to 4020 volts.
MAY 17, 2002
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FIGURE 4.15.2.2-5
4.15.2.3
TRANSFORMER TESTS
Transformers are tested to make sure that the transformer is functioning correctly or was not damaged
during transit (acceptance test). Preventive maintenance testing of the in-service transformers is
principally for monitoring the conditions of the transformer and evaluating the useful life still available.
New transformers are tested at the factory and need only to be acceptance tested upon receipt.
Acceptance tests provide a base line for determining transformer condition. Periodical maintenance tests
will monitor deterioration of transformer condition. Keep good records for historical documentation.
WARNING
ONLY QUALIFIED PERSONNEL SHOULD BE INVOLVED IN THE TRANSFORMER
TESTING TO AVOID POSSIBLE MISAPPLICATION OF TEST THAT CAN RESULT IN
PERSONAL INJURY.
YOU MUST FOLLOW THE TEST EQUIPMENT
MANUFACTURERS PROCEDURES FOR THE FOLLOWING TESTS. THE LISTED
PROCEDURES ARE FOR EXAMPLE ONLY.
4.15.2.3.1
INSULATION RESISTANCE TESTING
This test determines the dielectric strength and moisture content of solid insulation. Applying DC voltage
across solid insulation produces a current made up of three major components (capacitance charging
current, conduction or leakage current, and absorption current). Table 4.15.2.3.1-1 provides set-up
procedures for transformer testing. Figure 4.15.2.3.1-1 presents the circuit diagram for the test. Table
4.15.2.3.1-2 provides the procedures for the test.
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TABLE 4.15.2.3.1-1
SET-UP PROCEDURES FOR TRANSFORMER TESTING
STEP
ACTION
FIGURE
Set up megohmmeter (megger) per manufacturers instructions.

You must follow the test equipment manufacturers procedures for
the following tests. The following procedures are for example only.
Do not test in high humidity conditions.
Ensure the core iron is grounded.
Disconnect all connections (except ground).
Ensure bushings are clean and free of contaminants to avoid

surface leakage.
Ground each winding of the transformer at each of the terminals.
Un-ground any windings.
Locate maintenance log and record the following data:
Table
4.15.2.3.1-1
Megohmmeter used:
(1) Manufacturer
_________________________
(2) Model
_________________________
(3) Serial number
_________________________
(4) Voltage
_________________________
(5) Megohm range
_________________________
(6) Ambient Humidity
_________________________
(7) Ambient Temperature
_________________________
(8) Temperature correction factor _________________________

(See Procedures, Table 4.15.2.3.1-1, step 10.)
9
Make the following connections:

a.
High to low and ground (H-LG).
b.
Low to high and ground (L-HG).
c.
High and low to ground (HL-G).
MAY 17, 2002
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EARTH
MEGOHMMETER
(MEGGER)
H.V. LEAD
(LINE)
HIGH
VOLTAGE
LOW
VOLTAGE
H3
X3
H2
X2
H1
X1
SDC TRANSFOMER,
150kVA
GROUND
FIGURE 4.15.2.3.1-1
INSULATION RESISTANCE TESTING, HIGH TO LOW AND GROUND

(H-LG) (TYPICAL)
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TABLE 4.15.2.3.1-2
PROCEDURES FOR TRANSFORMER INSULATION RESISTANCE TESTING
STEP
ACTION
FIGURE
H-LG test. The high voltage terminal is connected to the line terminal
of the megohmmeter.
The low voltage terminals are short-circuited to each other and then
to ground.
The earth terminal of the megohmmeter is connected to transformer

ground.
The guard terminal is left unused (floating).
Insulation resistance measurements should be taken from: winding to

winding, and winding to ground for a duration of at least 1 minute at
1000 VDC.
Repeat steps 2 through 5 for the remaining 6 connection

configurations and record results.
Record the value in the maintenance log.

(1) High to low and ground (H-LG).
__________
(2) Low to high and ground (L-HG).
__________
(3) High and low to ground (HL-G).
__________
If the results are below minimum, use the guard circuit and repeat
test to check of surface leakage problems.
After test is completed, ground all terminals for a sufficient length of

time to bleed off any charges that may have built up during the test.
10
Insulation resistance is greatly affected by temperature. Insulation

resistance tests need to be corrected to a common temperature base
(20C). Use the values in Table 4.15.2.3.1-3 for temperature
correction of insulation resistance tests.
11
TABLE
4.15.2.3-1
Results
a. The overall minimum insulation resistance is 500 megohms
when tested at a minimum DC test voltage of 1000.
b. If any value fails to meet the minimum value, the transformer
is defective and must be replaced.
MAY 17, 2002
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TABLE 4.15.2.3.1-3
INSULATION RESISTANCE CONVERSION FACTORS
TEMPERATURE (DEGREES
MULTIPLIER
APPARATUS CONTAINING
SOLID INSULATION
32
0.40
41
0.45
10
50
0.50
15
59
0.75
20
68
1.00
25
77
1.30
30
86
1.60
35
95
2.05
40
104
2.50
45
113
3.25
50
122
4.00
55
131
5.20
60
140
6.40
65
149
8.70
70
158
10.00
75
167
13.00
80
176
16.00
4.15.2.3.2
TRANSFORMER TURNS RATIO (TTR) TEST
The TTR is primarily used as an acceptance test. It is also useful as a tool for investigating problems, as
well as an integral part of routine preventive maintenance program. Turns ratio testing provides a direct
means to detect loose or open connections, shorted or open turns in transformer windings, incorrect
polarity connections and to verify precisely the no-load voltage ratio of the transformer at all tap positions.
The turns ratio of a transformer is defined as the number of turns in one winding in relation to the number
of turns in the other winding of the same phase, which is also equal to the no-load voltage ratio. Defined
mathematically:
Ep
Es
MAY 17, 2002
Np
TR
Ns
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Where:
Ep = primary voltage
Es = secondary voltage
Np = number of turns primary
Ns = number of turns secondary
TR = turns ratio (primary to secondary)
For reliable operation and parallel connection of power and distribution transformers, it is extremely
important that the turns ratio be determined very precisely. The turns ratio is required to be within +
percent (.005) of the indicated nameplate voltage ratio in all transformers. This TTR test should be
performed annually as part of your routine maintenance program.
The nameplate voltage ratio (N.P.) of a transformer is defined as the line-to-line voltage of the primary
winding to the line-to-line voltage of the secondary winding at no load. Or mathematically:
Ep
N.P.
Es
Since the no-load voltage ratio is directly proportional to the turns ratio, an accurate measurement of the
turns ratio will provide the no-load voltage ratio, without having to work with high voltages.
When a transformer is excited by its low-voltage winding, the no-load voltage ratio is nearly equal to the
turns ratio. The difference between the two ratios is caused by a voltage drop in the winding that results
from the magnetizing current flow through the winding. Normally this difference is less than 0.1 percent
or .001. This same condition exists if the high-voltage winding is excited and a voltage drop is developed
in the winding.
By exciting a transformer winding with a known voltage and applying this same voltage to a reference
transformer (in which the exact turns ratio is known), a balance circuit can be used.
When both the transformer under the test and the reference test transformer voltage ratios are equal, the
turns ratio is obtained.
Transformer turns ratio test sets (TTR) are designed to operate on the above principle. In addition, the
tests are designed so that during the ratio tests, polarity, open or shorted turns, and the vectoral
relationships of the various transformer windings are checked.
Several different types of turns ratio test sets are manufactured. However, they all generally operate by
the same principle. Follow the manufacturers instructions for set-up and test procedures.
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4.15.3
REMOVAL/REPLACEMENT
Table 4.15.3-1 presents transformer removal/replacement procedures.

WARNING
TRANSFORMER IS HEAVY. LIFTING DEVICE CAPABLE OF LIFTING 1500 POUNDS
IS REQUIRED.
TABLE 4.15.3-1
TRANSFORMER REMOVAL/REPLACEMENT PROCEDURES
STEP
ACTION
DON
E
Remove SDC side panels (both sides).
Disconnect and tag all wires connected to the transformer.
Remove four nuts and bolts securing the transformer to the enclosure.
Using a lifting device, carefully lift transformer straight up out of the enclosure and place
on ground.
Inspect all wire and cable terminations and repair defective ends.
Test new transformer before installing. See Paragraph 4.15.2.3 for test procedures.
Lift transformer and slide back into SDC enclosure.
Align mounting holes for transformer to enclosure base.
Secure with bolts and nuts.
10
Attach wires and torque hardware to 30 foot pounds.
11
Remove tags.
12
Re-install SDC side panels.
MAY 17, 2002
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4.16
CONNECTORS
4.16.1
TASK REQUIREMENTS
Table 4.16.1-1 presents Connector task requirements.

locations.
TABLE 4.16.1-1
TASK COVERAGE
Figure 4.16.1-1 illustrates SDC connector
CONNECTOR TASK REQUIREMENTS

a. Inspection
b. Remove and Replace
Ohmmeter
SPECIAL EQUIPMENT
3/8 Allen wrench

MATERIALS/PARTS NEEDED FOR
REPLACEMENT
Connectors as required
DATA NEEDED
None
CONNECTORS
FIGURE 4.16.1-1
MAY 17, 2002
SDC CONNECTOR POSITIONS
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4.16.2
TASK ACTIVITIES
Table 4.16.2-1 presents SDC Connector repair tasks. Figure 4.16.1-2 illustrates connector pin
assignments for the three Phases (A, B, C) as well as Neutral (N) and Ground (G).
WARNING
DISCONNECT CABLES AT SOURCE IF NOT ALREADY DISCONNECTED, LETHAL
TABLE 4.16.2-1
TASK
Inspection
STEP
1
Repair
MAY 17, 2002
SDC CONNECTOR INSPECTION AND REPAIR TAS

ACTION
DONE
Switch all output connector circuit breakers to OFF. Disconnect all

output load cables. Using a Hot Line Stick and Lineman gloves, detach
all primary power cables from their bushing well inserts and attach the
cables to the adjacent corresponding parking stands. Disconnect the
Mission Essential Power generator input cable.
Remove the large side panel adjacent to the connectors.
Inspect connectors for signs of physical damage or deterioration, overheating, arcing, dirt or other contamination, or looseness of assembly or
attaching hardware. Check connector body, cap, insert, contacts, and
wire seal. Remove dirt or other contamination. Tighten loose assembly
or attaching hardware. Damaged connectors must be replaced.
Remove and retain the hardware that attaches the indicator light and low
voltage fuse panel to the back of the upper interconnection cover panel.
Remove and retain the hardware that attaches the upper and lower
interconnection cover panels and remove the panels.
Trace wires from damaged connector to attachment points. Tag

attachment points, tag wires, and disconnect wires. Retain attaching
hardware. Observe the amount of slack length available in the wires.
Remove hardware attaching connector to connector panel and retain.

Remove wire ties and harness clamps as required.
Remove damaged connector, with wires attached, from the front of the
connector panel.
If enough slack length was observed to permit wire reuse, tag wires and
cut wires as close as possible to the damaged connector. Otherwise,
use existing wires as samples to fabricate new wires and transfer tags.
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TABLE 4.16.2-1
TASK
SDC CONNECTOR INSPECTION AND REPAIR TASKS (CONT)
STEP
Repair
ACTION
Install wires into the new connector per the manufacturers instructions
and the wire tags. See Appendix B for crimping tool information.
Pass the wires through the connector panel from the front and attach the
new connector to the connector panel using retained hardware.
Re-thread the wires along their original path and secure with existing
harness clamps and new wire ties.
Reconnect tagged wires to tagged original attachment points using

retained hardware.
10
Check connector wiring using SDC Electrical Schematic, Appendix C.
11
Re-install the lower and upper interconnection cover panels using

retained hardware. Re-install the indicator light and low voltage fuse
panel to the back of the upper cover panel using retained hardware.
12
Replace the large side panel adjacent to the connectors.
13
Using a Hot Line Stick and Lineman gloves, reconnect the primary power
cables to the correct bushing well insets and/or reconnect the Mission
Essential Power generator input cable to connector J15.
14
Apply primary power of Mission Essential Power to the SDC.
15
Switch circuit breaker applicable to the replaced connector to the ON

position.
16
Check replaced connector for 120/208VAC using a multimeter. (see

Appendix B)
17
Check replaced connector for proper ABC phase rotation using a phase
sequence meter. (see Appendix B)
18
Reconnect all output load cables to applicable connectors and switch

applicable output connector circuit breakers to ON.
FIGURE 4.16.1-2
MAY 17, 2002
DONE
SDC CONNECTOR PIN ASSIGNMENTS
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APPENDIX A
SECONDARY DISTRIBUTION SYSTEM (SDC) PARTS LIST
A.1
PARTS
TABLE A.1-1
SECONDARY DISTRIBUTION CENTER (SDC) PARTS
ITEM
REF.
A, B,
C
DESCRIPTION
MFG.
PART NO.
QTY
U/M
FILTER, ALL METAL, 25.50 X 13.75

X 0.50
TAMPA
ARMATURE
WORKS
B24E99030080
EA
EFD SWITCHES, 3 POLE, 5.5KV,

CENTER POLE FUSED, FUSED AT
65E
ABB
DRG/8608C85/
EA
J902KECO
FILTER, ALL METAL, 14.0 X 6.0 X

0.50
TAMPA
ARMATURE
WORKS
B24E99030090
EA
ENCLOSURE, ALUMINUM,
WELDED/BOLTED
TAMPA
ARMATURE
WORKS
B24B99100240A
EA
CONSTRUCTION, SKID MOUNTED,

FORK LIFT POCKETS,
60.56" L X 47.63" W X 71.88" H
5
TRANSFORMER, 150kVA POWER,

4160 X 3810 V DELTA PRIMARY,
120/208V WYE SECONARY, DRY
TYPE, 150 DEGREE RISE, 50/60
HZ, 30KV BIL ON PRIMARY, 10kV
BIL ON SECONDARY, 220
DEGREES INSULATION CLASS,
STANDARD TAPS AND
ACCESSORIES
OLSUN
134580-A
EA
FILTER, ALL METAL, 25.50 X 10.50

X 0.50
TAMPA
ARMATURE
WORKS
B24E99030070
EA
DOOR HOLDER
EMKA
1087-U1
EA
EYE BOLT, SHOULDER, DROP

FORGED, 1"-8
McMASTER
3018T22
EA
GENERAL
ELECTRIC
THQB20
EA
GENERAL
ELECTRIC
TEC36100
12
EA
CARR
6.0" SHANK, 2.0" ID EYE

9
1ACB1 & BREAKER, CIRCUIT, 20A, 240VAC,

1ACB2 10KAIC
GROUND FAULT
10
2ACB1
THRU
2ACB12
MAY 17, 2002
BREAKER, CIRCUIT, MAG. TRIP,

100A, 600VAC
W/XXKAIC AT 240VAC RATING,
W/LOAD LUGS
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TABLE A.1-1
ITEM
REF.
11
12
3ACB
(MEP)

DESCRIPTION
MFG.
PART NO.
QTY
U/M
FLUSH LATCH W/MOUNTING

STUDS, T HANDLE, KEY
LOCKABLE, SOUTHCO #24-20-81210 (LV DOOR, KEYED HV DOOR)
SOUTHCO
12994-300LV
EA

250A, 600VAC
GENERAL
ELECTRIC
SFLA36AIO250
EA
GENERAL
ELECTRIC
SGLA36LAIO600
EA
MECHANICAL INTERLOCK
TAMPA
ARMATURE
WORKS
B24E99030700
EA
RECEPTACLE, 200A, 4P5W
ACC
90558C52412P-080
EA
OR
OR
MS
MS90558C52412P080
WOODHEAD
60W47
EA
OR
OR
_________
_____________
PASS &
PS5100R9-W
EA
PS560R9-W
EA

W/LOAD LUGS
13
4ACB
(MAIN)

600A, 600VAC
W/LINE LUGS
WITH SHUNT TRIP
14
15
J15
WALL MOUNT, CLASS "L"
16
J1 & J2
RECEPTACLE, 20A, 1 POLE,

120VAC
WATERTIGHT FLIP LID, FEMALE
17
18
J11 THRU RECEPTACLE, 100A, 250V, 4P5W,

J14
3-phase
J3 THRU RECEPTACLE, 60A, 250V, 4P5W, 3J10
phase
SEYMOUR
PASS &
SEYMOUR
19
GROUND ROD, METAL CLAD

COPPER, 8'-0" LONG, TWO PIECE
ASS'Y (TWO 4'-0" PCS), WITH
COUPLING AND CONNECTOR
CLAMP
TAMPA
ARMATURE
WORKS
GRD ROD 8
EA
20
PARKING STAND BRACKETS
TAMPA
ARMATURE
WORKS
B24E99021570
EA
21
BUSHING WELLS, 5KV, 200A, AIR

INSULATED LOADBREAK ELBOWS
W/COVERS, MFG. ELLIOTT
CENTRAL
7023-1152
EA
MALONEY
BUSHING WELL INSERTS, 200A
COOPER
LB1215
EA
22
MAY 17, 2002
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TABLE A.1-1
FIND
REF.
DESCRIPTION
MFG.
PART NO.
QTY
U/M
SOUTHCO
12994-300HV
EA
23
FLUSH LATCH W/MOUNTING

STUDS, T HANDLE, KEY
LOCKABLE, SOUTHCO #24-20-81210 (HV DOOR, KEYED DIFFERENT
THAN LV DOOR)
24
GROUND LUG (EXTERIOR)
BURNDY
KA2U
EA
25
GROUND CONNECTION BLOCK
BURNDY
BDB-212-500-1
BDA-24-500
EA
26
FASTENER, 1/4 TURN, WING KNOB,

28mm ENCLOSURE, 8mm CAM
EMKA
1000-U155, 1000U78,1000-113
EA
27
NEUTRAL CONNECTION BLOCK
BURNDY
BDB-212-500-1
BDA-24-500
EA
TOGGLE SWITCH, SINGLE POLE,

ON/OFF,
McGILL
90-0001
EA
GENERAL
ELECTRIC
0116B6708G5W
EA
BUSSMANN
HKP
EA
IDEC
ALD29911N-A-120
EA
IDEC
ALD29911N-A-120
EA
TAMPA
ARMATURE
WORKS
B24E99022280
EA
T&B
ADR80
EA
28
1SW
125VAC/20A, 240VAC/10A
29
1WIL,
2WIL, &
3WIL
30
INDICATING LAMP, WHITE LENS

CAP, 120VAC ET-16
FUSEHOLDER, 250V, 30A SCREWIN
(FOR 0.25 X 1.25 FUSE)
31
4AIL
PUSHBUTTON, ILLUMINATED,
AMBER LENS,
120 V, (1) NO & (1) NC CONTACT
31
4AIL
PUSHBUTTON, ILLUMINATED,
AMBER LENS,
120 V, (1) NO & (1) NC CONTACT
32
GROUND BUS, 1/4 X 1 COPPER
33
GROUND LUG (INTERIOR)
34
PLATE, IDENTIFICATION (PLATE)
RADIAN
1R0263
EA
35
LOAD J3
60 A RECPT
RADIAN
1R121213
EA
(LABEL)
36
LOAD J4
60 A RECPT
RADIAN
1R1212-4
EA
(LABEL)
37
LOAD J5
60 A RECPT
RADIAN
1R1212-5
EA
(LABEL)
MAY 17, 2002
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TABLE A.1-1
FIND
REF.
DESCRIPTION
MFG.
PART NO.
QTY
U/M
RADIAN
1R1212-11
EA
RADIAN
1R1212-12
EA
RADIAN
1R1212-13
EA
RADIAN
1R1212-14
EA
RADIAN
1R1212-15
EA
RADIAN
1R1212-77
EA
RADIAN
1R1212-78
EA
RADIAN
1R1212-79
EA
RADIAN
1R1212-80
EA
RADIAN
1R1212-2
EA
RADIAN
1R1212-1
EA
RADIAN
1R1212-45
EA
RADIAN
1R1212-58
EA
RADIAN
1R1212-59
EA
RADIAN
1R1212-60
EA
RADIAN
1R1212-61
EA
RADIAN
1R1212-62
EA
(LABEL)
RADIAN
1R1212-65
EA
1FU3
(LABEL)
RADIAN
1R1212-67
EA
1FU2
(LABEL)
RADIAN
1R1212-66
EA
38
LOAD J6
60 A RECPT
(LABEL)
39
LOAD J7
60 A RECPT
(LABEL)
40
LOAD J8
60 A RECPT
(LABEL)
41
LOAD J9
60 A RECPT
(LABEL)
42
LOAD J10
60 A RECPT
(LABEL)
43
LOAD J11
100 A RECPT
(LABEL)
44
LOAD J12
100 A RECPT
(LABEL)
45
LOAD J13
100 A RECPT
(LABEL)
46
LOAD J14
100 A RECPT
(LABEL)
47
LOAD J2
15 A RECPT
(LABEL)
48
LOAD J1
15 A RECPT
(LABEL)
49
LOAD J15
200 A INPUT
(LABEL)
50
NORMAL
(LABEL)
51
TRANSFORMER
HIGH TEMP
(LABEL)
52
A PHASE
ENERGIZED
(LABEL)
53
B PHASE
ENERGIZED
(LABEL)
54
C PHASE
ENERGIZED
(LABEL)
55
2FU1
56
57
MAY 17, 2002
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TABLE A.1-1
FIND
REF.
MFG.
PART NO.
QTY
U/M
58
1FU1
(LABEL)
RADIAN
1R1212-65
EA
59
2ACB2 LOAD J4
(LABEL)
RADIAN
1R1212-9
EA
60
2ACB4 LOAD J6
(LABEL)
RADIAN
1R1212-16
EA
61
2ACB6 LOAD J8
(LABEL)
RADIAN
1R1212-18
EA
62
2ACB8 LOAD J10
(LABEL)
RADIAN
1R1212-20
EA
63
2ACB10 LOAD J12
(LABEL)
RADIAN
1R1212-27
EA
64
2ACB12 LOAD J14
(LABEL)
RADIAN
1R1212-29
EA
65
4ACB MAIN
(LABEL)
RADIAN
1R1212-40
EA
66
3ACB2 MISSION
ESSENTIAL
RADIAN
1R1212-30
EA
(LABEL)
67
2ACB11 LOAD J13
(LABEL)
RADIAN
1R1212-28
EA
68
2ACB9 LOAD J11
(LABEL)
RADIAN
1R1212-26
EA
69
2ACB7 LOAD J9
(LABEL)
RADIAN
1R1212-19
EA
70
2ACB5 LOAD J7
(LABEL)
RADIAN
1R1212-17
EA
71
2ACB3 LOAD J5
(LABEL)
RADIAN
1R1212-10
EA
72
2ACB1 LOAD J3
(LABEL)
RADIAN
1R1212-8
EA
73
1ACB2 LOAD J2
(LABEL)
RADIAN
1R1212-7
EA
74
1ACB2 LOAD J1
(LABEL)
RADIAN
1R1212-6
EA
75
XFMR HIGH TEMP

OVERIDE SWITCH
RADIAN
1R1212-68
EA
(LABEL)
76
OVERIDE
(LABEL)
RADIAN
1R1212-63
EA
77
A PHASE
(LABEL)
RADIAN
1R1212-46
EA
MAY 17, 2002
DESCRIPTION
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TABLE A.1-1
FIND
REF.
DESCRIPTION
MFG.
PART NO.
QTY
U/M
78
OUTPUT 1
(LABEL)
RADIAN
1R1212-49
EA
79
TRANSF.
(LABEL)
RADIAN
1R1212-50
EA
80
OUTPUT 2
(LABEL)
RADIAN
1R1212-51
EA
81
B PHASE
(LABEL)
RADIAN
1R1212-47
EA
82
OUTPUT 1
(LABEL)
RADIAN
1R1212-49
EA
83
TRANSF.
(LABEL)
RADIAN
1R1212-50
EA
84
OUTPUT 2
(LABEL)
RADIAN
1R1212-51
EA
85
C PHASE
(LABEL)
RADIAN
1R1212-48
EA
86
OUTPUT 1
(LABEL)
RADIAN
1R1212-49
EA
87
TRANSF.
(LABEL)
RADIAN
1R1212-50
EA
88
OUTPUT 2
(LABEL)
RADIAN
1R1212-51
EA
89
INCOMING
CABLES
RADIAN
1R1212-55
EA
(LABEL)
90
A
PHASE
RADIAN
1R1212-52
EA
(LABEL)
91
OUTPUT 2
LOAD CONN.
RADIAN
1R1212-57
EA
(LABEL)
92
OUTPUT 1
LOAD CONN.
RADIAN
1R1212-56
EA
(LABEL)
93
B
PHASE
RADIAN
1R1212-52
EA
(LABEL)
94
C
PHASE
RADIAN
1R1212-54
EA
(LABEL)
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LOW VOLTAGE
Figure A.1-1A & Figure A.1-1B illustrates the Low Voltage (LV) front and side view of the SDC. Table
A.1-1 identifies the parts identified in the Figure. References to various electrical components in the
REF. column throughout this appendix refer to the schematic diagram, Appendix C.
FIGURE A.1-1A
MAY 17, 2002
SDC LOW VOLTAGE
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FIGURE A.1-1B
MAY 17, 2002
SDC LOW VOLTAGE
96
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SDC HIGH VOLTAGE
Figure A.1-2 illustrates the High Voltage (HV) view of the SDC. Table A.1-1 identifies the parts identified
in the Figure. References to various electrical components in the REF. column throughout this appendix
refer to the schematic diagram, Appendix C.
FIGURE A.1-2
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SDC HIGH VOLTAGE (HV) VIEW
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SDC PLAN VIEW

Figure A.1-3 illustrates the plan view of the SDC. Table A.1-1 identifies the parts identified in the Figure.
FIGURE A.1-3
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SDC PLAN VIEW
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END SECTION VIEW
Figure A.1-4 illustrates the end section view of the SDC. Table A.1-1 identifies the parts identified in the
Figure.
FIGURE A.1-4
MAY 17, 2002
END SECTION VIEW
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LOAD J3
60A RECPT
LOAD J4
60A RECPT
LOAD J5
60A RECPT
LOAD J6
60A RECPT
1ACB1 LOAD J1
1ACB2 LOAD J2
LOAD J7
60A RECPT
2ACB1 LOAD J3
2ACB2 LOAD J4
2ACB3 LOAD J5
2ACB4 LOAD J6
2ACB5 LOAD J7
2ACB6 LOAD J8
2ACB7 LOAD J9
2ACB8 LOAD J10
2ACB9 LOAD J11
2ACB10 LOAD J12
2ACB11 LOAD J13
2ACB12 LOAD J14
LOAD J8
60A RECPT
LOAD J9
60A RECPT
LOAD J10
60A RECPT
LOAD J11
100A RECPT
LOAD J12
100A RECPT
LOAD J13
100A RECPT
LOAD J14
100A RECPT
3ACB MISSION
ESSENTIAL
4ACB MAIN
LOAD J1
15A RECPT
M.E.P. J15
200A INPUT
LOAD J2
15A RECPT
FIGURE A.1-5A
MAY 17, 2002
SDC LOW VOLTAGE LABELS
100
SDC 8/60 4/100 COMM
USA TM 9-6115-485-14&P
FIGURE A.1-5B
MAY 17, 2002
SDC HIGH VOLTAGE LABELS
101
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A.2
OTHER SDC ITEMS
The items identified in Table A.2-1 are provided with the SDC.
TABLE A.2-1
OTHER SDC ITEMS
ITEM
NSN/PN
P/N 1R0256
DESCRIPTION / VENDOR CAGE & PART NO.
QTY
U/M
EA
#6 BARECOPPER WIRE, 6 FEET LONG
EA
MANUAL, SECONDARY DISTRIBUTION CENTER (SDC),

150kVA 8 EACH, 60 AMPERE, 4 EACH, 100 AMPERE
Radian Inc. CTM01646.1R0256
ELASTIMOLD
165LR-A-5240
200 AMP, 15KV LOADBREAK ELBOW FOR 5KV CABLE

(AF HARVEST FALCON)
EA
165LR-B-5240
200 AMP, 15KV LOADBREAK ELBOW FOR 15KV CABLE
EA
COOPER P/N
ISB215
PARKING STAND, 15KV, 200AMP COOPER P/N ISB215
EA
CAP, INSULATING
EA
ELASTIMOLD
P/N 161SOP
6
ELASTIMOLD
P/N160DR
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APPENDIX B
EXPENDABLE SUPPLIES, MATERIALS AND SPECIAL TOOLS LIST
B.1
The expendable supplies and materials required to support the SDC are identified in Table B.1-1.
Equivalent consumables are acceptable if the recommended materials are not available.
TABLE B.1-1
EXPENDABLE SUPPLIES AND MATERIALS LIST
DESCRIPTION
SPECIFICATION
VENDOR
P/N & CAGE
NSN
U/M
Sheet
MMM-A-1617, TY II
8040-00-664-4318
Pint
Use approved solvent.
Pint
7930-00-249-8036
Lot
MIL-L-2104C
9150-00-165-9435
Pint
8040-00-843-0802
Tube
MIL-G-46886A
Tube
Compound, cleaning
(electrical)
6850-00-057-9360
Tube
Tape (black) vinyl,

electrical, wide
5970-00-689-3444-
Roll
Tape (red) vinyl, electrical,

wide
5970-00-339-1291
Roll
Tape (blue) vinyl,

electrical, wide
5970-01-017-7388
Roll
Tape (white) vinyl,

electrical, wide
5970-00-832-4299
Roll
Tape, masking
7510-00-266-6711
Roll
Primer
Can
Paint, Desert Tan,

lusterless, color 33446 per
FED-STD-595
TT-E-529
Quart
Paint, olive drab, color

34088 per FED-STD-595
TT-E-529
Quart
Rag, wiping
7920-00-205-1711
Each
Sleeving, insulation, heat

shrinkable, 1 in dia.
5970-00-944-1450
Roll
Sandpaper
Adhesive
Cleaning solvent
Detergent
Lubrication oil
(Mechanical)
Silicon adhesive/sealant
Silicon grease
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B.2
SPECIAL TOOLS LIST
Table B.2-1 identifies special tools required for servicing the SDC. Table B.2-2 identifies crimping tool
requirements.
TABLE B.2-1
SPECIAL TOOLS LIST
DESCRIPTION
Crimping Tool (See Table
B.2-2 for manufacturers and
die configurations)
SPECIFICATION
NUMBER
VENDOR
P/N & (CAGE)
NSN
U/M
Each
Biddle
247001
Each
Digital Low Resistance

Ohmmeter
Lineman Gloves, 5,000V,
14-in. Large rolled edge cuff,
black, size 10
Pair
Hot Line Stick
81348
GGG-H-00134-1
Each
Megohmmeter Megger
Fluke 1520
Each
Multimeter
Fluke 87
Each
Phase Sequence Meter
Biddle 560060
Each
Transformer Turns Ratio

(TTR) Test Set
Biddle 550503
Each
Circuit Breaker Test Kit
Biddle
MS-2-115
Each
MAY 17, 2002
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TABLE B.2-2 CRIMPING TOOL AND DIE PART NUMBERS
5/8 DIAMETER
CONNECTOR
BARREL DIA.
NO. 4 THRU 2/0 STRANDED
CONDUCTOR SIZE
TOOL
BURNDY
DIE
Y34
Y35 OR Y39
3/4 DIAMETER
3/0 4/0 STRANDED
MD6
Y34
Y35 OR Y39
A243
U243
UBG
W243
WBG
U247
A25
AR
U25ART
U687
BG
W68
7
A27AR
NOSE
U247
MD6
U467
W247
U27ART
SOMERSET
TOOL
UT-3
UT-5
UT-15
UT-5
UT-15
(T AND B)
DIE
5/8
TV
54 H
TV
66
H-1, H-2
TOOL
KEARNEY
DIE
5/8
NOS
E
9/16
H-1, H-2
9/16
572
737
747
737
TOOL
12A
12A
DIE
B24 EA
B39 EA
ANDERSON TOOL
VC-5, VC-6
VC-5, VC-6
EEI REFERENCE
8A
10A
ALCOA
MAY 17, 2002
105
SDC 8/60 4/100 COMM
747
USA TM 9-6115-485-14&P
MAY 17, 2002
106
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APPENDIX C
SCHEMATIC DIAGRAM
C.1
SCHEMATIC DIAGRAM
Figure C.1-1 provides the electrical schematic for the SDC.
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MAY 17, 2002
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SDC 8/60 4/100 COMM
MAY 17, 2002
109
FIGURE C.1-1 SDC SCHEMATIC DIAGRAM
SDC 8/60 4/100 COMM
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MAY 17, 2002
110
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END OF MANUAL
USA TM 9-6115-485-14&P

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COMMERCIAL TECHNICAL MANUAL

COPYRIGHT 2001 RADIAN INC.

MAY 17, 2002

SDC 8/60 4/100 COMM

MAY 17, 2002

SDC 8/60 4/100 COMM

MAY 17, 2002

SDC 8/60 4/100 COMM

MAY 17, 2002

SDC 8/60 4/100 COMM

MAY 17, 2002

SDC 8/60 4/100 COMM

MAY 17, 2002

SDC 8/60 4/100 COMM

MAY 17, 2002

SDC 8/60 4/100 COMM

MAY 17, 2002

SDC 8/60 4/100 COMM

MAY 17, 2002

SDC 8/60 4/100 COMM

THIS PAGE IS INTENTIONALLY BLANK

MAY 17, 2002

SDC 8/60 4/100 COMM

COMMERCIAL TECHNICAL MANUAL (CTM) 01646.1R0256

CHAPTER 1.0 INTRODUCTION

REPORTING MANUAL/EQUIPMENT IMPROVEMENT RECOMMENDATIONS

EQUIPMENT DESCRIPTION AND DATA

PURPOSE, CAPABILITIES AND FEATURES

LOCATION OF MAJOR COMPONENTS

SDC DIMENSIONS, WEIGHTS AND POWER REQUIREMENTS

CHAPTER 2.0 ASSEMBLY AND INSTALLATION

MAY 17, 2002

SDC 8/60 4/100 COMM

UNLOADING AND INSPECTION UPON RECEIPT

GROUND ROD INSTALLATION

CONNECTING CABLES TO SDC

HIGH VOLTAGE SIDE

HIGH VOLTAGE SIDE

LOW VOLTAGE SIDE

MISSION ESSENTIAL POWER CONNECTIONS

PRIMARY POWER MODE CHECKS

MISSION ESSENTIAL MODE CHECKS

PREPARATION FOR MOVEMENT

SHORT TERM STORAGE

LONG TERM STORAGE

CHAPTER 3.0 OPERATIONS

OPERATORS CONTROLS AND INDICATORS

OPERATIONAL CHECKS AND PROCEDURES

MISSION ESSENTIAL POWER MODE

MEP MODE SHUTDOWN

MAY 17, 2002

SDC 8/60 4/100 COMM

OPERATING IN EMERGENCY CONDITIONS

OPERATING IN UNUSUAL CLIMATIC CONDITIONS

CHAPTER 4.0 MAINTENANCE

PREVENTIVE MAINTENANCE CHECKS AND SERVICES

GENERAL WIRE AND CABLE REPAIR

GENERAL ENCLOSURE REPAIR

GASKETS, INSULATION, AND INFORMATION PLATES

LOW VOLTAGE FUSES

MAY 17, 2002

SDC 8/60 4/100 COMM