Switchgear Maintenance Specification

Table of Contents
Contents 1
Contents 2

1. Introduction
1.1 General 3
1.2 Safety 3
1.3 Qualifications 3

2. Maintenance Administration
2.1 Service Sales Policy 4
2.2 Hours of Work 4
2.3 Scope of Work 4
2.4 Dealership Deductions 4
2.5 Dealership Responsibilities 4
2.6 Scheduling 5
2.7 Cancellation 5
2.8 Invoicing 5
2.9 Warranty 5

3. Maintenance and Inspection Guidelines

3.1 New Equipment 6
3.2 Maintenance Requirements 6
3.3 Environmental Consideration 6
3.4 Record Keeping 6
3.5 Inspection Cycle 7
3.6 Maintenance and Training 7
3.7 Repair Parts 7

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Table of Contents (cont)
4. Maintenance Requirements

4.1 General 8
4.2 Visual Inspection 8
4.2.1 Enclosure 8
4.2.2 Layout 8
4.2.3 Circuit Breakers 8
4.2.4 Protective Relays 8
4.2.5 Controls 8
4.3 Service Inspection
4.3.1 Enclosure 9
4.3.2 Controls 9
4.3.3 Circuit Breakers 10
4.3.4 Protective Relays 11
4.3.5 Grounds 11
4.3.6 Batteries 11
4.3.7 Communications 11
4.3.8 Remote PC, Displays and annunciation 11

4.4 System Test Requirements 12

4.4.1 Mode Testing 12
4.4.2 System Test 12

5. Documentation and Reports

5.1 General 13
5.2 Dealer Service Report 13
5.3 Equipment Maintenance and Inspection Report 13
5.4 Miscellaneous Maintenance and Inspection Report 13

Appendix
Sample Reports
- Daily Service report
- Switchgear Maintenance Summary
- Annual Maintenance Summary
- Low Voltage Maintenance Checklist
- Medium Voltage Maintenance Checklist

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1. Introduction
1.1 General
The purpose of this document is to outline equipment service and support policies and procedures
for Cat Switchgear products. This document is meant to provide general guidance for establishing a
maintenance program, communicating with the manufacturer and administration of Cat Switchgear
support. This document does not constitute a binding agreement and is not meant to serve as the
source document with regard to warranty, system operation, service contracts, pricing or service
sales. Specific policy documents are provided with purchased equipment, service agreements or
upon request. The information included in this document is current at time of publication. Please
contact Cat Switchgear with regard to conflicts with existing policies or procedures.

1.2 Safety
Most accidents that involve product operation, maintenance and repair are as a result of failing to
obey basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skill and tools to perform these functions properly
and safely. Caterpillar cannot anticipate every possible circumstance that might involve a potential
hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a
tool, procedure, work method or operating technique is chosen and not specifically recommended
by Caterpillar is used, you must assure that these actions are safe for you and others, equipment will
not be damaged or made unsafe by the methods you choose.

1.3 Qualifications
For the purpose of maintaining Cat Switchgear, qualified Caterpillar Technicians are those who
have participated in required product training and completed Level one (1) or Level two (L2)
certification programs through Caterpillar Electric Power training and certification process.
Specialized maintenance and testing such as circuit breaker testing, infrared scanning, hi-potential
testing, protective relay testing (with test device) and NETA testing, as examples, are not included
as part of the L1/L2 certification process. When required, these tests should only be performed by
those service engineers having received specialized training. Caterpillar recommends that
maintenance and repair of Cat Switchgear be performed by Caterpillar certified technicians and that
only original Cat Switchgear replacement parts are used. Qualification status can be verified by
contacting Cat Switchgear helpdesk at (866) 883-3879 or helpdesk@cat-iso.com. Switchgear Training
course information and schedule is available on the Caterpillar web site (DLMS) or by contacting Cat
Switchgear directly at (770) 442-9442.

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2. Maintenance Administration
2.1 Service Sales
Caterpillar service and repair parts may only be purchased through a Cat dealership. All service
quotes and purchase orders are subject to Cat Switchgear standard terms and conditions and may
carry project specific terms and conditions as requested by the individual customer. Specific terms
if applicable will be included in the service quote, contract or agreement.

2.2 Hours of Work

Unless otherwise stated all work will be performed between the hours of 7:30 AM and 5:00PM.
Should employees be required to work outside of normal business hours, the customer will be
invoiced separately according to our published rates unless included as part of a written agreement.

2.3 Scope of Work

Scope of work will be clearly defined within contract agreement and or quotation for services.
Should the customer request work be performed outside of the existing agreement or contract scope
of work, a Request for Quote (RFQ) shall be sent to Cat Switchgear for consideration. Any work
performed without formal authorization and not covered by written scope will not be covered under
existing warranties.

2.4 Dealership Deductions

The Dealership may be eligible for labor and expense deductions for services they perform as part
of the service agreement or contract. Deductions will be based on technical qualifications and
willingness to participate through performance of contracted services. Customer eligibility for
participation requires completion of Caterpillar Electric Power Training and Qualification Program
and Level 1/2 certification on Cat Switchgear products. Deductions, dealership responsibilities and
eligibility requirements are included in the terms and conditions of the agreement or contract and
priced accordingly. Dealerships are also eligible for a 10% discount on aftermarket parts and
services purchased in support of the equipment under contract.

2.5 Dealership Responsibilities

The dealership serves as the single point of contact to the equipment owner. The dealership is
responsible for communicating commercial terms and conditions, scheduling services and
performing those services as applicable to the specific service agreement or contract. Completed
service reports are required as part any service agreement.

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2.6 Scheduling
The dealership is responsible for scheduling services with equipment owner. The Caterpillar
Switchgear helpdesk should be notified with adequate lead time to for long lead materials,
personnel assignment and minimizing travel and expense (usually two weeks). Longer lead times
may be required for large projects or non Cat Switchgear product support.

Caterpillar Switchgear is responsible for providing method of procedure, required system conditions,
maintenance duration, test detail and communicating risk to loss of power continuity during
maintenance activity.

End user is responsible for establishing required system conditions for the completion of specified
maintenance and assuring equipment loads are protected for the duration of the maintenance period.
Cat Switchgear will not be responsible for contracted services not performed as a result of
equipment owner direction or inability to establish system conditions required to complete testing.

2.7 Cancellation
The dealership is responsible for providing advanced notice of service cancellation and is
responsible for any costs incurred by Cat Switchgear as a result of cancellation. Cancellation
expenses may include additional travel expense, equipment rental and any added expense associated
with rescheduling.

2.8 Invoicing
Invoicing terms and conditions are included with the service quotation. Service Agreements
exceeding one year may be invoiced up front or periodically on the anniversary of the agreement.
Service Agreements do not automatically renew upon expiration. Terms and pricing must be re-
negotiated upon expiration unless otherwise agreed to and included in the original terms of the
contract.

2.9 Warranty
Caterpillar Switchgear Aftermarket Warranty terms and condition govern those services and
materials provide by Cat Switchgear as part of this specification. No other representations,
guarantees or warranties, whether expressed or implied, are made by Cat Switchgear. Certificate of
Insurance and limits to liability are available upon request. Specifically excluded from any aftermarket
service sales agreement unless otherwise specified are:
Replacement of station batteries
Replacement of buswork or power cables
Repair of cabinet, enclosure or structure (other than minor touch-up painting)
Any compensation for authorized warranty work performed by the dealership in conjunction with this
agreement is administered through the Caterpillar Warranty (SIMSI) system.

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3. Maintenance and Inspection Guidelines
3.1 New Equipment
Cat Switchgear, installed by Caterpillar certified technicians in manufacturers recommended
environment, requires no scheduled maintenance other than routine housekeeping for the twelve (24)
month period following initial start up. This excludes station batteries and aftermarket products if
supplied with the system or by others, these products should be maintained per manufacturers
instruction. Housekeeping would include visual inspection, periodic removal of dust or debris,
review of system logs and verification of system status or displays.

3.2 Maintenance Requirements

It is the recommendation of Cat Switchgear that equipment be inspected annually, at a minimum,
starting the second year of equipment service. Annual inspection should include the visual, service
and test inspections outlined in sections 1-3 of this Maintenance Specification. When establishing
an equipment inspection cycle, consideration should be given with regard to critical nature of the
power application, environment the equipment is operated, age of the equipment and past inspection
results. Caterpillar Switchgear Service is available for consultation regarding maintenance planning
as required.

3.3 Environmental Consideration

For applications that include adverse environmental conditions such as high or low temperatures,
outdoor installation, high humidity or high particulate such dirt, dust, smoke, etc. more frequent
inspections should be considered. These type conditions are known to negatively impact useful
service life of electromechanical equipment and mitigated by a more aggressive inspection and
service cycle.

3.4 Record Keeping

Record keeping is an essential part of any maintenance program. Detailed records of equipment
scheduled and corrective maintenance, program changes and equipment modifications should be
maintained by the customer and with the equipment. Copies of service reports are required for
warranty claims and in support of service agreements or contracts. Sample report templates are
included in the appendix of this manual.

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3.5 Inspection cycle
Typical inspection cycle includes one to four inspection periods each year. These may include a
single annual inspection or a combination of visual, service and test inspections throughout the year
to complete the annual maintenance requirements. Figure 1 depicts general evaluation criteria
which may be used to establish an inspection cycle.

In this example an equipment owner with

aging equipment, in a moderate environment
for a non-critical manufacturing application
might elect a semi-annual maintenance plan.

Other service cycle considerations may

include maintenance cycle of like equipment
located within the facility, maintenance
history and local facility maintenance policy
and practices.

Only the manufacturers minimum service

requirements are clearly defined. Dealership
and the equipment owner experience is
essential in establishing a comprehensive
support plan.

Figure 1

3.6 Maintenance and Training

Support of this equipment requires specialized training and may require special tools, diagnostic
equipment or computer software. It is the recommendation of Caterpillar that maintenance and
repair only be performed by Caterpillar service staff specifically trained on this product. Repairs or
service performed by others including 3rd party electrical maintenance groups, unless specifically
authorized by the manufacturer are not covered by the customer service agreement nor would they
be warranted by the manufacturer.

3.7 Repair Parts

Original factory repair parts and system spares are available through Cat Switchgear and can be
ordered through the helpdesk or directly from CAT-ISO.com web site. Only original Cat repair
parts should be used in the maintenance and repair of this product. Materials furnished by others
are specifically excluded from the manufacturers warranty.

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4. Maintenance Requirements
4.1 General
Inspection points detailed below include the minimum manufacturers recommended requirements.
These inspection points may be performed during a single annual inspection or as part of a periodic
inspection cycle throughout the year. Inspection should be clearly documented and any
discrepancies noted should be addressed as quickly as possible. Due to hazards associated with
electric power, risk to equipment and equipment load, Caterpillar recommends that only Caterpillar
certified technicians perform this maintenance.

4.2 Visual Inspection Requirements

4.2.1 Switchgear Enclosure
Verify enclosures are properly anchored to the floor or switchgear pad
Verify enclosures are free from all moisture
Verify enclosures are properly coated and free from all rust or other corrosion
Verify enclosures are clean and free from all dust or other foreign debris
Verify enclosures are free from all signs of flash over or tracing
If supplied verify filters are in place and vents are not obstructed to air flow
4.2.2 Layout
Verify system layout corresponds with system one line located in the "G" drawings
Verify breaker cells are properly identified and match system one line
Verify breaker Amp frame and Amp trip match breaker schedule located in the "G" drawings
4.2.3 Circuit Breakers
For Digi Trip 1100 and 520 check for any logged faults (record as needed)
4.2.4 Protective Relays
Inspect relay and cases for physical damage
Note any alarm or warning

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4.2.5 Controls
Review event log as applicable, note alarms or warnings
Log all settings for the following items
System Generators Load Shed
Utility Gen Demand Priority
Verify system metering is accurate
Verify generator metering is accurate
Verify utility metering is accurate (if available)
Verify Tie metering is accurate (If availible)
Verify Distribution metering is accurate (If availible)
NOTE: System metering is verified during visual inspection through direct comparison with other
installed metering where available.

4.3 Service Inspection

4.3.1 Switchgear Enclosure
Verify heaters are operational
Verify enclosures are properly coated and free from all rust or other corrosion
Use touch up paint to cover any blatant scratches or bare metal as agreed to by site personnel
Verify enclosures are clean and free from all dust or other foreign debris
Clean as needed using soft bristle brush and vacuum (do not use compressed air)
Verify bus connections, power cables, splice bolts and mounting insulator
b l
Verify control wiring and connections, perform pull test and fastener check as applicable
Inspect sytem fuses and fuse holder for proper size and integrity
4.3.2 Controls
For Powerlynx PLC based controls verify Modbus Plus lights on the PLC's are flashing
For Powerlynx PLC based controls verify PLC "RUN" light is on
For Powerlynx PLC based controls verify Modbus Plus cables are secured properly
For Powerlynx 3.S based controls verify controller status indication, cabeling and connections
Verify system metering is accurate
Verify generator metering is accurate
Verify utility metering is accurate (If available)

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4.3.2 Controls (cont)
Verify Tie metering is accurate (If available)
Verify Distribution metering is accurate (If available)
NOTE: System metering is verified during maintenance inspection through direct comparison
with independent metering or test device.
Verfiy control wire connections (integrity and continuity)
Terminal blocks Control components CTs, VTs, PTs
Inspect metering PT's and control power transformers
Verify manual switches for free movement and contact continuity
Perform visual inspection of all wiring and connections for the following:
Tracking Overheating Insulation deterioration
Arcing Corona
4.3.3 Circuit Breakers
Discuss Circuit Breaker Testing with equipment owner. Breaker testing is limited to cleaning,
inspection and functional testing only.
For Digi Trip 1100 and 520 check for any logged faults (record as needed)
Verify protective settings are in accordance with coordination study (provided by customer)
Remove breakers (If allowed by customer)
Reference manufacturers maintenance guide prior to testing
Perform the following:
Pre-cleaning inspection
Using a DLRO test each breaker for contact resistance
Record reading on each breaker
Using a megger; test each breaker for dielectric insulation resistance
Record readings on each breaker
Clean and lubricate each breaker
Return breaker to service
Replace breakers and check electrical and manual close and trip operations

NOTE: Circuit breaker inspection should be omitted if section 4 of this procedure is performed
on a semi-annual bases. System mode testing outlined in section 5 should be performed if circuit
breaker service inspection in this section is completed.

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4.3 Service Inspection (cont)
4.3.4 Protective Relays
Discuss testing the protective relays with the equipment owner. Maintenance includes functional
testing of the relay only and does not constitute system protection test or setting evaluation.
Record the following
Model Number Serial Number Firmware Revision
Software Revision Control Voltage
Download all logged events (filtered and unfiltered)
Verify protective settings are in accordance with coordination study (provided by customer)
Using the test button on the relay; test the relay
4.3.5 Grounds
Verify all common and ground wire connection (integrity and continuity)
Tighten or repair as needed
Verify 24VDC negative is grounded to earth ground
4.3.6 Batteries
Discuss battery testing with the equipment owner, reference manufacturers installation and test
procedure.
Record station batteries model and date code information
Verify station battery connection
Verify connections are corrosion free
Verify connections are properly torqued
Record cell and float voltages, adjust per battery manufacturer's recommendation if required
Inspect and load test 24VDC best source
Inspect PLC battery, replace every 3 years or if last replacement date is unknown
4.3.7 Communications Network
Using MB Stat, Modscan 32 or Kepware monitor the network for error packets
4.3.8 Remote PCs and Touchscreen Panels
Verify all screens match what is displayed at the remote
Verify the system functionality, diplay graphics and screen refresh rate.

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4.4. System Test Requirements
4.4.1 Mode Testing
Reference system Sequence of Operations Page in the G Drawing Package, discuss Mode
testing, including overall system impact, with end user. Advise the equipment owner that the
utility must be removed from service to test the E-Mode and Load Shed

4.4.2 System Test

Review any locally generated or system specific test procedures. Using the Master Mode selector
switch; test each mode that is applicable to the project. Testing the emergency response mode (E-
Mode) can be done by one of the following:
Test with load switch (If supplied)
Individual ATS(s)
Test with load
Pulling the line jacks (Use extreme caution, should only be performed by facility or utility rep
Removing the Secondary VT fuses
Opening the utility breaker or switch

Note: If the utility breaker is controlled by PowerLynx the system will re-close the utility breaker
soon after opening. This should be expected

NOTE: The need for system mode testing should be evaluated following any system repair,
component replacement or system modification including program change. Additionally,
intrusive maintenance tasks such as breaker testing which requires removal from the cell would
warrant full or partial system test.

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5. Documentation and Reports
5.1 General
It is critical that equipment maintenance records are maintained for the life of the equipment and
that any changes to the equipment are formally documented. These records include scheduled
service reports, repair activity reports, modification to the system hardware or software.

Please send service information to:

helpdesk@cat-iso.com
or
Cat Switchgear
Attention: Helpdesk
Reference: Project Number
4955 Marconi Drive
Alpharetta, GA 30005

5.2 Dealer Service Report

Example reports are included in Appendix A, dealership generated forms are acceptable but must
include project number, date of service, technician name and contact information, numeric reference
to a specific service agreement, DSN or ticket number as well as a written description of services
provided and repair parts or materials consumed. Service reports are required as part of any service
contract agreement.

5.3 Equipment Maintenance and Inspection Report

Example maintenance records are included in Appendix A. These forms represent the basic
service reports required when performing scheduled maintenance. Completed forms are returned to
Caterpillar Switchgear for review, electronic filing and distribution to the dealership.

5.4 Miscellaneous Maintenance and Inspection Report

A service agreement may include specialized testing at the request of the end user. These include
Infrared Scanning, Protective Relay testing (with test set), High Potential (Hi Pot) cable testing,
NETA testing, etc. If included with a specific service agreement or contract these test when
performed require specific reports. These reports are not included as part of this document but are
available to technicians who have completed required training and are qualified to perform these
tests.

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