Instruction & Maintenance Manual
BOLT-LOC Type BP Switches - Series 2
Manual Number: 9810-10
Date: August, 1991
WARNING INSTRUCTIONS
TURN OFF SWITCH before removing or installing fuses.
TURN OFF POWER ahead of switch before doing work inside.
Replace all parts per instruction manual and close door before turning power ON.
General (800-4000 Amperes)
Type BP switches utilize a bolted pressure technique for reliable high current connections, featuring a quick-make, quick-break stored energy mechanism. This mechanism ensures anti-tease operation by moving switch blades at high speeds, irrespective of the operating handle's speed. The spring-operated mechanism requires both springs to be charged before manual closing. Once the closing spring is discharged, the switch can be opened manually or electrically (if equipped).
These switches comply with Underwriters Laboratories Standard UL977: Fused Power Circuit Devices. With Class L fuses, they are UL listed for circuits up to 600VAC maximum, capable of interrupting 200,000 RMS symmetrical amperes. The basic switch can interrupt 12 times its continuous ampere rating at 240, 480, and 600VAC.
Cable Connections: Adequate support for line and load cables is crucial to maintain switch function.
Square D Company Technical Service Division: Available for troubleshooting, start-up service, testing, maintenance, retrofit, and consultation. Contact: 1-(800) 634-2003.
Maintenance (800-4000 Amperes)
Periodic cleaning and lubrication are required. The factory-applied lubrication is sufficient initially. Maintenance intervals depend on usage and ambient conditions, with a maximum of one year for current-carrying parts and five years for the operating mechanism.
Lubrication Instructions
Ensure the switch is open and both springs are discharged before lubricating.
A. Current Carrying Parts
The blade/hinge contact area is factory lubricated. When needed, clean the area with CRC type CO contact cleaner #02016 (or equivalent) and a dry cloth. Apply a thin coat of Mobilith #21 grease to blade assemblies and line side terminal contact areas (refer to Figures 14 & 15 for specific models). Do not disassemble the blade from the hinge. Mobilith #21 grease is available from Mobil Oil Corporation or Square D Company.
B. Operating Mechanism
For 800-2000 Ampere switches, general refubrication with molybdenum disulfide impregnated grease is needed at least every 5 years. For 2500-4000 Ampere switches, relubricate the front cam, clutch pin (Figure 2), spring crank contact area (Figure 2), and the roller/pivot point of the closing latch (Figure 1) with molybdenum disulfide impregnated grease at least every 5 years. Other bearing surfaces (front latch pin, operator plate assembly needle bearing, etc.) may require sparing use of #20 weight oil depending on ambient conditions.
C. Arc Tips, Arc Suppressors
Check blade and stationary arc tips and arc suppressors for excessive wear and looseness (see Figures 14 & 15). Contact Square D Technical Service Division for replacement or inspection.
Exercising Operating Mechanism
The operating mechanism should be exercised periodically, not exceeding one year, to ensure proper operation.
Operation (800-2000 Ampere)
Manual Operating Mechanism
To Close:
- Ensure the fuse access door is closed and securely fastened with screws.
- Rotate the large handle counterclockwise from horizontal to the vertical position until it stops.
- Rotate the large handle clockwise from the vertical position to the horizontal position until the switch closes. Note: Resistance will be felt approximately 15 degrees from horizontal; continue rotating past this point.
CAUTION: Operate the handle as instructed to prevent mechanism damage.
To Open:
- Ensure the fuse access door is closed and securely fastened with screws.
- Rotate the small handle clockwise until the switch opens.
Note: Photos illustrate an upright switch. For inverted switches, the operation direction is the same, but the handle position differs.
PHOTO 1: Shows the fuse access door closed and fastened.
PHOTO 2: Shows the large handle in the horizontal position before closing.
PHOTO 3: Shows the large handle in the vertical position after initial rotation.
PHOTO 4: Shows the large handle in the horizontal position after closing the switch.
PHOTO 5: Illustrates the point of resistance felt during the closing operation.
PHOTO 6: Shows the small handle being rotated clockwise to open the switch.
Operation (2500-4000 Ampere)
Manual Operating Mechanism
The stored energy mechanism operates on a close-open cycle only and is interlocked to prevent incorrect sequences. To operate, both opening and closing springs must be charged, and either the door must be closed or the mechanism interlock defeated.
Note: Figure 3 illustrates an upright switch. For inverted switches, the handle direction is the same, but it points downwards.
To charge operating mechanism springs:
- Rotate the charging (large) handle counterclockwise approximately 90 degrees until the opening spring is latched.
- Rotate the charging (large) handle clockwise approximately 180 degrees until the closing spring is latched.
- The handle return spring will return the charging handle to a vertical position, which is its required position for switch operation.
With springs charged, the switch closes by manually rotating the manual trip handle clockwise until the closing spring releases. The stored energy opens the switch.
To open the switch manually, rotate the manual trip handle counterclockwise until the opening spring releases.
FIGURE 3: Front View (2500-4000 Ampere) shows the operating mechanism with components like the charging handle, manual trip handle, and points for spring charging.
Operation (800-4000 Amperes)
Electric Trip Operating Mechanism
Switches equipped with the electric trip option can be opened manually or electrically. Energizing the electric trip solenoid (Figure 4 for 800-2000A, Figure 6 for 2500-4000A) releases the opening spring. This can be initiated by a push button, blown main fuse detector, or a ground fault detector system. Power can only be supplied to the solenoid when the switch is closed, as the limit switch (Figure 4 or Figure 1) is only closed in the switch's closed position. Refer to the schematic diagram on page 16.
FIGURE 4: Illustrates the Electric Trip Mechanism for 800-2000 Ampere switches.
FIGURE 6: Shows the Electric Trip Mechanism, Position Indicator, and Solenoid for 2500-4000 Ampere switches.
Position Indicator
Located on the front of the operating mechanism and visible through a cover opening, the position indicator displays "CLOSED" or "OPEN", reflecting the state of the current-carrying parts.
FIGURE 5: Switch Position Indicator for 800-2000 Ampere switches.
FIGURE 6: Also shows the Position Indicator for 2500-4000 Ampere switches.
Mechanism Interlock
This interlock mechanically locks the operating mechanism when the fuse door is opened, preventing manual trip handle rotation. (See Figure 7 for 800-2000A, Figure 6 for 2500-4000A).
FIGURE 7: Mechanism Interlock for 800-2000 Ampere switches, showing how the handle is prevented from moving when the door is open.
Fuse Door Interlock
For 800-2000 Ampere switches, the fuse door interlock prevents opening the door when the switch is closed. It can be overridden by qualified personnel by inserting a screwdriver into the interlock bypass screw and turning clockwise (see Figure 8).
FIGURE 8: Fuse Door Interlock Defeat for 800-2000 Ampere switches, illustrating the bypass screw.
For 2500-4000 Ampere switches, the interlock prevents door opening in either the open or closed position. It can be overridden by qualified personnel by removing the charging handle and turning a screwdriver in the door interlock defeat screw counterclockwise (see Figure 9).
FIGURE 9: Fuse Door Interlock Defeat for 2500-4000 Ampere switches, showing the bypass screw and the need to remove the charging handle.
Adjustments (800-4000 Amperes)
The operating mechanism and switch blade components are designed and assembled to not require field adjustments under normal operating conditions. The open gap is factory-set. Contact pressure is controlled by the switch design. For any required adjustments, contact Square D Technical Services.
Padlocking Instructions (800-4000 Amperes)
Padlocking is only possible when the switch is in the OPEN position. The design accommodates three 3/8" diameter shackle padlocks.
- Trip the switch to the open position as per operating instructions.
- For 800-2000 Ampere switches, slide padlocks through the holes and secure.
- For 2500-4000 Ampere switches, push in the padlock bar and secure. (See Figure 10B).
Inserting padlocks renders the switch inoperative.
FIGURE 10A: Padlock Provisions for 800-2000 Ampere switches.
FIGURE 10B: Padlock Bar for 2500-4000 Ampere switches.
Key Interlock Instructions
(800-2000 Amperes): An optional key interlock, Catalog Number BPKIP20, can lock the switch open. The assembly is mounted adjacent to the charging handle (See Figure 11A). With the mechanism uncharged (open), turning the key extends the lock bolt, rendering the mechanism inoperative.
(2500-4000 Amperes): An optional key interlock, Catalog Number BPKIP40, can lock the switch open. The assembly is mounted below the padlocking bar (see Figure 11B). With the mechanism uncharged (open), push in the padlock bar and turn the key to extend the lock bolt, rendering the mechanism inoperative.
FIGURE 11A: Key Interlock for 800-2000 Ampere switches.
FIGURE 11B: Key Interlock for 2500-4000 Ampere switches.
Phase Barrier Removal and Installation
(800-2000 Amperes)
Removal:
- Remove 4 spring clips securing the phase barrier shield and lift it off the barrier tabs.
- Remove 8 spring clips securing the phase barrier front and lift it off the barrier tabs.
- Lift individual phase barriers from their supports on the switch base.
Installation:
- Slide individual phase barriers into their supports on the switch base, seating the notch against the supports.
- Place the phase barrier front onto the phase barriers, aligning slots with tabs, and install 8 spring clips.
- Place the phase barrier shield over the blades and tabs, installing 4 spring clips.
FIGURE 12: Illustrates the Phase Barrier components and installation/removal steps for 800-2000 Ampere switches, showing barrier supports, clips, and shield placement.
Phase Barriers (2500-4000 Amperes)
Removal: Remove two 1/4-20 screws from each phase barrier and lift them out (see Figure 13).
Installation: Position tabs of the phase barriers into the slots in the base and align holes with arc suppressor holes. Install two 1/4-20 screws and torque to 25-30 in-lbs. Repeat for all phases.
FIGURE 13: Shows the Phase Barriers for 2500-4000 Ampere switches, illustrating screw removal for access and installation alignment.
Switch Nomenclature, Side View
FIGURE 14: Switch Side View (800-2000 Ampere) labels key components including Line Side Terminal, Blade, Blade Arc Tip, Stationary Arc Tip, Arc Suppressor, Operating Mechanism, Charging Handle, Connecting Rod, and Load Side Terminal.
FIGURE 15: Switch Side View (2500-4000 Ampere) labels similar components to Figure 14, including Base Mounting Channel, Hinge, Blade Stop, and notes lubrication points for Mobilith #21 grease on blade connections and line side terminals.
Accessories & Replacement Parts
(800-2000 Amperes)
| Item | Description | Part Number |
|---|---|---|
| 1 | Electric Trip Kit | BPET20 |
| 2 | Charging Handle | 40556-063-01 |
| 3 | Solenoid (Specify 120 VAC or 240 VAC) | 44003-125-01 |
| 4 | Limit Switch | 40556-129-50 |
| 5 | Door Interlock Assembly | 40556-124-50 |
| 6 | Key Interlock Bracket Kit | BPKIP20 |
| 7 | Auxiliary switch Kit | BPAS20 |
| 8 | Inverted Switch Barrier Kit | BPINV20 (upright) 40274-796-01 (inverted) 40274-797-01 |
| 9 | Position Indicator Nameplate | 40274-796-01 (upright) 40274-797-01 (inverted) |
| 10 | Blown Main Fuse Detector | BPBMFD |
(2500-4000 Amperes)
| Item | Description | Part Number |
|---|---|---|
| 1 | Electric trip Kit | BPET40 |
| 2 | Solenoid (specify 120 VAC or 240 VAC) | 44003-125-01 |
| 3 | Limit Switch | 4090016 |
| 4 | Door Interlock Kit | B44003-312-50 |
| 5 | Charging Handle | 44005-077-01 |
| 6 | Position Indicator Nameplate | 44005-031-01 (Upright) 44005-032-01 (Inverted) |
| 7 | Key Interlock Provision Kit | BPKIP40 |
| 8 | Auxiliary switch Kit | BPAS40 |
| 9 | Inverted Switch Barrier Kit | BPINV30 (2500A-3000A) |
| 10 | Blown Main Fuse Detector | BPBMFD |
Ordering Instructions: When ordering replacement parts, provide part descriptions and complete nameplate data (CLASS, TYPE, MANUFACTURING NUMBER, OPTIONS).
Options
Field or Factory Installed
| Item | Description | Field Installable Kit Catalog Number (800-2000A) | Field Installable Kit Catalog Number (2500-4000A) |
|---|---|---|---|
| 1 | Key Interlock Provisions (order keyed interlock separately) | BPKIP20 | BPKIP40 |
| 2 | Auxiliary Switch | BPAS20 | BPAS40 |
| 3 | Blown Main Fuse Detector | BPBMFD | BPBMFD |
Operation and installation instructions are included with each option.
Factory Installed Only
| Item | Description |
|---|---|
| 1 | Electric Trip |
| 2 | Ground Fault Protection |
| 3 | Capacitor Trip Unit |
| 4 | Phase Failure Relay |
| 5 | Ammeter/Voltmeter |
| 6 | Ammeter and Switch |
| 7 | Control Power Transformer |
| 8 | Potential Transformers for Voltmeters |
| 9 | Current Transformers for Ammeters |
| 10 | Grounded B Phase |
| 11 | Tie Switch |
Ordering Instructions for Options: Provide option catalog number and complete switch nameplate data, including series number and other pertinent information.
Square D Technical Service Division: Contact for troubleshooting, start-up service, testing, maintenance, retrofit, and consultation. Phone: 1-(800) 634-2003.
Wiring Diagram with Electric Trip Option (800-4000 Amperes)
The diagrams illustrate control wiring for the electric trip mechanism, which can be activated by a remote push button, a blown main fuse detector (BMFD), or other signals. Control power (120/240 VAC 60 HZ) requires a customer-supplied fuse. A transient suppressor (Class 8501 Type GG) is required when using a Class 6640 Type GP MP1 Monitor Panel with a BMFD or remote push button (for 120 VAC trip coils only).
FIGURE 16: Wiring Diagram (Standard Diagrams Form "E") shows the schematic for electric trip operation using a remote push button and control power.
FIGURE 17: Wiring Diagram (Modified Diagrams Form "BIE") shows the schematic triggered by a Blown Main Fuse Detector or Remote Push Button, including control wiring fuse details and BMFD control circuit contacts.
Legend: Explains symbols for external power connections, electric trip coil, limit switch contacts (closed when switch is closed), BMFD, and transient suppressor.
Notes: Detail usage for single operator electric-trip, solenoid ratings (120/240 VAC 60 HZ), minimum control power transformer requirements (1 KVA for 120 VAC coil), and minimum operating voltage for the electric trip coil (55% of rated voltage).
Fuse Installation (2500-3000 Ampere)
IMPORTANT INSTRUCTIONS FOR FUSE REMOVAL AND INSTALLATION:
TURN OFF SWITCH BEFORE REMOVING OR INSTALLING FUSES.
If fuses are above the mechanism:
- Remove the fuse to the left of the center fuse before removing the center fuse.
- Install the center fuse before installing the fuse to the left of the center fuse.
If fuses are below the mechanism:
- Remove the fuse to the right of the center fuse before removing the center fuse.
- Install the center fuse before installing the fuse to the right of the center fuse.
FIGURE 18: Illustrates the fuse installation process, highlighting the fuse holders and the sequence for removal/installation.
Dimension Drawings
The document includes detailed dimension drawings for both 800-2000 Ampere and 2500-4000 Ampere switches. These drawings cover:
- Mounting Dimensions: Providing specifications for base mounting channels and overall unit dimensions.
- Ventilation Requirements: Detailing minimum ventilation clearances required around the enclosures for proper operation and heat dissipation.
- Front Panel Openings and Drillings: Specifying dimensions for panel cutouts, handle openings, interlock provisions, and nameplate mounting for both upright and inverted switch configurations.
- Enclosure Door Shield and Alternate Materials: Information on door shields and their mounting.
These dimensions are critical for proper installation and integration into electrical systems.
