Welcome to today’s video, where we’re diving deep into the wiring, components, and functionality of the Square D 5000M switchgear, featuring an ERMS (Energy Reduction Maintenance Setting) kit. If you’re an electrical technician, engineer, or simply interested in understanding switchgear wiring, stick around as we walk through each component step-by-step!
1. Opening the Panel: Control Terminal Blocks
Here, you’ll find several blocks, including COM, UC1, UC2, and UC3, which form the communication and control backbone of the switchgear:
COM (Communication Terminal Block): This block is essential for relaying signals throughout the system. Four wires connect here, leading back to a communication device hidden behind the trip unit.
White Wire Routing: Follow the white wire across the panel, tracing how it routes from the control terminal block to the IOM (Input/Output Module). This route facilitates data transfer from the communication device to the module.
2. Tracing Connections: UC3 and the Neutral Bar
We’ll follow this connection down to see how the white neutral wire is integrated:
Wiring Route: The neutral wire loops down and eventually links to the neutral bar, completing the neutral circuit connection and ensuring proper grounding and stability in the system.
Power Supply for the Trip Unit: Alongside the neutral, two blue wires are connected, supplying DC power to the trip unit. This power setup keeps the unit activated, enabling it to display essential information.
3. Blue Screen Activation on Arm Switch
The functionality of the arm switch, which, when turned on, activates the trip unit display:
Blue Screen Indicator: The screen lights up in blue when the arm switch is engaged, providing a clear, visual confirmation that the ERMS feature is active and that the system is operating in reduced-energy mode for maintenance safety.
4. Black Tubing and Neutral Current Transformers (CTs)
Trace the black tubing, which contains multiple small wires routed to the rear:
Neutral CTs in the Back: Inside this tubing, we find connections to the neutral current transformers (CTs) at the back of the switchgear. These CTs monitor and control neutral current flow, playing a critical role in balancing the electrical load.
Wiring Path: Wires extend from the neutral CTs to the top and bottom connectors, establishing a reliable circuit for neutral current monitoring and regulation.
5. DC Power Supply Wiring and Transformer Step-Down
Transformer Overview: The 480V incoming power is stepped down to 120V AC through the control power transformer. Then, the power supply converts 120V AC to 24V DC, distributing the required DC voltage across various components.
Input/Output Paths: This includes a focus on the red and white wires leading up from the terminal blocks to the power supply, ensuring efficient power distribution.
6. Switch Wiring and IOM Module Integration
Wiring Connections: Three main wires-red, black, and white-link the switch to the IOM module. Additionally, a jumper wire connects the switch’s power to the module, completing the circuit for trip control.
Power Supply Links: Wire 33 connects the DC power source to the IOM module, ensuring adequate power, while the X2 connection reinforces power flow and reliable communication between the switch and module.
7. Communication Cord and BCMULP Module
The communication cord and its role in connecting to the BCMULP, a critical communication module behind the trip unit:
BCMULP Module Setup: This module receives data from the communication cord, allowing the ERMS system to send and receive information needed for managing energy settings and ensuring safety during maintenance.
DC Power Source: The blue DC input wires that connect to the BCMULP originate from the main power supply, sustaining the communication flow even when the switchgear is under load.
8. Final Power Distribution Path and Fuses
To wrap things up, we trace the power distribution through the fuse block:
480V Input to 120V Step-Down: Power enters from the 480V line side of the fuse block, then follows a series of connections that ensure smooth step-down and safe power distribution.
Fuse Configuration: Each fuse block is rated at 0.8 amps, guarding against potential overcurrent situations and protecting the critical components downstream.
9. System Overview and ERMS Activation
Finally, we’ll provide a comprehensive look at how all these connections enable the ERMS functionality:
Switch Activation and Display Response: Toggling the ERMS switch triggers the IOM module and trip unit to shift the system into safe, low-energy maintenance mode, confirmed by the blue screen indicating proper function.
Thanks for watching this detailed breakdown of the Square D 5000M switchgear with an ERMS kit. If you found this helpful, please like, comment, and subscribe for more technical deep dives. Let us know any questions you have in the comments. See you in the next video!