2. Red Tags
We all use them at some time but hate to see them when looking for
spares n’ parts. Too many times have I signed on as reefer to a ship that
only has crates of red tagged modules and no ready to go spares.
It is my hope that this presentation will encourage my fellow Union
Brothers to use their mechanical abilities to effectively rebuild even the
nastiest looking modules. Here we will rebuild the ones in these
pictures.
3.
4.
5. Tools
Wire brushes large and small
Bore brushes
Medium grain crocus cloth
7/16 ¼ drive ratchet and 7/16 nut driver
Long flat head screwdriver
Phillips head screwdriver
5/16 nut driver
Receptacle test equipment
Electrical parts cleaner
226 electrical parts lubricant
111 silicone valve sealant
6. Break it down
Most ESL 480V 32Amp modules with mechanical
safety interlocks can be easily broken down. On one
model it is necessary to secure ground pin plunger with a
ty-rap to the on/off plunger or it will spring out and cost
a lot of time reassembling. This module pictured has its
ground pin plunger secured in the interlock and is
assembled in a unit for fast receptacle change out.
7. Step 1
For complete breakdown you will need to unscrew
on/off plunger head with small pipe wrenches after wire
brushing and PB Blasting seam.
Step 2
Remove the 4 bolts securing receptacle to frame
8.
9. Step 3
Remove the 2 top screws securing the circuit breaker
handle actuator to on/off plunger rod. The actuator will
slide off with the circuit breaker but if not removing CB
then just remove lower side screw below CB switch
handle and slide it up
10. Step 4
Upper 2 screws securing CB and ground lug connection
plate with ground wire attached
11. Lower 2 screws securing CB and ground pin assembly to
frame
12. Remove the 4 screws securing circuit breaker to frame.
Set aside ground lug and attachment frame. The circuit
breaker is now free to slide up for access to the B phase
wire lug. Loosen lug screws and remove circuit breaker. If
on/off plunger is still in the way, see step 5.
13. Step 5
Remove the 2 pan heads securing ground pin plunger
assembly to frame. The on/off plunger may now be
moved out of way to loosen B phase lug. Lift off circuit
breaker, ground pin plunger assembly and on/off plunger
with sleeve and spring. The receptacle can be removed
anytime the 3 phase CB lugs are loose.
14. The third screw in step 5 picture above the on/off
plunger rod and the 2 pan heads secure the gasket plate
to frame face, sealing the on/off plunger rod. This can be
removed for cleaning and resealing with 111 silicone
valve sealant.
15. Step 6
This is what you are most likely to see. Thus the wire
brushes or, if you have air, a wheel on a gun.
17. But first check the frame for straightness or warpage or
all that cleaning is a waste of time. We are now ready for
reassembly.
18. Troubleshooting
The red tag and note indicated trouble with module
tripping. The fact that it tripped on a splitter is irrelevant
unless the splitter was at fault which we will never know.
A close inspection of the module will reveal the cause of
tripping.
In this case high resistance through the A phase of the
circuit breaker and water intrusion.
19. But other mechanical wear and improper reassembly
can present problems.
Notice broken edge along bottom of sleeve at top
center of picture. The roll pin holds the sleeve against the
spring pressure which provides safety disconnect of
electrical power. This action opens the circuit breaker if
the plug is removed from receptacle before pulling down
on on/off plunger rod.
This becomes a safety issue if not properly working so
close inspection of these small parts is important. The
20. roll pin can be pushed out with a punch and small
hammer.
This roll pin has sheared ends. The safety release and
interlock are inoperable nor can this module be powered
on.
21. Use of wrong parts in reassembly can compromise
operation and safety. Here improper ground wire
connection will not provide adequate ground protection.
Ring terminal is too large for this application. Securing
screws and ground pin are not proper parts for this
model.
22. The pin on left is the one installed in previous picture.
The pin on right is the correct replacement part.
23. Overheated plugs can melt and warp plastic
receptacles. Bench test receptacles and replace if
necessary.
27. If you are not replacing receptacle with a new complete
part make sure you use proper ground connection parts.
Screws, washers and spacers for proper reassembly.
29. Align ground wire connection plate, screws and
washers with spacers and screw into threaded bores of
ground pin.
30. Slide on/off plunger rod through seal bore in face plate.
Slide spring onto plunger till it rests on sleeve. Slide
ground pin plunger interlock unit over on/off plunger till
it rests on spring.
33. The circuit breaker can now be installed. Insert the 3
wire leads from receptacle and tighten lugs on circuit
breaker. Make sure the wire leads have a nice helical
spiral to them and no sharp bends like in the yellow A
phase wire. The wires should neatly coil 1 turn as the CB
is lowered into position. They can then be moved out of
the way of moving parts.
The ground pin interlock unit can now be secured to
face plate with the 2 pan head screws into back of gasket
plate on other side.
Slide CB mounting holes over the 4 holes in frame, align
with the 2 holes in ground pin interlock unit frame on
bottom and push a long screw through. Over a washer,
hand tighten nut on backside so CB can be maneuvered
to insert the rest of screws. Refer to Step 5 and Step 4
in Breakdown.
Place ground lug connection plate over the 2 holes at
top of CB with ground lug on left side with a long screw
through lug, plate and CB. The long ground wire from
receptacle feeds up on right side and its terminal is
secured to plate with long screw and washer through
plate and CB.
34.
35. .
The 4 mounting screws for the red GD 22K breaker are
larger in diameter than the screws used for the blue GD
22K circuit breaker and are not interchangeable as the
bores through the breakers are different.
With circuit breaker and ground pin interlock unit
securely fastened, replace CB handle actuator.
36. Aligning the circuit breaker handle actuator
The next 6 pictures show the position of the circuit
breaker handle actuator in relation to the circuit breaker
handle and on/off plunger rod. If this is not assembled
properly the module will not power on or off.
The circuit breaker handle is sandwiched between the 2
side screws which provide the lifting force to power on
the module, and the downward force to power off.
37.
38.
39. Before securing circuit breaker handle actuator, insert
bottom handle lifting screw. With circuit breaker switch
in off position make certain that screw is under switch
handle.
Now the 2 top pan head screws can be loosely inserted
with lock washers.
Then the upper screw is fed through in opposite
direction of lower lifting screw over the top of circuit
breaker switch handle. The upper screw is what forces
the circuit breaker switch handle down, opening the
circuit breaker and disconnecting power to receptacle.
40.
41.
42.
43. The circuit breaker actuator plate is adjustable for most
effective actuating position. Tighten the 2 top plate pan
head screws and turn both side actuating screw’s nuts
until they just touch the plate sides. If overtightened they
will crimp the actuator. The screws should rotate freely.
The on/off plunger head removed in Step 1 can now
be replaced to complete the reassembly.
44.
45. Testing
To confirm smooth and proper operation of our rebuilt
module we use a plug with pins extended out from cable
end.
Does the on/off plunger actuate the circuit breaker
closed and open?
Does the interlock release when plug is removed
without pulling down on/off plunger rod?
For continuity through breaker to plug and on/off
plunger to ground pin we use an ohm meter.
For phase to phase and each phase to ground
resistance values we use a megohmeter.
53. And finally external surfaces and ground connection
points are given a coating to extend life of module. Cover
with plastic if stored for long in dirty locations.
