IB-46110

IB-46110INSTRUCTIONS

POWELL ELECTRICAL MANUFACTURING COMPANY8550 MOSLEY DRIVE • HOUSTON, TEXAS 77075 • USA

PHONE (713) 944-6900 • FAX (713) 947-4453

Installation Maintenance Renewal Parts

http://www.powellelectric.comhttp://www.powellservice.com

©2001 POWELL ELECTRICAL MANUFACTURING COMPANY ALL RIGHTS RESERVED. 09/2004

Class E2 Medium-Voltage Controllerswith Drawout Vacuum Contactors5.0kV Voltage Class 400A and Class 800A7.2kV Voltage Class 400A and Class 800A

Class E2 Medium-Voltage Controllers withDrawout Vacuum Contactors

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ContentsSection Page

I. INTRODUCTION .............................................................................................................. 7A. SCOPE .................................................................................................................................................. 7

B. PURPOSE ............................................................................................................................................. 7

C. INSTRUCTION BULLETINS AVAILABLE ELECTRONICALLY ............................................................ 7

II. SAFETY ........................................................................................................................... 7A. GENERAL ............................................................................................................................................. 8

B. SPECIFIC .............................................................................................................................................. 8

C. X-RAYS.................................................................................................................................................. 8

D. SAFETY LABELS .................................................................................................................................. 8

III. EQUIPMENT DESCRIPTION ........................................................................................... 9A. GENERAL ............................................................................................................................................. 9

B. CLASS E2 MEDIUM-VOLTAGE CONTROLLER ................................................................................ 10

C. RATINGS ............................................................................................................................................. 11

D. BASIC IMPULSE LEVEL ..................................................................................................................... 11

E. FACTORY PRODUCTION DIELECTRIC TEST ................................................................................. 11

F. MEDIUM-VOLTAGE CONTACTORS .................................................................................................. 12

G. MANUAL ISOLATING MECHANISM .................................................................................................. 12

H. MECHANICAL INTERLOCKING ......................................................................................................... 13

I. AUXILIARY COMPARTMENTS .......................................................................................................... 14

J. POWER FUSES .................................................................................................................................. 14

K. STARTING AUTOTRANSFORMERS OR REACTORS ...................................................................... 14

L. DIMENSIONS ...................................................................................................................................... 14

IV. INSTALLATION .............................................................................................................. 16A. GENERAL ........................................................................................................................................... 16

B. RECEIVING ......................................................................................................................................... 16

C. STORAGE ........................................................................................................................................... 16

D. HANDLING .......................................................................................................................................... 16

E. POSITIONING OF THE ENCLOSURE ............................................................................................... 17

F. REMOVING THE MEDIUM-VOLTAGE VACUUM CONTACTOR ....................................................... 19

1) Removing the Vacuum Contactor from the Lower High-Voltage Compartment ........................... 19

G. POWER CONNECTIONS ................................................................................................................... 22

H. GROUNDING ...................................................................................................................................... 22

I. CONNECTIONS .................................................................................................................................. 25

J. MAIN BUS ASSEMBLY INSULATION ................................................................................................. 26


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Contents

Section PageK. INCOMING POWER CONNECTIONS ............................................................................................... 26

1) Wrapping Bus Joint ....................................................................................................................... 26

2) Applying PVC Boots ...................................................................................................................... 26

3) Cleaning Bus Insulation ................................................................................................................ 27

L. INCOMING POWER CONNECTIONS ............................................................................................... 27

M. MOTOR CONNECTIONS ................................................................................................................... 27

N. POWER CABLE TERMINATION ........................................................................................................ 27

O. INSULATING PRIMARY CABLES....................................................................................................... 28

P. GROUND FAULT CURRENT TRANSFORMERS (THROUGH TYPE) .............................................. 28

Q. CONTROL CABLES AND CONNECTIONS ........................................................................................ 29

R. SURGE PROTECTION ....................................................................................................................... 30

S. MECHANICAL OPERATION CHECK ................................................................................................. 30

T. SAFETY INTERLOCKS ...................................................................................................................... 30

1) Isolating Switch Operating Handle ................................................................................................ 30

2) Door Interlocks .............................................................................................................................. 31

3) Contactor - Isolating Switch Mechanical Interlock ........................................................................ 31

4) Door Interference .......................................................................................................................... 31

5) Line Stab Insulating Shutter .......................................................................................................... 31

VII. OPERATION................................................................................................................... 33A. GENERAL ........................................................................................................................................... 33

B. PREPARATION OF THE CONTROLLER FOR OPERATION ............................................................ 33

1) Cleaning ........................................................................................................................................ 33

2) Lubricating ..................................................................................................................................... 33

3) Manual Operation ......................................................................................................................... 33

4) Adjustments .................................................................................................................................. 33

C. TEST POWER CIRCUIT ..................................................................................................................... 34

D. CLASS E2 MEDIUM-VOLTAGE CONTROLLER COMMISSIONING ................................................. 34

E. PRE-OPERATION TEST ..................................................................................................................... 34

1) Preparing for the Pre-Operation Test ............................................................................................ 34

2) Performing the Pre-Operation Test ............................................................................................... 35

F. INSPECTION, MAINTENANCE, AND SERVICING THE VACUUM CONTACTOR ........................... 35

1) Medium-Voltage Vacuum Contactor Adjustments ......................................................................... 35

2) Isolating Switch Adjustment .......................................................................................................... 35

3) Power Fuse Inspection .................................................................................................................. 35


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Contents

Section Page

Figures

Figure Page

G. MAINTENANCE .................................................................................................................................. 36

1) Maintenance Precautions.............................................................................................................. 36

2) Preventative Maintenance Guidelines .......................................................................................... 36

VI. RECOMMENDED RENEWAL PARTS AND REPAIR PROCEDURES........................... 37A. ORDERING INSTRUCTIONS ............................................................................................................. 37

B. RECOMMENDED RENEWAL PARTS ................................................................................................ 37

1) Renewal Parts Quantity ................................................................................................................ 37

C. REPAIR PROCEDURES ..................................................................................................................... 37

Figure 1. Typical Class E2 Medium-Voltage Controllers ..............................................................................9Figure 2. Two-High Vertical Section Rear View (400 A) .............................................................................10Figure 3. High- and Low-Voltage Compartments ........................................................................................ 10Figure 4. Type SL Medium Voltage Vacuum Contactor 400 A - Front View ...............................................12Figure 5. Type SJA Medium Voltage Vacuum Contactor 800A - Front View .............................................. 12Figure 6. Isolating Switch Operating Handle Padlocking Provision ...........................................................13Figure 7. Tilt-Out Potential Transformer Compartment (Optional) ............................................................. 14Figure 8. Typical Dimensions for the Class E2 Medium-Voltage Controllers ............................................. 15Figure 9. Recommended Method for Lifting an Indoor Lineup ................................................................... 16Figure 10. Access Hole for Anchor Bolts .....................................................................................................17Figure 11. Typical Class E2 Medium-Voltage Controller Floor Plans .......................................................... 18Figure 12. Opening High Voltage Compartment Door .................................................................................. 19Figure 13. Type SJA Vacuum Contactor 800A Power Fuse Removal .......................................................... 20Figure 14. Type SL Vacuum Contactor 400A Power Fuse Removal ............................................................ 20Figure 15. Close-up showing Vacuum Contactor Detent Latch ....................................................................20Figure 16. Vacuum Contactor Stopped by Contactor Detent Latch ..............................................................20Figure 17. Vacuum Contactor Removed from Compartment using Contactor Lift Bar ................................21Figure 18 a. Contactor Removed from Upper Compartment using a PowlVac/AmpGuard

Lift Truck (Amp Guard Lift Truck is also available) ..................................................................... 22Figure 18 b. Amp Guard Lift Truck (Part # 46039G01) ...................................................................................22Figure 19. Isolating Switch and Control Power Interlock (CPI) Auxiliary Switch Terminal Block .................22Figure 20. Incoming Power Connections (Bus Barrier and Bus Boot Removed) .........................................23Figure 21. Splice Plate Connection ..............................................................................................................23Figure 22. Class E2 Medium Voltage Controller Unit 400A ......................................................................... 24Figure 23. Class E2 Medium Voltage Controller Unit 800A ......................................................................... 24Figure 24. Proper Bolt Assembly .................................................................................................................. 25Figure 25. Main Bus and Splices (Bus Barrier Removed) ............................................................................ 26Figure 26. Wrapping of Bus ..........................................................................................................................26Figure 27. Load Terminal .............................................................................................................................. 28Figure 28. Low-Voltage Compartment .......................................................................................................... 29Figure 29. Wire Way ..................................................................................................................................... 29Figure 30. Shutter Assembly ........................................................................................................................ 32Figure 31. Blown Fuse Indicator ................................................................................................................... 36


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Appendix

Tables

Tables Page

Appendix Class E2 Medium-Voltage Controller and Vacuum Contactor Repair and Request Form ................ 43

Table A. Horsepower, Current, and Voltage Ratings ........................................................................................ 11Table B. Voltage and Interrupting Ratings of Class E2 Controllers .................................................................. 11Table C. General Guideline for Incoming Line ................................................................................................. 24Table D. Bolt Torque Values for PowlVac Class E2 Medium-Voltage Controllers ............................................25Table E. Cuttler-Hammer Publication References ........................................................................................... 35Table F. Renewal Parts .................................................................................................................................... 38Table G. Medium-Voltage Vacuum Contactor Type SL 400A Renewal / Replacement Parts ..........................39Table H. Medium-Voltage Vacuum Contactor Type SJA 800A Renewal / Replacement Parts ........................ 40Table I. ACLS, CLS70 Current-Limiting Fuses (R-Type) ................................................................................41Table J. ACLE, AHLE, NCLPT Current-Limiting Fuses (E-Type) ....................................................................42


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BEFORE ANY ADJUSTMENT, SERVICING, PARTS REPLACEMENT, OR ANYOTHER ACT IS PERFORMED REQUIRING PHYSICAL CONTACT WITH THEELECTRICAL WORKING COMPONENTS OR WIRING OF THIS EQUIPMENT, THEPOWER SUPPLY MUST BE DISCONNECTED. FAILURE TO FOLLOW THISWARNING MAY RESULT IN INJURY OR DEATH.

WARNING!

THIS EQUIPMENT MAY CONTAIN HIGH VOLTAGES AND CURRENTS WHICHCAN CAUSE SERIOUS INJURY OR DEATH.

THE EQUIPMENT IS DESIGNED FOR USE, INSTALLATION, AND MAINTENANCEBY KNOWLEDGEABLE USERS OF SUCH EQUIPMENT HAVING EXPERIENCEAND TRAINING IN THE FIELD OF HIGH VOLTAGE ELECTRICITY. THISDOCUMENT, AND ALL OTHER DOCUMENTATION SHALL BE FULLY READ,UNDERSTOOD, AND ALL WARNINGS AND CAUTIONS SHALL BE ABIDED BY.IF THERE ARE ANY DISCREPANCIES OR QUESTIONS, THE USER SHALLCONTACT POWELL ELECTRICAL MANUFACTURING COMPANY IMMEDIATELYAT 1-800-480-7273.

WARNING!


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THE INFORMATION IN THIS INSTRUCTION BULLETIN IS NOT INTENDED TO EXPLAIN ALLDETAILS OR VARIATIONS OF THE CLASS E-2 MEDIUM-VOLTAGE CONTROLLERS WITHDRAWOUT CONTACTORS, NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY ORHAZARD TO BE MET IN CONNECTION WITH INSTALLATION, TESTING, OPERATION, ANDMAINTENANCE OF THE EQUIPMENT. FOR ADDITIONAL INFORMATION AND INSTRUCTIONSFOR PARTICULAR PROBLEMS, WHICH ARE NOT PRESENTED SUFFICIENTLY FOR THEUSER’S PURPOSES, CONTACT POWELL ELECTRICAL MANUFACTURING COMPANY AT1-800-480-7273.

I. INTRODUCTION

A. SCOPE

This information in this instruction bulletin describesthe following Class E2 Medium-Voltage Controllers:

5.0 kV, and 7.2 kV Voltage Class for 400 A

5.0 kV, and 7.2 kV Voltage Class for 800 A

B. PURPOSE

The information in this instruction bulletin is intendedto provide information required to properly operateand maintain the Medium-Voltage Controllers de-scribed in A. SCOPE.

This instruction bulletin provides:

1. Safety guidelines

2. General descriptions of the operation andmaintenance of the medium-voltage controller

3. Instructions for installation and placing themedium-voltage controller into service

4. Instructions for part replacement

5. Information for ordering renewal parts

The illustrations contained in this document may notrepresent the exact construction details of eachparticular type of Class E2 Vacuum Controller. Theillustrations in this document are provided as generalinformation to aid in showing component locations.

To the extent required, the products described hereinmeet the applicable ANSI, IEEE, and NEMA Stan-dards; however, no such assurance is given withrespect to local codes and ordinances which mayvary greatly.

C. INSTRUCTION BULLETINS AVAILABLEELECTRONICALLY

Many Powell Electrical Manufacturing CompanyInstruction Bulletins are available through a link onthe Web site, http://www.powellservice.com. Formore information visit http://powellelectric.com. Tocontact the Powell Apparatus Service Division(PASD) call 1-800-480-7273 or 713-944-6900, oremail PASD at [email protected].

II. SAFETY

Study this instruction bulletin and all other associateddocumentation before uncrating the medium-voltagecontrollers.

Each user has the responsibility to instruct andsupervise all personnel associated with usage,installation, operation, and maintenance of thisequipment on all safety procedures. Furthermore,each user has the responsibility of establishing asafety program for each type of equipment encoun-tered.

The medium-voltage controllers described in thisinstruction bulletin are operated by a high-energy,high-speed mechanism that is interlocked to providespecific operating sequences. It is mandatory thatthe following rules be observed to ensure the safetyof personnel associated with usage, installation,operation, and maintenance of these controllers.THE SAFETY RULES IN THIS INSTRUCTIONBULLETIN ARE NOT INTENDED TO BE A COM-PLETE SAFETY PROGRAM. THE RULES AREINTENDED TO COVER ONLY SOME OF THEIMPORTANT ASPECTS OF PERSONNELSAFETY RELATED TO CLASS E2 MEDIUM-VOLTAGE CONTROLLERS.

IMPORTANT!


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A. GENERAL

1. Only supervised and qualified personnel trainedin the usage, installation, operation, and mainte-nance of Medium-Voltage Controllers shall beallowed to work on this equipment. It is manda-tory that this instruction bulletin, any supple-ments, and service advisories be studied, under-stood, and followed.

2. Maintenance programs must be consistent withboth customer experience and manufacturer’srecommendations, including service advisoriesand instruction bulletin(s). A well-planned andexecuted routine maintenance program is essen-tial for Medium-Voltage Controller reliability andsafety.

3. Service conditions and Medium-Voltage Control-ler applications shall also be considered in thedevelopment of safety programs. Variablesinclude ambient temperature; humidity; actualcontinuous current; thermal cycling; number ofoperations; interrupting duty; and any adverselocal conditions including excessive dust, ash,corrosive atmosphere, vermin, and insect prob-lems.

B. SPECIFIC

1. DO NOT WORK ON AN ENERGIZEDMEDIUM-VOLTAGE CONTROLLER. Beforeperforming maintenance work on a Medium-Voltage Controller, de-energize and disconnectthe power supply for the controller, and removethe Medium-Voltage Controller from service.

2. DO NOT WORK ON AN ENERGIZEDMEDIUM-VOLTAGE VACUUM CONTACTOR.Before performing work on a vacuum contactor,remove the vacuum contactor from service andremove it from the Medium-Voltage Controller.

3. DO NOT WORK ON A MEDIUM-VOLTAGECONTROLLER VACUUM CONTACTORWHEN THE CONTROL CIRCUIT IS ENER-GIZED.

4. EXTREME CARE MUST BE EXERCISED TOKEEP ALL PERSONNEL, TOOLS, ANDOTHER OBJECTS CLEAR OF MECHANISMSWHICH ARE TO BE OPERATED, DIS-CHARGED, OR RELEASED. These medium-voltage vacuum contactors utilize high energymechanisms. These mechanisms must beserviced only by skilled and knowledgeablepersonnel. Detailed information regarding these

mechanisms is found in this instruction bulletinand in the instruction bulletin for the vacuumcontactors.

5. DO NOT ATTEMPT TO CLOSE THE VACUUMCONTACTOR ON AN ENERGIZED CIRCUIT.

6. DO NOT USE AN OPEN VACUUMCONTACTOR AS THE SOLE MEANS OFISOLATING A HIGH VOLTAGE CIRCUIT.FOR COMPLETE ISOLATION, THE ISOLAT-ING SWITCH MUST BE IN THE OFF POSI-TION.

7. ALL COMPONENTS SHALL BE DISCON-NECTED BY MEANS OF A VISIBLE BREAKAND SECURELY GROUNDED FOR THESAFETY OF PERSONNEL PERFORMINGMAINTENANCE OPERATIONS ON THEMEDIUM-VOLTAGE CONTROLLER.

8. Interlocks are provided to ensure the properoperating sequences of the Medium-VoltageController and vacuum contactors for the safetyof the user. If for any reason an interlock doesnot function as described, DO NOT MAKE ANYADJUSTMENTS, MODIFICATION, OR DE-FORM THE PARTS. DO NOT FORCE THEPARTS INTO POSITION. CONTACT POWELLELECTRICAL MANUFACTURING COMPANYFOR INSTRUCTIONS.

C. X-RAYS

X-Rays may be generated when high voltage is appliedacross the contacts of a vacuum interrupter. Theintensity of x-radiation depends on the level of peakvoltage and the size of the contact gap. At the normaloperating voltage for this type of equipment, thex-radiation levels are negligible. At the voltagesspecified for testing, personnel shall be located nocloser than one (1) meter (about 4 feet) from thevacuum contactor. THE VACUUM CONTACTORSHALL BE EITHER FULLY OPEN, OR FULLYCLOSED WHEN MAKING HIGH POTENTIALTESTS. DO NOT PERFORM TESTS WITHCONTACTS PARTIALLY OPEN.

D. SAFETY LABELS

The medium-voltage controller has DANGER,WARNING, CAUTION, and instruction labels at-tached to various locations. All equipment DANGER,WARNING, CAUTION, and instruction labels shall beobserved when the medium-voltage controller ishandled, operated, or maintained.


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III. EQUIPMENT DESCRIPTION

A. GENERAL

Class E2 Medium-Voltage Controllers are designed tocomply with NEMA STD ICS 3 Part 2 and UL 347.These controllers are described as metal-enclosed,high-interrupting capacity, drawout, motor starterequipment with manual isolation. Each controller andstarter is designed for specific applications and thecomponents and functions are determined by thepurchaser’s specifications and needs. See Figure 1.

Starting, stopping, and overload protection areessential control functions for all types of AlternatingCurrent (AC) motors. Short-circuit protection is abasic function included in Class E2 controllers.Additionally, a large variety of protective devices andfunctions can be included in each controller depend-ing on the particular application and the type of motorbeing controlled, such as synchronous or wound-rotormotors.

These instructions are prepared as a general guidethat provides the necessary general information forthe Class E2 Medium-Voltage Controller’s type andfunction. These instructions also include a suggestedmethod of installation with demonstrative techniquesfor the operation and maintenance of the equipment.Separate instructions covering particular equipment,devices, or components are not included in thisinstruction bulletin, but are available upon request.The purchaser should interpret these instructions forapplicability to his particular controller by referring tothe drawings supplied with the controller.

The basic P-46110 Vacuum Controller is an assemblyof components and conductors for motor starting,arranged for convenient access in an enclosure whichallows space and facilities for cable termination, withsafety interlocking of the doors and isolator to pre-vent inadvertent entrance to high voltage parts. Thisequipment is rated 7200 volts maximum and may beused on distribution voltages from 2400 to 7200 volts.Installation, operation, and service should be per-formed only by experienced personnel trained andqualified in this class of equipment.

Figure 1. Typical Class E2 Medium-Voltage Controllers

a. Class E2 Medium-Voltage Controller Unit 400A b. Class E2 Medium-Voltage Controller Unit 800A

ba


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B. CLASS E2 MEDIUM-VOLTAGECONTROLLER

In general, the Class E2 Medium-Voltage Controllerconsists of one-high or two-high vertical sections(Figure 2) of medium voltage compartments. EachMedium-Voltage Controller consists of a high-voltageand low-voltage compartment (Figure 3). Also, eachcompartment has a separate door and interior barri-ers between the two compartments.

To open the high-voltage compartment door, thepower must be disconnected by a sequence ofmanual operations which require opening medium-voltage vacuum contactor and de-energizing theload, operating the isolating device, and unlatchingthe door. The low-voltage compartment door may beentered without disconnecting the power.

CONTROL POWER MAY BE PRESENT IN THELOW VOLTAGE COMPARTMENT. THE LOW-VOLTAGE COMPARTMENT SHALL ONLY BEENTERED WITH EXTREME CARE.

CAUTION!

Figure 2. Two-High Vertical Section Rear View (400 A)

a. Type SL Medium-Voltage Vacuum Contactor 400Ab. High-Voltage Compartmentc. Low-Voltage Compartment

Figure 3. High- and Low-Voltage Compartments

a

b c


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C. RATINGS

Refer to the specific job drawings for the detail ratingapplicable to a particular controller. The basic ratings

D. BASIC IMPULSE LEVEL

The basic impulse level is 60kV for the 5 and 7.2kVClass Controllers. The basic impulse level excludescontrol transformers, starting reactors, and autotrans-formers.

E. FACTORY PRODUCTION DIELECTRIC TEST

The Factory Production Dielectric Test is:

2.25 X Nominal Voltage Rating + 200VAC.

NOTE: Field Dielectric tests, if required, should belimited to 75% of Factory Dielectric Test Values.

equal or exceed NEMA STD ICS 3, and are summa-rized in Table A and Table B.

Table B. Voltage and Interrupting Ratings of Class E2 Controllers

Rated Insulation Voltage Class E2 Interrupting Ratings (Fused)

Maximum Volts, rms Amperes (rms), Symmetrical* Three-Phase Symmetrical MVA at Nominal Utilization Voltage

2500 40,000 or 50,000 160 or 200 at 2300V 5000 40,000 or 50,000 280 or 350 at 4000V 5000 40,000 or 50,000 320 or 400 at 4600V 7200 40,000 or 50,000 460 or 570 at 6600V

* The asymmetrical interrupting rating is 1.6 times the symmetrical values shown.

2200 – 2400V 4000 – 08000V 6600 – 7200V

SYNC SYNC SYNC Continuous

Current Amperes

Induction 0.8 1.0

Induction0.8 1.0

Induction 0.8 1.0

180 700 700 900 1250 1250 1580 2000 2000 2500 360 1500 1500 1750 2500 2500 3000 4000 4000 5000 720 2500 2500 3000 4500 4500 5000 8000 8000 10,000

Table A. Horsepower, Current, and Voltage Ratings


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F. MEDIUM-VOLTAGE CONTACTORS

Two types of medium-voltage vacuum contactorsemployed in the Class E2 Medium-Voltage Controllerare the Type SL 400A (Figure 4) and the Type SJA800 A (Figure 5). Each vacuum contactor has afeature that is designed to close and interrupt the ACpower circuit under normal conditions or to interruptthe circuit under overload emergency conditions.Another feature of each design is short-circuit protec-tion. This includes current-limiting fuses as specifiedfor the application.

The Type SL 400A medium-voltage vacuum contactorand isolating switch combinations will accommodatethe R-Type, and the E-Type clip mount hookeye fusesas specified in Tables I and J. The Type SL 400A andthe Type SJA 800A medium-voltage vacuumcontactors are similar in design with the exceptionthat the Type SJA 800A design application consists ofhigher capacity current carrying parts. Fuse mainte-nance for the two applications is similar. The TypeSJA 800A application uses the current-limiting fuseTypes: ACLS, CLS70, and AHLE. A dual voltagerating allows the fuses to be used in both the 2400and 4800 volt systems.

NOTE: A medium voltage vacuum 400A contactorand 800A contactor is not interchangeable.

Vacuum contactors are magnetically operated by theapplication of either AC or DC power, depending uponcircuit requirements. The contactors may be oper-ated by DC from rectifiers included with the equip-ment. The minimum closing voltage is 85% of thecoil rated voltage. The dropout voltage will varyconsiderably between the AC and DC magnets, butthe dropout voltage for the AC magnet could be ashigh as 60% of the coil-rated voltage.

A mechanically latched contactor function (optional)is used when the vacuum contactor must stay closedduring severe under-voltage conditions. Applicationsinclude fire pumps and transformer feeders. Thelatched contactor is available with or without amanual or electrical release and latch.

G. MANUAL ISOLATING MECHANISM

P-46110 Controllers following the NEMA definitionand contain means for manually isolating the powercircuit by operation of a disconnecting device. Themanual isolating mechanism of the Class E2 Me-dium-Voltage Controller enables personnel to isolatethe power circuit with a manually operated three-pole, Figure 5. Type SJA Medium Voltage Vacuum

Contactor 800A - Front View

Figure 4. Type SL Medium Voltage VacuumContactor 400 A - Front View

a. Detent Latchb. Control Power Transformer (CPT)c. Power Fuses (e)d. Interlocke. Control Power Transformer Primary Fuses (2)f. Test-Run Plugg. Control Receptacleh. Control Power Transformer Secondary Fuse

b

a

cd

e

fg

h


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primary circuit disconnecting device. The isolatingmechanism consists essentially of non-load breakfinger type stab assemblies mounted on a drawoutisolating switch. Operation of the handle mechanismdisengages the line fingers from the primary bus.

The isolating switch is a non load-break device. Itmust never close or interrupt a power load. Anelectrical and mechanical interference interlockensure that the contactor is open before the isolatingmechanism can be operated. However, it does havea limited capacity for interrupting the single-phasecontrol power and potential transformers excitingcurrent. In terms of transformer ratings, the maxi-mum load is the equivalent of an unloaded (excitingcurrent only) 6 kVA transformer.

An insulated shutter linked to the operating mecha-nism covers the points of line bus exposure, thuseffectively isolating all live parts inside the controllerwhen the isolating switch mechanism is in the OFF orOFF and HORIZONTAL position. Load current isNOT interrupted by the finger stabs. A mechanicaland electrical interference interlock ensures that thecontactor is open before the isolating mechanism canbe operated. The isolating switch handle positionsare ON, OFF, and OFF and HORIZONTAL.

The isolating switch handle can be padlocked in theON and OFF positions (Figure 6).

H. MECHANICAL INTERLOCKING

The Class E2 Medium-Voltage Controller is designedfor the medium-voltage vacuum contactor to performnormal load current interrupting. The power fusesare designed to interrupt fault currents.

NOTE: The manual isolator will not interrupt anyfault current.

A mechanical interference system (mechanicalinterlock) is included in all Class E2 Medium-VoltageVacuum Controllers. The interference systemprevents opening of the manually operated isolatingmechanism, unless the vacuum contactor is in theOPEN position. This is to ensure that the contactorhas opened the power circuit and interrupted thecurrent. The Control Power Interlock (CPI) AuxiliarySwitch, which is located on the isolating switch,opens the main contactor control power when theisolating switch is in the OFF position. The manualisolator SHOULD NEVER BE FORCIBLY OPER-ATED.

3. The OFF and HORIZONTAL or door openingposition (Figure 12, D): The isolating switch is inthe OPEN position, the controller is de-energized,grounded, and the high-voltage compartmentdoor can be opened.

The isolating switch operating handle has threedistinct positions described as follows:

1. The ON position (Figure 11, A): The isolatingswitch is in the CLOSED position, the high-voltage compartment door is interlocked shut,and the controller may be energized.

2. The OFF position (Figure 11, B): The isolatingswitch is in the OPEN position, the high-voltagecompartment door is interlocked shut, and thecontroller is de-energized and grounded.

FORCIBLY MOVING THE ISOLATING SWITCHOPERATING HANDLE TO THE OFF POSITIONWILL OPEN THE VACUUM CONTACTOR ANDDISCONNECT THE LOAD FROM THECIRCUITS.

CAUTION!

Figure 6. Isolating Switch OperatingHandle Padlocking Provision

THIS MECHANICAL INTERFERENCE SYSTEMMUST NOT BE DEFEATED TO OPEN THEHIGH-VOLTAGE COMPARTMENT DOOR WITHTHE CLASS E2 MEDIUM-VOLTAGECONTROLLER ENERGIZED. DEFEATING THEINTERLOCK WILL EXPOSE ENERGIZEDCOMPONENTS AND MAY RESULT IN INJURYOR DEATH.

WARNING!


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J. POWER FUSES

Current-limiting fuses, designed for motor startingservice, are used for all high-interrupting capacitymotor controllers and provide short-circuit protection.

The following is a brief description of the power fusesused in the P46110 design. More detailed informa-tion regarding power fuses can be found in Cutler-Hammer I.B. 48021 and Technical Data BulletinTD02003001E.

Interrupting ratings are as shown in the earlier tablesin these instructions (Table B).

The SL 400A vacuum contactor and isolating switchcombinations will accommodate R-Type andE-Type fuses.

The Type SJA 800A utilizes the following current-limiting fuse types: ACLS, CLS70, and AHLE.

Transformer feeders frequently contain generalpurpose current-limiting fuses. Coordinationinformation for fuses can be furnished upon request.

K. STARTING AUTOTRANSFORMERS ORREACTORS

Reduced-voltage starters include a reactor or au-totransformer designed for starting duty in accor-dance with NEMA ICS 3. The duty cycle for themedium-duty application is three starts, 30 secondsapart, followed by a one-hour rest. A heavier-dutycycle will cause overheating and possible damage tothe reactor or autotransformer.

L. DIMENSIONS

Refer to the equipment drawings for the specificdimensions and an outline of the equipment.

The Class E2 Medium-Voltage Controllers 400Aapplication is normally a one-high or two-high con-struction with typical dimensions of 26" or 36" inwidth, 38" in depth, and 92" in height. The Class E2Medium-Voltage Controllers 800A application isnormally a one-high construction with typical dimen-sions of 28" in width, 38" in depth, and 92" in height.These dimensions exclude channel bases and liftingmembers for indoor construction. For typical outlinedimensions refer to Figure 8.

NOTE: No emergency condition can justify forcibleoperation of the MANUAL ISOLATOR WITH thevacuum contactor in the CLOSED position. TheMANUAL ISOLATOR MUST only be operated whenthe vacuum contactor is in the OPEN position.

The high-voltage compartment door is locked closedby a mechanical interference system linked to themanual isolating switch. The locking action preventsthe door from being opened unless the isolatingswitch is OPEN. Exposure to high-voltage or liveparts is also prevented.

I. AUXILIARY COMPARTMENTS

A variety of enclosure sizes and medium-voltagecompartments are furnished in Class E2 Medium-Voltage Controller lineups for various applications.The following list contains examples of enclosuresand compartments.

1. Bus transitions to metal-clad gear

2. Bus transitions to transformers

3. Cable entranced compartments

4. Starting reactor autotransformer compartments

5. Relay and metering compartments

6. Potential transformer compartments (Figure 7.)

Figure 7. Tilt-Out Potential TransformerCompartment (Optional)

a. Potential Transformer (PT) Compartment Doorb. Secondary Disconnectc. Potential Transformersd. Compartment Floore. Tilt-Out PT Support

a b c d e


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Figure 8. Typical Dimensions for the Class E2 Medium-Voltage Controllers

NOTE: The drawings in Figure 8 SHOULD NOT be used for any construction purposes.For construction information, refer to the specific drawings furnished with the equipment.

RIGHT SIDE VIEW

FRONT VIEW

ISOLATING

SWITCH

FUSES

400AMP

CONTACTOR

INST.

COMPT

.

RIGHT SIDE VIEW

FRONT VIEW

ISOLATING

SWITCH

FUSES

400AMP

CONTACTOR

ISOLATING

SWITCH

FUSES

400AMP

CONTACTOR

UPPER

INST.

DOOR

LOWER

INST.

DOOR

Class E2 Medium-Voltage Controller (400A)

Two-High Construction 36"W X 36.75"D X 92"HOne-High Construction 26"W X 36.75"D X 92"H

One-High Construction 28"W X 36.75"D X 92"H

Class E2 Medium-Voltage Controller (800A)

ISOLATING

SWITCH

FUSES

400AMP

CONTACTOR

INST.

DOOR

FRONT VIEW

BUS DIMENSIONS TYP.

FOR ALL STANDARD

UNITS.

RIGHT SIDE VIEW


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16

IV. INSTALLATION

A. GENERAL

This section contains information on preparingequipment for operation including receiving, storage,handling, positioning, power connections, grounding,and mechanical operation tests.

B. RECEIVING

NOTE: Read paragraph D. HANDLING in thissection before handling the controller(s). Class E2Medium-Voltage Controllers are fabricated as rigid,floor-mounted, self-supporting steel unit verticalsection(s). They are shipped in an upright position,and should be kept in an upright position whenreceived.

NOTE: Any questions regarding equipment handlingshould be referred to Powell Electrical ManufacturingCompany.

When controllers are received, the purchaser shouldcheck the material received with the shipping list toensure that all parts have been included. If equip-ment damage is found or suspected, file claims assoon as possible with the transportation company andnotify the nearest representative of Powell ElectricalManufacturing Company.

Some equipment, devices, or components may beshipped separately. Examples of items that may beshipped separately are top-mounted resistors orcurrent potential transformers (CPT). These compo-nents are identified by a number coinciding with thenumber on the section on which they are to bemounted.

C. STORAGE

When equipment cannot be installed immediately, itshould be stored in a clean, dry, and ventilatedlocation to reduce condensation. Use a protectivecovering on stored equipment to prevent dirt andcontaminated substances from depositing on themovable parts and electrical contact surfaces. Whenthe equipment is subject to low temperatures ormoisture, energize the anti-condensation heaters toprevent corrosion. There should be approximately250W of heat per vertical section. Before energizingthe heaters, remove all cartons and miscellaneousmaterial from inside the units. No specific formula

for the amount of heat per vertical section can begiven as it varies greatly due to local climatic andstorage conditions. The stored equipment should beinspected at regular intervals during the time it isstored for accumulation of moisture or evidence ofcondensation. If moisture or evidence of condensa-tion is found, the amount of heat per vertical sectionshould be increased.

D. HANDLING

The Class E2 Medium-Voltage Controller should belifted, positioned, and handled by suitable liftingdevices of adequate load ratings. (See Figure 9.) Amaximum of 3 units can be lifted together. Duringhandling, the rigging lengths of lifting equipment,such as slings or cables, should be set or adjusted tocompensate any unequal load distribution to maintainthe equipment in an upright position. Refer to the jobdrawings for the specific lifting weight specifications.

INDOOR EQUIPMENT SHOULD NOTBE STORED OUTDOORS, EVEN IF IT ISCOMPLETELY COVERED WITH A TARPAULINOR PLASTIC SHEET.

CAUTION!

Figure 9. Recommended Method forLifting an Indoor Lineup


IB-46110

17

It is preferable to handle P-46100 Controllers withoverhead cranes, by the lifting means provided. Foroutdoor non-walk-in equipment, lifting angles areprovided on the side of the structure, near the top.For outdoor walk-in enclosures, lifting channels areprovided which are attached to the base of theequipment. Spreaders should be used in the slingsabove the enclosure to prevent damage to theequipment top edges. Do not attempt to lift equip-ment by using the angles installed on the sides. Theangles are provided only to insure that the equipmentwill not tip over if it is top heavy by tying it downduring shipment. The angles are not intended to beused for lifting purposes. Slings should be tied toreferenced angles to prevent tipping. If bases arefurnished, the equipment may be moved on an evensurface by the use of rollers or heavy duty pipe underthe base. Any force to move or jack the equipmentmust be applied to the base and not the equipment.

The use of fork lift trucks is not recommended, sincethe forks may damage the enclosure or interior partsof the equipment. If no other method of handling isavailable, the forks must go under the base bottom toavoid damage to the equipment.

E. POSITIONING OF THE ENCLOSURE

To enable proper operation of equipment, it is essen-tial to securely fasten the lineups in a true uprightposition on a smooth, level surface. The floor shouldbe leveled to within 1/8" for every 10 linear feet.Figure 10 illustrates various Medium-Voltage Control-ler floor plans. The equipment position should allowfor the proper removal of the medium-voltagevacuum contactor.

When three or more controller units are to be ar-ranged in one continuous lineup, THE CENTERSHIPPING UNIT SHOULD BE THE FIRST LO-CATED. The other shipping lineup should then beinstalled in successive order in each direction fromthe center of the structure.

After positioning the equipment, check the equipmentto ensure it is level. If necessary, shims may beinserted beneath the equipment base to achieve alevel condition.

When the equipment is in the proper position, it canbe bolted to the floor by using the holes located at thefront and rear bottom of the vertical sections (Figure10). Refer to the job drawings for the specific floorplan which specifies the location of the access holes.

(THIS SPACE IS INTENTIONALLY BLANK.)

Figure 10. Access Hole for Anchor Bolts

a. Access holes

a


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18

Figure 11. Typical Class E2 Medium-Voltage Controller Floor Plans

Class E2 Medium-Voltage Controller (400A) - One-High Construction Floor Plan

FEEDER EXITABOVE ONLY

CONTROL EXIT ABOVE ONLY

CONTROL EXITBELOW ONLY

FEEDER EXITBELOW ONLY

Class E2 Medium-Voltage Controller (400A) - Two-High Construction Floor Plan

T - L E A D F E E D E R L A N D I N GO P P O S I T E F E E D E R E N T R Y E N D

T - L E A D F E E D E R L A N D I N GO N F E E D E R E N T R Y E N D

S H E L F D I V I D E RC A B L E O P E N I N G

F E E D E R E N T R Y / E X I T A B O V E A N D B E L O W

C O N T R O L E N T R Y / E X I TA B O V E A N D B E L O W

Class E2 Medium-Voltage Controller (800A) - One-High Construction

TOP ENTRYVIEW

BOTTOM ENTRYVIEW

T-LEADSBOTTOM ENTRY

CONTROL EXIT ABOVE ONLY

NOTE: The drawings in Figure 11 should NOT be used for any construction purposes. For constructioninformation, refer to the specific drawings furnished with the equipment.


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F. REMOVING THE MEDIUM-VOLTAGEVACUUM CONTACTOR

1) Removing the Vacuum Contactor from theLower High-Voltage Compartment

The vacuum contactor is equipped with four wheelsand a bracket for inserting a contactor lift bar toenable removal of the vacuum contactor for inspec-tion and maintenance. The two processes necessaryto remove the vacuum contactor are opening thelower, high-voltage compartment door and removingthe vacuum contactor. The process for opening thedoor and removing the vacuum contactor from thelower and upper compartments are explained in thefollowing procedures.

a) Opening the High-Voltage Compartment Door

To open the high-voltage compartment door, refer toFigure 12 and the following procedures.

1. On Position: When isolating switch operatinghandle is in the ON position (Figure 12, A), theisolating switch is in the closed position, the high-voltage compartment door is interlocked shut,and the controller may be energized.

2. OFF Position: When the switch is in the OFFposition (Figure 12, B), the isolating switch is inthe OPEN position, the high-voltage compart-ment door is interlocked shut, and the controlleris de-energized and grounded.

3. HORIZONTAL position: With the operatinghandle rotated 90° counterclockwise (Figure 12,C) to the HORIZONTAL position (Figure 12, D),the isolating switch is in the OPEN position, thecontroller is de-energized, grounded, and thehigh-voltage compartment door can be opened.

DO NOT WORK ON A MEDIUM-VOLTAGECONTROLLER, VACUUM CONTACTOR, WITHTHE CONTROL CIRCUIT ENERGIZED.

CAUTION!

Figure 12. Opening High VoltageCompartment Door

A. ON Position

B. OFF Position

C. Handle Being Rotated 90°Counterclockwise

D. Horizontal Position


IB-46110

20

b) Removing the Vacuum Contactor from theLower Compartment.

1. Visually inspect the isolating switch to ensure it isin the OPEN position and that the insulatingshutter displays the CLOSED indicating stripes.See Section N. SAFETY INTERLOCKS, 4) TheShutter Assembly Insulating Shutter.

2. Confirm that the fuses are de-energized.

3. Using a fuse puller, remove the power circuitfuses. (See Figure 13, b and Figure 14, b).

5. Disconnect the two, three-point plugs on the rightfront of the isolating switch.

NOTE: DO NOT disconnect the control powerinterlock (CPI) wires from the terminals on theplugs located on the isolating switch. Theterminal blocks are plug-in type. Simply discon-nect the CPI auxiliary switch terminal blocks byunplugging them.

6. Lift the vacuum contactor detent latch (Figure 15,a) on the left side of the vacuum contactor.Carefully roll the vacuum contactor out of thehigh-voltage compartment to the detent position.

The contactor detent latch stops the vacuumcontactor from being completely removed fromthe compartment (Figure 16).

4. Disconnect the 12-point secondary control circuitplug from the right side of the vacuum contactorand stow it so that the cable will not be damaged.

7. Press down on the contactor detent latch andcarefully roll the vacuum contactor out of thehigh-voltage compartment and onto the floor. Acontactor lift bar may be used when removing thevacuum contactor from the compartment asillustrated in Figure 17.

NOTE: Store the vacuum contactor in a safelocation to prevent damage to it while it is outsideof the compartment.

DO NOT WORK ON A MEDIUM-VOLTAGECONTROLLER VACUUM CONTACTOR WITHTHE CONTROL CIRCUIT ENERGIZED.

CAUTION!

Figure 13. Type SJA Vacuum Contactor 800APower Fuse Removal

a. Power Fuse (3) b. Fuse Puller

a

b

ba

Figure 14. Type SL Vacuum Contactor 400APower Fuse Removal

a. Power Fuse (3) b. Fuse Puller

a. Contactor Detent Latch

Figure 15. Close-up showing VacuumContactor Detent Latch

a

Figure 16. Vacuum Contactor Stopped byContactor Detent Latch


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21

c) Removing the Vacuum Contactor from theUpper High-Voltage Compartment

It is recommended to use a lift truck to remove thevacuum contactor from the upper high-voltagecompartment in a two-high vertical section.

To remove the vacuum contactor from the uppercompartment perform the following procedures:

1. Visually inspect the isolating switch to ensure it isin the OPEN position and that the insulatingshutter displays the CLOSED indicating stripes(Figure 20, b). See Section T. SAFETY INTER-LOCKS, 5) The Shutter Assembly InsulatingShutter.

2. Confirm that the fuses are de-energized.

3. Using a fuse puller, remove the power circuitfuses. (See Figure 13, b and Figure 14, b).

4. Disconnect the 12-point the secondary controlcircuit plug from the right side of the vacuumcontactor and stow it so that the cable will not bedamaged.

5. Disconnect the two three point plugs on the rightfront of the isolating switch.

NOTE: DO NOT disconnect the control powerinterlock (CPI) wires from the terminals on theplugs located on the isolating switch. The

terminal blocks are plug-in type. Simply discon-nect the CPI auxiliary switch terminal blocks byunplugging them.

6. Move the lift truck to the front of the compartmentand align the two pins on the leading edge of thelift truck with the two holes in the upper high-voltage compartment clip.

Ensure that the pins are securely fastened in theholes and the lift truck brake is set prior to rollingthe vacuum contactor onto the lift truck.

7. Lift the vacuum contactor detent latch (Figure 15,a) on the left side of the vacuum contactor andcarefully roll the vacuum contactor out of thehigh-voltage compartment to the detent position(Figure 16).

8. Press down on the contactor detent latch andcarefully roll the vacuum contactor out of thehigh-voltage compartment onto the lift truck tray(Figure 18a and 18b).

9. With the contractor securely latched on the lifttruck tray, release the lift truck brake and movethe lift truck away from the compartment.

10. Lower the lift truck tray to just above the floor andmove the lift truck to the required location. Lowerthe tray to floor level and remove the contactor.

NOTE: Store the vacuum contactor in a safe locationto prevent damage to it while it is outside of thecompartment.

CAUTION!

DO NOT WORK ON A MEDIUM-VOLTAGECONTROLLER VACUUM CONTACTOR WITHTHE CONTROL CIRCUIT ENERGIZED.

Figure 17. Vacuum Contactor Removed fromCompartment using Contactor Lift Bar

Figure 18 a. Contactor Removed from UpperCompartment using a PowlVac/AmpGuardLift Truck (Amp Guard Lift Truck is also available)


IB-46110

22

G. POWER CONNECTIONS

The Class E2 Medium-Voltage Controller must begrounded before power connections are made. SeeSection H. GROUNDING.

External power cable connections should be installedin the controller after the equipment is placed in thepermanent location and the grounding connectionsdescribed in Section H. GROUNDING are com-pleted. Grounding cables must be connected to theequipment ground bus and all high-voltage terminalsthat must be handled or touched during the powerconnection and installation process.

To access the power cable connections, it may benecessary to remove the isolating switch and thevacuum contactor. The procedure(s) for removingthe contactors are listed above. The following stepsdescribe the procedure for removing the manualisolating switch and accessing the power connection.

1. De-energize and ground the equipment.

2. Remove the two retaining bolts from the isolatingswitch front cover. (See Figure 19, c.)

3. Disconnect the control power interlock (CPI)auxiliary switch terminal blocks.

NOTE: DO NOT disconnect the control powerinterlock (CPI) wires from the terminals on theplugs located on the isolating switch. Theterminal blocks are plug-in type. Simply discon-nect the CPI auxiliary switch terminal blocks byunplugging them.

4. Remove the controller with caution. There is nostop block to engage the controller as it rolls outof the cell, and the equipment is heavy. The400A assembly weighs approximately 75 poundsand the 800A assembly weighs approximately100 pounds.

5. To install the external power cable connections,see Section I. INCOMING POWER CONNEC-TIONS AND MOTOR CONNECTIONS.

H. GROUNDING

Before power connections can be made, theswitchgear vertical sections must be grounded. Aground bus is furnished with lugs at each end forconnection to the station grounding system (Figure20).

The ground bus is bolted to the rear on the top of thecenter shelf. It is arranged so that connections to thestation ground can be made in any unit. Whereequipment is shipped in more than one group, thesections of ground bus must be connected by usingthe splice plates furnished with the equipment (Figure21).

Assemble the ground bus joints as outlined under“Connections.” The switchgear ground bus must beconnected to the station ground bus by a conductorhaving a current carrying capacity equal to that of theswitchgear ground bus. It is very important that theequipment be adequately grounded to protect theoperator from injury when short circuits or otherabnormal occurrences take place and to insure thatall parts of the equipment, other than live parts, areat ground potential.

Figure 18 b. Amp Guard Lift Truck (Part #46039G01)

Figure 19. Isolating Switch and Control PowerInterlock (CPI) Auxiliary Switch Terminal Block

a. Retaining Bolts Removed (2)b. Isolating Switchc. Control Power Interlock (CPI)

Auxiliary Switch Terminal Block (2)

a

b

c


IB-46110

23

It is recommended that the connection to the stationground have a cross section of 500,000 circular mils(240 mm2) or greater if the soil in which it is buried isof such character as to cause appreciable corrosion.This is especially true where electrolysis from straycurrents or contact with dissimilar metals exists. Theresistance of the soil surrounding a station grounddepends on the condition of the soil, as well as itschemical content. Dry, loose, sandy, or frozen soilswill have a high resistance as compared with moistsoils or soils containing ashes, cinders, or salt solu-tion. The IEEE Standard 142 states that groundingimpedance in the range of 1 to 5 ohms is generallyacceptable for industrial substations. Ground resis-tance testing is recommended to verify that theground resistance falls within this range.

Figure 22 shows the grounding connection for the400A controller equipment. Notice there is a groundclip located on the bottom, left, side rail (Figure 22,d). Figure 23 shows the grounding connection for the800A controller.

Table C lists recommended maximum cable sizesand cables per phase for equipment with only frontaccess. For equipment cable requirements thatexceed the recommended maximum cable sizes,equipment rear access and rear cable extensions areneeded. The extension depth shall be determined bythe specific equipment requirements.

Figure 20. Incoming Power Connections(Bus Barrier and Bus Boot Removed)

Class E2 Medium-Voltage Controller Unit 400A

Class E2 Medium-Voltage Controller Unit 800A

Figure 21. Splice Plate Connection

SHIPPING SPLIT

WHEN REQUIRED

UNIT TO UNIT SPLICE

TOP VIEW

UNIT GROUND BUS

FRONT VIEW

6.250

1.1251.125


IB-46110

24

Table C. General Guideline for Incoming Line

Construction Type Continuous Current

Ampheres Maximum Cable Size

Cable per Phase

One-High Vertical Section 400 A 500 mcm 1

Two-High Vertical Section 400 A 500 mcm 1

One-High Vertical Section 800 A 500 mcm 2

Note: For construction type, one-high and two-high vertical section 400 A (only), 2 cables ( 4/o or smaller) atmaximum cable size 500 mcm may be included per phase.

b

c

d

a

Figure 23. Class E2 Medium VoltageController Unit 800A

(The rear barrier is removed for illustration.)

a. Ground Connectionb. Line Devices (3)c. Interlockd. Load Devices (3)

b

a

c

d

Figure 22. Class E2 Medium VoltageController Unit 400A

a. Ground Connection(To circuit breaker or other equipment)

b. Shutter Assemblyc. Load Devices (3)d. Ground Clip (400A)


IB-46110

25

I. CONNECTIONS

The main bus bars and other connection bars arecopper. The connection surfaces are silver surfacedor equivalent. The silver plating used on boltedcontact surfaces is approximately 0.0001" thick. Allfield assembled joints in primary conductors, regard-less of method of insulation, should be made asfollows:

1 Wipe the surface clean with a lint-free cloth. Donot use sandpaper or any abrasive on the platedsurface. Avoid handling of cleaned surface asmuch as possible. If the surface is tarnished,clean it with silver polish and then wash it withdenatured alcohol.

2. Join the clean contact surfaces by using thehardware provided. The correct length of boltmust be used in each joint to insure that electricalclearances at bolt locations are maintained. As ageneral rule, when using 1/2" diameter bolts, thebolt should be 1" longer than the combinedthickness of the copper bars being bolted to-gether. For example, if three 1/4"-thick copperbars are to be connected, the bolt should be1-3/4" long. In addition to proper length bolts, thebolt assembly must include flat washers, split-ringlock washers, and nuts. All hardware must beSAE Grade 5 or better. See Figure 24 for theproper assembly of hardware.

3. In some cases, external connections are made tothe equipment main bus by bars. The equipmentbars are normally silver plated. Unplated bars,either copper or aluminum should not be used toconnect to plated bars.

4. All field assembled primary conductor joints andterminations must be insulated for the operatingvoltage. There are two methods of insulatingjoints: taping joints or applying boots whereapplicable. A detailed procedure for joint insula-tion is described under Section K. MAIN BUSASSEMBLY.

NOTE: All hardware must be tightened to thetorque values listed in Table D.

ALL EXPOSED PRIMARY BUS AND CABLEJOINTS AND CONNECTIONS SHOULD BEINSULATED FOR THE CORRECT SYSTEMINSULATION RATING.

CAUTION!

Figure 24. Proper Bolt Assembly

Table D. Bolt Torque Values for PowlVac ClassE2 Medium-Voltage Controllers

NOTE: The bolt head drawings in the following tableare not to scale. Locate the Bolting Torque label onequipment for an accurate drawing of bolt sizes.


IB-46110

26

J. MAIN BUS ASSEMBLY INSULATION

To insulate the main bus assembly, remove the rearcompartment covers. Then, bolt the splice plates andbus bars together, following assembly instructions asgiven under Section J. CONNECTIONS. Tightenbolts properly. See Table D.

To provide adequate bus joint insulation, use any ofthe following methods:

• Wrapping bus joints, using tape or heatshrink material

• Applying PVC (polyvinyl chloride) boots

K. INCOMING POWER CONNECTIONS

Incoming power connections to the main bus may beconnected in various configurations depending on theequipment application (Figure 25). Review theelevation drawings delivered with the equipment forsite-specific connection details.

NOTE: Refer to site-specific project drawings forrecommended and available conduit space for top orbottom access.

1) Wrapping Bus Joint

1. Fill all cavities around the contact nuts andconnection bars with the Solar CompoundsCorporation Solarite KM1592 compound. Form asmooth surface for taping, thus preventing airvoids.

NOTE: The compound is not an insulatingmedium and should not be used for that purpose.

2. Wrap the bus joint with 3 layers, 2/3 lap, ofScotch Super 33+ black insulating tape, main-taining tension on the tape while wrapping.Where there are sharp angles, apply additionallayers to obtain the equivalent of the insulationon the flat surfaces.

3. Over the black tape, apply 2 layers, 2/3 lap, ofScotch 35 red insulating tape (Figure 26).

NOTE: One layer wound 2/3 lap requires 3 turnsaround bar in one width of the tape. One layerthickness is 3 times tape thickness.

2) Applying PVC Boots

1. Prepare all joints as outlined under Section J.CONNECTIONS.

2. Place the PVC boot over the joint. The bootshould fit snugly around all conductors, andflanges must contact each other in a smoothjoint.

3. Secure the boot with the furnished nylon wire tiesto complete the joint insulation.

NOTE: The PVC insulation boots are furnishedfor standard configurations. Special configurationconditions may require taped joints if PVC bootsare not available.

4. Replace all covers previously removed.

CAUTION!

THE OPERATING TEMPERATURE OFCONDUCTORS IN THESWITCHGEAR MAYREACH 105°C. ANY INSULATING MATERIALUSED IN THE METAL-CLAD SWITCHGEARMUST BE SUITABLE FOR THISTEMPERATURE.

Figure 25. Main Bus and Splices(Bus Barrier Removed)

Figure 26. Wrapping of Bus


IB-46110

27

3) Cleaning Bus Insulation

The main bus bar is insulated with a high-tempera-ture thermoplastic or thermoset material that pro-vides dielectric and mechanical properties. Clean theinsulation to provide optimum insulation properties.

Only use denatured alcohol or isopropyl alcohol toclean the insulation. Wear protective gloves andgoggles and clean the main bus bar in a well-venti-lated area. Wipe dirt or other foreign matter from theinsulation with a clean cloth saturated with onlydenatured or isopropyl alcohol.

M. MOTOR CONNECTIONS

Motor lead cables may enter or terminate from eitherthe top or the bottom access openings of the verticalsection. The load terminals (Figure 27, a) arelocated behind the low-voltage compartment. Accessthe load terminals through the front of the 400A twohigh, medium-voltage compartment, or the front orrear of the 800A vertical section. To easily accessthe load terminals through the compartment front,remove the vacuum contactor and the isolatingswitch if required. Remove the rear compartmentbarrier to access the load terminals from the equip-ment rear. After motor cables are terminated,insulating boots must be installed on the load termi-nals.


As an option, barriers may be installed so that theload cables between two vacuum contactors areisolated in the same vertical section.

N. POWER CABLE TERMINATION

Cables should be prepared for termination in accor-dance with the instructions of the cable manufacturer.However, the following general recommendations aregiven for proper cable termination in equipment.

1. Pull in the cables in accordance with the equip-ment outline diagram specifications. Position thecables for maximum clearance between thephases, ground, and other cables, or wire runs.Refer to the specific job drawings and thisinstruction bulletin for the recommended locationfor the incoming cables.

2. Prepare the cable for termination in accordancewith the manufacturer’s instructions.

3. Bolt the cable terminals to the bus or other pointof termination.

4. If contact between the cable and an adjacent buscannot be avoided, tape the bus in the immediatevicinity of the cable contact point so that thesurface creepage distance from the cable to thebare bus bar is at least three inches. Thus, thesurface creepage from the bare bus where thecable terminates, to the bare part of the buswhere the cable touches, will be a distance of atleast seven inches. The thickness of tape on thebus should be approximately 5/32".

L. INCOMING POWER CONNECTIONS

Incoming power connections to the main bus may beconnected in various configurations depending on theequipment application (Figure 27). Review theelevation drawings delivered with the equipment forsite-specific connection details.


USE ALCOHOL IN A WELL-VENTILATED AREATO AVOID INHALING VAPORS.

CAUTION!

DO NOT USE ANY COMMERCIAL SOAP-BASED OR DETERGENT-BASED CLEANERBECAUSE THEY MAY DAMAGE THEINSULATION MATERIAL. DO NOT USECARBON TETRACHLORIDE. AVOIDPROLONGED EXPOSURE TO SOLVENTVAPORS. USE SOLVENTS IN A WELL-VENTILATED AREA.

CAUTION!


IB-46110

28

5. Terminate any ground return and cable shielddrains to the compartment ground bus.

6. Run all the low-voltage wires so as to avoid anypossible contact with high-voltage lines.

Before any primary cable connections are made, thecables should be identified to indicate their phaserelationship with the switchgear connections. This isnecessary to insure that motors will rotate in theproper direction and that the phase rotation is thesame when interconnecting two different sources ofpower.

Normally, compression terminals are used to termi-nate primary cables. When shielded cables are used,proper stress relief must be provided at the cabletermination. This may be done by the use of a com-mercially available cable terminator, many types ofwhich are available, or by the use of a stress cone,which can be either hand-built or the prepackagedtype. In all cases, carefully follow the cablemanufacturer’s recommendations for installation ofthe type of cable being used. Normally, no insulationor stress relief materials are furnished for cableterminations.

O. INSULATING PRIMARY CABLES

All field assembled joints for primary cable termina-tions should be prepared as outlined under Section J.Connections. Upon completion of the cable termina-tion, care must be exercised when taping the ex-posed termination. Section K. MAIN BUS ASSEM-BLY INSULATION, can be used for guidance ininsulating techniques. However, in all cases, carefullyfollow the manufacturer’s recommendations forinsulating the type of cable termination being used.

P. GROUND FAULT CURRENTTRANSFORMERS (THROUGH TYPE)

Through-type current transformers are furnishedwhere specified for sensitive protection againstground faults. These transformers may be installed ina horizontal position directly above or below theprimary cable terminals, so that the primary cable orcables can pass through them.

Where armored cable is used, the armor must beterminated and grounded before the cable passesthrough the transformer. Armor clamps are fur-nished for this purpose when specified.

a

Figure 27. Load Terminal

a. Load Terminals (Bus boots are removed)


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29

When lead or other conducting sheath cable, or cablewith shielding tape or braid is used, it is recom-mended that the sheath or shield be grounded solidlyto the switchgear ground bus. The ground lead shouldbe bonded to the sheath or shield on the side of thecurrent transformer away from the primary terminals.In cases where the ground cannot be applied beforethe cable passes through the transformer, bond thelead to the sheath or shield between the transformerand the primary terminals. The ground conductormust then be passed back along the cable paththrough the current transformer before being con-nected to the ground bus.

Q. CONTROL CABLES AND CONNECTIONS

The low-voltage compartment where control connec-tions are made is completely isolated from the high-voltage compartment (Figure 28).

Available space for both the top and bottom controlwiring conduits are designed for easy accessibility.Conduits should be placed in accordance with theoutline drawings.

Control connections are made through terminalblocks in the low-voltage compartment (Figure 28).Refer to the schematic and wiring diagrams furnished

a

Figure 28. Low-Voltage Compartment

Figure 29. Wire Waya. Wire Way Opening

for each specific job for connection of all field controlwires to the designated terminal blocks. A continuoushorizontal wire way opening (Figure 29, a), located atthe top, allows for electrical control interconnectionsbetween the vacuum contactors throughout thevertical sections.

When control conduits enter the unit from below, theconduit should not extend more than 1 inch abovethe floor. The control cables may be pulled throughthe conduits before or after theswitchgear is installed,whichever is more convenient. If the control conduitsenter from above, drill the top cover of the enclosureto suit the conduits, being careful not to damageexisting wire bundles. Fasten the conduits to thecover with locknuts.

Connect the cables to the terminal blocks in accor-dance with the wiring diagrams furnished for thespecific job.

The cables from the control power source totheswitchgear must be large enough to avoid exces-sive voltage drop when the controllers are operated.

CONTROL WIRING TERMINAL BLOCKS ARESUPPLIED IN GREAT VARIETY DEPENDINGUPON INDIVIDUAL CUSTOMERSPECIFICATIONS. REFER TO THEMANUFACTURER’S INSTRUCTIONS FOR THETERMINAL BLOCKS SUPPLIED FORSPECIFIC CONNECTIONRECOMMENDATIONS SUCH AS MAXIMUMTORQUE VALUES, ETC.

CAUTION!


IB-46110

30

Where units have been split for shipment, any controlor other secondary leads that must be reconnectedacross the split will be arranged with terminal blocksin a convenient location so that the wires can beeasily reconnected. The wires will be cut to lengthand formed before being folded back so that aminimum time will be required for reconnecting them.Refer to the schematic and wiring diagrams furnishedfor each specific job for connection of all controlwires to the designated terminal blocks.

R. SURGE PROTECTION

It is the responsibility of the purchaser to providesuitable surge arrestors to protect the switchgearfrom damage due to lightening or other electricalsurges. When surge arrestors are furnished as part ofthe switchgear, the primary cable termination isinsulated at the factory unless it must be discon-nected for shipment. When this connection is com-pleted in the field, it is necessary to insulate theprimary connection before the switchgear is ener-gized. Normally, PVC boots are supplied to insulatethese connections.

S. MECHANICAL OPERATION CHECK

T. SAFETY INTERLOCKS

Before placing the Class E2 Medium-Voltage Control-ler into service, it is recommended that the user isfamiliar with the safety interlocks.

To perform the mechanical operation check, it isnecessary to reinstall any of the primary circuitcomponents that were removed previously to facili-tate assembly and cable terminations.

To reinstall the isolating switch, lift the assembly andslide it fully into the compartment rails. Connect thetwo, three-point plugs on the right front of the isolat-ing switch. Install the two retaining bolts on theisolating switch front cover. Install the vacuumcontactor using the contactor lift bar to assist and rollthe vacuum contactor into the compartment.

NOTE: Ensure that the contactor detent latch, whichis located on the lower left side of the vacuumcontactor end plate, is positioned behind the stopbracket mounted on the left side of the contactor rail.

1) Isolating Switch Operating Handle

The isolating switch can be placed in the OPENposition by moving the operating handle through avertical arc from the ON position to the OFF position.From the OFF position, the isolating switch may thenbe rotated 90 degrees counterclockwise to theHORIZONTAL position. Refer to Section IV. IN-STALLATION, F. REMOVING THE MEDIUM-VOLTAGE VACUUM CONTACTOR and see Figure12.

In both the ON and OFF positions, a portion of theoperating handle housing extends over the high-voltage compartment door and prevents the high-voltage compartment door from being opened. Toopen the door, the operating handle must be placedin the HORIZONTAL position.

FAILURE TO PERFORM THIS OPERATIONCOULD RESULT IN FAILURE OF THE UNIT TOOPERATE SAFELY AND RELIABLY.

CAUTION!

THE EQUIPMENT MUST BE DE-ENERGIZEDAND GROUNDED PRIOR TO PERFORMINGANY TESTS OR CHECKS OF THE SAFETYINTERLOCKS DESCRIBED BELOW. FAILURETO DE-ENERGIZE AND GROUND THEEQUIPMENT PRIOR TO PERFORMING THESETESTS OR CHECKS MAY RESULT IN INJURYOR DEATH.

WARNING!

DUE TO ELECTRICAL CLEARANCEREQUIREMENTS, THE FOUR PHASEBARRIERS SUPPLIED WITH THECONTACTOR MUST BE INSTALLED BEFORETHE CONTACTOR IS ENERGIZED.

CAUTION!


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With the operating handle in the OFF position, eithera single padlock or up to three padlocks, locked inplace, will prevent the handle from being placed ineither the ON or HORIZONTAL positions. Padlockscan be used to prevent unauthorized entry into thehigh-voltage compartment and any accidental closingof the isolating switch while maintenance work isperformed.

2) Door Interlocks

With the isolating switch operating handle in theHORIZONTAL position, the high-voltage compart-ment door can be opened. As soon as the dooropens, a mechanical interlock prevents movement ofthe operating handle. It is designed to prevent theuser from accidentally operating the isolation switchhandle and closing the starter on to the line with theenclosure door open.

The mechanical interlock is a spring-loaded plungerlocated just behind the door. When the door isopened, the interlock extends and prevents theoperating handle from being placed in the OFFposition accidentally. If the user wished to observethe operation of the isolation switch during installationor maintenance procedures, this interlock must bedeliberately defeated to move the handle to the OFFposition.

3) Contactor - Isolating Switch MechanicalInterlock

The isolating switch functions only as a disconnectand must never close on to or interrupt a power load.To prevent this, a mechanical interlock between thevacuum contactor and the isolating switch is pro-vided. If the vacuum contactor is in the CLOSEDposition, the interlock lever on the vacuum contactorarmature actuates a mechanical linkage which locksthe operating handle operating mechanism of theisolating switch.

4) Door Interference

The SLA contactor is equipped with a projection barattached to the upper front edge of the right-handside sheet. Its function is to ensure that the contactoris properly racked into position by providing anobstacle to door closure if the load jaws are not fullyengaged with the load stabs.

DO NOT OPERATE THE CONTACTOR IF THEDOOR INTERFERENCE PREVENTS DOOR CLOS-ING.

5) Line Stab Insulating Shutter

When an isolating switch is installed, both a shutterand a rear line stab barrier are in place in the control-ler structure and are intended to prevent accidentalaccess to the line bus. As the isolating switch isopened, the sliding tray (Figure 30) mechanicallydrives the insulating shutter closed across the threeline stab openings in the rear barrier. As the shuttercloses the openings, green and white striped labelsare uncovered to visually indicate that the shutter isclosed. With the isolating switch in the fully openposition, the fuse jaw finger assemblies and the lineside of the main fuses are connected to the groundbar.

UNDER THESE CONDITIONS THE EXPOSEDLINE TERMINAL STABS OF THE STARTERMAY BE ENERGIZED AT LINE POTENTIAL.

CAUTION!

DEFEATING THE ISOLATING SWITCHINTERLOCK ALLOWS THE USER TO CLOSETHE ISOLATING SWITCH ON TO LINE STABS.THE EQUIPMENT MUST BE DE-ENERGIZEDAND GROUNDED PRIOR TO PERFORMINGTHIS ACT. THE USER SHOULD ALSO BEFULLY AWARE OF THE HAZARDS INVOLVEDWITH THE RESULTS OF DEFEATING THISINTERLOCK, BE FAMILIAR WITH THEOPERATION OF THE ISOLATING SWITCH,AND TAKE ALL APPROPRIATE SAFETYPRECAUTIONS. THE OPERATING HANDLEMUST BE RETURNED TO THE HORIZONTALPOSITION TO CLOSE THE HIGH-VOLTAGECOMPARTMENT DOOR. MOVING THEOPERATING HANDLE FROM THE OFFPOSITION TO THE HORIZONTAL POSITIONAUTOMATICALLY RESETS THE INTERLOCK.

CAUTION!


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(THIS AREA IS INTENTIONALLY BLANK.)

When the isolating switch is removed from the starterstructure, a latch lever on the shutter assembly isactivated. It is designed to hold the insulating shutterclosed. This latch may be deliberately bypassed andthe shutter moved to the open position.

The shutter assembly and ground connection arevisible from the front of the medium-voltage compart-ment and proper operation of the shutter and groundconnection should be checked prior to energizing theequipment.

Figure 30. Shutter Assembly

a. Shutter Assembly (400A)b. Isolating stripes

a

b. Shutter Assembly (800A)

b


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33

VII. OPERATION

A. GENERAL

A test power interlock circuit enables each completeunit to be tested without applying power to the motor.After all control-circuit connections are made, thecontroller should be put through its complete operat-ing sequence in the test position, as a final check. Awiring diagram, which indicates circuits and connec-tions, is shipped from the factory with the Class E2Medium-Voltage Controller. All external wiring fromthe controller must be connected in accordance withthe wiring diagram.

B. PREPARATION OF THE CONTROLLER FOROPERATION

1) Cleaning

Clean away dirt and dust, and remove packingmaterial which interferes with the operation of thecontroller’s devices. For cleaning, use a brush, softcloth, or a vacuum cleaner. Do not use compressedair to clean the equipment. This may result in loosedirt or grit being blown into bearings or other criticalparts, thus causing excessive wear. Do not usedetergent for cleaning. Only use denatured alcoholor isopropyl alcohol to clean the insulation. See H.MAINTENANCE of this section for complete cleaninginformation.

Ensure that the Class E2 Medium-Voltage Controlleris clean before operation begins. After the equipmentis placed in the required location and the cables areconnected, carefully clean the compartment andequipment.

Before the panel can be operated, even for a tryoutwithout power, all devices must be placed in fulloperating condition. To protect equipment duringshipment, blocks and ties were applied to parts suchas the armature of many of the relays and vacuumcontactors. Ensure all blocks and ties are removedto prepare the Class E2 Medium-Voltage Controllerfor full operating condition.

Inspect the compartment and equipment for loosehardware, wires, and tools that may have beeninadvertently left inside the compartment duringinstallation.

2) Lubricating

The seating surfaces of laminated AC contactors,relay magnets, and the end of shafts may be coatedwith a heavy–grease rust preventative. Beforeoperating the vacuum contactors, the rust preventa-tive should be wiped off and the magnet seatingsurfaces should be coated with a thin film of lightmachine oil.

3) Manual Operation

Operate each device by hand to confirm that themoving parts operate freely without binding. Ensureelectrical contact tips are clean, free of grease andcontamination, and have a good surface contact.

4) Adjustments

The relays and contactors are carefully adjusted atthe factory. However, if adjustments are needed,refer to the instruction documents for information onindividual devices. The Class E2 Medium-VoltageController can be operated after all connections aremade, parts are assembled, and equipment andcomponents are thoroughly adjusted and inspected.

CARE SHOULD BE TAKEN DURING THECLEANING OPERATION TO PREVENT ANYDIRT FROM BEING BLOWN INTO THEINACCESSIBLE SPACE OF THE DEVICES.

CAUTION!

WHEN CLEANING BUS BAR INSULATION,ONLY DENATURED ALCOHOL ORISOPROPYL ALCOHOL SHOULD BE USED TOREMOVE FOREIGN MATERIAL FROM THEINSULATION SURFACE. FAILURE TO DO SOMAY DAMAGE THE DIELECTRIC AND/OR THEMECHANICAL PROPERTIES OF THEINSULATION.

CAUTION!


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34

C. TEST POWER CIRCUIT

The procedures in this section describe how tomanually check the operating condition of the ClassE2 Medium-Voltage Controller without energizing themotor.

A complete operational check of the controller can bemade without applying voltage to the motor or to thebus as follows:

1. The isolating-device handle must be in the OFFposition. In the OFF position, contacts of themechanically operated test-power interlock willopen the secondary circuit of the control-powertransformer, thereby isolating it.

2. For convenience during maintenance when itmay be desirable to energize the contactor or thecontrol circuit only, a control power test plug isprovided. To use the test plug, simply disconnectit from its socket, (under the control transformeron the contactor), and plug it into a 60 cycle, 115volt single phase power supply. Special plugsmay be provided when specified by the user.

When the male plug is transferred to the testpower supply, it automatically disconnects fromthe control power transformer to prevent feed-back of high voltage into the power circuits.Check to be sure no inadvertent bypass of thisarrangement has been made in the wiring beforerelying on this safety feature.

E. PRE-OPERATION TEST

The information in this section gives instructions forpreparing for the pre-operation test and performingthe pre-operation test.

D. CLASS E2 MEDIUM-VOLTAGECONTROLLER COMMISSIONING

The Class E2 Medium-Voltage Controller andVacuum Contactor Repair and Test Form (AppendixA) provides a list of items to be checked before theClass E2 Medium-Voltage Controller is commis-sioned.

1) Preparing for the Pre-Operation Test

Use the following information to prepare for the pre-operation test:

1. Ensure the motor control center is de-energized.

2. Complete all power and control connections.

3. Install manual isolator switches, contactors, andfuses.

4. Remove the required safety grounds.

5. Disconnect the following elements from thecircuits to be tested:

• Control Transformers

• Potential Transformers

• Starting Reactors

• Auto-Transformers

• Motors

DISCONNECT THIS TEMPORARY CIRCUITAND CONNECT THE PLUG TO THERECEPTACLE ON THE CONTACTOR BEFORERETURNING THE UNIT TO SERVICE.

CAUTION!

THIS TEST PROCEDURE REQUIRES THATTHE MOTOR CONNECTION CABLES BEDISCONNECTED FROM THE MOTORTERMINALS AND BE PROPERLY INSULATEDOR ISOLATED TO WITHSTAND PRIMARYVOLTAGE AT THE MOTOR TERMINALS. THISTEST SHALL ONLY BE PERFORMED BYQUALIFIED PERSONNEL TRAINED ANDCERTIFIED IN HIGH-VOLTAGE TESTINGPROCEDURES. ADHERENCE TO ALL SITE-SPECIFIC HIGH-VOLTAGE SAFETYPROCEDURES SHALL BE STRICTLYENFORCED. FAILURE TO FOLLOW THISSAFETY PRECAUTION MAY RESULT ININJURY OR DEATH.

WARNING!


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3) Power Fuse Inspection

Inspect the condition of all current-limiting fuses afterevery fault current condition. Visually inspect thepower fuse blown fuse indicator (Figure 32, a). Orperform continuity tests to determine the condition ofthe fuses. When visually inspecting a fuse, if thecolored indicator on top of the fuse extends outwards,the fuse is in the OPEN position or blown. Comparethe existing fuse resistance value to a new fuse valueto determine the condition of the fuse.

Perform continuity tests to determine the condition ofthe control power transformer primary fuses andcontrol power transformer secondary fuses. Com-pare the existing fuse resistance value to a new fusevalue to determine the condition of the fuse.

As required, replace fuses only with new fuses withthe same catalog number, type, voltage rating,current rating, frequency rating, and maximuminterrupting rating. Refer to the Operating Instruc-tions label for complete instructions on fuse replace-ment. The operating instructions label is located onthe inside compartment door of the medium-voltagecontroller.

2) Performing the Pre-Operation Test

1. Perform an insulation resistance (megger)dielectric test between the phases at the motorterminals, and between phases and phase toground of the main bus to ensure that no shortcircuits are present. Record all test values forfuture use.

2. Close all compartment doors and apply power tothe medium-voltage motor control center.

3. Close the isolating switch by placing the operat-ing handle in the extreme upper position until itlatches into the ON position (Figure 12, A). If theoperating handle is not properly closed andlatched, the contact marked control powerinterlock will not close.

NOTE: If the isolating switch operating handlecannot be placed in the ON position, de-energizeand ground the equipment. Check the mechani-cal interlocking of the isolating switch. In order toplace the operating handle in the ON position, thehigh-voltage compartment door must be fullyclosed and the vacuum contactor must be in theOPEN position.

4. Operate the Class E2 Medium-Voltage Controllerin the normal manner using the pilot devices(usually push buttons) provided.

5. After the operation tests are made, connect themotor and check it for proper rotation.

F. INSPECTION, MAINTENANCE, ANDSERVICING THE VACUUM CONTACTOR

1) Medium-Voltage Vacuum ContactorAdjustments

All adjustments pertaining to the vacuum contactorare described in the following Cutler-Hammer Publi-cations:

400 A, Type SL, 2.2 kV – 7.2 kV ...... I.B.48021800 A, Type SJA 2.2 kV – 7.2 kV ..... I.B.48005

2) Isolating Switch Adjustment

Normally, the isolating switch will not require anyadjustment; however, if parts are removed or re-placed, it may be necessary to make adjustments inthe mechanism. Refer to the Cutler-Hammer Publi-cations I.B. 48021 and I.B 48005 for completeinformation. See Table E.

Storage and Handling I.B.48001

Class E2 Medium-Voltage Controllers Isolating Switch 400 A I.B.48021 Isolating Switch 800 A I.B.48005

Medium-Voltage Vacuum Contactor Vacuum Bottle Subassembly Vacuum Contactor Latch Type L64 Auxiliary Contact Type SL 400A Type SJA 800A

Table E. Cuttler-Hammer Publication References


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3. Mechanical wear and fatigue on moving parts

4. Environmental heat and humidity

5. Loose hardware, connections, and joints

When needed, correct all adverse conditions asfollows: clean equipment; protect equipment fromadverse conditions; replace worn parts; lubricatespecific parts; and properly tighten loose hardware,connections, and joints.

Inspect all sections of the Class E2 Medium-VoltageController, including the high-voltage compartmentdoor interlock. The following list contains generalrecommendations for inspecting equipment.

1. Check for the presence of dust or dirt in thecompartment and on equipment. Specificallycheck for accumulation of any dust or dirt con-tamination on the insulators. Voltage failures canresult from tracking across contaminated insulat-ing surfaces.

2. Check for abrasive material accumulated in theisolating switch mechanism and mechanicalinterlock bearing and cam surfaces.

3. Check for a buildup of dust or dirt that will reduceany air or surface voltage clearances.

4. Excessive heating can reduce spring tension onthe primary connection stabs. Check stab springtension regularly, especially during excessiveheat conditions.

5. Excessive heat can cause the wiring and cableinsulation to breakdown. Check all wires andcables for any evidence of melting, discoloring,and deterioration.

6. The isolating switch mechanism has a life ex-pectancy of approximately 1000 operations. Ifthe application requires that the mechanismoperates more than twice each day, the mecha-nism should be checked at the end of each 1000operations, otherwise a yearly inspection isrecommended.

7. Periodic dimensional inspections of the isolatingswitch mechanism and mechanical interlocks arestrongly recommended. Refer to the properCutler-Hammer Publication as found in SectionVII. OPERATION, G. MAINTENANCE, 2)Preventive Maintenance Guidelines.

8. Check all dimensions when any part of theisolating switch mechanism and mechanicalinterlock is replaced to ensure that the system isin safe working order.

G. MAINTENANCE

1) Maintenance Precautions

The equipment described in this information bulletincontains hazardous voltages and currents sufficientto cause death, electric shock, or severe injury forpersonnel. De-energize the equipment beforeperforming any maintenance work. Lock out thedisconnecting means in accordance with NFPA 70E,“Electric Safety Requirements for Employee Safetyin the Workplace.”

2) Preventative Maintenance Guidelines

A preventative maintenance schedule, includingcleaning, inspection, and testing should be estab-lished to obtain the best service and reliability fromthe Class E2 Medium-Voltage Controller. Thefrequency and interval of preventive maintenanceshould be scheduled according to operating and localconditions and established needs and trends asdetermined by periodic maintenance and testrecords. If assistance is required for setting up theproper interval schedule for maintenance, contactPowell Electrical Manufacturing Company.

During preventive maintenance and inspection,check equipment for the following deterioratingconditions:

1. Contamination by dirt and dust in the environ-ment including wood fibers, coal dust, cement,lamp black, and lint

2. Contamination by chemicals in the environmentsuch as sulfur dioxide, chlorine, hydrocarbons,hydrogen sulfide and salt water

a

Figure 31. Blown Fuse Indicator

a. Blown Fuse Indicator


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VI. RECOMMENDED RENEWALPARTS AND REPAIRPROCEDURES

A. ORDERING INSTRUCTIONS

To order renewal parts from Powell Apparatus Ser-vice Division (PASD) visit the Web site atwww.powellservice.com or call 1-800-480-7273.When ordering parts always specify the completenameplate information, which includes the following:

• Controller Type

• Serial Number

• Rated Voltage

• Rated Amps

• Impulse Withstand

• Control Voltage (for control devices and coils)

To obtain part information, review the renewal partstables in the appropriate instruction bulletin. Whenordering parts, specify the part name, description,and part catalog number if the part is listed in arenewal parts table. If the part does not appear in aninstruction bulletin Renewal Parts table, provide adescription of the part along with a marked illustrationfrom the instruction bulletin, a photo, or a sketch ofthe needed part.

B. RECOMMENDED RENEWAL PARTS

For timely and cost-effective replacement of worn,broken, or damaged parts, a sufficient supply ofrenewal parts should be purchased and storedappropriately. (See Section IV INSTALLATION, C.STORAGE.) Maintaining a supply of renewal partsenables the purchaser to replace damaged partsquickly with a result of reducing the amount ofservice interruption time. See Tables F, G, H, I, and Jfor a list of renewal parts for equipment described inthis document.

1) Renewal Parts Quantity

The needed quantity of renewal spare parts varies.The purchaser should determine which parts and thequantity needed depending on their particular appli-cation and the following factors:

• Amount of time to acquire renewal parts

• Critical need for continuous operation

• Harsh environmental conditions that mayaffect part stability

• Severe service requirements that may affectpart durability

The parts tables included in this instruction bulletinmay list recommended quantities of renewal parts tobe carried in stock. As a minimum, it is recom-mended that one set of renewal parts be stocked perunit.

Over time, improvements may be made to renewalparts. Therefore, spare or renewal parts may not beidentical to the original parts. However, the furnishedreplacement parts are interchangeable with theoriginal parts.

C. REPAIR PROCEDURES

Powell Electrical Manufacturing Company recom-mends that only qualified technicians perform main-tenance on the equipment described in this instruc-tion bulletin. Therefore, if vacuum contactors areinstalled in a location that is not maintained by aqualified technician, a spare vacuum contactorshould be stored on site for vacuum contactorreplacement. Thus, the spare vacuum contactor canbe placed into service and the malfunctioning unitcan be returned to the factory for reconditioning.


IB-46110

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*Contact Powell Apparatus Service Division (PASD) for additional catalog numbers.

Table F. Renewal Parts

Description Catalog No. Description Catalog No.

Load Stab Assembly 400A 2A96124G03 Load Stab Assembly 800A

STA-800A 46910G01


Line Stab Assembly 400A 2A96124G02 Line Stab Assembly 800A

SJA 2044A50G28


Isolating Switch 400A 1A96056G11 Isolating Switch SJA 786A50G01


Operating Arm 400A 3509C92G01 Fuse Puller 400A 827D924G01


Control Plug (12 pt.) 400A (14 ga) 800A (14 ga)

46050G03 46050G05

Fuse Puller 800A 3440D69G01


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Table G. Medium-Voltage Vacuum Contactor Type SL 400A Renewal / Replacement Parts

Description Catalog No.

Vacuum Interrupter Bottles 2147A58G02

Contactor PC Board 2147A58G03

Contactor Auxiliary Contacts

2 N/O and 2 N/C

3 N/O and 3 N/C

2147A58G04

2147A58G05

Contactor Coil Kit (main/dual) 2147A58G11

Contactor Phase Barrier Kit 2147A58G12

Bottle Clamp Assembly 2147A58G15

CPT Primary Fuse Clips and Mounting 2147A58G16

Fuse Support Tray and Barrier Support 2147A58G17

PT Primary Fuse Clips and Mounting 2147A58G18

Main Fuse Clip Kit 2147A58G20

Contactor Line Bus 2147A58G21

Return Spring Assembly 2147A58G22

Mechanical Latch Assembly 2147A58G24

Contactor Trip Coil (latch units)

24 VDC

48 VDC

125 VAC - VDC

250 VAC - VDC

2147A58G25

2147A58G26

2147A58G27

2147A58G28

Contactor Line Fingers and Support Kit 2147A58G50

Contactor Load Fingers and Support Kit 2147A58G51

Control Power Transformer (CPT)

750 VA, 2400 V

750 VA, 4160 V

2000 VA, 2400 V

2000 VA, 4160 V

C 75A1D1C2

C 75E1D1C2

C 20A1D1C2

C 75E1D1C2

Control Power Transformer (CPT) 578D461G03


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Table H. Medium-Voltage Vacuum Contactor Type SJA 800A Renewal / Replacement Parts

Description Catalog No. Notes

Vacuum Interrupter Subassemblies 2147A87G03 Includes: shunt, load supports, load fingers.

Contactor Auxiliary Contacts (L-64)

1 NO INC

2 NO

2 NC

843D943G21

843D943G22

843D943G23

Contactor Coil Kit

120 VAC

240 VAC

214A88G11

214A88G12

Contactor Phase Barrier Kit 2147A89G07

CPT Primary Fuse Clips and Mounting Set (3) 2147A47G16

Fuse Support Tray and Contactor Phase Barrier Support

2147A89G06

Pt Primary Fuse Clips and Mounting Set (3) 2147A47G16

Main Fuse Clip Kit (Fuse Load Fingers) 2147A71G15

Mechanical Latch Assembly

120 VAC continuous – 48 VDC Intermittent

230 VAC continuous – 125 VDC Intermittent

2147A88G22

2147A88G23

Contactor Trip Coil (Latch Units)

115 VAC

230 VAC

5259C73H01

5259C73H02

Single trip coil assembly without interlocks, precable, or magnet parts.

Contactor Line Fingers and Support Kit (Qty. 3)

2147A89G01

Contactor Load/Line Fingers without Support Kit 2147A89G02

(Qty. 3)

L-63 Interlock 578D461G03


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Table I. ACLS, CLS70 Current-Limiting Fuses (R-Type)

Type ACLS Current-Limiting Fuses for use with Class E2 Medium-Voltage Controllers (400 A)

8.3 kV Max. (7.2 kV Nom.) 12" Clip Center

"R"

Des

Amp

Rating

Catalog No.

Sym.

(int.)

2R 70 8ACLS-2R 50,000

3R 100 8ACLS-3R 50,000

4R 130 8ACLS-4R 50,000

5R 150 8ACLS-5R 50,000

Single 6R 170 8ACLS-6R 50,000

7.2 kV Max. 12" Clip Center

9R 390 7ACLS-9R 50,000

Single

12R 450 7ACLS-12R 50,000

Type CLS70 Current-Limiting Fuses for use with Class E2 Medium-Voltage Controllers (800 A)

5.08 kV Max. (4.8 kV Nom.) Special Controller Mounting

"R"

Des

Amp

Rating

Catalog No.

Sym.

(int.)

12R 230 5CLS70-12R 50,000

24R 450 5CLS70-24R 50,000

32R 600 5CLS70-32R 50,000

36R 650 5CLS70-36R 50,000

Double 44R 700 5CLS70-44R 50,000

Type ACLS Current-Limiting Fuses for use with Class E2 Medium-Voltage Controllers (400 A)

5.08 kV Max. (2.4 – 4.8 Nom.) 12" Clip Center

"R"

Des

Amp

Rating Catalog No.

Sym.

(int.)

2R 70 5ACLS-2R 50,000

3R 100 5ACLS-3R 50,000

4R 130 5ACLS-4R 50,000

5R 150 5ACLS-5R 50,000

6R 170 5ACLS-6R 50,000

9R 200 5ACLS-9R 50,000

Single 12R 230 5ACLS-12R 50,000

18R 390 5ACLS-18R 50,000

24R 450 5ACLS-24R 50,000

Double 26R 480 5ACLS-26R 50,000


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Table J. ACLE, AHLE, NCLPT Current-Limiting Fuses (E-Type)

Type NCLPT Current-Limiting Fuses for use with Control Power Transformer

5.5 kV Max. 5" Clip Center, Non-Indicating

Amp

Rating

Catalog No.

Sym.

(int.)

1E 5NCLPT-1E 63,000

3E 5NCLPT-3E 63,000

Single 5E 5NCLPT-5E 63,000

Type CLS70 Current-Limiting Fuses for use with Class E2 Medium-Voltage Controllers (800 A)

5.08 kV Max. (4.8 kV Nom.) Special Controller Mounting

Amp

Rating

Catalog No.

Sym.

(int.)

600E 5CLS70-600E 40,000

Double 750E 5CLS70-750E 40,000

Type AHLE Current-Limiting Fuses for use with Class E2 Medium-Voltage Controllers (400 A)

5.5 kV Max. (4.8 Nom.) 12" Clip Center

Amp

Rating

Catalog No.

Sym.

(int.)

Single

250C 5AHLE-250E 63,000

7.2 kV Max. 12" Clip Center

300E 5AHLE-300E 63,000

350E 5AHLE-350E 63,000

400E 5AHLE-400E 63,000

Single 450E 5AHLE-450E 63,000

Type AHLE Current-Limiting Fuses for use with Class E2 Medium-Voltage Controllers (400 A)


Amp

Rating

Catalog No.

Sym.

(int.)

40E 8AHLE-40E 50,000

50E 8AHLE-50E 50,000

65E 8AHLE-65E 50,000

80E 8AHLE-80E 50,000

100E 8AHLE-100E 50,000

125E 8AHLE-125E 50,000

150E 8AHLE-150E 50,000

Single 180E 8AHLE-180E 50,000

200E 8AHLE-200E 50,000

250E 8AHLE-250E 50,000

300E 8AHLE-300E 50,000

Double 350E 8AHLE-350E 50,000

Type ACLE Current-Limiting Fuses for use with Class E2 Medium-Voltage Controllers (400 A)


Amp

Rating

Catalog No.

Sym.

(int.)

25E 5ACLE-25E 50,000

30E 5ACLE-30E 50,000

50E 5ACLE-50E 50,000

65E 5ACLE-65E 50,000

80E 5ACLE-80E 50,000

100E 5ACLE-100E 50,000

125E 5ACLE-125E 50,000

150E 5ACLE-150E 50,000

200E 5ACLE-200E 50,000

Single 225E 5ACLE-225E 50,000


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Appendix

Class E2 Medium-Voltage Controller and Vacuum Contactor Repair and Test Form

Customer Name: Date:

Equipment Location: Ref. Powell S.O. # :

Customer P.O. :

Circuit I.D. :

Vacuum Contactor Specifications

Mfg./Model # : _________________ Serial # : ________________ Ref. Mfg. IB # : ________________

Contactor Rating: __________ Amps, __________kV, __________ kAClose Voltage: ___48 V DC ___120 V DC

___125 V DC___ 240 V DC

Trip Voltage: ___48 V DC ___120 V DC

___125 V DC___ 240 V DC

System

Voltage: ___________kV

Motor

Capacity: ___________HP

Vacuum Contactor Type

D.A.L. :_____ Soft-Start _____

Latch Trip Coil ?

Yes _____ No_____

Class E2 Medium-Voltage Controller and Vacuum Contactor Start-up/Maintenance Checks

Initials or N/A Initials or N/A

Shipping Bracket Removed "Late-Break" Coil Contact Adjustment

Cleanliness Coil Resistor(s) Properly Sized

Phase Barriers / (Arc Chutes, If applicable.) Contact Force Measurement

Primary Disconnecting Device: Critical Adjustments Verified, (if applicable)

Shutter Assembly Operation CPT Rating and Wiring Connections

Isolating Switch Operating Handle CPT Fuses:

Alignment Primary

Interlock(s): Secondary

Door Interlock(s) CT Ratio and Polarity

"Closed–Door" Interlocks Tightness of T-Lead Connection

Position Interlock(s) Ground Connections

Mechanical Latch (if applicable) Protective Relay Test(s)

Line Stabs: Electrical Function Test

Pressure "Start-Run" Vacuum Contactor Interlock Ckt.

Lubricant Pri. Ckt.:

Control Plug Megger

Control Power Interlock (CPI) Auxiliary Switch I.R. Test

Vacuum Contactor Primary Circuit Tests

*Vacuum Interrupter Resistance A phase B phase C phase *Vacuum Integrity A phase B phase C phase

micro-ohms Pass/Fail

*Hi–Potential ac5.0 kV – 13.2 kV AC

7.2 kV – 18.2 kV AC

*Hi–Potential dc5.0 kV – 18.7 kV AC

7.2 kV – 25.6 kV AC

Mico–Amps

Vacuum Contactor Tested in "Open" Position Vacuum Contactor Tested in "Closed" Position

Top Bottom

1 1

2 2

3 3

Maintenance Performed (give exact Description(s) and Location(s) of all Maintenance Performed):

Parts Replacement (give exact Location(s), Quantit(ies), and Description(s) of all Parts to be Replaced):

Comments:

Tests by:

Note: Items marked with an * are optional

Note: Only the tests necessary to verify performance of the repair(s) are required (for repaired vacuum contactors).


IB-46110

44

IndexA

Adjustments 33Autotransformer 14Auxiliary compartment 14

B

Basic impulse level 11

C

Class E2 Medium-VoltageController 10

Class E2 Medium-VoltageControllers

introduction 9Class E2 medium-voltage

controllers 9one-high 10two-high 10

Cleaning 33Commissioning 34

D

Description 9basic impulse level 11manual isolating method 12mechanical Interlock 13medium-voltage Contactors 12power fuses 14ratings 11

E

Equipment Descriptiondimensions 14general 9

F

Factory Production Dielectric Test11

G

Grounding 22

H

Handling 16High-voltage compartment 19

I

Installation 16grounding 22handling 16positioning 17power connections 22receiving 16removing the medium-voltage

vacuum contactor 19storage 16

Instruction bulletinavailable electronically 7introduction 7purpose 7scope 7

Introduction 7Isolating switch 35

L

Lower high-voltage compartment19

Lubricating 33

M

Maintenance 36Manual isolating mechanism 12Manual operation 33Mechanical interlocks 13Medium-voltage vacuum

contactors 12Motor starter 9

O

Operation 33adjustments 33general 33lubricating 33manual operation 33

P

Parts 37ordering 37renewal 37repair 37

Positioning of the exterior 17Power connections 22Power fuse 35

ACLS, CLS70 Current-LimitingFuese (R-TYPE) 41

ACLS, CLS70 Current-LimitingFuse (R-Type) 42

Power fuses 14Pre-operation test 34Preparation 33

Cleaning 33

R

Ratings 11power fuse tables 41

current-limiting fuses (R-Type)41

Receiving 16Removing the medium-voltage

vacuum contactor 19

S

Safety 7description 7general 8labels 8specific 8X-Rays 8

Safety labels 8Storage 16

T

Test power circuit 34

X

X-Rays 8


IB-46110

45

Notes


IB-46110

46

Notes


IB-46110

47

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POWELL ELECTRICAL MANUFACTURING COMPANY8550 MOSLEY DRIVE • HOUSTON, TEXAS 77075 • USA

PHONE (713) 944-6900 • FAX (713) 947-4453http://www.powellelectric.comhttp://www.powellservice.com

©2001 POWELL ELECTRICAL MANUFACTURING COMPANY ALL RIGHTS RESERVED. 09/2004

INSTRUCTIONS IB-46110

CLASS E2 MEDIUM-VOLTAGE CONTROLLERS WITHDRAWOUT VACUUM CONTACTORS

5.0 kV Voltage Class for SL 400A and SJA 800A7.2 kV Voltage Class for SL 400A and SJA 800A

Documents

IB-46110