01.4IB.46210A E2-AR®
Medium Voltage Controller
Arc Resistant Motor Control With
Eaton Contactors
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E2-AR® Medium Voltage Controller with
Eaton Contactor
Contact Information
Powell Electrical Systems, Inc.
www.powellind.com
info@powellind.com
Service Division
PO Box 12818
Houston, Texas 77217-2818
Tel: 713.944.6900
Fax: 713.948.4569
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01.4IB.46210A
01.4IB.46210A
Signal Words
Qualified Person
As stated in ANSI Z535.4-2007, the signal word is
a word that calls attention to the safety sign and
designates a degree or level of hazard seriousness.
The signal words for product safety signs are
“Danger”, “Warning”, “Caution” and “Notice”.
These words are defined as:
For the purposes of this manual, a qualified
person, as stated in NFPA 70E®, is one who has
skills and knowledge related to the construction
and operation of the electrical equipment and
installations and has received safety training to
recognize and avoid the hazards involved. In
addition to the above qualifications, one must also
be:
!
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
!
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
!
1. trained and authorized to energize,
deenergize, clear, ground, and tag circuits
and equipment in accordance with
established safety practices.
2. trained in the proper care and use of
personal protective equipment (PPE)
such as rubber gloves, hard hat, safety
glasses or face shields, flash clothing, etc.,
in accordance with established safety
practices.
3. trained in rendering first aid if necessary.
CAUTION
CAUTION, used with the safety alert symbol,
indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
CAUTION
CAUTION, used without the safety alert
symbol, is used to address practices not
related to personal injury.
NOTICE
NOTICE is used to address practices not related
to personal injury.
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01.4IB.46210A
01.4IB.46210A
Contents
Ch 1 General Information .................................................................................................1
A. Scope ................................................................................................................................................................2
B.Purpose .............................................................................................................................................................2
C. Instruction Bulletins Available Electronically .....................................................................................................2
Ch 2 Safety ........................................................................................................................3
A.
B.
C.
D.
E.
F.
Safe Work Condition . ........................................................................................................................................3
Safety Guidelines ...............................................................................................................................................3
General .............................................................................................................................................................4
Specific ..............................................................................................................................................................4
X-Rays ..............................................................................................................................................................5
Safety Labels .....................................................................................................................................................5
Ch 3 Equipment Description .............................................................................................6
A. General .............................................................................................................................................................6
B.Class E2-AR Medium Voltage Controller ...........................................................................................................6
C.Ratings . ............................................................................................................................................................9
D. Basic Impulse Level ......................................................................................................................................... 10
E.Factory Production Dielectric Test .................................................................................................................. 10
F. Medium Voltage Contactors ........................................................................................................................... 10
G. Manual Isolation Switch ................................................................................................................................. 11
H. Mechanical Interlocking .....................................................................................................................13
I.Auxiliary Compartments ......................................................................................................................15
J.Power Fuses ......................................................................................................................................15
K. Starting Autotransformers or Reactors . ......................................................................................................... 16
L. Dimensions ........................................................................................................................................16
Ch 4 Installation ..............................................................................................................17
A.General ............................................................................................................................................17
B.Receiving . .........................................................................................................................................17
C. Storage .......................................................................................................................................................... 17
D.Handling ........................................................................................................................................................ 18
E.Positioning of the Enclosure ............................................................................................................................ 20
F.Removing the Medium Voltage Vacuum Contactor ............................................................................................ 20
1) Removing the Vacuum Contactor from the High Voltage Compartment ................................................................20
G.Power Connections ......................................................................................................................................... 22
H. Grounding ...................................................................................................................................................... 23
I .C onnections ............................................................................................................. 23
J. Main Bus Assembly Insulation . ........................................................................................................................ 25
K. Incoming Power Connections ........................................................................................................................... 25
1) Wrapping Bus Joint ................................................................................................................................................................25
2) Applying PVC Boots ...............................................................................................................................................................28
3) Cleaning Bus Insulation ........................................................................................................................................................28
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E2-AR® Medium Voltage Controller with
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01.4IB.46210A
Contents
L. Motor Connections . ....................................................................................................................................... 30
M.Power Cable Termination ................................................................................................................................. 30
N. Insulating Primary Cables ................................................................................................................................ 31
O. Ground Fault Current Transformers (Through Type) . ...................................................................................... 31
P.Control Cables and Connections ..................................................................................................................... 31
Q. Surge Protection ............................................................................................................................................ 32
R. Mechanical Operation Check ........................................................................................................................... 32
S. Safety Interlocks ............................................................................................................................................ 33
1) Isolating Switch Operating Handle ....................................................................................................................................33
2) Door Interlocks ........................................................................................................................................................................33
3)Contactor - Isolating Switch Mechanical Interlock ........................................................................................................34
4) Door Interference ...................................................................................................................................................................34
Ch 5 Operation ................................................................................................................35
A. General .......................................................................................................................................................... 35
B.Preparation of the Controller for Operation . .................................................................................................. 35
1)Cleaning ...................................................................................................................................................................................35
2)Lubricating ...............................................................................................................................................................................35
3) Manual Operation .................................................................................................................................................................36
4)Adjustments .............................................................................................................................................................................36
5) Pre-Startup Checks .................................................................................................................................................................36
6) Contactor Interlock Pre-Start Up Check ............................................................................................................................36
C.Test Power Circuit .......................................................................................................................................... 37
D.Hi-Pot and Megger Test .................................................................................................................................. 38
1) Preparing for the Hi-Pot and Megger Test ........................................................................................................................38
2) Performing the Hi-Pot and Megger Test ...........................................................................................................................38
E.Pre-Operation Test ......................................................................................................................................... 39
F. Start-Up Procedure ........................................................................................................................................ 39
1)
2)
3)
4)
5)
6)
Preliminary Checks .................................................................................................................................................................39
Setting of Adjustable Protective Devices ..........................................................................................................................40
Medium Voltage Vacuum Contactor Inspection ............................................................................................................40
Medium Voltage Vacuum Contactor Testing ..................................................................................................................40
Isolating Switch Adjustment ................................................................................................................................................40
Power Fuse Inspection ...........................................................................................................................................................41
Ch 6 Maintenance ...........................................................................................................42
A. Maintenance Precautions ................................................................................................................................ 42
B.Preventative Maintenance Guidelines ................................................................................................................ 42
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01.4IB.46210A
Contents
Ch 7 Recommended Renewal Parts and Replacement Procedures ...............................44
A.Ordering Instructions . .................................................................................................................................... 44
B.Recommended Renewal Parts ........................................................................................................................... 44
1) Renewal Parts Quantity ........................................................................................................................................................44
C.Replacement Procedures .................................................................................................................................. 44
1) Fuse Removal/Replacement Procedure ............................................................................................................................45
2) Auxiliary Contacts Inspection and Replacement ...........................................................................................................46
D.Replacement Parts . ......................................................................................................................................... 47
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E2-AR® Medium Voltage Controller with
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01.4IB.46210A
Figures
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
iv
Class E2-AR® Medium Voltage Controllers 400A & 800A ...............................7
Two-High Vertical Section Rear View (400A) ..................................................8
High and Low Voltage Compartments ...........................................................9
Eaton Type SL Medium Voltage Vacuum Contactor 400A ...........................11
Eaton Type SJA Medium Voltage Vacuum Contactor 800A .........................11
Isolating Switch Operating Handle ..............................................................12
Typical Dimensions for Class E2-AR Medium Voltage Controllers ...............14
Recommended Method for Lifting an Indoor Lineup ...................................18
Typical Class E2-AR® Medium Voltage Controller Floor Plans .....................19
Ground Bus Splicing Configuration ..............................................................24
Insulation of Bus Bar .....................................................................................26
Single Bus Bar Connection Joint ...................................................................26
Double Bus Bar Connection Joint .................................................................27
Tee Connection Joint .....................................................................................27
Dead End Bus Joint Insulation ......................................................................28
Class E2-AR® Medium Voltage Controller Unit 400A ....................................29
Class E2-AR® Medium Voltage Controller Unit 800A ....................................29
Low Voltage Compartment ...........................................................................31
Wire Way ........................................................................................................31
Isolation Switch Interlock .............................................................................34
Mechanical Interlock Verification ................................................................37
Blown Fuse Indicator .....................................................................................41
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01.4IB.46210A
Tables
Table A Horsepower, Current, and Voltage Ratings ........................................................10
Table B Voltage and Interrupting Ratings of Class E2-AR
Medium Voltage Controllers ...............................................................................10
Table C General Guideline for Outgoing Feeder Cables ..................................................23
Table D Bolt Torque Values for Class E2-AR® Medium Voltage Controllers ....................25
Table E Bus Wrapping Components .................................................................................25
Table F Insulation of Bus Bar ............................................................................................26
Table G Insulation of Single Bus Bar Connection Joint ...................................................26
Table H Insulation of Double Bus Bar Connection Joint ..................................................27
Table I Insulation of Tee Connection Joint .......................................................................27
Table J Insulation of Tee Connection Joint ......................................................................28
Table K Eaton Publication References .............................................................................41
Table L Medium Voltage Vacuum Contactor Eaton 400A SL
Renewal/Replacement Parts ................................................................................47
Table M Medium Voltage Vacuum Contactor Eaton 800A SJA
Renewal/Replacement Parts ...............................................................................48
Table N R-Rated Clip-On Fuses for 400A Contactor ........................................................49
Table O R-Rated Bolt-On Fuses for 800A Contactor ........................................................50
Table P E-Rated Clip-On Fuses for 400A Contactor .........................................................51
Table Q E-Rated Bolt-On Fuses for 800A Contactor ........................................................51
Table R Control Relays ......................................................................................................52
Table S Current Transformers ..........................................................................................52
Table T Ground Current Transformers .............................................................................52
Table U Control Power Transformers - SNC .....................................................................53
Table V Control Power Transformer Primary Fuses .........................................................53
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E2-AR® Medium Voltage Controller with
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01.4IB.46210A
Appendix
Appendix A- Class E2 Medium Voltage Controller and Vacuum Contactor
Repair and Test Form...................................................................................54
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01.4IB.46210A
Ch 1 General Information
!
WARNING
The equipment described in this document may contain high voltages and currents which can
cause serious injury or death.
The equipment is designed for use, installation, and maintenance by qualified users of such
equipment having experience and training in the field of high voltage electricity. This document
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 shall contact Powell
immediately at 1.800.480.7273.
!
WARNING
Before any adjustment, servicing, part replacement, or any other act is performed requiring
physical contact with the electrical working components or wiring of this equipment, the power
supply must be disconnected. Failure to follow this warning may result in injury or death.
NOTICE
The information in this instruction bulletin is not intended to explain all details or variations of the
Powell equipment, nor to provide for every possible contingency or hazard to be met in connection
with installation, testing, operation, and maintenance of the equipment. For additional
information and instructions for particular problems, which are not presented sufficiently for the
user’s purposes, contact Powell at 1.800.480.7273.
NOTICE
Powell reserves the right to discontinue and to change specifications at any time without incurring
any obligation to incorporate new features in products previously sold.
General Information
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E2-AR® Medium Voltage Controller with
Eaton Contactor
A.Scope
The information in this instruction bulletin
describes the following Arc Resistant Medium
Voltage Controllers (E2-AR®):
•
•
5.0kV, and 7.2kV Voltage Class for 400A
5.0kV, and 7.2kV Voltage Class for 800A
Note: You may see the Class E2-AR
equipment referred to as MVMCC-AR®.
B.Purpose
The information in this instruction bulletin is
intended to provide information required to
properly operate and maintain the Medium
Voltage Controllers described in Ch 1 General
Information, A. Scope.
This instruction bulletin provides:
1.
2.
3.
4.
5.
6.
7.
Safety guidelines
General descriptions of the operation and
maintenance of the Medium Voltage controller Instructions for installation and placing the Medium Voltage controller into service
Instructions for part replacement
Information for ordering renewal parts
Procedure for critical adjustments
Illustrations, photographs, and description of the controllers
The illustrations contained in this document
may not represent the exact construction
details of each particular type of Class E2-AR
Medium Voltage Controller. The illustrations
in this document are provided as general
information to aid in showing component
locations only.
!
01.4IB.46210A
WARNING
Be sure to follow the appropriate safety
precaution while handling any of the
equipment. Failure to do so may result in
serious injury or death.
To the extent required, the products described
herein meet the applicable ANSI, IEEE, and
NEMA Standards; however, no such assurance
is given with respect to local codes and
ordinances which may vary greatly.
C.Instruction Bulletins Available Electronically
NOTICE
Changes to the instruction bulletin may be
implemented at any time and without notice.
Go to www.powellind.com to ensure use of
the current instruction bulletin for the Powell
equipment.
For more information visit
www.powellind.com. To contact the Powell
Service Division call 1.800.480.7273 or
713.944.6900, or email
info@powellservice.com.
For specific questions or comments pertaining
to this instruction bulletin email
documents@powellind.com with the IB
number in the subject line.
All illustrations and photos are shown using
deenergized equipment.
2
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General Information
01.4IB.46210A
Ch 2 Safety
A. Safe Work Condition
The information in Ch 2 Safety, A. Safe Work
Condition is quoted from NFPA 70E 2012 - Article
120, 120.1 Establishing an Electrically Safe Work
Condition.
120.1 Process of Achieving an Electrically Safe
Work Condition
1. Determine all possible sources of electrical
supply to the specific equipment. Check
applicable up-to-date drawings, diagrams,
and identification tags.
2. After properly interrupting the load current,
OPEN the disconnecting device(s) for each
source.
3. Wherever possible, visually verify that all
blades of the disconnecting devices are
fully OPEN or that drawout type circuit
breakers are withdrawn to the fully
disconnected position.
4. Apply lockout/tagout devices in accordance
with a documented and established policy
5. Use an adequately rated voltage detector
to test each phase conductor or circuit part
to verify they are deenergized. Test each
phase conductor or circuit part both phaseto-phase, and phase-to-ground. Before and
after each test, determine that the voltage
detector is operating satisfactorily.
Safety
6. Where the possibility of induced voltages
or stored electrical energy exists, ground
the phase conductors or circuit parts
before touching them. Where it could be
reasonably anticipated that the conductors
or circuit parts being deenergized
could contact other exposed energized
conductors or circuit parts, apply ground
connecting devices rated for the available
fault duty.
B.Safety Guidelines
Study this instruction bulletin and all other
associated documentation before uncrating
the motor control.
Each user has the responsibility to instruct
and supervise all personnel associated with
usage, installation, operation, and maintenance
of this equipment on all safety procedures.
Furthermore, each user has the responsibility of
establishing a safety program for each type of
equipment encountered.
The medium voltage controllers described
in this instruction bulletin is operated by an
electromagnet assembly through a mechanical
linkage. It is mandatory that the following
rules be observed to ensure the safety of
personnel associated with usage, installation,
operation, and maintenance of the equipment.
The safety rules in this instruction bulletin are
not intended to be a complete safety program.
The rules are intended to cover only some of the
important aspects of personnel safety related to
Class E2-AR® Medium Voltage Controllers.
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E2-AR® Medium Voltage Controller with
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C. General
1. Only supervised and qualified personnel
trained in the usage, installation, operation,
and maintenance of the motor control shall
be allowed to work on this equipment. It
is mandatory that this instruction bulletin,
any supplements, and service advisories be
studied, understood, and followed.
2. Maintenance programs must be consistent
with both customer experience and
manufacturer’s recommendations,
including service advisories and instruction
bulletin(s). A well-planned and executed
routine maintenance program is essential
for equipment’s reliability and safety.
3. Service conditions and controller
applications shall also be considered in the
development of safety programs. Variables
include ambient temperature; humidity;
actual continuous current; thermal cycling;
number of operations; interrupting duty;
and any adverse local conditions including
excessive dust, ash, corrosive atmosphere,
vermin, and insect infestations.
D.Specific
1. DO NOT WORK ON AN ENERGIZED CLASS
E2-AR® MEDIUM VOLTAGE CONTROLLER.
Before performing maintenance work on
a Class E2-AR Medium Voltage Controller,
deenergize and disconnect the power
supply for the controller, and remove the
Class E2-AR Medium Voltage Controller
from service.
2. DO NOT WORK ON AN ENERGIZED
MEDIUM VOLTAGE VACUUM
CONTACTOR. Before performing work on
a vacuum contactor, remove the vacuum
contactor from service and remove it from
the Class E2-AR Medium Voltage Controller.
4
01.4IB.46210A
3. DO NOT WORK ON A CLASS E2-AR
MEDIUM VOLTAGE CONTROLLER
VACUUM CONTACTOR WHEN THE
CONTROL CIRCUIT IS ENERGIZED.
4. EXTREME CARE MUST BE EXERCISED
TO KEEP ALL PERSONNEL, TOOLS, AND
OTHER OBJECTS CLEAR OF MECHANISMS
WHICH ARE TO BE OPERATED,
DISCHARGED, OR RELEASED. These
contactors utilize high energy mechanisms.
These mechanisms must be serviced only
by skilled and knowledgeable personnel.
Detailed information regarding these
mechanisms is found in this instruction
bulletin and in the instruction bulletin for
the vacuum contactors.
5. DO NOT ATTEMPT TO MANUALLY CLOSE
THE VACUUM CONTACTOR ON AN
ENERGIZED CIRCUIT.
6. DO NOT USE AN OPEN VACUUM
CONTACTOR AS THE SOLE MEANS OF
ISOLATING A HIGH VOLTAGE CIRCUIT.
FOR COMPLETE ISOLATION, THE
ISOLATING SWITCH MUST BE IN THE
OFF POSITION.
7. ALL COMPONENTS SHALL BE
DISCONNECTED BY MEANS OF A
VISIBLE BREAK AND SECURELY
GROUNDED FOR THE SAFETY
OF PERSONNEL PERFORMING
MAINTENANCE OPERATIONS ON
THE CLASS E2-AR MEDIUM VOLTAGE
CONTROLLER.
8. Interlocks are provided to ensure the
proper operating sequences of the Class
E2-AR Medium Voltage Controller and
vacuum contactors for the safety of the
user. If for any reason an interlock does not
function as described, DO NOT MAKE ANY
ADJUSTMENTS, MODIFICATION, OR
DEFORM THE PARTS. DO NOT FORCE
THE PARTS INTO POSITION. CONTACT
POWELL FOR INSTRUCTIONS.
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Safety
01.4IB.46210A
E. X-Rays
X-Rays may be generated when high voltage
is applied across the contacts of a vacuum
interrupter. The intensity of x-radiation
depends on the level of peak voltage and
the size of the contact gap. At the normal
operating voltage for this type of equipment,
the x-radiation levels are negligible. At the
voltages specified for testing, personnel shall
be located no closer than one (1) meter (about
3 feet) from the vacuum contactor. THE
VACUUM CONTACTOR SHALL BE EITHER
FULLY OPEN, OR FULLY CLOSED WHEN
MAKING HIGH POTENTIAL TESTS. DO
NOT PERFORM TESTS WITH CONTACTS
PARTIALLY OPEN.
F.Safety Labels
The Medium Voltage controller has DANGER,
WARNING, CAUTION, and instruction labels
attached to various locations. All equipment
DANGER, WARNING, CAUTION, and
instruction labels shall be observed when
the Medium Voltage controller is handled,
operated, or maintained.
Safety
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E2-AR® Medium Voltage Controller with
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Ch 3 Equipment Description
A.General
Portions of the following text have been taken
from Eaton Instructional Leaflet IB 48041,
effective December 2009.
01.4IB.46210A
The basic P-17172 Vacuum Controller is an
assembly of components and conductors
for motor starting, arranged for convenient
access in an enclosure which allows space
and facilities for cable termination, with safety
interlocking of the doors and isolator to
prevent inadvertent entrance to high voltage
parts. This equipment is rated 7200 volts
maximum and may be used on distribution
voltages from 2400 to 7200 volts. Installation,
operation, and service should be performed
only by experienced personnel trained and
qualified in this class of equipment.
Class E2-AR® Medium Voltage Controllers are
designed to comply with applicable NEMA ICS
Standards Publications and UL 347.
These controllers are described as
metal-enclosed, high-interrupting capacity
motor starter equipment with manual isolation.
Each controller and starter is designed for
B. Class E2-AR Medium Voltage Controller
specific applications and the components and
In general, the Class E2-AR Medium Voltage
functions are determined by the purchaser’s
Controller consists of one-high or
specifications and needs (Figure 1).
two-high vertical sections of medium voltage
Starting, stopping, and overload protection
compartments. Each Class E2-AR Medium
are essential control functions for all types of
Voltage Controller consists of a high voltage
Alternating Current (AC) motors. Short-circuit
and low voltage compartment. Also, each
protection is a basic function included in
compartment has a separate door and barriers
Class E2-AR Medium Voltage controllers.
between the two compartments.
Additionally, a large variety of protective
The controller consists of a non-load break
devices and functions can be included in
isolation switch, medium voltage current
each controller depending on the particular
limiting fuses, one or more Type SL
application and the type of motor being
vacuum-break contactors, a set of current
controlled, such as synchronous or
transformers, plus control and protection
wound-rotor motors.
devices. The isolating switch has a limited
These instructions are prepared as a general
transformer magnetizing currents. The
guide that provides the necessary general
controller is designed to start, stop, and
information for the Class E2-AR Medium
protect a three-phase medium voltage motor.
Voltage Controller’s type and function. These
The controller may also be used to switch
instructions also include a suggested method
transformer windings or capacitor loads.
of installation with demonstrative techniques
For applications other than those indicated,
for the operation and maintenance of the
consult Powell. Each controller occupies all
equipment. Separate instructions covering
or a portion of a steel structure that may also
particular equipment, devices, or components
enclose a horizontal bus system to distribute
are not included in this instruction bulletin,
power to two or more sections and a vertical
but are available upon request. The purchaser
bus system to connect individual starters to the
should interpret these instructions for
horizontal bus.
applicability to his particular controller by
referring to the drawings supplied with the
controller.
6
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Equipment Description
01.4IB.46210A
Figure 1
Class E2-AR® Medium Voltage Controllers 400A & 800A
a
b
a. 400A Controller
b. 800A Controller
Equipment Description
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E2-AR® Medium Voltage Controller with
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Starters are available with bolt-in or clip-in
main fuses. Contactors may have bolted
connections or stab-in connections to the
starter cell.
Figure 2
01.4IB.46210A
Two-High Vertical Section Rear View
(400A)
The flow of current through a starter with
bolted fuses and a stab-in contactor can be
described as follows:
The line finger assembly mounted at the
back of the enclosure serves to connect
the isolation switch moving stabs to the
controller line terminals when the switch is
closed. Power flows from the switch moving
stabs through a flexible shunt to the upper
fuse mountings. The fuses are connected to
the lower fuse mountings that contain the
line-side stab connections to the line finger
assemblies for the main contactor. With
the main contactor energized, power flows
through the contactor’s vacuum interrupters to
the contactor load fingers, which are engaged
on to the contactor load-side stabs. Medium
voltage cables connect the load-side stabs to
the motor load connections. The contactor is
held in place by a set of rails mounted in the
lower part of the cell. Current transformers
are typically mounted immediately behind
the main contactor, under the load-side stabs.
The motor load connections are mounted to
the left of the main fuses in the rear of the
compartment, facing forward.
To open the high voltage compartment
door, the power must be disconnected by
a sequence of manual operations which
require opening the Medium Voltage vacuum
contactor and deenergizing the load, operating
the isolating device, and unlatching the door.
The low voltage compartment door may be
entered without disconnecting the power.
The low voltage components are mounted
in the low voltage control compartment
located on the front of the controller
medium voltage door. The low voltage
compartment is fabricated from steel sheets
to provide isolation from the medium voltage
components mounted behind the low voltage
compartment. A window is provided in the
low voltage compartment to allow the user to
view the position of the isolation switch before
entering the medium voltage compartment.
8
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Equipment Description
01.4IB.46210A
!
C.Ratings
CAUTION
Refer to the specific job drawings for the detail
ratings applicable to a particular controller. The
basic ratings equal or exceed NEMA STD ICS
3, and are summarized in Table A, Horsepower,
Current, and Voltage Ratings and Table B, Voltage
and Interrupting Ratings of Class E2-AR® Medium
Voltage Controllers.
Control Power may be present in the low
voltage compartment. The low voltage
compartment shall only be entered with
extreme care.
Figure 3
High and Low Voltage
Compartments
a
b
c
d
e
a.
b.
c.
d.
Isolation Swich Position View Window
Low Voltage Compartment
High Voltage Compartment
Type SL Medium Voltage Vacuum
Contactor 400A
e. Contactor Hold Down Bolt
Equipment Description
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E2-AR® Medium Voltage Controller with
Eaton Contactor
01.4IB.46210A
Table A Horsepower, Current, and Voltage Ratings
2200-2400V
Continuos
Current
(Amperes)
Induction
360
640
4000-5000V
SYNC
0.8
1.0
1350
1350
1750
2500
2500
3500
Induction
6600-7200V
SYNC
0.8
1.0
2500
2500
3000
4500
4500
6000
Induction
SYNC
0.8
1.0
4000
4000
5000
7000
7000
9500
Table B Voltage and Interrupting Ratings of Class E2-AR Medium Voltage Controllers
Rated Insulation Voltage
Class E2-AR® Interrupting Rating (Fused)
Maximum Volts, rms
Amperes (rms) Symmetrical
2500
50000
5000
50000
7200
50000
Note: For additional vacuum contactor
ratings information refer to Eaton
Technical Data TD02003001E.
D. Basic Impulse Level
The basic impulse level test voltage for motor
control centers rated up to 7.2kV is 45kV. An
optional 60kV voltage level is available with the
addition of a single surge arrestor on each pole
of the main bus per line-up.
E. Factory Production Dielectric Test
The Factory Production Dielectric Test is:
•
2.25 X Nominal Voltage Rating + 2000VAC.
Note: Field Dielectric tests, if required,
should be limited to 75% of Factory
Dielectric Test Values.
10
F. Medium Voltage Contactors
Two types of medium voltage vacuum
contactors employed in the Class E2-AR®
Medium Voltage Controller are the Eaton Type
SL 400A (Figure 4) and the Eaton Type SJA
800A (Figure 5). Each vacuum contactor has a
feature that is designed to close and interrupt
the AC power circuit under normal conditions
or to interrupt the circuit under overload
emergency conditions. Another feature of
each design is short circuit protection. This
includes current limiting fuses as specified for
the application.
The Eaton Type SL 400A Medium Voltage
vacuum contactor and isolating switch
combinations will accommodate the R-Type,
and the E-Type bolt-in fuses as standard and
clip-mounted hookeye fuses as an option,
as specified in Table N R-Rated Clip On Fuses
and Table P E-Rated Clip On Fuses. The Eaton
Type SL 400A and the Eaton Type SJA 800A
Medium Voltage vacuum contactors are
similar in design with the exception that the
Type SJA 800A design application consists of
higher capacity current carrying parts. Fuse
maintenance for the two applications is similar.
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Equipment Description
01.4IB.46210A
The Eaton Type SJA 800A application uses the
current limiting fuse types: ACLS, CLS70, and
AHLE. A dual voltage rating allows the fuses
to be used in both the 2400 and 4800 volt
systems.
Note: The Medium Voltage vacuum 400A
contactor and 800A contactor are not
interchangeable.
Vacuum contactors are magnetically operated
by the application of either AC or DC power,
depending upon circuit requirements. The
contactors may be operated by DC from
rectifiers included with the equipment. The
minimum closing voltage is 85% of the coil
rated voltage. The dropout voltage will vary
considerably between the AC and DC magnets,
but the dropout voltage for the AC magnet
could be as high as 60% of the coil-rated
voltage.
A mechanically latched contactor function
(optional) is used when the vacuum contactor
must stay closed during severe under-voltage
conditions. Applications include fire pumps
and transformer feeders. The latched contactor
is available with or without a manual or
electrical release and latch.
the main controller compartment, allowing
access to the controller for inspection and
maintenance. For standard applications, the
isolation switch includes ground fingers that
ground the line side of the power fuses when
the switch is in the open position. The isolation
switch has a mechanical endurance rating of
10,000 operations. Isolation switches in starters
with double-barrel fuses are supplied with
additional phase barriers that must be installed
to maintain the proper dielectric rating of the
starter.
Figure 4
Eaton Type SL Medium Voltage
Vacuum Contactor 400A
Figure 5
Eaton Type SJA Medium Voltage
Vacuum Contactor 800A
G. Manual Isolation Switch
The P-17172 Controllers follow the NEMA
definition and contain means for manually
isolating the power circuit by operation of a
disconnecting device. The manual isolating
mechanism of the Class E2-AR Medium Voltage
Controller enables personnel to isolate the
power circuit with a manually operated
three-pole, primary circuit disconnecting
device. The controller isolation switch is a
non-load break device. Mechanical and
electrical interlocks are provided to ensure that
the main contactor is deenergized before the
switch can be operated. In the open position,
the switch isolates medium voltage from
Equipment Description
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11
E2-AR® Medium Voltage Controller with
Eaton Contactor
The isolating switch is a non-load break device.
It must never close or interrupt a power
load. Electrical and mechanical interference
interlocks ensure that the contactor is open
before the isolating mechanism can be
operated. However, it does have a limited
capacity for interrupting the single-phase
control power and potential transformers
exciting current. In terms of transformer
ratings, the maximum load is the equivalent
of an unloaded (exciting current only) 6kVA
transformer.
!
WARNING
Ampgard controllers are sometimes
energized by a back-fed condition that allows
the medium voltage compartment to be
energized with the isolation switch in the
open position. Study the plant single line
diagrams to make certain that no back feed
situation exists before entering the medium
voltage compartment.
!
01.4IB.46210A
controller load. With the handle in the down
position, the switch is open and medium
voltage is isolated from the controller and the
controller load.
An isolation switch viewing window is
provided in the upper rear corner of the low
voltage control compartment (Figure 3, a).
After opening the isolation switch and before
opening the medium voltage door, the switch
should be visually examined through the
viewing window to verify that it is in the open
position. Three green and white “barber poles”
will be visible when the switch is in the open
position and the shutter assembly is in the
isolating position.
The isolating switch handle can be padlocked
in the ON and OFF positions (Figure 6, b & c).
Figure 6
Isolating Switch Operating Handle
a
CAUTION
b
All power sources must be isolated and locked
out before servicing the equipment.
For applications where the controller is back
fed, the grounding fingers should be removed
from the isolation switch.
The switch consists of a fixed rear portion and
a removable front portion. The fixed portion
includes the controller line fingers and a
moveable shutter that isolates the line fingers
when the switch is in the open position. The
removable portion is operated by a handle
mechanism that extends through the controller
medium voltage door. With the handle in the
up position, the switch is closed and medium
voltage is available for connection to the
12
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c
d
a. b.
c.
d.
ON Position
Padlock Provision (ON)
Padlock Provision (OFF)
OFF Position
Equipment Description
01.4IB.46210A
The isolating switch operating handle has two
distinct positions described as follows:
1.The ON position (Figure 6, a): The isolating
switch is in the CLOSED position, the high
voltage compartment door is interlocked
shut, and the controller may be energized.
2.The OFF position (Figure 6, d): The
isolating switch is in the OPEN position,
the high voltage compartment door is
not interlocked shut, and the controller is
deenergized and grounded.
H. Mechanical Interlocking
The Class E2-AR® Medium Voltage Controller
is designed for the Medium Voltage vacuum
contactor to perform normal load current
interrupting. The power fuses are designed to
interrupt fault currents.
Note: The manual isolator will not interrupt any
fault current.
Controllers are manufactured with several
built-in interlock provisions and safety
features to reduce hazards and provide proper
operating sequences:
•
•
A mechanical interlock prevents opening
the medium voltage door with the switch
in the closed position. Ensure that the
medium voltage door is fully closed and
latched using the two latches on the right
side of the door to prevent damage to the
interlock bracket on the back of the door.
An additional interlock prevents closing of
the switch unless the medium voltage door
is closed (Figure 21, a). On controllers that
require two structures (reduced voltage
starters, for example), the door to the
second structure will also be interlocked
with the switch-operating mechanism.
Equipment Description
The second door must be closed before the
main door is closed. Both doors must be
closed before the switch operator can be
moved to the closed position.
Note: Attempting to close the switch with
the door open can cause damage to
the operating mechanism.
Mechanical and electrical interlocks are
provided to ensure that the non-load break
isolation switch cannot be opened or closed
unless the main contactor is deenergized
(Figure 21, e). Do not attempt to force the
switch-operating mechanism with the main
contactor closed. The handle mechanism is
designed to fail before the isolation switch can
be opened with the main contactor closed.
!
CAUTION
Applying excessive force to the switch handle
with the mechanical interlocks engaged will
result in damage to the switch.
An electrical interlock is provided to
disconnect the control power transformer
secondary before the isolating switch stabs
are disconnected from the controller line
fingers. This interlock ensures that the switch
is breaking transformer magnetizing current
only. Do not connect additional loads to the
controller isolating switch.
!
WARNING
If loads greater than the interrupting rating
of the switch are connected to the switch,
equipment damage, personal injury, or death
may occur.
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13
E2-AR® Medium Voltage Controller with
Eaton Contactor
Figure 7
01.4IB.46210A
Typical Dimensions for Class E2-AR Medium Voltage Controllers
E2-AR Medium Voltage Controller (400A) - Two High Construction 36”w x 50”d x 90”h
(Shown with Plenum)
E2-AR Medium Voltage Controller (400A) - Two High Construction
(Shown with Plenum)
118.41
118.41
87.50
68.13
66.75
49.00
55.35
43.00
36.00
25.25
22.13
4.50
50.00
35.94
Side View
Front View
E2-AR Medium Voltage Controller (800A) - One High Construction
(Shown with Plenum)
E2-AR Medium Voltage Controller (800A) - One High Construction
(Shown with Plenum)
118.41
92.12
58.53
48.53
38.53
35.94
50.00
Front View
Side View
Note: The drawings in Figure 7 should NOT be used for any construction purposes.
For construction information, refer to the specific drawings furnished with the equipment.
14
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Equipment Description
01.4IB.46210A
An optional key interlock may be provided to
lock the switch in the open position for special
configurations. Refer to the specific order
drawings to determine if key interlocks have
been provided.
Note: No emergency condition can justify
forcible operation of the MANUAL
ISOLATOR WITH the vacuum contactor
in the CLOSED position. The MANUAL
ISOLATOR MUST only be operated when
the vacuum contactor is in the OPEN
position.
CAUTION
When the vacuum contactor is closed, the
isolating switch cannot be physically moved to
the open position.
!
WARNING
This mechanical interference system must
not be defeated to open the high voltage
compartment door with the Class E2-AR
Medium Voltage Controller energized.
Defeating the interlock will expose energized
components and may result in injury or
death.
I.Auxiliary Compartments
A variety of enclosure sizes and Medium
Voltage compartments are furnished in
Class E2-AR Medium Voltage Controller
lineups for various applications. The following
list contains examples of enclosures and
compartments.
Equipment Description
1.
2.
3.
4.
Bus to metal-clad switchgear
Bus transitions to transformers
Cable entrance compartments
Starting reactor and autotransformer
compartments
5. Relay and metering compartments
6. Potential transformer compartments
J.Power Fuses
Current-limiting fuses, designed for motor
starting service, are used for all
high-interrupting capacity motor controllers
and provide short-circuit protection.
The following is a brief description of the
power fuses used in the P-17172 design. More
detailed information regarding power fuses can
be found in the Eaton IB 48041 and Technical
Data Bulletin TD02003001E.
Interrupting ratings are as shown in Table B,
Voltage and Interrupting Ratings of Eaton
Class E2-AR Medium Voltage Contactors of these
instructions.
The Type SL 400A vacuum contactor
and isolating switch combinations will
accommodate R-Type and E-Type bolt-in or
clip-in fuses.
The Type SJA 800A vacuum contactor
and isolating switch combinations will
accommodate R-Type and E-Type bolt-In fuses.
Transformer feeders frequently contain general
purpose current-limiting fuses. Coordination
information for fuses can be furnished upon
request.
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15
E2-AR® Medium Voltage Controller with
Eaton Contactor
01.4IB.46210A
K.Starting Autotransformers or Reactors
Reduced-voltage starters include a reactor or
autotransformer designed for starting duty in
accordance with NEMA ICS 3. The duty cycle
for the medium-duty application is three starts,
30 seconds apart, followed by a one-hour rest.
A heavier-duty cycle will cause overheating
and possible damage to the reactor or
autotransformer.
L. Dimensions
Refer to the equipment drawings for the
specific dimensions and an outline of the
equipment. The Class E2-AR Medium Voltage
Controllers 400A application is normally a
one-high or two-high construction with typical
dimensions of 36" in width, 50" in depth, and
92" in height. The Class E2-AR Medium Voltage
Controllers 800A application is normally a
one-high construction with typical dimensions
of 36" in width, 50" in depth, and 92" in height.
These dimensions exclude channel bases,
plenums, and lifting members for indoor
construction. For typical outline dimensions
refer to Figure 7.
16
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Equipment Description
01.4IB.46210A
Ch 4 Installation
C.Storage
A.General
This section contains information on preparing
equipment for operation including receiving,
storage, handling, positioning, power
connections, grounding, and mechanical
operation tests.
B.Receiving
Note: Read Ch 4 Installation, D. Handling
before handling the controller(s).
Class E2-AR® Medium Voltage Controllers
are fabricated as rigid, floor-mounted,
self-supporting, steel unit vertical
section(s). They are shipped in an upright
position, and should be kept in an upright
position when received.
Note: Any questions regarding equipment
handling should be referred to Powell.
When controllers are received, the purchaser
should check the material received with the
shipping list to ensure that all parts have been
included. If equipment damage is found or
suspected, file claims as soon as possible with
the transportation company and notify the
nearest representative of Powell.
Some equipment, devices, or components
may be shipped separately. Examples of items
that may be shipped separately are resistors or
power factor capacitors. These components
are identified by a number coinciding with the
number on the section on which they are to be
mounted.
Installation
Shipping and storage of electrical equipment
requires measures to prevent the deterioration
of the apparatus over a long unused period.
The mechanical and dielectric integrity must
be protected. Electrical equipment is designed
for use in a variety of environments. When
the equipment is in transit and storage, these
design considerations are not fully functional.
In general, the following measures must be
considered.
1. Equipment designed for indoor installation
must be stored indoors in a climate
controlled environment to prevent
condensation of moisture. Exposure to rain
and the elements, even for a short period,
can permanently damage the equipment.
Space heaters within the equipment should
be energized, if so equipped. Humidity
controlling desiccant materials should
be utilized when space heaters are not
provided or cannot be energized. The
temperature should be kept above 33°F/1°C
and below 140°F/60°C. The relative
humidity should be kept below 60% or a
dew point of 15°C/59°F. The equipment
should be stored in such a manner as
to leave all doors and panels accessible
for inspection. The equipment must be
inspected on a routine basis to assure
operational integrity.
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17
E2-AR® Medium Voltage Controller with
Eaton Contactor
2. Equipment designed for outdoor exposure
may be stored either in indoor or outdoor
storage locations. The equipment must
be protected from airborne external
contaminates if stored outdoors. Outdoor
storage will also require additional care
to maintain temporary covers over
the openings and shipping splits. The
equipment must be provided with control
power to facilitate the energization of
space heaters, as well as other temperature
and humidity controlling equipment. The
temperature should be kept above freezing
(>33°F/1°C) and below (<140°F/60°C). The
relative humidity should be kept below
60% or a dew point of 15°C/59°F. The
equipment should be stored in such a
manner as to leave all doors and panels
accessible for inspection. The equipment
must be inspected on a routine basis to
assure its integrity.
3. The auxiliary control devices, ship loose
material and protective relays must also
be protected. This includes items such as
battery chargers, UPS systems, lighting,
installation hardware and air conditioning.
If prolonged storage is anticipated,
humidity controlling desiccant materials
should be utilized. Desiccant packets
should be installed in all compartments and
packing containers.
D. Handling
The Class E2-AR Medium Voltage Controller
should be lifted, positioned, and handled
by suitable lifting devices of adequate load
ratings. A maximum of 3 units can be lifted
together. During handling, the rigging lengths
of lifting equipment, such as slings or cables,
should be set or adjusted to compensate any
unequal load distribution to maintain the
equipment in an upright position. Refer to
the job drawings for the specific lifting weight
specifications.
18
01.4IB.46210A
It is preferable to handle P-17172 Controllers
with overhead cranes, by the lifting means
provided (Figure 8). If bases are furnished,
the equipment may be moved on an even
surface by the use of rollers or heavy duty pipe
under the base. Any force to move or jack the
equipment must be applied to the base and
not the equipment.
Figure 8
Recommended Method for
Lifting an Indoor Lineup
The use of fork lift trucks is not recommended,
since the forks may damage the enclosure or
interior parts of the equipment. If no other
method of handling is available, the forks must
go under the base bottom to avoid damage to
the equipment.
Each controller is properly adjusted at the
factory before shipment. However, vibration
and mechanical stresses imposed by transit and
installation can adversely affect mechanical
interlocks and other adjustments; therefore, a
final inspection is essential before energizing.
If this inspection reveals any portion of the
controller has come out of adjustment, the
controller should be readjusted according to
information in this instruction book or by a
qualified service engineer.
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Installation
01.4IB.46210A
Figure 9
Typical Class E2-AR® Medium Voltage Controller Floor Plans
E2=AR Medium Voltage Controller (400A) - Two High Construction
E2-AR Medium Voltage Controller (400A) - Two High Construction
36.00
35.94
1.13
6.00
6.00
5.25
11.00
49.00
4.00
3.38
4.75
50.00
9.00
22.31
23.06
17.06
15.00
1.13
1.00
0.63
2.13
6.00
6.00
7.78
Base Plan
Top View
E2-AR Medium Voltage Controller (800A) - One High Construction
35.94
0.63
1.13
1.00
1.13
4.50
2.34
11.00
26.50
1.13
6.00
6.00
1.13
Base Plan
Note: The drawings in Figure 9 should NOT be used for any construction purposes. For construction
information, refer to the specific drawings furnished with the equipment.
Installation
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19
E2-AR® Medium Voltage Controller with
Eaton Contactor
E. Positioning of the Enclosure
F. Removing the Medium Voltage Vacuum Contactor
To enable proper operation of equipment,
it is essential to securely fasten the lineups
in a true upright position on a smooth, level
surface. The floor should be leveled to within
1/8" for every 10 linear feet. Figure 9 illustrates
various Medium Voltage Controller floor plans.
The equipment position should allow for the
proper removal of the Medium Voltage vacuum
contactor.
!
CAUTION
Do NOT work on a Medium Voltage Controller
vacuum contactor with the control circuit
energized.
!
WARNING
When three or more controller units are to
be arranged in one continuous lineup, THE
CENTER SHIPPING UNIT SHOULD BE THE
FIRST LOCATED. The other shipping lineup
should then be installed in successive order in
each direction from the center of the structure.
All work on this contactor should be done
with the main disconnect device open. As
with any contactor of this voltage, there is
danger of electrocution and/or severe burns.
Make certain that the power is off. Check for
voltage with voltage sensor or a meter of the
appropriate range.
After positioning the equipment, check the
equipment to ensure it is level. If necessary,
shims may be inserted beneath the equipment
base to achieve a level condition.
1) Removing the Vacuum Contactor from the
High Voltage Compartment
The recommended practice is to weld the
switchgear structure to the floor channels
using a tack weld at points indicated for
anchoring on the drawing. After welding, any
damaged paint should be removed and the
weld and surrounding metal should be painted
to deter corrosion. If welding facilities are not
available, the switchgear should be bolted to
the floor channels.
!
CAUTION
Do NOT work on a Medium Voltage Controller
vacuum contactor with the control circuit
energized.
20
01.4IB.46210A
The two processes necessary to remove
the vacuum contactor are opening the
high voltage compartment door and
removing the vacuum contactor. The
process for opening the door and removing
the vacuum contactor from the lower and
upper compartments are explained in the
following procedures.
a. Opening the High Voltage
Compartment Door
To open the high voltage compartment
door follow these procedures:
i. ON Position: When isolating switch
operating handle is in the ON
position (Figure 6, a), the isolating
switch is in the closed position, the
high voltage compartment door is
interlocked shut and the controller
may be energized.
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Installation
01.4IB.46210A
ii. OFF Position: When the
switch is in the OFF position
(Figure 6, d), the isolating switch is in
the OPEN position, the high voltage
compartment door is shut, and
the controller is deenergized and
grounded.
iii. If the switch is in the ON position,
open the contactor contacts by
operating the electrical control
switch on the compartment front
door or other means as required
by the specific equipment
configuration. Once the contactor
primary contacts are open and
the contactor is deenergized, the
isolation switch handle may be
moved from the ON position to the
OFF position. With the isolation
switch handle in the OFF position
and the contactor primary contacts
open, the switchgear compartment
high voltage door may be opened
by lifting the latch handle and
pulling on the door.
b. Removing the Vacuum Contactor from
the Lower Compartment
i. Visually inspect the isolating switch
to ensure it is in the OPEN position
and that the insulating shutter
displays the CLOSED indicating
stripes.
ii. Confirm that the fuses are
deenergized.
iii. For 400A contactors, the fuses may
be removed using a fuse puller
for the clip-on style fuses or by
removing the bolts for the bolt-on
style fuses. For 800A contactors, the
fuses may be removed by removing
the bolts holding the fuses in place.
Installation
iv. Disconnect the secondary control
circuit plug from the left side of the
vacuum contactor and stow it so
that the cable will not be damaged.
v. Remove the bolt from the
hold-down bracket (Figure 3, e).
vi. Unsnap pin collar from the interlock
rod clevis and remove pin.
vii. Remove bolts for contactor line and
load connections (bolt-in unit only).
viii.Carefully remove the contactor from
the compartment.
!
CAUTION
The contactor weighs in excess of 50 lbs. and
assistance may be required to safely remove
it from the compartment and transport
it. Failure to use caution when moving the
contactor may result in equipment damage
and/or personal injury.
ix. If the contactor is being replaced,
move the contactor interlock lever
to the new contactor.
x. Reverse the procedure to reinstall
the contactor.
xi. Adjust the contactor interlock rod
according to the Contactor Interlock
Rod Adjustment procedure.
Note: Store the vacuum contactor in a safe
location to prevent damage to it while
it is outside of the compartment.
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21
E2-AR® Medium Voltage Controller with
Eaton Contactor
c. Removing the Vacuum Contactor from
the Upper High Voltage Compartment
!
CAUTION
Do NOT work on a Medium Voltage Controller
vacuum contactor with the control circuit
energized.
To remove the vacuum contactor from the
upper compartment perform the following
procedures:
i. Visually inspect the isolating switch to
ensure it is in the OPEN position and
that the insulating shutter displays the
CLOSED indicating stripes.
ii. Confirm that the fuses are deenergized.
iii. For 400A contactors, the fuses may be
removed using a fuse puller for the
clip-on style fuses or by removing the
bolts for the bolt-on style fuses.
iv. Disconnect the secondary control circuit
plug from the left side of the vacuum
contactor and stow it so that the cable
will not be damaged.
v. Remove the bolt from the
hold-down bracket (Figure 3, e).
vi. Unsnap pin collar from the interlock rod
clevis and remove pin.
vii. Remove bolts for contactor line and
load connections (bolt-in unit only).
viii.Carefully remove the contactor from the
compartment.
!
CAUTION
The contactor weighs in excess of 50 lbs. and
assistance may be required to safely remove
it from the compartment and transport
it. Failure to use caution when moving the
contactor may result in equipment damage
and/or personal injury.
22
01.4IB.46210A
ix. If the contactor is being replaced, move
the contactor interlock lever to the new
contactor.
x. Reverse the procedure to reinstall the
contactor.
xi. Adjust the contactor interlock rod
according to the Contactor Interlock
Rod Adjustment procedure.
Note: Store the vacuum contactor in a safe
location to prevent damage to it while
it is outside of the compartment.
G.Power Connections
The Class E2-AR® Medium Voltage Controller
must be grounded before power connections
are made. See Ch 4 Installation, H. Grounding.
External power cable connections should be
installed in the controller after the equipment
is placed in the permanent location and the
grounding connections described in
Ch 4 Installation, H. Grounding are completed.
Grounding cables must be connected to the
equipment ground bus and all high voltage
terminals that must be handled or touched
during the power connection and installation
process.
Table C, General Guideline for Outgoing Feeder
Cables lists recommended maximum cable
sizes and cables per phase for equipment
with only front access. For equipment cable
requirements that exceed the recommended
maximum cable sizes, equipment rear access
and rear cable extensions are needed. The
extension depth shall be determined by the
specific equipment requirements.
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Installation
01.4IB.46210A
H.Grounding
Before power connections can be made, the
switchgear vertical sections must be grounded.
A ground bus is furnished with lugs at each
end for connection to the station grounding
system. It is arranged so that connections to
the station ground can be made in any unit.
Where equipment is shipped in more than one
group, the sections of ground bus must be
connected by using the splice plates furnished
with the equipment (Figure 10).
Assemble the ground bus joints as outlined
under Ch 4 Installation, I. Connections. The
switchgear ground bus must be connected to
the station ground bus by a conductor having
a current carrying capacity equal to that of the
switchgear ground bus. It is very important
that the equipment be adequately grounded
to protect the operator from injury when
short circuits or other abnormal occurrences
take place and to insure that all parts of the
equipment, other than live parts, are at ground
potential.
It is recommended that the connection to the
station ground have a cross section of 500,000
circular mils (240 mm2) or greater if the soil
in which it is buried is of such character as to
cause appreciable corrosion. This is especially
true where electrolysis from stray currents
or contact with dissimilar metals exists. The
resistance of the soil surrounding a station
ground depends on the condition of the soil, as
well as its chemical content. Dry, loose, sandy,
or frozen soils will have a high resistance as
compared with moist soils or soils containing
ashes, cinders, or salt solution.
The IEEE Standard 142 states that grounding
impedance in the range of 1 to 5 ohms is
generally acceptable for industrial substations.
Ground resistance testing is recommended to
verify that the ground resistance falls within
this range.
Installation
Figure 17 shows the grounding connection
for the 400A controller equipment. Figure 18
shows the grounding connection for the 800A
controller.
Table C General Guideline for Outgoing Feeder
Cables
Construction
Type
Continuous
Current
(Amperes)
Maximum
Cable Size
Cable
per
Phase
One-High
Vertical
Section
360
500 mcm
1
Two-High
Vertical
Section
360
500 mcm
1
One-High
Vertical
Section
640
500 mcm
2
I .C o n n e c t i o n s
The main bus bars and other connection bars
are copper. The connection surfaces are silver
surfaced or equivalent. The silver plating used
on bolted contact surfaces is approximately
0.0001" thick. All field assembled joints in
primary conductors, regardless of method of
insulation, should be made as follows:
1. Wipe the surface clean with a lint-free cloth.
Do not use sandpaper or any abrasive
on the plated surface. Avoid handling of
cleaned surface as much as possible. If
the surface is tarnished, clean it with silver
polish and then wash it with denatured
alcohol.
2. Join the clean contact surfaces by using the
hardware provided. The correct length of
bolt must be used in each joint to insure
that electrical clearances at bolt locations
are maintained. As a general rule, when
using 1/2" diameter bolts, the bolt should
be 1" longer than the combined thickness
of the copper bars being bolted together.
For example, if three 1/4"-thick copper bars
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23
E2-AR® Medium Voltage Controller with
Eaton Contactor
are to be connected, the bolt should be
1-3/4" long. In addition to proper length
bolts, the bolt assembly must include flat
washers, split lock washers, and nuts. All
hardware must be SAE Grade 5 or better.
!
WARNING
Figure 10
01.4IB.46210A
Ground Bus Splicing Configuration
a
b
c
d
Replace all barriers before reenergizing the
equipment. Failure to do so may result in
damage to the equipment and injury or death
to the operating personnel
3. In some cases, external connections are
made to the equipment main bus by bars.
The equipment bars are normally silver
plated. Unplated bars, either copper or
aluminum should not be used to connect
to plated bars.
4. All field assembled primary conductor
joints and terminations must be insulated
for the operating voltage. There are two
methods of insulating joints: taping joints
or applying boots where applicable. A
detailed procedure for joint insulation is
described under Ch 4 Installation,
J. Main Bus Assembly Insulation.
Note: All hardware must be tightened to
the torque values listed in Table D,
Bolt Torque Values for Class E2-AR®
Medium Voltage Controllers.
24
a.
b.
c.
d.
3/8 - 16 Hex Head Bolt
3/8 Inch Flat Washer Type A
Horizontal Ground Splice Plate
Horizontal Bus Bar
!
WARNING
Replace all barriers before reenergizing the
equipment. Failure to do so may result in
damage to the equipment and injury or death
to the operating personnel
CAUTION
All exposed primary bus and cable joints and
connections should be insulated for the correct
system insulation rating.
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Installation
01.4IB.46210A
Table D Bolt Torque Values for Class E2-AR®
Medium Voltage Controllers
Bolt
Dimensions
(inches)
5/8
Bolt
Head
Torque
Ft-Lbs
Kg-M
55-70
7.6-9.7
1/2
35-50
4.8-6.9
3/8
20-30
2.8-4.2
1/4
5-7
0.7-0.97
Note: The bolt head drawings in the table
above are not to scale. Locate the
Bolting Torque label on equipment for
an accurate drawing of bolt sizes.
J. Main Bus Assembly Insulation
To insulate the main bus assembly, remove the
rear compartment covers. Assemble the splice
plates and bus bars by following assembly
instructions given in Ch 4 Installation,
I. Connections. All hardware must be tightened
to the torque values listed in Table D, Bolt
Torque Values for Class E2-AR Medium Voltage
Controllers.
CAUTION
The operating temperature of conductors
in the switchgear may reach 105˚C. Any
insulating material used in the switchgear
must be suitable for this temperature.
Installation
To provide adequate bus joint insulation, use
any of the following methods:
•
Wrapping bus joints, using tape or heat
shrink material
• Applying PVC (polyvinyl chloride) boots
K.Incoming Power Connections
Incoming power connections to the main bus
may be connected in various configurations
depending on the equipment application.
Review the elevation drawings delivered with
the equipment for site-specific connection
details.
Note: Refer to site-specific project drawings
for recommended and available conduit
space for top or bottom access.
1) Wrapping Bus Joint
Wrapping of joints with insulating tape is
an acceptable alternative to booting the
bus conductor joints. For some complex
or unusual joints, the formed bus boots
described above may not be available. Bus
conductor joints to be tape wrapped must
use the following procedure to maintain
proper insulation characteristics within the
switchgear.
Table E Bus Wrapping Components
Part Number
Description
0282A3529 P004
2” wide tape
0282A3529 P005
4” wide tape
0282A3529 P008
Electrical grade rubber based (RB)
putty
Note: Electrical grade RB putty will be used
only when required to grade voids
and smooth out sharp edges of joints
and pothead, terminator or entrance
bushing connections.
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25
E2-AR® Medium Voltage Controller with
Eaton Contactor
Figure 11
Insulation of Bus Bar
Figure 12
Single Bus Bar Connection Joint
.048 (1.2) Approximate
Dimension (Tape Tension)
1/2W
01.4IB.46210A
Epoxy Insulation
Thermoplastic Sleeving
or Tape Insulation
“W”
“B” - 1/2 LAP
1 - Layer, 1/2 LAP = 2 Thicknesses
“A”
.50 (12.7)
Min
1/2W
“W”
.50 (12.7)
Min
.096 (2.4) Approximate
Dimension (Tape Tension)
2 - Layers, 1/2 LAP = 4 Thicknesses (Shown)
3 - Layers, 1/2 LAP = 6 Thicknesses (Not Shown)
4 - Layers, 1/2 LAP = 8 Thicknesses (Not Shown)
“C”
Circular or Square Tubes are Taped
in the Same Manner as Rectangular Bars
HV Tape - 2” (50.8) or 4” (101.6) Wide
Rolls X 30 (9144) ft Long 0282A3529P004 or P005
Table G Insulation of Single Bus Bar
Connection Joint
Diagram of 1/2 LAP Starting with
1 Full Turn - Apply with Mastic Side Down
NOTE: Overlap an Expired Roll by 1/2 Turn
1.75 (44.4)
or
3.5 (88.9)
“A” + 1/4
Approximate Tensioned Dimensions
Begin Taping at
“A” + 1/4” “A” = Contact Surface
Table F Insulation of Bus Bar
Insulation
Number
Range
of Layers
(volts)
Approx. Footage of Tape Required to
Insulate (1) Linear Foot of Bus Bar
(2” & 4” Wide Rolls are 30’ Long)
Tape
Width
(inches)
Bar Sizes (inches)
1/8 x 2 ¼ x 3 ½ x 3 ¼ x 4 ½ x 4 ¼ x 6 ½ x 6
¼ x 2 3/8 x 3 5/8 x 3 3/8 x 4 5/8 x 4 3/8 x 6 5/8 x 6
600V to
5000V
1 Layer •
½ Lap *
“C”
RB Putty *
2
4
5
6
8
9
11
12
4
2
3
3
4
5
5
6
Insulation
Level (kV)
Inner Filler
“A”
Outer Wrap
“B”
“C”
(inches)
5
3 Layers
HV Tape ∆
2 Layers
HV Tape ∆
3
26
2” or 3”
Bars
4” or 6”
Bars
1 Roll HV
Tape ∆
2 Rolls
HV Tape ∆
Note: * Electrical grade rubber base putty
0282A3529 P008 in roll form will be
used to grade voids and smooth out
sharp edges of joints. This putty has
no insulation value.
1 roll is ½” x 1½” x 5’ long.
Note: Apply tape at medium tension to
produce a void-free uniform build-up
of tape. A medium tension stretches
a 0.030”x2” tape down to 0.024”x13/4”
and 0.030”x4” down to 0.024”x31/2”.
Apply with mastic side down.
Approx. Number Rolls
per Joint of HV Tape ∆
∆ High voltage insulating tape
0282A3529 P004 - Roll is .030 x 2” x 30’
long. Apply with mastic side down.
* Apply 3 layers - 1/2 lap for conductors
passing through CT’s.
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Installation
01.4IB.46210A
Figure 13
Double Bus Bar Connection Joint
Figure 14
“C”
4” (101.6) Wide
PAD HV Tape #
“C”
.50 (12.7)
Min
“A”
Tee Connection Joint
Epoxy Insulation Thermoplastic Sleeving
or Tape Insulation
“B”
.50 (12.7)
.50 (12.7)
“A”
Min
Min
.50 (12.7)
Min
“B”
RB Putty *
Framework
“A”
“A”
RB Putty *
Framework
“C”
“C”
“A”
RB Putty *
Both Ends
“C”
“B”
“B”
“A”
4” (101.6) Wide
PAD HV Tape #
RB Putty *
Framework
.50 (12.7)
Min
“A”
“B”
Table H Insulation of Double Bus Bar
Connection Joint
Insulation
Level (kV)
Inner Filler
“A”
Outer Wrap
“B”
5
RB Putty* &
3 Layers HV Tape #
3 Layers HV Tape ∆
2 Layers
HV Tape ∆
“C”
(inches)
3
Approx. Number of Rolls
per Joint of HV Tape ∆
2” or 3”
Bars
4” or 6”
Bars
1/2 Roll RB Putty *
1 Roll HV Tape #
1 Roll RB Putty *
2 Roll HV Tape #
Note: * Electrical grade rubber based putty
0282A3529 P008 in roll form will be
used to grade voids and smooth out
sharp edges of joints
# HV Tape 0282A3529 P005 roll is
.030” x 4” x 30’ long.
∆ HV Tape 0282A3529 P004 roll
is .030” x 2” x 30’ long. Apply with
mastic side down.
Installation
Overlap Tape in a
Figure Eight Pattern
+
+
+
+
RB Putty *
Both Ends
“A”
“B”
.50 (12.7)
Min
Table I Insulation of Tee Connection Joint
Insulation
Level (kV)
Inner Filler
“A”
Outer Wrap
“B”
“C”
(inches)
5
RB Putty* &
3 Layers HV Tape ∆
2 Layers
HV Tape ∆
3
Approx. Number of Rolls
per Joint of HV Tape ∆
2” or 3”
Bars
4” or 6”
Bars
1/2 Roll RB Putty *
1 Roll HV Tape ∆
1 Roll RB Putty *
2 Rolls HV Tape ∆
Note: * Electrical grade rubber based putty
0282A3529 P008 in roll form will be
used to grade voids and smooth out
sharp edges of joints. This putty has
no insulation value.
1 roll is 1/8” x 1½” x 5’ long.
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∆ HV Tape 0282A3529 P004 roll
is .030” x 2” x 30’ long. Apply with
mastic side down.
27
E2-AR® Medium Voltage Controller with
Eaton Contactor
Figure 15
Dead End Bus Joint Insulation
Pre-Insulation Epoxy Insulation
Thermoplastic Sleeving or Tape Insulation
“C”
Min
50 (12.7)
Min
Apply RB Putty Sparingly
to Grade-Out and Round Off
Pre-Insulation
“A”
“B”
Crisscross Tape in a
Figure Eight Pattern to
Fully Cover End
1) Cut and Apply 1-Strip of
Tape to Form a Boot Over End
“B” Layers - 1/2 LAP
2) Apply RB Putty Sparingly
to Round Off End of Bar
3) Continue with “A” Layer
of HV Tape.
Note: The PVC insulation boots are
furnished for standard configurations.
Special configuration conditions may
require taped joints if PVC boots are
not available.
d. Replace all covers previously removed.
3) Cleaning Bus Insulation
The main bus bar is insulated with a high
temperature thermoplastic or thermoset
material that provides dielectric and
mechanical properties. Clean the insulation
to provide optimum insulation properties.
Table J Insulation of Tee Connection Joint
Insulation
Level (kV)
Inner Filler
“A”
Outer Wrap
“B”
“C”
(inches)
34.5
RB Putty* &
4 Layers HV Tape ∆
5 Layers
HV Tape ∆
7
4” or 6”
Bars
1/4 Roll RB Putty * 1/4 Roll RB Putty *
3/4 Roll HV Tape ∆ 11/2 Rolls HV Tape ∆
Note: * Electrical grade rubber based putty
0282A3529 P008 in roll form will be
used to grade voids and smooth out
sharp edges of joints. This putty has
no insulation value.
1 roll is 1/8” x 1½” x 5’ long.
∆ HV Tape 0282A3529 P004 roll
is .030” x 2” x 30’ long. Apply with
mastic side down.
2) Applying PVC Boots
a. Prepare all joints as outlined under
Ch 4 Installation, I. Connections
b. Place the PVC boot over the joint.
The boot should fit snugly around all
conductors, and flanges must contact
each other in a smooth joint.
c. Secure the boot with the furnished
nylon wire ties to complete the joint
insulation.
28
!
Approx. Number of Rolls
per Joint of HV Tape ∆
2” or 3”
Bars
01.4IB.46210A
CAUTION
Use alcohol in a well-ventilated area to avoid
inhaling vapors.
!
CAUTION
Do NOT use any commercial soap-based
or detergent-based cleaner because it may
leave an electrical conducting residue as it
dries. Do NOT use hydrocarbon or petroleum
based solvents because it may damage the
insulation material. Do NOT use carbon
tetrachloride. Avoid prolonged exposure to
solvent vapors. Use solvents in a
well-ventilated area.
Only use denatured alcohol or isopropyl
alcohol to clean the insulation. Wear
protective gloves and goggles and clean
the main bus bar in a well ventilated area.
Wipe dirt or other foreign matter from the
insulation with a clean cloth saturated with
only denatured or isopropyl alcohol.
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Installation
01.4IB.46210A
Figure 16
Class E2-AR® Medium Voltage
Controller Unit 400A
Figure 17
a
Class E2-AR® Medium Voltage
Controller Unit 800A
a
b
b
c
c
d
e
a. Isolation Switch and Shutter
b. Load Terminals
c. Power Fuses
d. Ground Connection
e.Contactor
d
e
a. Load Terminals
b. Isolation Switch and Shutter
c. Power Fuses
d.Contactor
e. Ground Connection
Installation
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29
E2-AR® Medium Voltage Controller with
Eaton Contactor
L. Motor Connections
Motor lead cables may enter or terminate from
either the top or the bottom access openings
of the vertical section. The load terminals are
located behind the low voltage compartment.
Access the load terminals through the
front of the 400A two high, vertical section
(Figure 16, b) or the front of the 800A vertical
section (Figure 17, a). After motor cables are
terminated, insulating boots must be installed
on the load terminals.
Note: Refer to site-specific project drawings
for recommended and available
conduit space for top or bottom
access.
As an option, barriers may be installed
so that the load cables between two
vacuum contactors are isolated in the
same vertical section.
4. If contact between the cable and an
adjacent bus cannot be avoided, tape the
bus in the immediate vicinity of the cable
contact point so that the surface creepage
distance from the cable to the bare bus bar
is at least three inches. Thus, the surface
creepage from the bare bus where the
cable terminates, to the bare part of the bus
where the cable touches, will be a distance
of at least seven inches. The thickness of
tape on the bus should be approximately
5/32".
5. Terminate any ground return and cable
shield drains to the compartment ground
bus.
6. Run all the low voltage wires so as to avoid
any possible contact with high voltage
lines.
Before any primary cable connections are
made, the cables should be identified to
indicate their phase relationship with the
switchgear connections. This is necessary to
ensure that motors will rotate in the proper
direction and that the phase rotation is the
same when interconnecting two different
sources of power.
Normally, compression terminals are used
to terminate primary cables. When shielded
cables are used, proper stress relief must
be provided at the cable termination. This
may be done by the use of a commercially
available cable terminator, many types of
which are available, or by the use of a
stress cone, which can be either
hand-built or the prepackaged type.
In all cases, carefully follow the cable
manufacturer’s recommendations for
installation of the type of cable being
used. Normally, no insulation or stress
relief materials are furnished for cable
terminations.
M.Power Cable Termination
Cables should be prepared for termination in
accordance with the instructions of the cable
manufacturer. However, the following general
recommendations are given for proper cable
termination in equipment.
1. Pull in the cables in accordance with the
equipment outline diagram specifications.
Position the cables for maximum clearance
between the phases, ground, and other
cables, or wire runs. Refer to the specific
job drawings and this instruction bulletin
for the recommended location for the
incoming cables.
2. Prepare the cable for termination in
accordance with the manufacturer’s
instructions.
3. Bolt the cable terminals to the bus or other
point of termination.
30
01.4IB.46210A
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Installation
01.4IB.46210A
N.Insulating Primary Cables
Figure 18
Low Voltage Compartment
All field assembled joints for primary cable
terminations should be prepared as outlined
under Ch 4 Installation, I. Connections. Upon
completion of the cable termination, care
must be exercised when taping the exposed
termination.
Ch 4 Installation, J. Main Bus Assembly
Insulation, can be used for guidance in
insulating techniques. However, in all
cases, carefully follow the manufacturer’s
recommendations for insulating the type of
cable termination being used.
O.Ground Fault Current Transformers
(Through Type)
Through-type current transformers are
furnished where specified for sensitive
protection against ground faults. These
transformers may be installed above or below
the power cable entrance, so that the primary
cable or cables can pass through them.
When lead or other conducting sheath cable
or cable with shielding tape or braid is used,
it is recommended that the sheath or shield
be grounded solidly to the switchgear ground
bus. The ground lead should be bonded to
the sheath or shield on the side of the current
transformer away from the primary terminals.
Control connections are made through
terminal blocks in the low voltage
compartment (Figure 18). Refer to the
schematic and wiring diagrams furnished for
each specific job for connection of all field
control wires to the designated terminal
blocks. A continuous horizontal wire way
opening (Figure 19), located at the top, allows
for electrical control interconnections between
the vacuum contactors throughout the vertical
sections.
Figure 19
Wire Way
P.Control Cables and Connections
The low voltage compartment
(Figure 3, a) where control connections are
made is completely isolated from the high
voltage compartment. Available space for both
the top and bottom control wiring conduits are
designed for easy accessibility. Conduits should
be placed in accordance with the outline
drawings.
Installation
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31
E2-AR® Medium Voltage Controller with
Eaton Contactor
When control conduits enter the unit from
below, the conduit should not extend more
than 1 inch above the floor. The control cables
may be pulled through the conduits before
or after the switchgear is installed, whichever
is more convenient. If the control conduits
enter from above, drill the top cover of the
enclosure to suit the conduits, being careful
not to damage existing wire bundles. Fasten
the conduits to the cover with locknuts.
Connect the cables to the terminal blocks in
accordance with the wiring diagrams furnished
for the specific job. The cables from the control
power source to the switchgear must be large
enough to avoid excessive voltage drop when
the controllers are operated.
Where units have been split for shipment, any
control or other secondary leads that must be
reconnected across the split will be arranged
with terminal blocks in a convenient location
so that the wires can be easily reconnected.
The wires will be cut to length and formed
before being folded back so that a minimum
of time will be required for reconnecting them.
Refer to the schematic and wiring diagrams
furnished for each specific job for connection
of all control wires to the designated terminal
blocks.
01.4IB.46210A
Q.Surge Protection
It is the responsibility of the purchaser to
provide suitable surge arresters to protect
the motor control center from damage due
to lightning or other electrical surges. When
surge arresters are furnished as part of the
switchgear, the primary cable termination
is insulated at the factory unless it must
be disconnected for shipment. When this
connection is completed in the field, it is
necessary to insulate the primary connection
before the switchgear is energized. Normally,
PVC boots are supplied to insulate these
connections.
R. Mechanical Operation Check
To perform the mechanical operation check,
it is necessary to reinstall any of the primary
circuit components that were removed
previously to facilitate assembly and cable
terminations.
!
CAUTION
Due to electrical clearance requirements, any
phase barriers supplied with the contactor
must be installed before the contactor is
energized.
CAUTION
Control wiring terminal blocks are supplied
in great variety depending upon individual
customer specifications. Refer to the
manufacturer’s instructions for the terminal
blocks supplied for specific connection
recommendations such as maximum torque
values, etc.
32
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Installation
01.4IB.46210A
S.Safety Interlocks
!
WARNING
The equipment must be deenergized and
grounded prior to performing any tests or
checks of the safety interlocks described in
this section. Failure to deenergize and ground
the equipment prior to performing these tests
or checks may result in injury or death.
Before placing the Class E2-AR® Medium
Voltage Controller into service, it is
recommended that the user is familiar with the
safety interlocks.
1) Isolating Switch Operating Handle
The isolating switch can be placed in the
ON position by moving the operating
handle upwards to its mechanical
stop. Resistance to movement is felt
approximately ¾ through the travel from
OFF to ON. This resistance force is the
making of the isolation switch blades to
their mating contacts. Do not leave the
switch with the operation handle less than
fully open or closed.
In the ON position a formed angle tab
projects downward from the operating
handle mechanism and engages a
latching hoop welded to the inside of the
compartment door. The engagement
of the tab in the hoop prevents the high
voltage door from being opened while the
isolation switch is in the ON position.
that protrudes through a clearance hole
in the enclosure immediately above the
switch handle. When this contact surface
of the compartment door depresses the
rounded pin, a mechanical catch is released
and allows the isolation switch handle to
be moved from one position to another.
This interlock prevents the isolation
switch handle from operating without the
compartment door being fully closed and
latched.
2) Door Interlocks
With the isolating switch operating handle
in the OFF position, the high voltage
compartment door can be opened. As soon
as the door opens, a mechanical interlock
prevents movement of the operating
handle. It is designed to prevent the user
from accidentally operating the isolation
switch handle and closing the starter on to
the line with the enclosure door open.
The mechanical interlock is a
spring-loaded lever located just behind
the door. When the door is opened,
the interlock extends and prevents the
operating handle from being placed in the
ON position accidentally. If the user wishes
to observe the operation of the isolation
switch during installation or maintenance
procedures, this interlock must be
deliberately defeated to move the handle
to the ON position.
On the inside surface of the high
voltage compartment door is a small
projection located immediately above
the operating handle opening. This
projection engages a rounded pin from
the isolation switch handle mechanism
Installation
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33
E2-AR® Medium Voltage Controller with
Eaton Contactor
!
3)Contactor - Isolating Switch Mechanical
Interlock
CAUTION
Defeating the isolating switch interlock allows
the user to close the isolating switch on to line
stabs. The equipment must be deenergized
and grounded prior to performing this act.
The user should also be fully aware of the
hazards involved with the results of defeating
this interlock, be familiar with the operation of
the isolating switch, and take all appropriate
safety precautions. The operating handle
must be returned to the off position to close
the high voltage compartment door. Moving
the operating handle from the on position
to the off position automatically resets the
interlock.
Figure 20
01.4IB.46210A
The isolating switch functions only as a
disconnect and must never close on to
or interrupt a power load. To prevent
this, a mechanical interlock between the
vacuum contactor and the isolating switch
is provided. If the vacuum contactor is in
the CLOSED position, the interlock lever on
the vacuum contactor armature actuates
a mechanical linkage which locks the
operating handle operating mechanism of
the isolating switch.
4) Door Interference
The Eaton contactor and isolation switch
are equipped with interlocks intended
to prevent improper operation of the
contactor and isolating switch. The door to
the high voltage compartment is equipped
with two interlocks. These are to prevent
the isolation switch from moving to the ON
position without the door being closed,
and to prevent the door from being opened
with the isolation switch in the ON position.
Isolation Switch Interlock
a
b
a. Compartment Door
b. Isolation Switch-OFF Position
If the isolation switch mechanism interlock
has been defeated for inspection purposes,
the door to the high voltage compartment
will not fully close or latch. To fully close
and latch the high voltage compartment
door, the contactor must be tripped, and
the isolation switch handle moved to the
OFF position. Only then can the high
voltage compartment door be fully closed
and latched shut. Do not attempt to close
the contactor and put into service if the
high voltage door is not fully closed and
properly latched.
DO NOT OPERATE THE CONTACTOR IF
THE DOOR INTERFERENCE PREVENTS
DOOR CLOSING.
34
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Installation
01.4IB.46210A
Ch 5 Operation
A.General
A test power interlock circuit enables each
complete unit to be tested without applying
power to the motor. After all control-circuit
connections are made, the controller should
be put through its complete operating
sequence in the test position, as a final check.
A wiring diagram, which indicates circuits and
connections, is shipped from the factory with
the Class E2-AR® Medium Voltage Controller.
All external wiring from the controller must
be connected in accordance with the wiring
diagram.
B.Preparation of the Controller for Operation
1) Cleaning
Ensure that the Class E2-AR Medium
Voltage Controller is clean before
operation begins. After the equipment
is placed in the required location and the
cables are connected, carefully clean the
compartment and equipment.
CAUTION
Clean away dirt and dust, and remove
packing material which interferes with
the operation of the controller’s devices.
For cleaning, use a brush, soft cloth, or a
vacuum cleaner. Do not use compressed
air to clean the equipment. This may
result in loose dirt or grit being blown into
bearings or other critical parts, thus causing
excessive wear. Do not use detergent for
cleaning. Only use denatured alcohol or
isopropyl alcohol to clean the insulation.
See Ch 6 Maintenance, B. Preventative
Maintenance Guidelines for complete
cleaning information.
!
CAUTION
When cleaning bus bar insulation, only
denatured alcohol or isopropyl alcohol
should be used to remove foreign material
from the insulation surface. Failure to do
so may damage the dielectric and/or the
mechanical properties of the insulation.
2) Lubricating
Care should be taken during the cleaning
operation to prevent any dirt from being
blown into the inaccessible space of the
devices.
Before the panel can be operated, even
for a tryout without power, all devices
must be placed in full operating condition.
To protect equipment during shipment,
blocks and ties were applied to parts such
as the armature of many of the relays and
vacuum contactors. Ensure all blocks
and ties are removed to prepare the Class
E2-AR Medium Voltage Controller for full
operating condition.
Operation
Inspect the compartment and equipment
for loose hardware, wires, and tools that
may have been inadvertently left inside the
compartment during installation.
The seating surfaces of laminated AC
contactors, relay magnets, and the end of
shafts may be coated with a heavy–grease
rust preventative. Before operating the
vacuum contactors, the rust preventative
should be wiped off and the magnet
seating surfaces should be coated with a
thin film of light machine oil.
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35
E2-AR® Medium Voltage Controller with
Eaton Contactor
3) Manual Operation
Operate each device by hand to confirm
that the moving parts operate freely
without binding. Ensure electrical
contact tips are clean, free of grease and
contamination, and have a good surface
contact.
4) Adjustments
The contactors are carefully adjusted at
the factory. However, if adjustments are
needed, refer to the instruction documents
for information on individual devices. The
Class E2-AR® Medium Voltage Controller
can be operated after all connections are
made, parts are assembled, and equipment
and components are thoroughly adjusted
and inspected.
5) Pre-Startup Checks
The dielectric strength of the vacuum
interrupters should be checked before the
contactor is energized for the first time
and regularly thereafter to detect at the
earliest possible date any deterioration in
the dielectric strength of the interrupter,
because this may result in an interruption
failure. The test is best performed with
the contactor removed from the controller
cubicle. Removal instructions can be
found later in this instruction book in
the Maintenance section. If testing is
performed with the contactor installed,
care must be taken to ensure no damage
is inflicted on the controller control power
transformer (CPT), potential transformers
(PT), or to the controller load. Removal of
the primary fuses is sufficient to protect
the CPT or PT’s. Cables to the load should
be disconnected. Although an AC test is
recommended, a DC test may be performed
36
01.4IB.46210A
if only a DC test unit is available. A good
vacuum interrupter will withstand a
16kV - 60Hz test or a 23kV -DC test across
the normally open contact gap. When
performing DC tests, the voltage should be
raised in discrete steps until the final test
voltage is reached. When tested with an AC
high-potential tester, expect a capacitance
leakage current of approximately 1
milliampere per interrupter. Refer to
Eaton IB-48018N for more information
on dielectric testing of the vacuum
interrupters.
The insulation level of the starter should
be checked and recorded before the unit is
energized.
Enclosure doors should close easily. Do
not force doors closed, but rather look for
improperly positioned contactors, isolating
switches, or other devices.
Ensure that all phase barriers are in good
condition and are properly installed. Note
that larger and/or additional barriers are
used when double-barrel fuses are in use.
6) Contactor Interlock Pre-Start Up Check
!
WARNING
Do NOT work on a Medium Voltage
Controller vacuum contactor with the control
circuit energized. Verify with a hotstick or
appropriate measuring device that all circuits
are free of voltage. Failure to do so my result
in personal injury or death.
a. Ensure that all power to the equipment
is removed.
b. Open the isolation switch.
c. Open the medium voltage door.
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Operation
01.4IB.46210A
d. Verify that the mechanical interlocks
between the contactor and handle
mechanism are connected and
functioning properly.
e. The switch drive rod connection
(Figure 21, b) and the contactor
interlock rod connections
(Figure 21, e) should be verified by
operating the handle mechanism,
open-to-close-to-open. The door
interlock plunger (Figure 21, a) must be
held in by hand during this operation.
f. Verify that the pivot arm
(Figure 21, c) on the handle mechanism
drops down and makes contact with
the cam (Figure 21, d) after the handle is
fully closed.
Figure 21
a
b
c
d
e
Note: Failure to contact the cam may
indicate a problem with the
adjustment of the aluminum interlock
arm on the contactor.
g. Close the main contactor with test
power and attempt to operate
the switch while holding the door
interlock plunger in (Figure 21, a). The
mechanical interlock should prevent the
switch from operating.
h. Avoid putting excessive force on the
operating handle during this operation
or damage to the handle mechanism
may occur.
Mechanical Interlock Verification
a. Mediumv Voltage Door
Interlock Plunger
b. Switch Drive Rod
c. Pivot Arm
d.Cam
e. Contactor Interlock Rod
C.Test Power Circuit
The procedures in this section describe how to
manually check the operating condition of the
Class E2-AR Medium Voltage Controller without
energizing the motor.
A complete operational check of the controller
can be made without applying voltage to the
motor or to the bus as follows:
1. The isolating-device handle must be in the
OFF position. In the OFF position, contacts
of the mechanically operated test-power
interlock will open the secondary circuit
of the control-power transformer, thereby
isolating it.
Operation
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37
E2-AR® Medium Voltage Controller with
Eaton Contactor
2. For convenience during maintenance
when it may be desirable to energize the
contactor or the control circuit only, a
control power test plug is provided. To
use the test plug, move the selector switch
(located inside the low voltage instrument
compartment) to the TEST position and
plug the 115 volt single phase power
supply into the receptacle located to the
right of the selector switch. Special plugs
may be provided when specified by the
user.
When the male plug is transferred to
the test power supply, it automatically
disconnects from the control power
transformer to prevent feedback of high
voltage into the power circuits. Check
to be sure no inadvertent bypass of this
arrangement has been made in the wiring
before relying on this safety feature.
To disconnect the test plug, rotate the
selector switch to the NORMAL position
and remove the test plug from the power
source receptacle.
c. Install the primary fuses for the
contactor.
d. Remove the required safety grounds.
e. Disconnect the following elements from
the circuits to be tested.
• Control Transformers
• Potential Transformers
• Starting Reactors
•Auto-Transformers
•Motors
2) Performing the Hi-Pot and Megger Test
The integrity of the insulation should
be checked before the medium voltage
equipment is energized. Use a high voltage
AC insulation tester or a “Megger” for this
test. If a Megger is used, a 5000V type is
recommended.
!
D. Hi-Pot and Megger Test
!
a. Ensure the motor control center is
deenergized.
b. Complete all power and control
connections.
38
CAUTION
Disconnect the power factor correction
capacitors (if equipped) before performing
the Hi-Pot test. Failure to do so may result in
personal injury or damage to the equipment.
1) Preparing for the Hi-Pot and Megger Test
Use the following information to prepare
for the pre-operation test:
WARNING
Use extreme caution when performing high
voltage test on the equipment. Failure to do
so may result in injury or death.
CAUTION
Disconnect this temporary circuit and connect
the plug to the receptacle on the contactor
before returning the unit to service.
01.4IB.46210A
!
CAUTION
Remove all primary fuses for the control
power transformer and/or the potential
transformer. Failure to do so may cause
damage to the equipment during the Hi-Pot
test.
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Operation
01.4IB.46210A
Insulation can be tested from phase to
phase and from phase to ground. The
recommended level for AC Hi-Pot testing is
(2 x VLL) volts, where VLL is the rated
line-to-line voltage of the power system.
The leakage current must be less than
20mA. Record the result for future
comparison testing.
If a Megger is used, it should indicate
50,000 megohms or greater if the unit is
isolated from the line and the motor. If the
unit is connected to a motor, the Megger
should indicate 5,000 megohms or greater
(phase to ground).
E.Pre-Operation Test
!
3. Operate the Class E2-AR® Medium Voltage
Controller in the normal manner using
the pilot devices (usually push buttons)
provided.
4. After the operation tests are made, connect
the motor and check it for proper rotation.
F.Start-Up Procedure
WARNING
This test procedure requires that the motor
connection cables be disconnected from the
motor terminals and be properly insulated
or isolated to withstand primary voltage at
the motor terminals. This test shall only be
performed by qualified personnel trained and
certified in high voltage testing procedures.
Adherence to all site-specific high voltage
safety procedures shall be strictly enforced.
Failure to follow this safety precaution may
result in injury or death.
After finishing the megger test, follow these
procedures to complete a pre-operation test:
1. Close all compartment doors and apply
power to the medium voltage motor
control center.
2. Close the isolating switch by placing the
operating handle in the extreme upper
position until it latches into the ON position
(Figure 6, a). If the operating handle is not
properly closed and latched, the contact
marked control power interlock will not
close.
Operation
Note: If the isolating switch operating
handle cannot be placed into the ON
position, deenergize and ground the
equipment. Check the mechanical
interlocking isolation switch. In
order to place the operating handle
in the ON position, the high voltage
compartment door must be fully
closed and the vacuum contactor
must be in the OPEN position.
1) Preliminary Checks
Verify the following:
•
•
•
•
•
•
•
•
•
•
•
Contactor current and voltage ratings
are correct for the attached load
Control voltage is correct
Heater elements (if provided) in
overload relay are secure and
undamaged
Equipment is properly grounded
External power and control connections
match electrical drawings
All hardware is correctly reinstalled and
torqued to specifications
All barriers are replaced to correct
positions
All fuses are correct class, type, and
rating
Mechanical interlocks and isolation
switches function properly
Ensure that relays are programmed
Ensure that interior of compartment
is free from dirt, loose bolts, tools, or
metal chips. Vacuum if necessary.
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39
E2-AR® Medium Voltage Controller with
Eaton Contactor
•
•
All tools are accounted for. If you
cannot locate a tool, do NOT energize
the equipment until the tool is found.
Settings for protective relays are correct
4) Medium Voltage Vacuum Contactor Testing
a. Turn the selector switch to the NORMAL
position.
2) Setting of Adjustable Protective Devices
Controllers may contain protective devices,
such as solid-state motor protection relays,
overcurrent relays, incomplete sequence
timers, and other devices critical to the
proper operation of the starter. Due to the
wide variation in job site parameters, these
devices are not set at the factory. It is the
purchaser’s responsibility to ensure that all
adjustable devices are properly set before
energizing the equipment. Warranty is void
if adjustable devices are not properly set
prior to initially starting the equipment.
!
WARNING
01.4IB.46210A
!
CAUTION
Some control circuit configurations may
require control jumpers to let the contactor
close during the test procedure. Do NOT
jumper any isolation switch contacts such as
ISa or ISb. Using jumpers for these contacts
may result in equipment damage or injury to
operating personnel.
b. Electrically operate the contactor
several times. Inspect the armature
plate to verify that it fully contacts the
magnetic cores.
5) Isolating Switch Adjustment
Failure to properly set adjustable devices may
result in equipment damage, personal injury,
or death.
3) Medium Voltage Vacuum Contactor
Inspection
All adjustments pertaining to the vacuum
contactor are described in the following
Eaton Publications:
Normally, the isolating switch will not
require any adjustment; however, if
parts are removed or replaced, it may be
necessary to make adjustments in the
mechanism Ch 5 Operation, B. Preparation
of the Controller for Operation,
6) Contactor Interlock Pre-Start Up Check.
Refer to the Eaton IB 48041 and Technical
Data Bulletin TD02003001E. See Table K,
Eaton Publication References.
400A - IB 48041
800A - IB 48041
40
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Operation
01.4IB.46210A
6) Power Fuse Inspection
Table K Eaton Publication References
Inspect the condition of all current-limiting
fuses after every fault current condition.
Visually inspect the power fuse blown fuse
indicator (Figure 22, a) or perform continuity
tests to determine the condition of the
fuses. When visually inspecting a fuse, if the
colored indicator on top of the fuse extends
outwards, the fuse is in the OPEN position or
blown. Compare the existing fuse resistance
value to a new fuse value to determine the
condition of the fuse.
Storage and Handling
Class E2-AR® Medium Voltage
Controllers
Isolating Switch 400A
Isolating Switch 800A
48041
48041
TD02003001E
Medium Voltage Vacuum Contactor
Vacuum Contactor Subassembly
Vacuum Contactor Latch
48041
48041
TD02003001E
Figure 22
Perform continuity tests to determine the
condition of the control power transformer
primary fuses and control power transformer
secondary fuses. Compare the existing
fuse resistance value to a new fuse value
to determine the condition of the fuse. As
required, replace fuses only with new fuses
with the same catalog number, type, voltage
rating, current rating, frequency rating, and
maximum interrupting rating. Refer to the
Operating Instructions label for complete
instructions on fuse replacement. The
operating instructions label is located on the
inside compartment door of the Medium
Voltage controller.
Operation
48041
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Blown Fuse Indicator
a
a. Blown Fuse Indicator
41
E2-AR® Medium Voltage Controller with
Eaton Contactor
Ch 6 Maintenance
During preventive maintenance and
inspection, check equipment for the following
deteriorating conditions:
A. Maintenance Precautions
!
WARNING
The equipment described in this information
bulletin contains hazardous voltages and
currents sufficient to cause death, electric
shock, or severe injury for personnel.
Deenergize the equipment before performing
any maintenance work.
Lock out the disconnecting means in
accordance with NFPA 70E, “Electric Safety
Requirements for Employee Safety in the
Workplace.”
B.Preventative Maintenance Guidelines
A preventative maintenance schedule,
including cleaning, inspection, and testing
should be established to obtain the best
service and reliability from the Class E2-AR®
Medium Voltage Controller. The frequency and
interval of preventive maintenance should be
scheduled according to operating and local
conditions and established needs and trends as
determined by periodic maintenance and test
records. If assistance is required for setting up
the proper interval schedule for maintenance,
contact Powell.
42
01.4IB.46210A
1. Contamination by dirt and dust in the
environment including wood fibers, coal
dust, cement, lamp black, and lint
2. Contamination by chemicals in the
environment such as sulfur dioxide,
chlorine, hydrocarbons, hydrogen sulfide
and salt water
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 as
follows: clean equipment; protect equipment
from adverse conditions; replace worn parts;
lubricate specific parts; and properly tighten
loose hardware, connections, and joints.
Inspect all sections of the Class E2-AR Medium
Voltage Controller, including the high voltage
compartment door interlock. The following
list contains general recommendations for
inspecting equipment.
1. Check for the presence of dust or dirt in
the compartment and on equipment.
Specifically check for accumulation of
any dust or dirt contamination on the
insulators. Voltage failures can result from
tracking across contaminated insulating
surfaces.
2. Check for abrasive material accumulated
in the isolating switch mechanism and
mechanical interlock bearing and cam
surfaces.
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Maintenance
01.4IB.46210A
3. Check for a buildup of dust or dirt that will
reduce any air or surface voltage clearances.
4. Excessive heating can reduce spring tension
on the primary connection stabs. Check
stab spring tension regularly, especially
during excessive heat conditions.
5. Excessive heat can cause the wiring and
cable insulation to breakdown. Check
all wires and cables for any evidence of
melting, discoloring, and deterioration.
6. The isolating switch mechanism has a
life expectancy of approximately 10,000
operations. If the application requires
that the mechanism operates more than
twice each day, the mechanism should
be checked at the end of each 1000
operations, otherwise a yearly inspection is
recommended.
7. Periodic dimensional inspections of
the isolating switch mechanism and
mechanical interlocks are strongly
recommended.
8. Check all dimensions when any part
of the isolating switch mechanism and
mechanical interlock is replaced to ensure
that the system is in safe working order.
Maintenance
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43
E2-AR® Medium Voltage Controller with
Eaton Contactor
Ch 7 Recommended Renewal Parts and
Replacement Procedures
A.Ordering Instructions
To order renewal parts from Powell Service
Division call 1.800.480.7273. When ordering
parts always specify the complete nameplate
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
parts tables in the appropriate instruction
bulletin. When ordering parts, specify the part
name, description, and part catalog number if
the part is listed in a renewal parts table. If the
part does not appear in an instruction bulletin
Renewal Parts table, provide a description of
the part along with a marked illustration from
the instruction bulletin, a photo, or a sketch of
the needed part.
1) Renewal Parts Quantity
The needed quantity of renewal spare parts
varies. The purchaser should determine
which parts and the quantity needed
depending on their particular application
and the following factors:
•
•
•
•
Amount of time to acquire renewal
parts
Critical need for continuous operation
Harsh environmental conditions that
may affect part stability
Severe service requirements that may
affect part durability
The parts tables included in this instruction
bulletin may list recommended quantities
of renewal parts to be carried in stock. As a
minimum, it is recommended that one set
of renewal parts be stocked per unit.
Over time, improvements may be made to
renewal parts. Therefore, spare or renewal
parts may not be identical to the original
parts. However, the furnished replacement
parts are interchangeable with the original
parts.
C. Replacement Procedures
B.Recommended Renewal Parts
For timely and cost-effective replacement of
worn, broken, or damaged parts, a sufficient
supply of renewal parts should be purchased
and stored appropriately.
(See Ch 4 Installation, C. Storage)
Maintaining a supply of renewal parts
enables the purchaser to replace damaged
parts quickly with a result of reducing the
amount of service interruption time. See
Ch 7 Recommended Renewal Parts and
Replacement Procedures, D. Replacement Parts,
Table L through Table V for a list of renewal parts
for equipment described in this document.
44
01.4IB.46210A
Powell recommends that only qualified
technicians perform maintenance on the
equipment described in this instruction
bulletin. Therefore, if vacuum contactors are
installed in a location that is not maintained
by a qualified technician, a spare vacuum
contactor should be stored on site for vacuum
contactor replacement. Thus, the spare
vacuum contactor can be placed into service
and the malfunctioning unit can be returned to
the factory for reconditioning.
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Recommended Renewal Parts and Replacement Procedures
01.4IB.46210A
!
WARNING
The equipment described in this information
bulletin contains hazardous voltages and
currents sufficient to cause damage to severe
injury or death to the operating personnel.
Deenergize the equipment before performing
any maintenance work.
1) Fuse Removal/Replacement Procedure
a. Bolt-On Fuse
You will need the following tools for this
procedure:
•
•
•
•
•
•
³/₈ Inch Drive Ratchet
2 Inch Extension
6 Inch Extension
12 Inch Extension
½ Inch Socket
³/₈ Inch Drive Torque Wrench
Note: The fuse configuration will determine
what length of extension will be
required to access the mounting
hardware. The fuse configuration will
also determine what size of interphase
barriers are installed. The lower
barriers can be removed to provide
better access to the fuse mounting
nuts.
i. Remove the two lower and two upper
mounting nuts, lock and flat washers
from the mounting studs
ii. Remove the fuse from the fuse
mounting studs
iii. Install the replacement fuse on the four
mounting studs. Hold the fuse in place
and install the two upper flat washers,
lock washers and nuts. Torque the nuts
to 12 ft-lbs.
Recommended Renewal Parts and Replacement Procedures
iv. Install the two lower flat washers, lock
washers, and nuts. Torque the nuts to
12 ft-lbs.
v. If the interphase barriers were
previously removed, ensure they are
properly reinstalled.
b. Clip-On Fuse
Note: The interphase barriers located at
the bottom of the fuse assembly can
be removed to ease the removal and
installation of the fuse.
An optional tool for this procedure is the
Fuse Puller, part # 827D924G01.
i. Place the cup section of the fuse puller
over the top of the fuse
ii. Pull back on the fuse puller with a quick
motion to dislodge the upper portion of
the fuse from the top fuse clip
iii. Set the fuse puller aside
iv. Remove the lower portion of the fuse
from the fuse clip by pulling up and
slightly rotating the fuse in one entire
movement
v. To install the replacement fuse, place
the fuse between the fuse clips
!
WARNING
Ensure that the correct barriers are used
with double-barrel fuses. Failure to install
the correct barriers can result in equipment
damage, sever injury, or death.
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45
E2-AR® Medium Voltage Controller with
Eaton Contactor
01.4IB.46210A
2) Auxiliary Contacts Inspection and
Replacement
!
CAUTION
Deenergize the equipment before performing
any maintenance work. Failure to do so may
result in injury or death to the operating
personnel.
a. Inspect the auxiliary contacts for wear,
scorching or heat damage. Replace any
damaged contacts. The contact have
a mean time between failure (MTBF)
rating of 20 million operations if used
within the operating specifications.
b. To remove the contact, turn both the
D-head fasteners until the flat sections
are aligned with the edge of the
contact.
c. Remove the contact from the housing.
d. Disconnect the wires from the auxiliary
contact.
e.Reverse steps b through d to install the
new auxiliary contact.
f. Ensure the contact is correctly
positioned into the contact carrier.
46
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Recommended Renewal Parts and Replacement Procedures
01.4IB.46210A
D. Replacement Parts
Table L Medium Voltage Vacuum Contactor Eaton 400A SL Renewal/Replacement Parts
Item
Number
Description
120V Control
Part
Number
1
Three (3) SL Vacuum Bottles
2147A58G02
2
SL Contactor Control Circuit Board
2147A58G03
3
SL Contactor Auxiliary Contacts 2NO/2NC
2147A58G04
4
SL Contactor Phase Barriers (Set of 4)
2147A58G12
5
SL Contactor Fuse Tray & Barrier Support
2147A58G17
CPT & PT Primary Fuses
6
7
0.81-inch dia. 5kV Max, 1 Amp (Set of 3)
2147A11G61
0.81-inch dia. 5kV Max, 3 Amp (Set of 3)
2147A11G49
0.81-inch dia. 5kV Max, 5 Amp (Set of 3)
2147A11G55
SL Contactor Operating Coils
2147A58G11
Latch Coil with Rectifier
8
24VDC
2147A58G25
48VDC
2147A58G26
125VAC-DC
2147A58G27
250VAC-DC
2147A58G28
Fuse Clips
9
10
SL PT Contactor Mechanical Latch Assembly
2147A58G18
SL CPT Primary Fuse Clips & Mounting (Set of 2)
2147A58G16
SL Contactor Main Fuse Clips (Set of 3)
2147A58G20
SL, Roll-Out Contactor Line Finger & Support (Set of 3)
2147A58G50
11
SL, Roll-Out Contactor Load Finger & Support (Set of 3)
2147A58G51
12
SL Contactor Return Spring Assembly
2147A58G22
Isolation Switches
13
Isolation Switch Handle, Housing, and Clevis
2147A41G08
Isolation Switch Tray with Fuse Clamps
2147A41G22
Isolation Switch Microswitch Assembly
2147A01G01
Recommended Renewal Parts and Replacement Procedures
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47
E2-AR® Medium Voltage Controller with
Eaton Contactor
01.4IB.46210A
Table M Medium Voltage Vacuum Contactor Eaton 800A SJA Renewal/Replacement Parts
Item
Number
1
Description
120V Control
Part
Number
Three (3) Vacuum Bottles with Shunt, Support, & Fingers
2147A87G03
Contactor Coils
2
120VAC (Set of 2)
2147A88G11
240VAC (Set of 2)
2147A88G12
3
Contactor Tune-Up Kit
2147A99G04
4
Contactor Miscellaneous Parts Kit
2147A88G15
Contactor Magnet Assembly with Coil
5
6
120VAC
2147A88G02
240VAC
2147A88G03
Contactor Magnet Assembly without Coil
2147A88G04
Interlocks
7
L-63 Interlock (Coil Circuit)
578D461G03
L-64 Auxiliary Interlocks 1NO/1NC
843D943G21
L-64 Auxiliary Interlocks 2 NO
843D943G22
L-64 Auxiliary Interlocks 2 NC
843D943G23
Barrier Assemblies
8
Contactor Barrier Assembly
2147A89G07
Contactor Fuse Support & Barrier Assembly
2147A89G06
Load or Line Fingers
9
Contactor Line Fingers with Copper Support
2147A89G01
Contactor Line or Load Fingers without Copper Support
2147A89G02
Contactor Fuse Load Fingers (Between Contactor & Fuse) (Set of 3)
2147A71G15
CPT & PT Primary Fuses
10
0.81-inch dia. 5kV Max, 1 Amp (Set of 3)
2147A11G61
0.81-inch dia. 5kV Max, 3 Amp (Set of 3)
2147A11G49
0.81-inch dia. 5kV Max, 5 Amp (Set of 3)
2147A11G55
1.00-inch dia. 5kV Max, 1 Amp (Set of 3)
2147A11G63
1.00-inch dia. 5kV Max, 3 Amp (Set of 3)
2147A11G46
1.00-inch dia. 5kV Max, 5 Amp (Set of 3)
2147A11G53
Isolation Switches
11
48
Isolation Switch Handle, Housing, & Clevis
2147A71G08
Isolation Switch Tray Assembly with Line Fingers
2147A81G22
Isolation Switch Microswitch Assembly
2147A01G01
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Recommended Renewal Parts and Replacement Procedures
01.4IB.46210A
Table N R-Rated Clip-On Fuses for 400A Contactor
Voltage Rating of 2.4 & 5.5kV
“R”
Designation
Ampere
Rating
Symmetrical
Interruption
Part
Number
2R
70
50kA
A480R2R-1
3R
100
50kA
A480R3R-1
4R
130
50kA
A480R4R-1
6R
170
50kA
A480R6R-1
9R
200
50kA
A480R9R-1
12R
230
50kA
A480R12R-1
18R
390
50kA
A480R18R-1
24R
450
50kA
A480R24R-1
“R”
Designation
Ampere
Rating
Symmetrical
Interruption
Part
Number
2R
70
50kA
A072F1D0R0-2R
3R
100
50kA
A072F1D0R0-3R
4R
130
50kA
A072F1D0R0-4R
6R
170
50kA
A072F1D0R0-6R
9R
200
50kA
A072F1D0R0-9R
12R
230
50kA
A072F1D0R0-12R
18R
390
50kA
A072F1D0R0-18R
24R
450
50kA
A072F1D0R0-24R
Voltage Rating of 7.2kV
Recommended Renewal Parts and Replacement Procedures
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49
E2-AR® Medium Voltage Controller with
Eaton Contactor
01.4IB.46210A
Table O R-Rated Bolt-On Fuses for 800A Contactor
Voltage Rating of 2.4 & 5.5kV
“R”
Designation
Ampere
Rating
Symmetrical
Interruption
Part
Number
2R
70
50kA
A051B1DAR0-2R
3R
100
50kA
A051B1DAR0-3R
4R
130
50kA
A051B1DAR0-4R
6R
170
50kA
A051B1DAR0-6R
9R
200
50kA
A051B1DAR0-9R
12R
230
50kA
A051B1DAR0-12R
18R
390
50kA
A051B2DAR0-18R
19R
300
50kA
A051B1DAR0-19R
24R
450
50kA
A051B2DAR0-24R
32R
540
50kA
A051B2DAR0-32R
38R
600
50kA
A051B2DAR0-38R
48X
750
50kA
A051B3DAR0-48X
57X
900
50kA
A051B3DAR0-57X
“R”
Designation
Ampere
Rating
Symmetrical
Interruption
Part
Number
2R
70
50kA
A072B1DAR0-2R
3R
100
50kA
A072B1DAR0-3R
4R
130
50kA
A072B1DAR0-4R
6R
170
50kA
A072B1DAR0-6R
9R
200
50kA
A072B1DAR0-9R
12R
230
50kA
A072B1DAR0-12R
18R
390
50kA
A072B2DAR0-18R
19R
300
50kA
A072B2DAR0-19R
24R
450
50kA
A072B2DAR0-24R
32R
540
50kA
A072B2DAR0-32R
38R
600
50kA
A072B2DAR0-38R
48X
750
50kA
A072B3DAR0-48X
57X
900
50kA
A072B3DAR0-57X
Voltage Rating of 7.2kV
50
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Recommended Renewal Parts and Replacement Procedures
01.4IB.46210A
Table P E-Rated Clip-On Fuses for 400A Contactor
Voltage Rating of 2.4 & 5.5kV
“E”
Designation
Ampere
Rating
Symmetrical
Interruption
Part
Number
30E
30
63kA
A055F1D0R0-30E
40E
40
63kA
A055F1D0R0-40E
50E
50
63kA
A055F1D0R0-50E
65E
65
63kA
A055F1D0R0-65E
80E
80
63kA
A055F1D0R0-80E
100E
100
63kA
A055F1D0R0-100E
125E
125
63kA
A055F1D0R0-125E
150E
150
63kA
A055F1D0R0-150E
175E
175
63kA
A055F1D0R0-175E
200E
200
63kA
A055F1D0R0-200E
250E
250
63kA
A055F2D0R0-250E
300E
300
63kA
A055F2D0R0-300E
350E
350
63kA
A055F2D0R0-350E
Table Q E-Rated Bolt-On Fuses for 800A Contactor
Voltage Rating of 5.5kV
“E”
Designation
Ampere
Rating
Symmetrical
Interruption
Part
Number
30E
30
63kA
A055B1D0R0-30E
40E
40
63kA
A055B1D0R0-40E
50E
50
63kA
A055B1D0R0-50E
65E
65
63kA
A055B1D0R0-65E
80E
80
63kA
A055B1D0R0-80E
100E
100
63kA
A055B1D0R0-100E
125E
125
63kA
A055B1D0R0-125E
150E
150
63kA
A055B1D0R0-150E
175E
175
63kA
A055B1D0R0-175E
200E
200
63kA
A055B1D0R0-200E
250E
250
63kA
A055B2D0R0-250E
300E
300
63kA
A055B2D0R0-300E
350E
350
63kA
A055B2D0R0-350E
400E
400
63kA
A055B2D0R0-400E
450E
450
63kA
A055B2D0R0-450E
500E
500
63kA
A055B2D0R0-500E
600E
600
63kA
A055B2D0R0-600E
750E
750
63kA
A055B3D0R0-750E
Recommended Renewal Parts and Replacement Procedures
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E2-AR® Medium Voltage Controller with
Eaton Contactor
01.4IB.46210A
Table R Control Relays
Control Relay - AC
Part Number
Description
80026-097-01
Allen Bradley Bulletin 700-CF400, 120VAC, 4-N.O., COIL # TA473V
Control Relay - DC
Part Number
Description
100-C12ZD400
Allen Bradley Bulletin 100-C, 4-N.O., CONTACTS 110VDC
Table S Current Transformers
Part Number
Description
21-101
CT/ITI 100:5A, C10
21-101MR
CT/ITI 100:5A, MR
21-151
CT/ITI 150:5A, C20
21-201
CT/ITI 200:5A, C20
21-250
CT/ITI 25:5A
21-251
CT/ITI 250:5A, C20
21-301
CT/ITI 300:5A, C20
21-400
CT/ITI 40:5A
21-401
CT/ITI 400:5A, C50
21-401MR
CT/ITI 400:5A, MR
21-500
CT/ITI 50:5A
21-501
CT/ITI 500:5A
21-601
CT/ITI 600:5A
21-601MR
CT/ITI 600:5A, MR
21-750
CT/ITI 75:5A, C10
21-801
CT/ITI 800:5A
Table T Ground Current Transformers
52
Part Number
Description
115-500
CT/ITI 50:5A
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01.4IB.46210A
Table U Control Power Transformers - SNC
Part Number
Description
P21847
1kVA, 2400V-120V
P21848
1kVA, 4200V-120V
P21850
1kVA, 7200V-120V
P21876
1kVA, 2400-120/240V
P21877
1kVA, 4200-120/240V
P21852
2kVA, 2400V-120V
P21853
2kVA, 4200V-120V
P21854
2kVA, 7200V-120V
Table V Control Power Transformer Primary Fuses
400A Contactor 2.4 & 5.5kV (fuse holder not required)
Part Number
Description
A500T1E-1
1E, 5kV fuses for 1kVA CPT
A500T2E-1
2E, 5kV fuses for 2kVA CPT
400A Contactor 7.2kV (fuse holder not required)
Part Number
Description
A720T1E-1
1E, 7.2kV fuses for 1kVA CPT
A720T2E-1
2E, 7.2kV fuses for 2kVA CPT
800A Contactor 2.4 & 5.5kV (fuse holder required)
Part Number
Description
2033A73G03
C-H, MV fuse holder
A500T1E-1
1E, 5kV fuses for 1kVA CPT
A500T2E-1
2E, 5kV fuses for 2kVA CPT
800A Contactor 7.2kV (fuse holder required)
Part Number
Description
2033A73G03
C-H, MV fuse holder
2103A88H01
C-H fuse clip adapter plate
8NCLPT-1E
C-H, 7.2kV fuses for 1kVA CPT
8NCLPT-2E
C-H, 7.2kV fuses for 2kVA CPT
Recommended Renewal Parts and Replacement Procedures
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53
E2-AR® Medium Voltage Controller with
Eaton Contactor
01.4IB.46210A
Appendix A- 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, _____kA
Close Voltage: _____ 48VDC _____ 120VDC
_____ 125VDC _____ 240VDC
Trip Voltage: _____ 48VDC
_____ 125VDC
System Voltage: __________ kV
Motor Capacity: __________ HP
Vacuum Contactor Type
D.A.L.: _____ Soft Start_____
_____ 120VDC
_____ 240VDC
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
micro-ohms
*High Potential AC
5.0kV-13.2kV AC
7.2kV-18.2kV AC
*High Potential DC
5.0kV-18.7kV AC
7.2kV-25.6kV AC
Micro-Amps
*Vacuum Integrity
B Phase
Pass/Fail
Vacuum Contactor Tested in “Open” Position
Top
Bottom
Vacuum Contactor Tested in “Closed” Position
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), quantities, and description(s) of all parts to be replaced):
Comments:
Tests By:
54
A Phase
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C Phase
01.4IB.46210A
E2-AR® Medium Voltage Controllers
Arc Resistant Motor Control With
Eaton Contactors
February 2014
Powell Electrical Systems, Inc.
Service Division - Houston
PO Box 12818 • Houston, TX • 77217
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©2006 Powell Industries, Inc. • All rights reserved.
Tel: 713.944.6900 • Fax: 713.948.4569
www.powellind.com
info@powellind.com