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IB182047EN AFL

Instruction Booklet IB182047EN
Effective February 2018
Arc flash limiter (AFL)
conversion system
Contents
Description
Page
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 AFL conversion system and components. . . . .
3 Typical installation performed by qualified
personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 AFL conversion system control unit . . . . . . . . .
5 Maintenance............................
6 Parts List................................
Appendix A...............................
2
3
5
7
8
8
9
Instruction Booklet IB182047EN
Arc flash limiter (AFL)
conversion system

Effective February 2018
Warnings and cautions
m WARNING
IMPROPERLY OPERATING OR MAINTAINING THIS ARC FLASH LIMITER
(AFL) CONVERSION SYSTEM CAN RESULT IN DEATH, SERIOUS PERSONAL
INJURY, OR PROPERTY DAMAGE.
READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING
ANY OPERATION OR MAINTENANCE OF THE CIRCUIT BREAKER OR OTHER
SYSTEM COMPONENT.
INSTALLATION OF THIS AFL CONVERSION SYSTEM MUST BE PERFORMED
ONLY BY QUALIFIED PERSONNEL THAT ARE TRAINED FOR THE
INSTALLATION.
SYSTEM MAINTENANCE SHOULD BE ATTEMPTED ONLY BY QUALIFIED
PERSONNEL. THIS INSTRUCTION BOOK SHOULD NOT BE CONSIDERED
ALL INCLUSIVE REGARDING OPERATION OR MAINTENANCE PROCEDURES.
IF FURTHER INFORMATION IS REQUIRED, CONTACT YOUR EATON
REPRESENTATIVE.
m WARNING
ALL SAFETY CODES, SAFETY STANDARDS, AND/OR REGULATIONS AS
THEY MAY BE APPLIED TO THIS TYPE OF EQUIPMENT MUST BE STRICTLY
FOLLOWED.
SERIOUS INJURY, INCLUDING DEATH, CAN RESULT FROM FAILURE TO
FOLLOW PROCEDURES OUTLINED IN THIS MANUAL, OR COMPLY WITH
THE REQUIREMENTS OF APPLICABLE STANDARDS.
1 Introduction
1.1 Preliminary comments and safety precautions
This technical document is intended to cover most aspects associated with the application, operation, and maintenance of the Eaton
arc flash limiter (AFL) conversion system equipped with a Type
VCP-TR circuit breaker. It is provided as a guide for authorized and
qualified personnel only. Please refer to the specific WARNINGS and
CAUTIONS in Section 1.1.2 before proceeding.
If further information is required by the purchaser regarding a
particular operation, application, or maintenance activity, contact your
Eaton representative.
1.1.1 Warranty and liability information
NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING
WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OF
MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE
OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING
THE INFORMATION, RECOMMENDATIONS, AND DESCRIPTIONS
CONTAINED HEREIN.
In no event will Eaton be responsible to the purchaser or user in
contract, in tort (including negligence), strict liability or otherwise
for any special, indirect, incidental or consequential damage or loss
whatsoever, including but not limited to damage or loss of use of
equipment, plant, or power system, cost of capital, loss of power,
additional expenses in the use of existing power facilities, or claims
against the purchaser or user by its customers resulting from the
use of the information and descriptions contained herein.
2
EATON www.eaton.com
1.1.2 Safety precautions
All safety codes, safety standards, and/or regulations must be strictly
observed in the operation and maintenance of this system.
m WARNING
THE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE
PROCEDURAL STEPS IN THIS DOCUMENT ARE FOR PERSONNEL SAFETY
AND PROTECTION OF EQUIPMENT FROM DAMAGE. AN EXAMPLE OF A
TYPICAL WARNING LABEL HEADING IS SHOWN ABOVE TO FAMILIARIZE
PERSONNEL WITH THE STYLE OF PRESENTATION. THIS WILL HELP TO
INSURE THAT PERSONNEL ARE ALERT TO WARNINGS, WHICH MAY
APPEAR THROUGHOUT THE DOCUMENT. IN ADDITION, CAUTIONS ARE
ALL UPPER CASE AND BOLDFACE AS SHOWN BELOW.
m CAUTION
COMPLETELY READ AND UNDERSTAND THE MATERIAL PRESENTED IN
THIS DOCUMENT BEFORE ATTEMPTING OPERATION OR APPLICATION OF
THE EQUIPMENT. IN ADDITION, ONLY QUALIFIED PERSONEL SHOULD BE
PERMITTED TO PERFORM ANY WORK ASSOCIATED WITH THE EQUIPMENT.
ANY WIRING INSTRUCTIONS PRESENTED IN THIS DOCUMENT MUST BE
FOLLOWED PRECISELY. FAILURE TO DO SO COULD CAUSE PERMANENT
EQUIPMENT DAMAGE.
1.2 General information
The purpose of this instruction booklet is to provide instructions for
the operation and maintenance of AFL conversion system equipped
with a VCP-TR circuit breaker. Designed to Institute of Electrical and
Electronics Engineers (IEEE) Standards for reliable performance,
ease of handling, and simplified maintenance, VCP-TR circuit breakers provide reliable control and protection for electrical equipment
and circuits. In addition, these technologically advanced circuit
breakers provide higher insulation levels in less space, thus reducing
the overall switchgear size.
m WARNING
SATISFACTORY PERFORMANCE OF THE AFL CONVERSION SYSTEM
IS CONTINGENT UPON PROPER APPLICATION AND ADEQUATE
MAINTENANCE. THIS INSTRUCTION BOOKLET MUST BE CAREFULLY
READ AND FOLLOWED IN ORDER TO OBTAIN OPTIMUM PERFORMANCE
FOR LONG USEFUL LIFE OF THE CIRCUIT BREAKER AND OTHER SYSTEM
COMPONENTS.
m WARNING
THE AFL CONVERSION SYSTEM DESCRIBED IN THIS INSTRUCTION
BOOKLET IS DESIGNED AND TESTED TO OPERATE WITHIN THEIR
NAMEPLATE RATINGS. OPERATION OUTSIDE OF THESE RATINGS MAY
CAUSE THE EQUIPMENT TO FAIL, RESULTING IN DEATH, SEVERE BODILY
INJURY, AND PROPERTY DAMAGE.
ALL SAFETY CODES, SAFETY STANDARDS AND/OR REGULATIONS AS
THEY MAY BE APPLIED TO THIS TYPE OF EQUIPMENT MUST BE STRICTLY
FOLLOWED.
Instruction Booklet IB182047EN
Arc flash limiter (AFL) 
conversion system
Effective February 2018

2. AFL conversion system and components
2.1 How the AFL conversion system works
Eaton’s arc flash limiter (AFL) conversion system reduces the
available incident energy on the secondary side of a high voltage
transformer by replacing the fuses of a fused disconnect switch with
a vacuum circuit breaker. The hybrid design eliminates the original
primary fuses, provides vacuum breaker technology with primary
short circuit protection via a feeder protection relay, and adds Eaton’s
arc flash reduction maintenance switch (ARMS) to lower arc flash
levels on the secondary bus of the switchgear.
The most typical form of an AFL provides the VCP-TR medium
voltage circuit breaker to take the place of the fuses in the existing
switch enclosure, and adds CT’s on the breaker. A new control
unit utilizing a feeder protection relay is mounted in the control unit
for primary overcurrent protection and a set of current sensors are
added to the secondary side of the transformer to feed the ARMS
feature on the breaker trip unit. In some cases, the original disconnect switch is retained.
The control unit also includes a breaker control switch and breaker
status LEDs for breaker control.
The 520MCV trip unit with Maintenance Mode in the breaker interfaces with the ARMS switch mounted in the control unit. When the
ARMS switch on the control unit activates the maintenance mode of
the trip unit which reduces the arc flash setting for the secondary of
the transformer.
When ARMS is engaged, if a high fault current is detected on the
secondary side of the transformer, the current sensors feed that
information back to the trip unit in the breaker and quickly trip the
breaker on the primary side based on the fault on the secondary
side.
Due to the introduction of the vacuum breaker close coupled to
the transformer, a snubber is added. This can be a custom tuned
snubber based on the specifications of Eaton’s Power Systems
Engineering (PSE) Group, or a standard “off the shelf” snubber at
the customer’s discretion.
Figure 1. Typical system single line before and after AFL conversion system installation.
EATON www.eaton.com
3
Instruction Booklet IB182047EN
Arc flash limiter (AFL)
conversion system

Effective February 2018
•
Current sensors: Special 1 A secondary current sensors are
installed on the secondary (low voltage) side of the transformer
and feed back to the trip unit. For sensor details and available
ratios, see Eaton drawings 69C3011 and 70C1527.
•
Control unit: A control unit with a feeder protection relay, arc
flash maintenance reduction switch (ARMS), and breaker controls
and indication control the circuit breaker.
•
RC snubber assembly/Protec-Z: The addition of a vacuum breaker
into the existing transformer circuit will introduce an increased
risk of destructive high voltage transients into the system.
Transient voltages have been proven to cause transformer failures
during switching. To mitigate this risk, it is highly recommended
Eaton Power Systems Engineering (PSE) conduct a switching
transient study to determine the optimal surge protection (surge
arrester, RC snubber, and/or damping resistor) needed to mitigate
site specific transient voltages. The recommended surge protection (most often a snubber assembly) will be integrated into the
AFL conversion system installation.
NNote: For more information about such transformer failures, see the white
paper ‘’Transformer Failure Due to Circuit Breaker Induced Switching
Transients” by Shipp, Dionise, Lorch, and Macfarlane.
NNote: For more information about custom snubber assemblies, see
Eaton instruction book IB02105001E. If a switching transient study is not
performed, a “one size fits all” Protec-Z solution can be provided as an alternative. However, this is not recommended.
2.3 Protection details
2.3.1 Primary protection
Figure 2. System single line protection with AFL conversion system.
2.2 System components
Eaton AFL conversion systems are designed specifically to meet
each customer’s needs, requirements, and existing electrical components. The basic components of the typical AFL conversion system
are identified in the following bulleted list. For information on any
non-standard components included in the AFL conversion system
due to a customer’s unique electrical components or requirements,
please refer to the product information included with each component.
•
•
•
4
Circuit breaker: VCP-TR medium voltage breaker, fixed mounted
or drawout. Provided with 520MCV trip unit with maintenance
mode, shunt trip, and spring release. See Eaton instruction book
IB131016EN for detailed information.
Custom mounting pieces and bus work: The circuit breaker
will be installed in the existing switchgear enclosure using site
specific, custom manufactured mounting components and copper
bus. A site visit by an Eaton engineer is required to gather site
specific details and measurements.
Current transformers (CTs): Standard C50 class or higher relay
class, 5 A secondary current transformers are installed on the
primary (high voltage) side of the transformer. The CTs are
connected to the control unit feeder protection relay that provides
primary 50/51 over-current protection for the primary side of the
transformer.
EATON www.eaton.com
The current transformers on the primary side of the high voltage
transformer feed a feeder protection relay located in the control unit.
The feeder protection relay provides 50/51 over-current protection on
the primary side of the transformer. The relay trips the breaker via
the shunt trip during an over-current condition.
2.2.2 Arc flash reduction maintenance switch (ARMS)
The current sensors on the secondary side of the high voltage transformer feed the 520MCV trip unit. When the ARMS switch on the
control unit is engaged, the trip unit’s maintenance mode (ARMS) is
engaged, reducing the incident energy on the secondary side of the
transformer. The 520MCV trip unit trips the breaker during an overcurrent condition.
2.2.3 Control power
120 Vac/dc is required to power the control unit and must be
provided by the customer. A control power transformer can be
included in the AFL conversion system design to provide control
voltage if needed.
Relay and trip unit settings, including settings for the arc flash
reduction maintenance mode, are determined by a protection and
coordination study. It is highly recommended Eaton PSE perform
this study.
Instruction Booklet IB182047EN
Arc flash limiter (AFL) 
conversion system
Effective February 2018

3.Typical installation performed by qualified
personnel
m WARNING
INSTALLATION OF THIS AFL CONVERSION SYSTEM MUST BE PERFORMED
ONLY BY QUALIFIED PERSONNEL THAT ARE TRAINED FOR THE
INSTALLATION..
A summary of the typical installation procedures of the AFL conversion system that is performed by qualified field service technicians is
contained in the section below. These are the typical procedures.
The actual procedures for a specific installation may vary due to
the components included in the new AFL conversion system, the
original components being replaced, and the existing switchgear
enclosure.
Line copper bus
3.1 Typical installation procedure
Load copper bus
NNote: The order of the following procedures may vary due to the specific
installation.
•
Qualified field service technicians will remove and discard the
existing fuses and other components used for the disconnect
function. Often, this will include “gutting” (removing and discarding) everything in line after the original the disconnect switch.
•
Qualified field service technicians will install the new the basic
mounting structure/platform (usually comprised of custom unistrut and brackets) for the new breaker within the switchgear
enclosure. The structure will vary depending on the particular
enclosure and components.
CTs
Figure 4. Typical copper bus work and connection cables.
•
Qualified field service technicians will install the breaker to the
transformer connections. These will usually be copper bus work
(typically 1/4 by 2” or 1/4 by 3” [6.35 x 50.8 mm or 6.35 x 76.2
mm]). In some cases the connections will be cable instead of
copper bus work depending on the rating of the breaker and
transformer.
Refer to Appendix A for examples of normal joint and connection
field taping.
Figure 3. Typical uni-strut and brackets used for mounting the
breaker.
NNote: During AFL conversion system installation, qualified field service technicians will reference NEC Table 490.24 - “Minimum Clearance for Live Parts”
for all joints and connections and insure they meet the standards identified in
NEC Table 490.24.
•
Qualified field service technicians will install the disconnect
switch to breaker connections. These will usually be copper bus
work (typically 1/4 x 2” or 1/4 x 3” [6.35 x 50.8 mm or 6.35 x 76.2
mm]). In some cases the connections will be cable instead of
copper bus work depending on the rating of the breaker.
Refer to Appendix A for examples of normal joint and connection
field taping.
Figure 5. Typical current sensors installed during installation.
NNote: In some cases, Eaton may supply custom bus boots to use in place
of field taping if included purchase agreement.
•
Qualified field service technicians will install the red glass poly
(GP03 insulating material) phase barriers between phases A and B
and B and C as per the custom AFL conversion system design.
•
Qualified field service technicians will install the three current
transformers (CTs) and mounting brackets, if applicable, on the
breaker/primary side of the transformer. These will be wired into
the feeder protection relay to provide 50/51 protection.
•
Qualified field service technicians will install the three current
sensors on the secondary side of the transformer. These will be
wired into the trip unit of the breaker to provide instantaneous
breaker reaction.
EATON www.eaton.com
5
Instruction Booklet IB182047EN
Arc flash limiter (AFL)
conversion system

Effective February 2018
•
Qualified field service technicians will install the VCP-TR breaker
and make all necessary wiring connections. Typically, the VCP-TR
breaker installation includes installing and mounting the breaker
to the new mounting brackets/platform and modifying the existing
door, if necessary.
If the existing door must be modified, the proper size opening will
be cut from the door and a new door escutcheon and gasket will
be installed to fit properly around the breaker when the door is
closed.
Figure 7. Typical custom snubber.
•
Qualified field service technicians will install the control unit
either on the enclosure door or mounted remotely based on the
customer’s preference.
If a remotely mounted control unit is selected, the control unit
should be no farther then 25 cable feet (7.62 m) from the switchgear enclosure. If a greater distance is required, contact Eaton
PSE.
Figure 6. Typical VCP-TR breaker installed in the cell with the
door closed.
•
Qualified field service technicians will install a “snubber” (either a
standard Protec-Z or custom 3-phase assembly tuned specifically
to the installation).
When a vacuum breaker is close coupled to a transformer, it
can introduce high frequency transients into the system when
the breaker is opened or closed. To negate the high frequency
transients, Eaton provides a “snubber” with each AFL conversion
system.
If a custom tuned snubber is supplied with the AFL conversion
system, it was designed based on the results of the optional
study of the customer’s existing original electrical system
performed by Eaton PSE.
Figure 8. Typical control unit.
For more information on the control unit and its operation, refer to
“4. AFL conversion system control unit” later in this document.
NNote: Control unit requires 120 Vac or Vdc power (optional 24 or 48 Vdc available). Routing and supply of the control power is up to the customer.
NNote: If control power is not available at the facility, Eaton can supply a
control power transformer (CPT) at additional cost. A CPT can usually be
mounted in the switchgear enclosure, but if not, it can be mounted in another
local location.
•
6
EATON www.eaton.com
Qualified field service technicians will install two new AFL conversion system nameplates in prominent positions on the switchgear
enclosure of door. One label identifies the AFL assembly and the
other states the AFL electrical ratings.
Instruction Booklet IB182047EN
Arc flash limiter (AFL) 
conversion system
Effective February 2018

4. AFL conversion system control unit
4.1 Control unit components
The AFL conversion system control unit allows the operator to fully
control all AFL conversion system functions. It is normally mounted
to the door of the switchgear enclosure but can be mounted
remotely based on the customer’s preference.
1. Feeder protection relay
The feeder protection relay is fed by the current transformers
(CTs) and provides primary protection for the transformer. It
receives signals from the CTs located on the breaker and primary
side of the transformer and provides 50/51 protection.
6
4
2. Breaker control switch
The breaker control switch is used to open and close the breaker.
3. Red indicating LED/pushbutton
The red indicating LED/pushbutton indicates the breaker is
closed.
7
1
8
4. White indicating LED/pushbutton
The white indicating LED/pushbutton indicates the springs of the
breaker are charged.
5. Green indicating LED/pushbutton
The green indicating LED/pushbutton indicates the breaker is
open.
6. Blue indicating LED and switch
The blue indicating LED indicates the ARMS function is On.
5
2
3
Figure 9. Typical control unit components.
NNote: Control unit requires 120 Vac or Vdc power (optional 24 or 48 Vdc available). Routing and supply of the control power is up to the customer.
NNote: If control power is not available at the facility, Eaton can supply a
control power transformer (CPT) at additional cost. A CPT can usually be
mounted in the switchgear enclosure, but if not, it can be mounted in another
local location.
7. Padlockable ARMS on/off switch
The ARMS on/off switch allows the operator to activate or deactivate the ARMS system. It should be activated whenever service
is being performed on the secondary side of the transformer.
In the ARMS system, current sensors are located on the secondary side of the transformer and send signals to the 520MCV trip
unit in the breaker. When the ARMS system is active, a fault
indication on the secondary side of the transformer will instantaneously cause the breaker to trip.
The ARMS cover is padlockable in “On” position. The padlock
and key must be supplied by the customer. The key should be
stored based on the facilities preferences and lock-out/tag-out
procedures.
8. Quarter turn latch
The quarter turn latch is used to open and close the door on the
control unit.
EATON www.eaton.com
7
Instruction Booklet IB182047EN
Arc flash limiter (AFL)
conversion system

Effective February 2018
5. Maintenance
5.1 VCP-TR breaker
The standard maintenance procedures for VCP-TR breakers should
be followed. Please refer to the documentation supplied with the
breaker for specific details.
5.2 Custom snubber
If a custom snubber is included, the specified standard snubber
maintenance procedures should be followed. Please refer to the
documentation supplied with the snubber for specific details.
General major parts list
Table 1. AFL Conversion system
Description
Qty.
VCP-TR circuit breaker
Door escutcheon w/ gasket
Protec-Z 3-phase assembly (If a custom snubber is not purchased)
Current transformer
CT mounting bracket
Current sensor
AFL control unit - 120 Vac, NEMA 1
Copper, phase A load
1
1
1
3
3
3
1
1
Copper, phase B load
Copper, phase C load
Copper, phase A line
Copper, phase B line
Copper, phase C line
Phase barrier
Nameplate, “Eaton AFL Assembly”
Nameplate, “AFL Ratings”
1
1
1
1
1
2
1
1
Comment
Table 3. Torque values for copper BUS connectors
Table 2. Torque values for general mounting and screw size
conversion
Decimal size (in)
Standard size
.112
8
Torque (in-lbs)
4.40
Decimal size (in)
Torque (ft-lbs)
10
0.8
Standard size
Torque (in-lbs)
Torque (ft-lbs)
.250
1/4-20
60
5
.312
5/16-18
144
12
.138
6.32
18
1.5
.375
3/8-16
240
20
.164
8.32
36
3.0
.500
1/2-13
600
50
.190
10.32
46
3.8
.250
1/4-20
100
8.3
.312
5/16-18
206
17.2
.375
3/8-16
356
29.7
.438
7/16-14
572
47.7
.500
1/2-13
856
71.3
EATON www.eaton.com
NNote: The Protec-Z bushings (or capacitor bushings in the case of custom
snubbers) should NOT be torqued to full value as they will break. The
Protec-Z or capacitor bushings MUST only be torqued to 16-19 ft-lbs
(192-228 in-lbs).
Instruction Booklet IB182047EN
Arc flash limiter (AFL) 
conversion system
Effective February 2018

Appendix A. Field taping of joints and
connections
m WARNING
INSTALLATION OF THIS AFL CONVERSION SYSTEM MUST BE PERFORMED
ONLY BY QUALIFIED PERSONNEL THAT ARE TRAINED FOR THE
INSTALLATION
The figures contained in this Appendix give general rules to follow
when field taping joints and connections. These are provided for
reference only.
NNote: During the initial installation of the AFL Conversion System, all joints
and connections will made by qualified personnel that are trained for the
installation.
MATERIALS
PREINSULATION
PREINSULATION
PAD #1
PREINSULATION
PREINSULATION
FILLER - A PUTTY-LIKE MATERIAL.TRADE NAMES: DUCTSEALER, DUCT SEAL, EATON. NO.
53351BB AND 53351WX.
INSULATING - HIGH VOLTAGE EPR INSULATING TAPE. TRADE NAME: SCOTCH 130C TAPE,
EATON. NO. 45151SE.
DEFINITIONS
JOINT - AREA TO BE COVERED WITH TAPE. CONSISTS OF BARE CONDUCTOR AND 1.5
INCHES OF ANY PRE-INSULATION NEXT TO THE BARE CONDUCTOR.
PRE - INSULATION - ANY INSULATING COVERING OR COATING SUCH AS EPOXY COATING
OR INSULATING TUBING ADJACENT TO AN EXPOSED CONDUCTOR PRIOR TO TAPING.
FIG. 2: TYPICAL JOINT WITH 3 IN.
FIG. 1: TYPICAL JOINT WITH .12 THK.
MIN. FILLER OVER BARE JOINT.
WIDE X .030 TAPE OVER FILLER.
PREINSULATION
PREINSULATION PAD #2 PAD #1
PAD #4
PREINSULATION
PAD #3
PREINSULATION
PAD - ANY INSULATING TAPE APPLIED WHICH IS WIDER THAN ONE INCH. INCLUDES A
BAND OF TAPE CONSISTING OF ONE OR MORE TURNS WRAPPED DIRECTLY ON TOP OF
EACH OTHER.
LAYER - INSULATING TAPE, 1 INCH WIDE, WRAPPED FROM ONE END OF THE JOINT TO
THE OTHER, (OR TO A PAD) SO EACH SUCCEEDING TURN LAPS THE PREVIOUS TURN BY
THE AMOUNT SPECIFIED IN THE CHART.
OVERLAP - A SPECIFIED DISTANCE MEASURED ALONG THE PRE-INSULATION STARTING
FROM THE POINT WHERE THE PRE-INSULATION ENDS AND THE EXPOSED CONDUCTOR
BEGINS.
METHODS
1.0
1.0
1.0
FIG. 3: TYPICAL JOINT WITH Pads #2 & #3
(3 IN. WIDE X .030) TAPE
OVER PAD #1 AND FILLER.
Fig 4: TYPICAL JOINT WITH PAD #4
(3) 6.0 X .030 PIECES OF TAPE.
PAD #2 FILLER PAD #1
FIG. 5: 2 LAYERS OF 1.0 x .030
TAPE WITH 2/3 OVERLAP.
LAP
FO
ED
4
016
3
OTE
OINT
) AND
AS
1
Figure
Figure 10.
??. T-joint
T-joint field
Fieldtaping
Tapingmethods.
Methods.
2
PREINSULATION
PAD #3
9.0 (27 kV)
11.0 (38 kV) MIN.
INSUL.
TAPE
96
PAD #4
MAIN BUS/RISER JOINT.
1. ELONGATE INSULATING TAPE 10 TO 25 PERCENT DURING APPLICATION TO INSURE A
SMOOTH, TIGHT FIT. ON PADS ELONGATE CORNERS ONLY.
2. SHOULD A TAPE ROLL EXPIRE, START THE NEW ROLL BY OVERLAPPING THE PREVIOUS
END BY .5 TURN.
"T"-JOINTS, WITH-HARDWARE
1. CLEAN AREA OF DIRT AND FOREIGN MATTER
2. WIPE PREINSULATION WITH ISOPROPYL ALCOHOL
3. APPLY FILLER OVER BARE CONDUCTOR AND HARDWARE TO COVER AND SMOOTH OUT
THE SURFACE. BLEND CONTOUR INTO PRE- INSULATION SURFACES. TRY TO PREVENT
AIR POCKETS. COVER CONDUCTORS AND HARDWARE WITH AT LEAST .12 INCH OF FILLER
PER FIG. 1.
4. APPLY 3.00X.030 THICK PAD #1 OVER CENTER OF JOINT WITH 1 1/4 LAPS (FIG. 2). APPLY
3.00 X .030 THICK PAD #2 STARTING .50 INCH FROM CENTER AND EXTENDING OVER
PREINSULATION AT LEAST 1.0 INCH WITH 1 1/4 LAPS. APPLY 3.00 X .030 THICK PAD #3
STARTING 1.00 FROM PAD #2 AT CENTER AND EXTENDING 1.00 IN. OVER PREINSULATION
PER FIG. 3.
5. APPLY (3) 6.00 IN. WIDE X 12 IN. LONG X .030 IN THICK PADS (PAD#4) CENTERED ON THE
MAIN BUS AND EXTENDING 1.50 IN. DOWN RISER PER FIG. 4.
6. APPLY ONE LAYER OF INSULATING TAPE (1.00X.030) USING 2/3 LAP AND EXTENDING
0.50 INCH MINIMUM BEYOND THE PADS ON THE PREINSULATION (FIG. 5).
7. APPLY A SECOND LAYER OF INSULATING TAPE (1.00X.030) USING 2/3 LAP AND
EXTENDING 0.50 INCH MIN. FOR (27KV) AND 1.50 MIN. FOR (38KV) BEYOND THE FIRST
LAYER ON THE PREINSULATION PER FIG. 5.
RPRETED
TH
1994
1.0
GENERAL
DRAFTER
P. KIM
4/10/1991
DATE
MODEL FILENAME
ENGINEER
DATE
ENGINEERING CHANGE NOTICE NO.
MODEL REV
EATON CORPORATION - CONFIDENTIAL AND PROPRIETARY
THIS DOCUMENT, INCLUDING THE DRAWING AND INFORMATION
CONTAINED THEREON, IS CONFIDENTIAL AND IS THE EXCLUSIVE
PROPERTY OF EATON CORPORATION, AND IS MERELY ON LOAN
AND SUBJECT TO RECALL BY EATON CORPORATION AT ANY TIME.
EATON www.eaton.com
9
Instruction Booklet IB182047EN
Arc flash limiter (AFL)
conversion system

Effective February 2018
PREINSULATION
PREINSULATION
PAD #1
PREINSULATION
1.0
PAD #1
PREINSULATION
Fig. 7: TYPICAL JOINT WITH PAD #1 3 IN.
WIDE X 030 TAPE OVER FILLER.
Fig. 6: TYPICAL JOINT WITH .12 THK.
MIN. FILLER OVER BARE JOINT.
PREINSULATION PAD #2
3.00
PAD #3 PREINSULATION
1.0
THRU-JOINTS, WITH-HARDWARE
1. CLEAN AREA OF DIRT AND FOREIGN MATTER
2. WIPE PREINSULATION WITH ISOPROPYL ALCOHOL.
3. APPLY FILLER OVER BARE CONDUCTOR AND HARDWARE TO
COVER AND SMOOTH OUT THE SURFACE. BLEND CONTOUR
INTO PRE- INSULATION SURFACES. TRY TO PREVENT AIR
POCKETS. COVER CONDUCTORS AND HARDWARE WITH AT
LEAST .12 INCH OF FILLER PER FIG. 6.
4. APPLY 3.0X.030 THICK PAD #1 OVER CENTER OF JOINT WITH 1
1/4 LAPS (FIG.7).
5. APPLY 3.0X.030 THICK PAD #2 STARTING .50 INCH FROM
CENTER AND EXTENDING OVER PREINSULATION AT LEAST 1.0
INCH WITH 1 1/4 LAPS. APPLY 3.00 X .030 THICK PAD #3
STARTING 1.00 FROM PAD #2 AT CENTER AND EXTENDING 1.00
IN. OVER PREINSULATION PER FIG. 8.
6. APPLY ONE LAYER OF INSULATING TAPE (1.00X.030) USING
2/3 LAP AND EXTENDING 0.50 INCH MINIMUM BEYOND THE PADS
ON THE PREINSULATION PER FIG. 9.
7. APPLY A SECOND LAYER OF INSULATING TAPE (1.00X.030)
USING 2/3 LAP AND EXTENDING 0.50 INCH MINIMUM BEYOND
THE FIRST LAYER ON THE PREINSULATION PER FIG. 9.
1.0
Fig. 8: TYPICAL JOINT WITH PADS #2 & #3
(3 IN. WIDE X .030) TAPE
OVER PAD #1 AND FILLER.
PAD #2
FILLER
PAD #1
PAD #3
PREINSULATION
9.0 (27 kV) MIN.
11.0 (38 kV) MIN.
Figure ??.
11. Thru-joint
Thru-joint Field
field Taping
taping method.
Figure
Methods.
TITLE
JOINT TAPING
MODEL FILENAME
10
EATON www.eaton.com
MODEL REV
ALL REV. NOTES
LISTED ON SHT. 1
DWG NO
7819C90
REV
Instruction Booklet IB182047EN
Arc flash limiter (AFL) 
conversion system
Effective February 2018

Switchgear terminals
Power cables
All connections to ground (suc h as shielding)
must be carried through the current transformer
and solidly grounded on the load side of the CT
as shown. Use #6 wire with 600 V insulation.
Zero Sequence transformer
Lead, armor, conduit, and so on
Lead, armor, conduit, interstice ground conductors,
and so on. Must be terminated and solidly grounded
on the load side of the current transformer.
To Load
Cable connections to switchgear terminals
when used with Zero Sequence transformers
Insulated pothead bushing
Insulated pothead mounting
Electrical joint required between
pothead and lead covered or armored
power cables.
Pothead ground lead must be carried
through the Zero Sequence current
transformer and solidly grounded on
the load side of the ct as shown. Use
#6 wire with 600 V insulation.
Zero Sequence transformer
Power cables
Conduit must be terminated and
solidly grounded on the load side
of the current transformer.
Conduit, when used
To load
Cable connections to switchgear terminals
when used with Insulated Pothead.
Figure ??.
12. Zero
Zero Sequence
sequence current transformer
transformerconnections.
connection.
Figure
EATON www.eaton.com
11
Instruction Booklet IB182047EN
Effective February 2018
Arc flash limiter (AFL)
conversion system

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY
The information, recommendations, descriptions and safety notations in this document are based on Eaton Corporation’s (“Eaton”)
experience and judgment and may not cover all contingencies.
If further information is required, an Eaton sales office should be
consulted. Sale of the product shown in this literature is subject
to the terms and conditions outlined in appropriate Eaton selling
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for any special, indirect, incidental or consequential damage or loss
whatsoever, including but not limited to damage or loss of use of
equipment, plant or power system, cost of capital, loss of power,
additional expenses in the use of existing power facilities, or claims
against the purchaser or user by its customers resulting from the
use of the information, recommendations and descriptions contained
herein. The information contained in this manual is subject to change
without notice.
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Publication No. IB182047EN / TBG001376
February 2018
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