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 policies or other contractual agreement between Eaton and the purchaser. THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or other-wise 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. Eaton 1000 Eaton Boulevard Cleveland, OH 44122 United States Eaton.com © 2018 Eaton All Rights Reserved Printed in USA Publication No. IB182047EN / TBG001376 February 2018 Eaton is a registered trademark. All other trademarks are property of their respective owners.
